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BACKGROUND OF THE INVENTION
The invention relates to a heating coat-hanger for drying damp garments after washing.
It often happens that clothes which are intended to be worn immediately, or to be placed in a suitcase, are still damp. It is then necessary to iron the garment or wear another garment.
Apparatuses for heating garments using electric resistances such as described in French Pat. No. 1,540,372 are known. These apparatuses are not very satisfactory for damp garments because they present safety problems. Furthermore, they offer no support for the garment as it is being dried.
SUMMARY OF THE INVENTION
The object of the present invention is a coat-hanger enabling any kind of garment to be suspended and dried rapidly and efficiently without ironing or the necessity for any incorporated electric heating means.
This result is obtained by utilizing a hollow coat-hanger enabling hot air, provided by an existing appliance such as a hairdryer, to be distributed inside the suspended garment.
The coat-hanger consists of a central portion having an open neck with an internal central duct communicating with lateral ducts formed in the two branches of the coat-hanger. The ducts formed in the branches of the coat-hanger are open at the ends of the branches so as to enable hot air to escape into the sleeves of the suspended garment. Openings are provided in the branches, communicating with the ducts formed in the branches so as to permit the escape of hot air all along the branches, preferably perpendicular to these branches and in a downward direction. The central duct formed in the central neck of the coat-hanger has an opening at the bottom, between the two branches of the coat-hanger. Openings are also provided perpendicular to the central duct formed in the central neck of the coat-hanger. A pivoting shutter placed at the base of the central duct to selectively direct the hot air flowing through the upper part of the central duct is either completely towards the branches or below the coat-hanger.
Fins disposed vertically in the central duct preferentially direct the hot air below the coat-hanger when the shutter is open. These fins also retain the end of the hairdryer.
The central neck is extended below the branches so that the coat-hanger can be attached onto a supporting mount. The supporting mount includes a hollow column, having a central duct pierced with holes, permitting the hot air to escape externally about its periphery.
The upper part of the central duct of the coat-hanger is frustoconical to accomodate various types of hairdryers.
The coat-hanger also includes one or more rods suspended between the ends of the branches so that a pair of pants, for example, can be suspended beneath the bottom opening of the central duct. At least one of the rods ends below the openings in the branches and carries at its ends adapters for holding skirt loops.
A hoop is pivotally attached to the upper part of the central neck. The dimensions of this hoop are sufficient to enable the coat-hanger to be suspended on a rod and provide the space necessary for a hairdryer between the upper part of the central neck and the suspension rod. A jointed hook is attached to the upper part of the hoop. The removal of the jointed hook enables the coat-hanger to be easily carried on the shoulder. The jointed hook, if necessary, may be inserted into a protective bag.
BRIEF DESCRIPTION OF THE DRAWINGS
The attached drawings are given as non-limiting examples of the coat-hanger according to the invention, wherein:
FIG. 1 is an elevational view of the coat-hanger according to the invention, carrying a shirt;
FIG. 2 is a sectional view of the coat-hanger shown in FIG. 1 taken along line A--A, in which the pivoting shutter is shown in the position permitting hot air to flow through the lateral branches;
FIG. 3 is a sectional view of the coat-hanger shown in FIG. 1, in which the pivoting shutter is shown in the position permitting hot air to escape through the base of the central neck; and
FIG. 4 is a view of the coat-hanger according to the invention, placed on its mount.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The coat-hanger 1 is shown in FIG. 1. This coat-hanger 1 has a hollow central neck 2 adapted to receive the end 3 of a conventional hairdryer 4. This hairdryer 4 and its electric supply 5 is independent of the coat-hanger 1. The coat-hanger 1 has two lateral branches 6 and 7 connected to the central neck 2.
At least one rod 8 passing under a lower portion 9 of the neck 2 is connected to the ends of the branches 6 and 7. A hoop 10 is pivotally connected to the upper portion of the neck 2. This hoop 10 receives, at its upper part, a hook 11 which is preferably removable. A shirt 12 is shown as an example of a garment. A knob 13 operates a pivoting shutter as shall be described with reference to FIGS. 2 and 3.
The central neck 2 has an internal duct 14, the upper portion 15 of which is flared out so as to conveniently receive a hairdryer 4 as shown in FIG. 1. Internal duct 14 communicates with the ducts 16 and 17 formed in the lateral branches 6 and 7 and the openings 24 and 25 at the ends of these lateral branches. Internal duct 18 is an extension of duct 14 having an opening below the coat-hanger 1.
Within the duct 14 are fins 19 disposed parallel to the axis 20 of the internal ducts 14 and 18.
Within the duct 18 is a pivoting shutter 21 rotatable about a shaft 22 connected to the knob 13 located outside the lower portion 9 of the neck 2.
The ducts 18 and 14 are preferably cylindrical for convenience of manufacture and the pivoting shutter 21 is preferably a disk having a diameter slightly smaller than that of the duct 18.
The shutter 21 is shown in FIG. 4 in a horizontal position so as to block the duct 18. In this state, hot air blown into the duct 14, as indicated by the arrow 23, will flow through ducts 16 and 17.
In a preferred embodiment of the coat-hanger 1, openings 26 are formed in the lateral branches 6 and 7 between the internal ducts 16 and 17 and the exterior of the lateral branches 6 and 7. In this embodiment, closing of the shutter 21 will cause hot air to likewise leave through openings 26. Openings 27 are also provided perpendicular to the neck 2 to dry shirt collars.
The coat-hanger 1 is shown in FIG. 3, with the shutter 21 positioned vertically so as to permit air flow into the duct 18. It will be understood that in this state, the hot air arriving as indicated by the arrow 23 and guided by the fins 19, preferentially exits through the opening at the bottom of duct 18, indicated by the arrow 28.
It will be understood that if a pair of pants (not shown), for example, is hung on the rod 8 attached to the ends of the branches 6 and 7, it will be rapidly dried by the hot air coming from the duct 18.
The coat-hanger 1 is shown in FIG. 4 in combination with a mount 29. The mount 29 is constituted by a base 30 surmounted by a tube 31, preferably having a cylindrical cross-section. The interior of tube 31 is adapted to receive the lower portion 9 of the neck 2 of the coat-hanger 1, such that the tube 31 becomes an extension of the duct 18. The tube 31 is pierced by several openings 32. It will thus be understood that when the shutter 21 is positioned vertically, the hot air arriving as indicated by the arrow 23, passes as indicated by the arrow 28 into the mount 29, then exits through the openings 32 as indicated by the arrows 33. The hot air is thus distributed over the whole interior of a garment (not shown) hung on the coat-hanger 1 supported by the mount 29.
The advantages of the coat-hanger, according to the present invention, are clearly apparent from the preceding descriptions and Figures.
The coat-hanger, according to the present invention, enables any type of garment to be suspended.
The coat-hanger, according to the present invention, also permits the utilization of a conventional hairdryer, available to everyone, to dry a garment while traveling and, more particularly but not exclusively, to dry shirts.
This drying is carried out on a hanging garment and thus eliminates the need for ironing.
It will be apparent to those skilled in the art that many variations and modifications may be made from the above-described example of structure for the coat-hanger 1. Such variations and modifications are included within the intended scope of the claims appended hereto.
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A heating coat-hanger for drying damp garments after washing having a pair of lateral branches connected to a central neck. Ducts formed in the central neck and lateral branches, as well as other openings, permit hot air blown into the duct formed in the central neck to be distributed over a suspended garment.
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BACKGROUND
[0001] 1. Field of Invention
[0002] The invention relates generally to the field of oil and gas production. More specifically, the present invention relates to an adapter for a shaped charge used in perforating. Yet more specifically, the present invention relates to an adapter for a perforating shaped charge that couples a shaped charge in a perforating gun or tube configured for a different sized shaped charged.
[0003] 2. Description of Prior Art
[0004] Perforating systems are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations so that predetermined zones of the earth formations can be hydraulically connected to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore. The casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore.
[0005] One typical example of a perforating system 4 is shown in FIG. 1 . As shown, the perforating system 4 comprises one or more perforating guns 6 strung together to form a perforating gun string 3 , these strings of guns 6 can sometimes surpass a thousand feet of perforating length. Connector subs 18 provide connectivity between each adjacent gun 6 of the string 3 . Many gun systems, especially those comprised of long strings of individual guns, are conveyed via a conveyance means 5 . Examples of conveyances means 5 for deploying or suspending the gun systems within a wellbore include tubing, wireline or slickline.
[0006] Included with the perforating gun 6 are shaped charges 8 that typically include a housing, a liner, and a quantity of high explosive inserted between the liner and the housing. When the high explosive is detonated, quickly expanding explosive gases are formed whose force collapses the liner and ejects it from one end of the charge 8 at very high velocity in a pattern called a “jet” 12 . The jet 12 perforates the casing and the cement and creates a perforation 10 that extends into the surrounding formation 2 . The resulting perforation 10 provides fluid communication between the formation 2 and the inside of the wellbore 1 .
[0007] A side partial sectional view of a portion of a perforating gun 6 is illustrated in FIG. 2 . The perforating gun 6 includes an elongated cylindrical gun body 14 housing a gun tube 16 therein. A shaped charge 8 is mounted in the gun tube 16 generally orthogonal to the tube axis A X . The gun body 14 includes an optional recess 19 aligned with the shaped charge opening 11 to reduce gun body 14 material in the jet 12 path. A lower opening 15 through a portion of the gun body 16 receives the base 9 or closed end of the shaped charge 8 . A corresponding upper opening 17 receives the shaped charge 8 open end 11 therethrough; the openings ( 15 , 17 ) are generally aligned with the shaped charge axis A SC . Shaped charge 8 detonation typically occurs by sending a detonation signal through or along the conveyance means 5 from the surface 13 . A firing head 7 receives the signal that responds by igniting a detonation cord 20 that passes through the gun string 3 and connects to each shaped charge 8 . Igniting the detonation cord 20 creates a pressure wave that contacts each shaped charge 8 and activates an initiator 21 that in turn detonates the high explosive in the shaped charge 8 .
[0008] Typically the upper opening 17 in the gun tube 16 is sized to match the shaped charge 8 dimensions. Since shaped charges 8 may be produced in multiple standard sizes, gun tubes 16 having correspondingly sized openings ( 15 , 17 ) are required for these shaped charges 8 . In some instances, operational delays may occur if a properly dimensioned gun tube 16 is not available to accommodate certain sized shaped charges.
SUMMARY OF INVENTION
[0009] The present disclosure concerns a perforating system having an adapter used with shaped charges that allows shaped charges to be used in perforating systems configured for larger shaped charges. In one example the present disclosure includes a perforating system for use in a subterranean wellbore that includes a tubular shaped charge holder, an aperture formed through the tubular, where the aperture dimensions are defined by a first size. Also included is an adapter coupled to the shaped charge holder at the aperture, the adapter dimensions defined by a second size. A shaped charge is coupled in the adapter, the shaped charge having a shaped charge case with a closed end and an open end. The adapter is coupled to the shaped charge proximate to the charge case open end, the shaped charge case dimensions defined by a third size.
BRIEF DESCRIPTION OF DRAWINGS
[0010] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 is a partial cutaway side view of a perforating system.
[0012] FIG. 2 illustrates a partial cutaway of a portion of a perforating gun.
[0013] FIG. 3 is a perspective partial sectional view of a shaped charge having an adapter.
[0014] FIG. 4 is an overhead view of the shaped charge and adapter of FIG. 3 .
[0015] FIG. 5 is a side view of a shaped charge with an adapter in a perforating gun body.
[0016] FIG. 6 is a side view of a shaped charge with an adapter in a perforating gun body including a spacer shim.
[0017] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0018] The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0019] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
[0020] The present disclosure concerns an adapter used with a shaped charge, where the shaped charged is used in subterranean perforating for oil and gas hydrocarbon production. One example of a shaped charge 30 with an adapter 38 is provided in a perspective partial sectional view in FIG. 3 . As shown, the shaped charge 30 includes a shaped charge case 32 having a base 37 on one end and upwardly extending walls. The walls terminate in an opening 33 at the end of the case 32 opposite the base 37 . A frusto-conical liner 34 is inserted within the case 32 with its conical end disposed proximate the base 37 . High explosive 36 is disposed between the liner 34 and the inner circumference of the case 32 .
[0021] The adapter 38 is coupled to the charge casing 32 on its outer circumference and proximate the opening 33 . In the embodiment of FIG. 3 , the adapter 38 includes an annular collar 40 coupled to the charge case 32 by an interference fit. The adapter 38 includes a split section 42 extending axially through the adapter 38 at a location along the adapter 38 circumference. The adapter 38 circumference is thus expandable by increasing the split section 42 length. Forming the adapter 38 from an elastic material, such as steel, enhances interference coupling by internal stresses in the material urging together the adapter ends 43 adjacent the split section 42 . The collar 40 has an elongate cross-section with the elongate length substantially parallel to the shaped charge 30 axis A S .
[0022] An optional tab 44 is affixed to the inner circumference of the collar 40 extending radially inward towards the axis A S of the shaped charge 30 . The tab 44 may provide a stopping point for the shaped charge 30 upper terminal end and to align the shaped charge 30 within a shaped charge holder. Also formed on the inner circumference of the collar 40 is a raised profile 46 shown extending substantially along the entire inner circumference of the collar 40 . A corresponding groove 35 on the charge case 32 outer circumference registers with the inwardly protruding profile 46 . The profile 46 and groove 35 can be used as a latching means between the adapter 38 and shaped charge 30 as well as a means for aligning the adapter 38 on the shaped charge 30 .
[0023] The adapter 38 of FIG. 3 also includes a base member 48 extending radially outward from the collar 40 . As will be discussed in more detail below, the base member 48 outer diameter enables coupling between the shaped charge 30 and a shaped charge holder. Radially extending outward from the collar 40 outer surface is an annular disk-like connector ring 50 that terminates on its outer periphery at an annular outer ring 52 . The outer ring 52 has an elongate cross-section, with its elongate length generally perpendicular with the axis A S of the shaped charge 30 . The connector ring 50 includes apertures 51 formed therethrough at various locations along the connector ring 50 circumference. Optionally, however, the base 48 may include other configurations, such as a single member having a uniform cross-section around the entire circumference.
[0024] An overhead view of the combination shaped charge 30 with adapter 38 is provided in FIG. 4 . In this embodiment, the terminal ends of the tabs 44 are shown generally aligned with the shaped charge case 32 inner circumference thereby disposed above the entire width of the charge case 32 walls. Alternatively, the tabs 44 may extend over a portion of the charge case 32 wall width. The adapter 38 substantially circumscribes the shaped charge 30 outer circumference. Other embodiments of the adapter 38 exist where the adapter 38 circumscribes about 50% or more of the shaped charge 30 outer circumference.
[0025] A side partial sectional view of a shaped charge 30 with an adapter 38 is illustrated disposed within a perforating system. In this embodiment, the shaped charge 30 is combined with a shaped charge holder that is illustrated as a gun tube 56 . Optionally, the shaped charge holder could include a gun body. The gun tube 56 includes an opening 54 through a portion of its section on which the adapter 38 is coupled. For the purposes of discussion herein, the coupling comprises the adapter 38 outer diameter exceeding the opening 54 diameter thereby allowing the coupling 38 to rest over the shaped charge holder and retain the shaped charge 30 within the shaped charge holder 56 . As is known, shaped charges are available in multiple standard sizes, thus most shaped charge holders include openings or apertures configured to match those standard sizes. Use of the adapter 38 herein enables a shaped charge 30 having a particular size to be utilized within shaped charge holders 56 wherein the corresponding openings 54 may be one or more standard sizes greater than the standard size of the particular shaped charge 30 . Accordingly, a shaped charge having the adapter 38 described herein and equivalents thereof can be installed into more than one gun system or kit, where the gun systems include openings 54 of more than one size. Additionally, use of the adapter 38 also enables a single gun body 58 having the same size openings 54 to have installed individual shaped charges 30 of more than one size. For example, an embodiment exists where a gun body 58 has single size openings 54 , but includes some deep penetrating shaped charges and some gravel pack shaped charges, where the charges smaller than the openings 54 are adapted for installation with the adapter 38 .
[0026] As illustrated in FIG. 5 , the gun body 58 is disposed above the opening 33 of the shaped charge 30 . Thus, in the example shown, the dimensions of the opening 54 can be defined as having a first size, the dimensions of the adapter 38 can be defined as having a second size, and the dimensions of the shaped charge 30 can be defined as having a third size. The first size sufficiently exceeds the third size, such that the smaller shaped charge 30 passes through the opening 54 . However, because the adapter 38 has dimensions of a second size, wherein the second size exceeds the dimensions of the first size, the adapter 38 is shown coupled onto the shaped charge holder 56 . Additionally, due to the press fit or interference fit of the adapter 38 with the shaped charge 30 , the shaped charge 30 is affixed with the adapter, and also coupled with the shaped charge holder 56 by virtue of its connection with the adapter 38 .
[0027] With reference now to FIG. 6 , an example of a shim spacer 53 and adapter 38 is illustrated in a side partial sectional view. The shim spacer 53 , as shown in cross section, is an annular member disposed between the base member 48 lower surface and the gun tube 56 outer surface. Installing the shim spacer 53 positions the shaped charge 30 closer to the gun body 58 and can enhance shaped charge performance by adjusting jet 12 formation and extension. Jet 12 formation and extension can be a function of the jet 12 focal point, which is extended into the formation 2 by repositioning the shaped charge 30 as illustrated. Based on the formation encountered, adjusting the jet 12 formation can extend perforations 10 and increase hydrocarbon production from the formation 2 . Those skilled in the art have sufficient capabilities to adjust jet 12 formation by sizing and/or positioning the spacer shim 53 . The spacer shim 53 can be integral with the adapter 38 , or can be a separate component. The shim spacer 53 is not limited to an annular shape, but can have other configurations. Additionally, the shim spacer 53 can also be comprised of two or more elements spaced around the shaped charge 30 . Moreover, the present disclosure includes embodiments where a shim spacer 53 is installed with shaped charges that do not include an adapter, but where the shaped charges with a shim spacer 53 are disposed within the same size shaped charge holder.
[0028] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, the adapter 38 can also affix shaped charges within carrier strips and other charge holders. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
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A shaped charge for use with a perforating gun having an adapter that can couple the shaped charge with perforating gun systems of more than one size. An interference fit can couple the adapter to the open end of a shaped charge. The adapter includes a base section having an outer diameter exceeding the shaped charge outer diameter. The adapter larger diameter can be coupled to perforating gun systems formed to receive shaped charges whose outer diameters exceed the outer diameter of the shaped charge coupled to the adapter. Thus the adapter can couple a shaped charge to a perforating gun that might otherwise have fittings too large to accommodate the shaped charge.
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BACKGROUND
[0001] Tubular system operators are always receptive to new methods and devices to permit actuation of tubular tools such as those in industries concerned with earth formation boreholes, such as hydrocarbon recovery and gas sequestration, for example. It is not uncommon for various operations in these industries to utilize a temporary or permanent plugging device against which to build pressure to cause an actuation.
[0002] Sometimes actuating is desirable at a first location, and subsequently at a second location. Moreover, additional actuating locations may also be desired and the actuation can be sequential for the locations or otherwise. Systems employing droppable members, such as balls, for example, are typically used for just such purpose. The ball is dropped to a ball seat positioned at the desired location within the borehole thereby creating the desired plug to facilitate the actuation.
[0003] In applications where the first location is further from surface than the second location, it is common to employ seats with sequentially smaller diameters at locations further from the surface. Dropping balls having sequentially larger diameters allows the ball seat furthest from surface to be plugged first (by a ball whose diameter is complementary to that seat), followed by the ball seat second furthest from surface (by a ball whose diameter is complementary to that seat) and so on.
[0004] The foregoing system, however, creates increasingly restrictive dimensions within the borehole that can negatively impact flow therethrough as well as limit the size of tools that can be run into the borehole. Additionally, the number of discrete ball/seat combinations that can be run is limited as a result of the increasingly restrictive dimensions. Systems and methods that allow operators to increase the number of actuatable locations within a borehole without the drawbacks mentioned would be well received in the art.
BRIEF DESCRIPTION
[0005] Disclosed herein is a tubular actuating system. The system includes, a tubular, a plurality of same plugs runnable within the tubular, an actuator disposed within the tubular, and a seatable member disposed at the actuator configured to be respositionable relative to the actuator between an unseated position and a seated position upon passage of at least one of the plurality of same plugs.
[0006] Further disclosed herein is a method of actuating a tubular actuator. The method includes, running a runnable member within a tubular, contacting the tubular actuator with the runnable member, repositioning a seatable member, seating the seatable member, and pressuring up against the seated seatable member to actuate the tubular actuator.
[0007] Further disclosed herein is a tubular actuator. The actuator includes, a body disposable within a tubular being movable relative to the tubular, and a member being repositionable relative to the body from an unseated position to a seated position upon passage of at least one runnable member thereby.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0009] FIG. 1 depicts a partial cross sectional view of a tubular actuator disclosed herein being contacted with a runnable member;
[0010] FIG. 2 depicts a partial cross sectional view of the tubular actuator of FIG. 1 shown being contacted with another runnable member; and
[0011] FIG. 3 depicts a partial cross sectional view of the tubular actuator of FIG. 1 shown with a seatable member in a seated position.
DETAILED DESCRIPTION
[0012] 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.
[0013] Referring to FIGS. 1-3 , an embodiment of a tubular actuator disclosed herein is illustrated generally at 10 . The tubular actuator 10 includes, a body 14 , having a tubular shape, disposed within a tubular 18 , a seatable member 22 , illustrated in this embodiment as a flapper, a sleeve 26 , and an optional collar 30 . The flapper 22 , the sleeve 26 and the collar 30 are all repositionable relative to the body 14 in response to contact of the actuator 10 with runnable members 34 , also referred to herein as plugs or balls, which are runnable within the tubular 18 . The sleeve 26 , in this embodiment, is originally positioned in longitudinal alignment with and radially inwardly of the flapper 22 . This initial position of the sleeve 26 maintains the flapper 22 in an open position, as shown in FIGS. 1 and 2 .
[0014] The sleeve 26 has a profile 38 on an inner radial surface 42 engagably receptive to the balls 34 , as best shown in FIG. 2 . Pressure applied against the ball 34 , when engaged with the profile 38 , can urge the sleeve 26 to reposition to a downstream position as shown in FIG. 3 . When in the downstream position the sleeve 26 is no longer longitudinally aligned with the flapper 22 , thereby allowing the flapper 22 to reposition from the open position to a closed position wherein the flapper 22 is seatingly engaged with a seat 46 on the body 14 . A biasing member 40 , illustrated herein as a torsional spring can rotationally bias the flapper 22 toward the closed position. When the flapper 22 is seatingly engaged with the seat 46 any pressure increases upstream of the flapper 22 will increase forces applied to the actuator 10 thereby urging actuation thereof.
[0015] The optional collar 30 , if the actuator 10 is so equipped (as the one illustrated herein is), longitudinally overlaps the profile 38 of the sleeve 26 in its original position. This overlapping positioning holds collet fingers 50 , of the sleeve 26 , in a radially expanded position, as shown in FIG. 1 . Since the profile 38 is on the radially expanded portion of the sleeve 26 , the ball 34 is able to pass thereby without engaging the profile 38 . A profile 54 on the collar 30 , also engagable with the balls 34 , allows pressure applied against a ball 34 seated therewith to reposition the collar 30 to a downstream position as shown in FIGS. 2 and 3 . Once the collar 30 is disengaged from the overlapping position with the sleeve 26 the profile 38 is able to return to an unexpanded position wherein it is engagable with the balls 34 . An annular recess 58 in the body 14 is receptive to radially expanded collet fingers 62 of the collar 30 such that the ball 34 is able to pass thereby.
[0016] The foregoing construction allows an operator to run a ball 34 within the tubular 18 until it engages with the profile 54 . Pressuring up against the engaged ball 34 allows the sleeve to be moved downstream until the collet fingers 62 expand into the annular recess 58 thereby allowing the ball 34 to pass through the collar 30 , possibly to be used to actuate another tool located downstream thereof. The downstream movement of the collar 30 , in relation to the sleeve 26 , releases the collet fingers 50 thereby configuring the profile 38 to engage the next ball 34 to be run thereagainst. Pressure built upstream of the second ball 34 engaged with the profile 38 causes the sleeve 26 to move downstream thereby releasing the flapper 22 allowing the flapper 22 to move from the open position to the closed position. Once closed, the flapper 22 , being seated against the seat 46 , allows pressure to build upstream thereof to allow actuation of the actuator 10 . Such actuation may be used to open ports 66 through the tubular 18 , for example, to allow fluid treating such as fracturing or acidizing of a formation within which the tubular 18 is positioned, in the case of an application involved in the hydrocarbon recovery industry.
[0017] By allowing one or more of the balls 34 to pass, prior to the closing of the flapper 22 and subsequent actuation of the actuator 10 , the system employing a plurality of the actuators 10 and/or other conventional actuators that actuate, for example, upon engagement with a first of the balls 34 , can increase the number of actuatable zones with balls 34 of a particular size. This system alleviates the concerns associated with conventional systems that incorporate a plurality of actuators, each with smaller dimensions than the last, to permit actuation with balls of ever decreasing size. Some concerns being the decrease in production flows due to the smaller flow areas created by the smaller dimensions, and restrictions on the size of tools that can be employed during intervention due to the smaller dimensions. Additionally, the increased number of actuators can be employed to open an increased number of ports such as the ports 66 , thereby increasing a number of zones that can be fractured or treated for a given well.
[0018] 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.
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A tubular actuating system includes a tubular, a plurality of same plugs runnable within the tubular, an actuator disposed within the tubular, and a seatable member disposed at the actuator configured to be respositionable relative to the actuator between an unseated position and a seated position upon passage of at least one of the plurality of same plugs.
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FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a luminescence device and a metal coordination compound therefor. More specifically, the present invention relates to a luminescence device employing an organic metal coordination compound having platinum center metal as a luminescence material so as to allow stable luminescence efficiency, and a metal coordination compound adapted for use in the luminescence device.
[0002] An organic electroluminescence EL device has been extensively studied as a luminescence device with a high responsiveness and high efficiency.
[0003] The organic EL device generally has a sectional structure as shown in FIG. 1A or 1 B (e.g., as described in “Macromol. Symp.”, 125, pp. 1-48 (1997)).
[0004] Referring to the figures, the EL device generally has a structure including a transparent substrate 15 , a transparent electrode 14 disposed on the transparent substrate 15 , a metal electrode 11 disposed opposite to the transparent electrode 14 , and a plurality of organic (compound) layers disposed between the transparent electrode 14 and the metal electrode 11 .
[0005] Referring to FIG. 1, the EL device in this embodiment has two organic layers including a luminescence layer 12 and a hole transport layer 13 .
[0006] The transparent electrode 14 may be formed of a film of ITO (indium tin oxide) having a larger work function to ensure a good hole injection performance into the hole transport layer. On the other hand, the metal electrode 11 may be formed of a layer of aluminum, magnesium, alloys thereof, etc., having a smaller work function to ensure a good electron injection performance into the organic layer(s).
[0007] These (transparent and metal) electrodes 14 and 11 may be formed in a thickness of 50-200 nm.
[0008] The luminescence layer 12 may be formed of, e.g., aluminum quinolinol complex (representative example thereof may include Alq3 described hereinafter) having an electron transporting characteristic and a luminescent characteristic. The hole transport layer 13 may be formed of, e.g., triphenyldiamine derivative (representative example thereof may include α-NPD described hereinafter) having an electron donating characteristic.
[0009] The above-described EL device exhibits a rectification characteristic, so that when an electric field is applied between the metal electrode 11 as a cathode and the transparent electrode 14 as an anode, electrons are injected from the metal electrode 11 into the luminescence layer 12 and holes are injected from the transparent electrodes 14 .
[0010] The thus-injected holes and electrons are recombined within the luminescence layer 12 to produce excitons, thus causing luminescence. At that time, the hole transport layer 13 functions as an electron-blocking layer to increase a recombination efficiency at the boundary between the luminescence layer 12 and the hole transport layer 13 , thus enhancing a luminescence efficiency.
[0011] Referring to FIG. 1B, in addition to the layers shown in FIG. 1A, an electron transport layer 16 is disposed between the metal electrode 11 and the luminescence layer 12 , whereby an effective carrier blocking performance can be ensured by separating functions of luminescence, electron transport and hole transport, thus allowing effective luminescence.
[0012] The electron transport layer 16 may be formed of, e.g., oxadiazole derivatives.
[0013] In ordinary organic EL devices, fluorescence caused during a transition of luminescent center molecule from a singlet excited state to a ground state is used as luminescence.
[0014] On the other hand, not the above fluorescence (luminescence) via singlet exciton, phosphorescence (luminescence) via triplet exciton has been studied for use in organic EL device as described in, e.g., “Improved energy transfer in electrophosphorescent device” (D. F. O'Brien et al., Applied Physics Letters, Vol. 74, No. 3, pp. 442-444 (1999)) and “Very high-efficiency green organic light-emitting devices based on electrophosphorescence” (M. A. Baldo et al., Applied Physics Letters, Vol. 75, No. 1, pp. 4-6 (1999)).
[0015] The EL devices shown in these documents may generally have a sectional structure shown in FIG. 1C.
[0016] Referring to FIG. 1C, four organic layers including a hole transfer layer 13 , a luminescence layer 12 , an exciton diffusion-prevention layer 17 , and an electron transport layer 16 are successively formed in this order on the transparent electrode (anode) 14 .
[0017] In the above documents, higher efficiencies have been achieved by using four organic layers including a hole transport layer 13 of α-NPD (shown below), an electron transport layer 16 of Alq3 (shown below), an exciton diffusion-prevention layer 17 of BPC (shown below), and a luminescence layer 12 of a mixture of CPB (shown below) as a host material with Ir(ppy) 3 (shown below) or PtOEP (shown below) as a guest phosphorescence material doped into CBP at a concentration of ca. 6 wt. %.
[0018] Alq3: tris(8-hydroxyquinoline) aluminum (aluminum-quinolinol complex),
[0019] α-NPD: N4,N4′-di-naphthalene-1-yl-N4,N4′-diphenyl-biphenyl-4,4′-diamine (4,4′-bis[N-(1-naphthyl)-N-phenyl-amino]biphenyl),
[0020] CBP: 4,41-N,N′-dicarbazole-biphenyl,
[0021] BCP: 2,9-dimethyl-4,7-diphenyl-1,10-phenan-throline,
[0022] Ir(ppy) 3 : fac tris(2-phenylpyridine)iridium (iridium-phenylpyridine complex), and
[0023] PtEOP: 2,3,7,8,12,13,17,18-octaethyl-21H,23H-porphine platinum (platinum-octaethyl porphine complex).
[0024] The phosphorescence (luminescence) material used in the luminescence layer 12 has attracted notice. This is because the phosphorescence material is expected to provide a higher luminescence efficiency in principle.
[0025] More specifically, in the case of the phosphorescence material, excitons produced by recombination of carriers comprise singlet excitons and triplet excitons presented in a ratio of 1:3. For this reason, when fluorescence caused during the transition from the singlet excited state to the ground state is utilized, a resultant luminescence efficiency is 25% (as upper limit) based on all the produced excitons in principle.
[0026] On the other hand, in the case of utilizing phosphorescence caused during transition from the triplet excited state, a resultant luminescence efficiency is expected to be at least three times that of the case of fluorescence in principle. In addition thereto, if intersystem crossing from the singlet excited state (higher energy level) to the triplet excited state is taken into consideration, the luminescence efficiency of phosphorescence can be expected to be 100% (four times that of fluorescence) in principle.
[0027] The use of phosphorescence based on transition from the triplet excited state has also been proposed in, e.g., Japanese Laid-Open Patent Application (JP-A) 11-329739, JP-A 11-256148 and JP-A 8-319482.
[0028] However, the above-mentioned organic EL devices utilizing phosphorescence have accompanied with a problem of luminescent deterioration particularly in an energized state.
[0029] The reason for luminescent deterioration has not been clarified as yet but may be attributable to such a phenomenon that the life of triplet exciton is generally longer than that of singlet exciton by at least three digits, so that molecule is placed in a higher-energy state for a long period to cause reaction with ambient substance, formation of exciplex or excimer, change in minute molecular structure, structural change of ambient substance, etc.
[0030] Accordingly, the (electro)phosphorescence EL device is expected to provide a higher luminescence efficiency as described above, while the EL device is required to suppress or minimize the luminescent deterioration in energized state.
SUMMARY OP THE INVENTION
[0031] An object of the present invention is to provide a luminescence device capable of providing a high-efficiency luminescent state at a high brightness (or luminance) for a long period while minimizing the deterioration in luminescence in energized state.
[0032] Another object of the present invention is to provide a metal coordination compound as a material suitable for an organic layer for the luminescence device.
[0033] According to the present invention, there is provided a luminescence device, comprising: an organic compound layer comprising a metal coordination compound having a partial structure represented by the following formula (1):
[0034] wherein each of N and C represents an atom constituting a cyclic group.
[0035] According to the present invention, there is also provided a metal coordination compound, adapted for use in a luminescence device, having a partial structure represented by the following formula (1):
[0036] wherein each of N and C represents an atom constituting a cyclic group.
[0037] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0038] [0038]FIGS. 1A, 1B and 1 C are respectively a schematic sectional view of a layer structure of a luminescence device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In the case where a luminescence layer for an organic EL device is formed of a carrier transporting host material and a phosphorescent guest material, a process of emission of light (phosphorescence) may generally involve the following steps:
[0040] (1) transport of electron and hole within a luminescence layer,
[0041] (2) formation of exciton of the host material,
[0042] (3) transmission of excited energy between host material molecules,
[0043] (4) transmission of excited energy from the host material molecule to the guest material molecule,
[0044] (5) formation of triplet exciton of the guest material, and
[0045] (6) emission of light (phosphorescence) caused during transition from the triplet excited state to the ground state of the guest material.
[0046] In the above steps, desired energy transmission and luminescence may generally be caused based on various deactivation and competition.
[0047] In order to improve a luminescence efficiency of the EL device, a luminescence center material per se is required to provide a higher yield of luminescence quantum. In addition thereto, an efficient energy transfer between host material molecules and/or between host material molecule and guest material molecule is also an important factor.
[0048] Further, the above-described luminescent deterioration in energized state may presumably relate to the luminescent center material per se or an environmental change thereof by its ambient molecular structure.
[0049] For this reason, our research group has extensively investigated an effect of use of the metal coordination compound (platinum complex) having a partial structure of formula (1) as the luminescent center material and as a result, has found that the metal coordination compound having the partial structure of formula (1) allows a high-efficiency luminescence (e.g., luminescence efficiency of at least 1 cd/W) with a high brightness (luminance) for a long period (e.g., a luminance half-life of at least 500 hours at an initial luminance of 100 cd/m 2 ) (i.e., a decreased luminescent deterioration in energized state).
[0050] The metal coordination compound having a partial structure of formula (1) may preferably be represented by any one of the following formulas (1-1) to (1-6):
[0051] wherein CyN1 and CyN2 independently denote a cyclic group containing a nitrogen atom connected to Pt and capable of having a substituent, and CyC1 and CyC2 independently denote a cyclic group containing a carbon atom connected to Pt and capable of having a substituent, each of the substituents for CyN1, CyN2, CyC1 and CyC2 being selected from the group consisting of a halogen atom; nitro group; a trialkylsilyl group containing three linear or branched alkyl groups each independently having 1-8 carbon atoms; and a linear or branched alkyl group having 1-20 carbon atoms capable of including one or at least two non-neighboring methylene groups which can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C═C— and capable of including a hydrogen atom which can be replaced with a fluorine atom.
[0052] The metal coordination compound may more preferably be represented by the formula (1-1) or the formula (1-2) in order to allow further improved high-efficient luminance while minimizing the luminescent deterioration in energized state.
[0053] At least one of CyN1 and CyN2 in the formulas (1-1) to (1-6) may preferably be a substituted or unsubstituted cyclic group having a ring structure selected from the group consisting of pyridine, pyrimidine, pyrazoline, pyrrole, pyrazole, quinoline, isoquinoline, and quinoxaline. Further, at least one of CyC1 and CyC2 in the formulas (1-1) to (1-6) may preferably be a substituted or unsubstituted cyclic group selected from the group consisting of phenyl, naphthyl, thienyl, benzothienyl, and quinolyl.
[0054] The metal coordination compound (platinum complex) specifically represented by the above formulas (1-1) to (1-6) causes phosphorescence (luminescence) and is assumed to have a lowest excited state comprising a triplet excited state liable to cause metal-to-ligand charge transfer (MLCT* state). The phosphorescent emission of light (phosphorescence) is produced during the transition from the MLCT* state to the ground state.
[0055] The metal coordination compound according to the present invention has been found to provide a higher phosphorescence yield of 0.05-0.9 and a shorter phosphorescence life of 1-30 psec.
[0056] A phosphorescence yield (P(m)) is obtained based on the following equation:
P ( m )/ P ( s )=( S ( m )/ S ( s ))×( A ( s )/ A ( m )),
[0057] wherein P(m) represents a phosphorescence yield of an (unknown) objective luminescent material, P(s) represents a known (standard) phosphorescence yield of standard luminescent material (Ir(ppy) 3 ), S(m) represents an integrated intensity of (photo-)excited emission spectrum of the objective material, S(s) represents a known integrated intensity of the standard material, A(m) represents an absorption spectrum of an excited light wavelength of the objective material, and A(s) represents a known absorption spectrum of the standard material.
[0058] The shorter phosphorescence life is necessary to provide a resultant EL device with a higher luminescence efficiency. This is because the longer phosphorescence life increases molecules placed in their triplet excited state which is a waiting state for phosphorescence, thus lowering the resultant luminescence efficiency particularly at a higher current density.
[0059] Accordingly, the metal coordination compound according to the present invention is a suitable luminescent material for an EL device with a higher phosphorescence yield and a shorter phosphorescence life.
[0060] In a conventional phosphorescent EL device uses the platinum-porphiline complex (e.g., PtOEP described above) is used as the luminescent material. On the other hand, the metal coordination compound according to the present invention has a carbon-platinum bond (C—Pt bond) in its molecular structure, thus particularly effectively exhibiting a heavy atom effect of platinum (Pt) compared to the case of N—Pt bond (in PtOEP). As a result, a spin-orbit interaction is enhanced to realize a higher phosphorescence yield and a shorter phosphorescence life at the same time.
[0061] Further, molecules of the metal coordination compound have a shorter time period wherein they stay in the triplet excited state, thus prolonging the life of the EL device with less deterioration. In this regard, the metal coordination compound according to the present invention has been substantiated to exhibit excellent stability of luminance as shown in Examples described hereinafter.
[0062] In the case of phosphorescent (luminescent) material, luminescent characteristics are largely affected by its molecular environment. On the other hand, principal characteristics of the fluorescent material are studied based on photoluminescence.
[0063] For this reason, results of photoluminescence of the phosphorescent material do not reflect luminescent characteristics of the resultant EL device in many cases since the luminescent characteristics in the case of the phosphorescent material depend on a magnitude of polarity of ambient host material molecules, ambient temperature, presence state of the material (e.g., solid state or liquid state, etc. Accordingly, different from the fluorescent material, it is generally difficult to expect the resultant EL characteristics for the phosphorescent material by simply removing a part of characteristics from photoluminescence results.
[0064] As a feature of molecular structure, the platinum complex has a planar structure, energy transfer of triplet exciton (i.e., energy transfer from host material molecule in the triplet excited state to guest material molecule) is performed based on electron exchange between adjacent molecules (so-called Dexter transfer). Accordingly, a degree of overlapping of electron cloud between adjacent molecules is an important factor, so that the planar (molecular) structure is suitable for efficient energy transfer.
[0065] On the other hand, Ir(ppy) 3 (indium-phenylpyrimidine complex) as used in the above-described conventional EL device has a steric octahedral coordination structure, thus failing to perform efficient energy transfer (Dexter transfer) from host material molecule.
[0066] As described above, the metal coordination compound (platinum complex) according to the present invention is a suitable luminescent material for EL device.
[0067] The luminescence device (EL) device according to the present invention employs the above-mentioned metal coordination compound in an organic layer, particularly a luminescence layer.
[0068] Specifically, the luminescence device may preferably include the organic layer comprising the metal coordination compound between a pair of oppositely disposed electrodes comprising a transparent electrode (anode) and a metal electrode (cathode) which are supplied with a voltage to cause luminescence, thus constituting an electric-field luminescence device.
[0069] The liquid crystal of the present invention has a layer structure shown in FIGS. 1A to 1 C as specifically described above.
[0070] By the use of the metal coordination compound of the present invention, the resultant luminescence device has a high luminescence efficiency as described above.
[0071] The luminescence device according to the present invention may be applicable to devices required to allow energy saving and high luminance, such as those for display apparatus and illumination apparatus, a light source for printers, and backlight (unit) for a liquid crystal display apparatus. Specifically, in the case of using the luminescence device of the present invention in the display apparatus, it is possible to provide a flat panel display apparatus capable of exhibiting an excellent energy saving performance, a high visibility and a good lightweight property. With respect to the light source, it becomes possible to replace a laser light source of laser beam printer currently used widely with the luminescence device according to the present invention. Further, when the luminescence device of present invention is arranged in independently addressable arrays as an exposure means for effecting desired exposure of light to a photosensitive drum for forming an image, it becomes possible to considerably reducing the volume (size) of image forming apparatus. With respect to the illumination apparatus and backlight (unit), the resultant apparatus (unit) using the luminescence device of the present invention is expected to have an energy saving effect.
[0072] Hereinbelow, the metal coordination compound used in the luminescence device of the present invention will be described more specifically.
[0073] Specific and non-exhaustive examples of the metal coordination compound preferably having the above-mentioned formulas (1-1) to (1-6) may include those (Example Compound Nos. 101-267) shown in Tables 1-7.
[0074] In Tables 1-7, abbreviations for respective cyclic groups (CyN1, CyN2, CyC1, CyC2) represent groups shown below.
[0075] In the above structural formulas, an unconnected covalent (single) linkage extended from nitrogen atom (N) in a lower-right direction except for Pz′ is a linkage connected to platinum atom (Pt), and the other unconnected covalent linkage is a linkage connected to an adjacent cyclic group.
[0076] In the above structural formulas (Ph to Pz and Ph′ to Pz′), an unconnected covalent (single) linkage extended in an upper-right direction is a linkage connected to platinum atom (Pt), and the other unconnected covalent linkage extended in an upper direction is a linkage connected to an adjacent cyclic group.
TABLE 1 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 101 (1-1) Pr Pr Ph Ph H H H H 102 (1-1) Pr Pr Tn1 Tn1 H H H H 103 (1-1) Pr Pr Tn2 Tn2 H H H H 104 (1-1) Pr Pr Tn3 Tn3 H H H H 105 (1-1) Pr Pr BTn1 BTn1 H H H H 106 (1-1) Pr Pr BTn2 BTn2 H H H H 107 (1-1) Pr Pr Np Np H H H H 108 (1-1) Pr Pr Qn1 Qn1 H H H H 109 (1-1) Pr Pr Qn2 Qn2 H H H H 110 (1-1) Pa Pa Ph Ph H H H H 111 (1-1) Pa Pa Tn1 Tn1 H H H H 112 (1-1) Pa Pa Tn2 Tn2 H H H H 113 (1-1) Pa Pa Tn3 Tn3 H H H H 114 (1-1) Pa Pa BTn1 BTn1 H H H H 115 (1-1) Pa Pa BTn2 BTn2 H H H H 116 (1-1) Pa Pa Np Np H H H H 117 (1-1) Pa Pa Qn1 Qn1 H H H H 118 (1-1) Pa Pa Qn2 Qn2 H H H H 119 (1-1) Pz Pz Ph Ph H H H H 120 (1-1) Pz Pz Tn1 Tn1 H H H H 121 (1-1) Pz Pz Tn2 Tn2 H H H H 122 (1-1) Pz Pz Tn3 Tn3 H H H H 123 (1-1) Pz Pz BTn1 BTn1 H H H H 124 (1-1) Pz Pz BTn2 BTn2 H H H H 125 (1-1) Pz Pz Np Np H H H H
[0077] [0077] TABLE 2 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 126 (1-1) Pz Pz Qn1 Qn1 H H H H 127 (1-1) Pz Pz Qn2 Qn2 H H H H 128 (1-2) Pr Pr Ph Ph H H H H 129 (1-2) Pr Pr Tn1 Tn1 H H H H 130 (1-2) Pr Pr Tn2 Tn2 H H H H 131 (1-2) Pr Pr BTn1 BTn1 H H H H 132 (1-2) Pr Pr BTn2 BTn2 H H H H 133 (1-2) Pr Pr Np Np H H H H 134 (1-2) Pr Pr Qn1 Qn1 H H H H 135 (1-2) Pr Pr Qn2 Qn2 H H H H 136 (1-2) Pr Pr Qx Qx H H H H 137 (1-2) Pr Pr Qz1 Qz1 H H H H 138 (1-2) Pr Pr Qz2 Qz2 H H H H 139 (1-2) Pr Pr Cn1 Cn1 H H H H 140 (1-2) Pr Pr Cn2 Cn2 H H H H 141 (1-2) Pr Pr Pz Pz H H H H 142 (1-2) Pd Pd Ph Ph H H H H 143 (1-2) Pd Pd Tn1 Tn1 H H H H 144 (1-2) Pd Pd Tn2 Tn2 H H H H 145 (1-2) Pd Pd BTn1 BTn1 H H H H 146 (1-2) Pd Pd BTn2 BTn2 H H H H 147 (1-2) Pd Pd Np Np H H H H 148 (1-2) Pd Pd Qn1 Qn1 H H H H 149 (1-2) Pd Pd Qn2 Qn2 H H H H 150 (1-2) Pd Pd Qx Qx H H H H
[0078] [0078] Table 3 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 151 (1-2) Pd Pd Qz1 Qz1 H H H H 152 (1-2) Pd Pd Qz2 Qz2 H H H H 153 (1-2) Pd Pd Cn1 Cn1 H H H H 154 (1-2) Pd Pd Cn2 Cn2 H H H H 155 (1-2) Pd Pd Pz Pz H H H H 156 (1-2) Py1 Py1 Ph Ph H H H H 157 (1-2) Py1 Py1 Tn1 Tn1 H H H H 158 (1-2) Py1 Py1 Tn2 Tn2 H H H H 159 (1-2) Py1 Py1 BTn1 BTn1 H H H H 160 (1-2) Py1 Py1 BTn2 BTn2 H H H H 161 (1-2) Py1 Py1 Np Np H H H H 162 (1-2) Py1 Py1 Qn1 Qn1 H H H H 163 (1-2) Py1 Py1 Qn2 Qn2 H H H H 164 (1-2) Py1 Py1 Qx Qx H H H H 165 (1-2) Py1 Py1 Qz1 Qz1 H H H H 166 (1-2) Py1 Py1 Qz2 Qz2 H H H H 167 (1-2) Py1 Py1 Cn1 Cn1 H H H H 168 (1-2) Py1 Py1 Cn2 Cn2 H H H H 169 (1-2) Py1 Py1 Pz Pz H H H H 170 (1-2) Pa Pa Ph Ph H H H H 171 (1-2) Pa Pa Tn1 Tn1 H H H H 172 (1-2) Pa Pa Tn2 Tn2 H H H H 173 (1-2) Pa Pa BTn1 BTn1 H H H H 174 (1-2) Pa Pa BTn2 BTn2 H H H H 175 (1-2) Pa Pa Np Np H H H H
[0079] [0079] TABLE 4 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 176 (1-2) Pa Pa Qn1 Qn1 H H H H 177 (1-2) Pa Pa Qn2 Qn2 H H H H 178 (1-2) Pa Pa Qx Qx H H H H 179 (1-2) Pa Pa Qz1 Qz1 H H H H 180 (1-2) Pa Pa Qz2 Qz2 H H H H 181 (1-2) Pa Pa Cn1 Cn1 H H H H 182 (1-2) Pa Pa Cn2 Cn2 H H H H 183 (1-2) Pa Pa Pz Pz H H H H 184 (1-2) Py2 Py2 Ph Ph H H H H 185 (1-2) Py2 Py2 Tn1 Tn1 H H H H 186 (1-2) Py2 Py2 Tn2 Tn2 H H H H 187 (1-2) Py2 Py2 BTn1 BTn1 H H H H 188 (1-2) Py2 Py2 BTn2 BTn2 H H H H 189 (1-2) Py2 Py2 Np Np H H H H 190 (1-2) Py2 Py2 Qn1 Qn1 H H H H 191 (1-2) Py2 Py2 Qn2 Qn2 H H H H 192 (1-2) Py2 Py2 Qx Qx H H H H 193 (1-2) Py2 Py2 Qz1 Qz1 H H H H 194 (1-2) Py2 Py2 Qz2 Qz2 H H H H 195 (1-2) Py2 Py2 Cn1 Cn1 H H H H 196 (1-2) Py2 Py2 Cn2 Cn2 H H H H 197 (1-2) Py2 Py2 Pz Pz H H H H 198 (1-2) Pz Pz Ph Ph H H H H 199 (1-2) Pz Pz Tn1 Tn1 H H H H 200 (1-2) Pz Pz Tn2 Tn2 H H H H
[0080] [0080] TABLE 5 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 201 (1-2) Pz Pz BTn1 BTn1 H H H H 202 (1-2) Pz Pz BTn2 BTn2 H H H H 203 (1-2) Pz Pz Np Np H H H H 204 (1-2) Pz Pz Qn1 Qn1 H H H H 205 (1-2) Pz Pz Qn2 Qn2 H H H H 206 (1-2) Pz Pz Qx Qx H H H H 207 (1-2) Pz Pz Qz1 Qz1 H H H H 208 (1-2) Pz Pz Qz2 Qz2 H H H H 209 (1-2) Pz Pz Cn1 Cn1 H H H H 210 (1-2) Pz Pz Cn2 Cn2 H H H H 211 (1-2) Pz Pz Pz Pz H H H H 212 (1-3) Pr' Pr' Ph Ph H H H H 213 (1-3) Pd' Pd' Ph Ph H H H H 214 (1-3) Py1' Py1' Ph Ph H H H H 215 (1-3) Pa' Pa' Tn1 Tn1 H H H H 216 (1-3) Py2' Py2' Tn2 Tn2 H H H H 217 (1-3) Pz2' Pz2' BTn1 BTn1 H H H H 218 (1-4) Pr Pr Ph' Ph' H H H H 219 (1-4) Pd Pd Ph' Ph' H H H H 220 (1-4) Py1 Py1 Tn1' Tn1' H H H H 221 (1-4) Pa Pa Tn1' Tn1' H H H H 222 (1-4) Py2 Py2 Qx' Qx' H H H H 223 (1-4) Pz2 Pz2 Qz1' Qz1' H H H H 224 (1-5) Pr Pr' Ph Ph' H H H H 225 (1-5) Pd Pr' Ph Ph' H H H H
[0081] [0081] TABLE 6 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 226 (1-5) Pr Pr' Tn1 Ph' H H H H 227 (1-5) Pa Pr' Ph Ph' H H H H 228 (1-5) Pz Pr' Tn1 Ph' H H H H 229 (1-5) Pz Pr' Tn2 Ph' H H H H 230 (1-6) Pr' Pr' Ph' Ph' H H H H 231 (1-6) Pa' Pa' Ph' Ph' H H H H 232 (1-6) Pz' Pz' Ph' Ph' H H H H 233 (1-2) Pr Pr Ph Ph H OCH 3 H H 234 (1-2) Pr Pr Ph Ph CF 3 H H H 235 (1-2) Pr Pr Ph Ph H OCF 3 H K 236 (1-2) Pr Pr Ph Ph H F H H 237 (1-2) Pr Pr Ph Ph F H H H 238 (1-2) Pr Pr Ph Ph H C 2 H 5 H H 239 (1-2) Pr Pr Ph Ph C 2 H 5 H H H 240 (1-2) Pr Pr Ph Ph H H H CH 3 241 (1-2) Pr Pr Ph Ph H H H C 3 H 7 242 (1-2) Pr Pr Ph Ph H H H OCH 3 243 (1-2) Pr Pr Ph Ph H H H F 244 (1-2) Pr Pr Ph Ph H H H NO 2 245 (1-2) Pr Pr Ph Ph H H NO 2 H 246 (1-2) Pr Pr Ph Ph H H H CH 3 CH≡ CHCH 2 CH 3 247 (1-2) Pr Pr Ph Ph H H H CH 3 C═ CH 2 CH 3 248 (1-2) Pr Pr Ph Ph H H H CF 3 249 (1-2) Pr Pr Ph Ph H H U COOC 2 H 5 250 (1-2) Pr Pr Ph Ph H H U COOC 3 H 7
[0082] [0082] TABLE 7 Ex. Comp. Formula CyN1 CyN2 CyC1 CyC2 R1 R2 R3 R4 251 (1-2) Pr Pr Ph Ph H H CH 3 H 252 (1-2) Pr Pr Ph Ph H H F H 253 (1-2) Pr Pr Ph Ph H H OCH 3 H 254 (1-2) Pr Pr Ph Ph H H H SCH 3 255 (1-2) Pr Pr Tn1 Tn1 H H H Si(CH 3 ) 3 256 (1-2) Pr Pr Tn1 Tn1 H H H CH 3 257 (1-2) Pr Pr Tn1 Tn1 H H H OCH 3 258 (1-2) Pr Pr Tn1 Tn1 H H H F 259 (1-2) Pr Pr Tn1 Tn1 H H H CF 3 260 (1-2) Pr Pr Tn1 Tn1 H H H C 3 H 7 261 (1-2) Pr Pr Tn1 Tn1 F H H H 262 (1-2) Pr Pr Tn1 Tn1 H CH 3 H H 263 (1-2) Pr Pr Tn1 Tn1 H OCH 3 H H 264 (1-2) Pr Pr Tn1 Tn1 H CF 3 H H 265 (1-4) Pr Pr Ph' Ph' H H OCH 3 OCH 3 266 (1-6) Pr' Pr' Ph' Ph' H H OCH 3 H 267 (1-6) Pa' Pa' Ph' Ph' H H OCH 3 H
[0083] Of the metal coordination compound preferably having the above-mentioned formulas (1-1) to (1-6), those of formulas (1-1) and (1-2) may, e.g., be synthesized through the following reacton schemes.
[0084] Hereinbelow, the present invention will be described more specifically based on Examples with reference to the drawing.
EXAMPLES 1-11
[0085] In these examples, the following metal coordination compounds (Pt complexes) 1-11 were used in respective luminescence layers for Examples 1-11, respectively.
[0086] Each of luminescence devices having a structure shown in FIG. 1B were prepared in the following manner.
[0087] On a glass substrate (transparent substrate 15 ), a 100 nm-thick film (transparent electrode 14 ) of ITO (indium tin oxide) was formed by sputtering, followed by patterning to have an (opposing) electrode area of 3 mm 2 .
[0088] On the ITO-formed substrate, three organic layers and two metal electrode layers shown below were successively formed by vacuum (vapor) deposition using resistance heating in a vacuum chamber (10 −4 Pa).
[0089] Organic layer 1 (hole transport layer 13 ) (40 nm): α-NPD
[0090] Organic layer 2 (luminescence layer 12 ) (20 nm): mixture of CBP:Pt complex (metal coordination compound) (95:5 by weight)
[0091] Organic layer 3 (electron transport layer 16 ) (30 nm): Alq3
[0092] Metal electrode layer 1 (metal electrode 11 ) (15 nm): Al—Li alloy (Li=1.8 wt. %)
[0093] Metal electrode layer 2 (metal electrode 11 ) (100 nm): Al
[0094] Each of the thus-prepared luminescence devices was taken out of the vacuum chamber and was subjected to a continuous energization test in an atmosphere of dry nitrogen gas stream so as to remove device deterioration factors, such as oxygen and moisture (water content).
[0095] The continuous energization test was performed by continuously applying a voltage at a constant current density of 70 mA/cm 2 to the luminescence device having the ITO (transparent) electrode (as an anode) and the Al (metal) electrode (as a cathode), followed by measurement of luminance (brightness) with time so as to determine a time (luminance half-life) required for decreasing an initial luminance (80-120 cd/m 2 ) to ½ thereof.
[0096] The results are shown in Table 8 appearing hereinafter.
COMPARATIVE EXAMPLE 1
[0097] A comparative luminescence device was prepared and evaluated in the same manner as in Example 1-11 except that the Pt complex (metal coordination compounds 1-11) was changed to Ir-phenylpyrimidine complex (Ir(ppy) 3 ) shown below.
[0098] The results are shown in Table 8 below.
TABLE 8 Ex. No. Compound No. Luminance half-life (Hr) Ex. 1 1 500 Ex. 2 2 400 Ex. 3 3 600 Ex. 4 4 650 Ex. 5 5 950 Ex. 6 6 800 Ex. 7 7 850 Ex. 8 8 600 Ex. 9 9 450 Ex. 10 10 900 Ex. 11 11 550 Comp. Ex. 1 Ir(ppy) 3 350
[0099] The luminescence devices using the metal coordination compounds 3, 5, 6, 7 and 11 caused red luminescence, and the luminescence devices using the metal coordination compounds 2 and 4 caused orange luminescence. Further, the luminescence devices using the metal coordination compounds 1 and Ir(ppy) 3 caused green luminescence.
EXAMPLE 12 (SYNTHESIS OF COMPOUND 2)
[0100] [0100]
[0101] In a 3 liter-three necked flask, 14.6 g (90.6 mM) of 2-(2-thienyl)pyridine and 912 ml of anhydrous ether were placed and stirred at −70° C. or below in an argon gas stream. To the mixture, 62.2 ml (99.5 mM) of 1.6 M-t-butyllithium solution in pentane was added dropwise in ca. 35 min., followed by stirring at −70° C. for 40 min. At that temperature, a suspension of 8.5 g (19.0 mM) of cis-PtCl 2 [(C 2 H 5 ) 2 S] 2 in a mixture solvent of 289 ml of anhydrous ether and 73 ml of tetrahydrofuran (THF) was added dropwise in ca. 1 hour to the resultant mixture, followed by stirring at −70° C. for 30 min. and gradual temperature rise up to 0° C. in ca. 2 hours. To the reaction mixture, 912 ml of water was gradually added dropwise at 0° C. The organic layer was washed with common salt aqueous solution and the aqueous (water) layer was subjected to extraction with methylene chloride. The resultant organic layer (from the organic and aqueous layers) was dried with anhydrous sodium sulfate, followed by distilling-off of the solvent to obtain a residue. The residue was recrystallized from a mixture solvent (hexane/methylene chloride) to obtain 4.50 g of cis-bis[2-(2-thienyl)pyridinato-N,C 5 ′] platinum (II) (Yield: 45.8%).
EXAMPLE 13 (SYNTHESIS OF COMPOUND 5
[0102] [0102]
[0103] In a 1 liter-three necked flask, 26.6 g (168.5 mM) of 2-bromopyridine, 30.0 g (168.5 mM) of benzo[b]thiophene-2-boronic acid, 170 ml of toluene, 85 ml of ethanol and 170 ml of 2M-sodium carbonate aqueous solution were placed and stirred in a nitrogen gas stream at room temperature. Under stirring, to the mixture, 6.18 g (5.35 mM) of tetrakis(triphenyl-phosphine) palladium (0) was added, followed by heat-refluxing for 5.5 hours under stirring in nitrogen gas stream.
[0104] After the reaction , the reaction mixture was cooled, followed by extraction with cool water and toluene. The organic layer was washed with water until the system showed neutral, followed by distilling off of the solvent under reduced pressure to obtain a residue. The residue was purified by silica gel column chromatography (eluent: toluene/hexane=5/1) to obtain a colorless crystal. The crystal was purified by alumina column chromatography (eluent: toluene) and recrystallized from ethanol to obtain 12.6 g of 2-(pyridine-2-yl)benzo[b]thiophene (Yield: 35.4%).
[0105] In a 3 liter-three necked flask, 6.73 g (31.9 mM) of 2-(benzo[b]thiophene-2-yl)pyridine and 636 ml of anhydrous ether were placed and stirred at −70° C. or below in an argon gas stream. To the mixture, 21.9 ml (35.0 mM) of 1.6 M-t-butyllithium solution in pentane was added dropwise in ca. 20 min., followed by stirring at −70° C. for 50 min. At that temperature, a suspension of 2.97 g (6.68 mM) of cis-PtCl 2 [(C 2 H 5 ) 2 S] 2 in a mixture solvent of 101 ml of anhydrous ether and 25 ml of tetrahydrofuran (THF) was added dropwise in ca. 30 min. to the resultant mixture, followed by stirring at −70° C. for 1 hour. and gradual temperature rise up to 0° C. in ca. 2 hours. To the reaction mixture, 318 ml of water was gradually added dropwise at 0° C. The organic layer was washed with common salt aqueous solution and the aqueous (water) layer was subjected to extraction with methylene chloride. The resultant organic layer (from the organic and aqueous layers) was dried with anhydrous sodium sulfate, followed by distilling-off of the solvent to obtain a residue. The residue was recrystallized from a mixture solvent (hexane/methylene chloride) to obtain 3.10 g of cis-bis[2-(benzo[b]thiophene-2-yl)pyridinato-N,C 5 ′] platinum (II) (Yield: 75.4%).
EXAMPLE 14 (SYNTHESIS OF COMPOUND 3)
[0106] [0106]
[0107] In a 3 liter-three necked flask, 35.0 g (112 mM) of 2,2′-dibromobiphenyl and 650 ml of anhydrous ether were placed and stirred at −60° C. or below in an argon gas stream. To the mixture, 153 ml (0.245 mM) of 1.6 M-n-butyllithium solution in pentane was added dropwise in ca. 50 min., followed by temperature rise and stirring at room temperature for 3 hours. To a suspension of 25.0 g (56.0 mM) of cis-PtCl 2 [(C 2 H 5 ) 2 S] 2 in 833 ml of anhydrous ether cooled and kept at −10° C. or below, the resultant mixture was added dropwise in ca. 10 min., followed by stirring at −10° C. for 1 hour and gradual temperature rise up to 0° C. To the reaction mixture, 417 ml of water was gradually added dropwise at 0° C. The organic layer was washed with common salt aqueous solution and the aqueous (water) layer was subjected to extraction with methylene chloride. The resultant organic layer (from the organic and aqueous layers) was dried with anhydrous sodium sulfate, followed by distilling-off of the solvent to obtain a residue. The residue was successively recrystallized from a mixture solvent (hexane/ether) and a mixture solvent (hexane/methylene chloride) to obtain 1.77 g of a compound (A) (Yield: 7.2%).
[0108] In a 100 ml-three-necked flask, 21.3 g (136 mM) of 2,2′-dipyridyl was placed and melted at 80° C. in an argon gas stream, followed by addition of 1.73 g (1.98 mM) of the above-prepared compound (A). The mixture was stirred at 80° C. for 10 min. under reduced pressure and cooled to ca. 10° C. to crystallize the mixture. The crystallized mixture was dissolved in methylene chloride and thereto, hexane was added to reprecipitate a crystal. The crystal was recovered by filtration, followed by recrystallization from a mixture solvent (hexane/methylene chloride) to obtain 1.90 g of an objective compound (B) (Yield: 95.4%).
EXAMPLES 15-20 (SYNTHESIS OF COMPOUNDS 1, 4, 6, 7, 8 AND 11)
[0109] Compounds 1, 4, 6, 7, 8 and 11 were prepared in a similar manner as in Example 12, respectively.
EXAMPLES 21 AND 22 (SYNTHESIS OF COMPOUNDS 9 AND 10)
[0110] Compounds 9 and 10 were prepared in a similar manner as in Example 14, respectively.
[0111] As described hereinabove, according to the present invention, the metal coordination compound (Pt complex) preferably having the formulas (1-1) to (1-6) according to the present invention has a higher phosphorescence luminescence efficiency and a shorter phosphorescence life, thus being suitable as a luminescence material for an EL device.
[0112] The luminescence device (EL device) using the metal coordination compound according to the present invention allows a high-efficiency luminescence at a high luminescence for a long period of time while minimizing luminescence deterioration in energized state.
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A luminescence device is principally constituted by a pair of electrodes and an organic compound layer disposed therebetween. The organic compound layer contains a metal coordination compound characterized by having a partial structure represented by the following formula (1):
wherein each of X and C represents an atdm constituting a cyclic group.
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FIELD OF THE INVENTION
[0001] The present invention relates to a noble metal containing hydrogenation catalyst for the selective hydrogenation of 1, 4 butynediol to 1, 4 butenediol. The present invention also relates to a process for the preparation of the said catalyst. More particularly, the present invention relates to said hydrogenation catalyst for the selective preparation of 1, 4 butynediol to 1, 4 butenediol, and a process for the preparation of the said catalyst.
BACKGROUND OF THE INVENTION
[0002] 1, 4 butenediol is a useful intermediate in the production of pesticide, insecticide and vitamin B 6 . Being an unsaturated diol it can be used in the synthesis of many organic products such as tetrahydrofuran, n-methyl pyrrolidione, γ-butyrolactone, etc. It is also used as an additive in the paper industry, as a stabiliser in resin manufacture, as a lubricant for bearing systems and in the synthesis of allyl phosphates.
[0003] Prior art discloses the use of a number of catalysts for the manufacture of 1, 4 butenediol by the hydrogenation of 1, 4 butynediol. Most of the prior art patents are based on a combination of palladium with one or more mixed compounds of copper, zinc, calcium, cadmium, lead, alumna, mercury, tellurium, gallium, etc. GB A 871804 describes the selective hydrogenation of acetylinic compound in a suspension method using a Pd catalyst which has been treated with the salt solutions of Zn, Cd, Hg, Ga, Th, In, or Ga. The process is carried out at milder conditions with 97% selectivity for cis 1,2-butenediol and 3% to the trans form. Moreover, use of organic amines have been suggested as promoters in the catalyst system.
[0004] U.S. Pat. No. 2,681,938 discloses the use of a Lindlar catalyst (lead doped Pd catalyst), for the selective hydrogenation of acetylinic compounds. The drawback of this process is the use of additional amines such as pyridine to obtain good selectivity for 1, 4 butenediol.
[0005] German patent DE 1, 213, 839 describes a Pd catalyst doped with Zn salts and ammonia for the partial hydrogenation of acetylinic compounds. However, this catalyst suffers from the drawback of short lifetime due to poisoning.
[0006] German patent application DE A 2, 619, 660 describes the use of Pd/Al 2 O 3 catalyst that has been treated with carbon monoxide for the hydrogenation of butynediol in an inert solvent. The disadvantage of this catalyst is that is treated with carbon monoxide gas which is highly toxic and difficult to handle.
[0007] U.S. Pat. No. 2,961,471 discloses a Raney nickel catalyst useful for the partial hydrogenation of 1, 4 butynediol. The catalyst of this process gives a low selectivity for 1, 4 butenediol. Another U.S. Pat. No. 2,953,604 describes a Pd containing charcoal and copper catalyst for the reduction of 1,4 butynediol to 1,4 butenediol with 81% selectivity for 1,4 butenediol. However, this process results in the formation of a large number of side products and is therefore undesirable.
[0008] U.S. Pat. No. 4,001,344 discloses the use of palladium mixed with γ-Al 2 O 3 along with both zinc and cadmium or either zinc or cadmium together with bismuth or tellurium for the preparation of 1,4 butenediol by the selective hydrogenation of 1, 4 butynediol. However, a large number of residues are formed (7.5-12%) which lowers the selectivity of 1,4 butenediol to 88%.
[0009] U.S. Pat. Nos. 5,521,139 and 5,278,900 describes the use of a Pd containing catalyst for the hydrogenation of 1,4 butynediol to prepare 1,4 butenediol. The catalyst used is a fixed bed catalyst prepared by applying Pd and Pb or Pd and Cd successively by vapor deposition or sputtering to a metal gauze or a metal foil acting as a support. In this process also the selectivity obtained for cis 1,4 butenediol is 98%. The disadvantage of this process is that a trans butenediol with residues are also obtained.
[0010] All the above catalysts for the hydrogenation of butynediol to butenediol suffer from disadvantages such as they contain more than two metals along with other promoters such as organic amines. Their preparation becomes cumbersome and all the reported catalysts do not give complete selectivity for the desired product 1, 4 butenediol. The formation of side products and residues have also been reported which affect the efficiency of the process and the recovery of pure 1,4 butenediol is difficult. Another disadvantage that prior art catalysts suffer from is short life due to fast deactivation.
[0011] It is therefore important to obtain and/or develop catalysts that overcome the disadvantages of prior art catalysts used in the hydrogenation of 1,4 butynediol to 1,4 butenediol enumerated above.
OBJECTS OF THE INVENTION
[0012] The main object of the invention is to provide a novel hydrogenation catalyst for the selective preparation of 1, 4 butenediol that comprises a noble metal, individually or in combination with nickel, on a suitable support without poisoning at very specific preparation conditions for the selective production of 1, 4 butenediol.
[0013] It is another object of the invention to provide a process for the preparation of such novel hydrogenation catalysts for the preparation of 1,4 butenediol.
[0014] It is another object of the invention to provide a novel hydrogenation catalyst for the preparation of 1,4 butenediol that results in 100% conversion of the butynediol and 100% selectivity at mild process conditions.
[0015] It is another object of the invention to provide a catalyst with high stability that can be recycled several times without loss of activity and selectivity.
[0016] It is another object of the invention to provide a process for the preparation of 1,4 butenediol using the hydrogenation catalyst of the invention.
[0017] It is another object of the invention is to provide a novel catalyst for the selective hydrogenation of 1, 4 butynediol to 1, 4 butenediol that comprises only platinum on a suitable support, without poisoning at very specific preparation conditions.
[0018] It is an object of the invention to provide a process for the preparation of 1, 4 butenediol from 1,4 butynediol using a novel hydrogenation catalyst resulting in 1,4 butenediol of high purity by mere separation of the catalyst.
SUMMARY OF THE INVENTION
[0019] Accordingly the present invention provides a hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0% with the proviso that when B is Pt, z=0.
[0020] In one embodiment of the invention, B is Pd and z=0.2-10%.
[0021] The present invention also relates to a process for the preparation of a hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0% with the proviso that when B is Pt, z=0, said process comprising:
[0022] i. dissolving a noble metal precursor in a mineral acid by stirring at a temperature in the range between 60° C. to 120° C.;
[0023] ii. diluting the above solution by adding water;
[0024] iii. adjusting the pH of the solution to the range of 8-12 by adding a base;
[0025] iv. adding a support to the above solution;
[0026] v. heating the mixture to a temperature in the range of 60° C. to 120° C.;
[0027] vi. reducing the above mixture using a conventional reducing agent;
[0028] vii. separating the catalyst formed by any conventional method;
[0029] viii. washing and drying the product to obtain the said catalyst.
[0030] In a further embodiment of the invention, the noble metal comprises of palladium and z=0.2 to 15%, the catalyst obtained at the end of step viii above is mixed with a solution of nickel in a basic medium having a pH in the range of 8-12, the mixture stirred for about 1 hour and the catalyst is separated by any conventional method. The catalyst is then dried at about 150° C. up to 10 hours in static air, reduced at a temperature in the range of between 390-420° C. for a time period in the range of between 5-12 hours in a flow of hydrogen, the reduced catalyst is then separated by any conventional method and washed and dried to obtain the final catalyst containing palladium and nickel.
[0031] In one embodiment of the invention, the noble metal source is a noble metal salt selected from the group consisting of acetate, bromide, and chloride and the source of nickel is a salt of nickel selected from the group consisting of acetate, carbonate, chloride and nitrate.
[0032] In another embodiment of the invention, the support is a Group II A metal salt selected from the group consisting of acetates, nitrates, chlorides and carbonates of magnesium, calcium and barium and the source of zeolite is NH 4 -ZSM5.
[0033] In a further embodiment of the invention, the base used may be selected from the group consisting of sodium carbonate, potassium carbonate, potassium hydroxide, and sodium hydroxide.
[0034] In another embodiment of the invention, the reducing agent used is selected from the group consisting of hydrazine hydrate, hydrogen containing gas, and formaldehyde.
[0035] The present invention also relates to a process for the preparation of 1, 4 butenediol from 1, 4 butynediol said process comprising subjecting the 1,4 butynediol to hydrogenation by any conventional method characterised in that the catalyst used for the hydrogenation is of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0%.
[0036] In a further embodiment of the invention, the selectivity of the process at milder process conditions is 100%.
[0037] The present invention also relates to the use of a novel hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal, y=0.2 to 10%, C is nickel and z=0 to 15.0%, for the preparation of 1,4 butenediol.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The present invention achieves 100% conversion of 1,4 butynediol with 100% selectivity for cis 1,4 butenediol at mild process conditions. At higher temperatures, while 1, 4 butynediol is converted completely, the selectivity for cis 1, 4 butenediol is less, generally ≦90%. The formation of side products such as acetals, γ-hydroxybutaraldehyde, butanol at higher temperatures is also more pronounced.
[0039] The hydrogenation of 1,4 butynediol to 1,4 butenediol is carried out in an autoclave under stirring conditions in the presence of Pd or Pt containing catalyst suspended in a mixture of 1, 4 butynediol in water at 50° C. and 350 psig of H 2 pressure. The mixture is made alkaline (pH=8-10) by the addition of ammonia. Before pressurising the autoclave, it was ensured that there was no air in the autoclave. The hydrogenation is complete when the absorption of hydrogen is stopped or unchanged. After the reaction was complete, the reactor was cooled below ambient temperature and the contents were discharged and the reaction mixture analysed using a gas chromatograph.
[0040] The catalyst prepared as per the procedure described below in the examples can be reduced in a muffle furnace at 400° C. in hydrogen flow for a time period ranging between 5-12 hours, preferably 7 hours.
[0041] In a feature of the invention, high purity 1, 4 butenediol can be simply obtained by the removal of the catalyst from the product stream.
[0042] The present invention is described below by way of examples. However, the following examples are illustrative and should not be construed as limiting the scope of the invention.
EXAMPLE 1
[0043] Preparation of 1% Pd/MgCO 3 Catalyst
[0044] 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.02 gms of magnesium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 2
[0045] Preparation of 1% Pd/CaCO 3 Catalyst
[0046] 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.12 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 3
[0047] Recycling of 1% Pd/CaCO 3 Catalyst
[0048] This example illustrates the recycling of 1% Pd/CaCO3 catalyst wherein the catalyst preparation was similar to the disclosure in Example 2 above. The hydrogenation of 1, 4 butynediol was carried out by recycling the catalyst 10 times at 50° C. and 350 psig H 2 pressure as described earlier.
EXAMPLE 4
[0049] Preparation of 1% Pd/BaCO 3 Catalyst
[0050] 0.16 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.1 gms of barium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 5
[0051] Preparation of 1% Pd/NH 4 -ZSM5 Catalyst
[0052] 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.0 gms of NH 4 -ZSM5 was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 6
[0053] Preparation of 10% Ni-1% Pd/CaCO 3 Catalyst
[0054] 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.12 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. The dried catalyst is then mixed with a solution of nickel nitrate and stirred in basic medium (pH=9-10) for 1 hour, dried at 150° C. for 10 hours in static air and then reduced at 400° C. for 7 hours in a flow of hydrogen.
EXAMPLE 7
[0055] Preparation of 1% Pt/MgCO 3 Catalyst
[0056] 0.16 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.13 gms of magnesium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 8
[0057] Preparation of 1% Pt/CaCO 3 Catalyst
[0058] 0.17 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.03 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 9
[0059] Preparation of 1% Pt/BaCO 3 Catalyst
[0060] 0.16 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.05 gms of barium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours.
EXAMPLE 10
[0061] Performance of Palladium or Palladium and Nickel Supported Catalysts of the Invention as Prepared in Examples 1-6 Above
[0062] This example illustrates the performance of the palladium or palladium and nickel supported catalysts of the invention as prepared in Examples 1-6 above in the hydrogenation of 1,4 butynediol to 1, 4 butenediol.
Conversion Selectivity to Ex- of 1, 4 cis 1, 4 Reaction ample butynediol butenediol period No. Catalyst (%) (%) (hours) 1 1% Pd/MgCO 3 100 99.8 2 2 1% Pd/CaCO 3 100 98.2 1 3 1% Pd/CaCO 3 * 100 98 68 4 1% Pd/BaCO 3 100 100 2 5 1% Pd/NH 4 -ZSM 5 100 100 4 6 10% Ni- 1% 100 100 4 Pd/CaCO 3
EXAMPLE 11
[0063] Performance of Platinum Supported Catalysts of the Invention as Prepared in Examples 7-9 Above
[0064] This example illustrates the performance of the platinum supported catalysts of the invention as prepared in Examples 7-9 above in the hydrogenation of 1,4 butynediol to 1, 4 butenediol.
Conversion Selectivity Reaction Example of 1, 4 to cis 1, 4 period No. Catalyst butynediol (%) butenediol (%) (hours) 7 1% Pt/MgCO 3 100 99.8 2 8 1% Pt/CaCO 3 100 100 1 9 1% Pt/BaCO 3 100 99.9 2.5
[0065] Advantages of the Invention
[0066] 1. The catalyst of the invention is useful for the selective hydrogenation of 1, 4 butynediol to 1, 4 butenediol without poisoning.
[0067] 2. Substantially complete conversion of 1, 4 butynediol to 1, 4 butenediol with almost 100% selectivity to cis 1, 4 butenediol is obtained at milder process conditions.
[0068] 3. The separation of the product 1, 4 butenediol in pure form is achieved easily by the removal of the catalyst from the reaction mixture.
[0069] 4. The catalyst of the invention is capable of recycling several times without loss of activity or selectivity. The turn over number also is good.
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A hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from Pt or Pd, y=0.2 to 10%, C is nickel and z=0 to 15.0%, with the proviso that when B is Pt, z=0.
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[0001] This patent application is pending from the U.S. Provisional Application filed on Jul. 6, 2007.
FIELD OF THE INVENTION
[0002] This invention relates to an apparatus which is supported by ceiling joists allowing work to be accomplished above a ceiling, for example, in an attic. The invention more specifically relates to an apparatus which rests on or is supported by joists and which in turn supports a workman while lessening the likelihood of the workman stepping between joists and falling through a ceiling.
BACKGROUND OF THE INVENTION
[0003] Carpentry and other work in an attic with uncovered joists offers opportunities for the workman to step between joists and onto structurally unsound ceiling materials. Damage to ceiling materials and injury have been common in the construction industry when the unintentional step occurs allowing the workman to place weight on a surface not structurally intended to bear such forces. Prior portable platforms include U.S. Pat. No. 5,915,785 to Walker; U.S. Pat. No. 4,068,446 to Brueske; U.S. Pat. No. 5,022,670 to Cote et al; U.S. Pat. No. Des. 318,575 to Applebaum; U.S. Pat. No. 5,148,890 to Sipe; U.S. Pat. No. 4,121,690 to Rawlings et al; and U.S. Pat. No. 4,730,424 to Green et al.
[0004] The patents referred to herein are provided herewith in an Information Disclosure Statement in accordance with 37 CFR 1.97.
SUMMARY OF THE INVENTION
[0005] The support apparatus is designed to safely support individuals working above ceilings in new or existing residential dwellings. It provides a stable work surface to prevent workers from falling through the ceiling of the residence causing personal injury and damage to the residence. Ceiling damage from worker missed steps, dropped tools and workers falling through the ceiling represent the largest cause of damage claims for electricians, construction contractors, and residential installers.
[0006] The support apparatus is designed to fit through a standard 24″ by 24″ ceiling access and expand to provide a 62″ by 24″ work platform. It is also designed to safely support individuals that weigh in excess of 300 lbs. The support apparatus design features a hinge mechanism that allows it to be folded into a compact package for transportation, lifting and deployment in an attic environment. The design is also very light weight for convenience in lifting it into an attic space. The support apparatus features built-in slots spaced 24″ apart that cause it to lock in place over standard spaced joists in a residential ceiling. The support apparatus also includes built-in handholds on each end and on both sides of the device for easy carrying and maneuvering of the unit. A workman will normally use two of these support apparatuses in performing work above a ceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other features and advantages of the present invention will become more readily appreciated as the same become better understood by reference to the following detailed description of the preferred embodiment of the invention when taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 is a top plan view of a support apparatus ( 1 ) showing the top side ( 100 ), first side ( 110 ), second side ( 120 ), first end ( 130 ), second end ( 140 ), first part ( 150 ), second part ( 160 ), handle ( 200 ) extending from the first side ( 110 ) and or the second side ( 120 ), handle aperture ( 210 ), longitudinal axis ( 400 ), hinge ( 410 ) and magnet ( 500 ).
[0009] FIG. 2 is a bottom plan view of the support apparatus ( 1 ) bottom side ( 600 ) and bottom side structural support ( 610 ) in addition to features seen in FIG. 1 .
[0010] FIG. 3 is a top plan of the support apparatus ( 1 ) in the form comprised of a single planar part ( 170 ) with handles ( 200 ) shown extending from the first side ( 110 ), the second side ( 120 ) and the first end ( 130 ).
[0011] FIG. 4 is a top plan view showing support apparatus ( 1 ) where the handles ( 200 ) are integral with the first part ( 150 ) and the second part ( 160 ).
[0012] FIG. 5 is a side elevation of a support apparatus ( 1 ) illustrating a first part ( 150 ) and a second part ( 160 ) joined by a hinge ( 410 ).
DETAILED DESCRIPTION
[0013] FIGS. 1 , 2 , 3 and 4 illustrates the support apparatus ( 1 ). The support apparatus ( 1 ) is, in the preferred embodiment, a planar structure having a top side ( 100 ), a bottom side ( 600 ), a first side ( 110 ), a second side ( 120 ), a first end ( 130 ) and a second end ( 140 ). At least one handle ( 200 ) is formed at either or both of the first side ( 110 ) and the second side ( 120 ) and or at the first end ( 130 ) and or at the second end ( 140 ). As seen in FIGS. 1 , 2 and 3 , the handle ( 200 ), in the preferred embodiment, extends outwardly from the first side ( 110 ) and or the second side ( 120 ). Seen in FIG. 3 is an illustration of another embodiment wherein a handle ( 200 ) extends from the first end ( 130 ) with this view simply illustrative of a handle ( 200 ) extending from either or both of the first end ( 130 ) or the second end ( 140 ).
[0014] Also seen in FIGS. 1 through 4 is the at least one handle aperture ( 210 ) from the top side ( 100 ) to the bottom side ( 600 ) proximal the respective first side ( 110 ) and or the second side ( 120 ) and or the first end ( 130 ) and or the second end ( 140 ).
[0015] FIGS. 1 and 3 show a longitudinal axis ( 400 ) centrally positioned from the first end ( 130 ) to the second end ( 140 ). FIG. 3 illustrates the apparatus ( 1 ) comprised of a single planar part ( 170 ). FIGS. 1 , 2 and 4 show the apparatus ( 1 ) comprised of a first part ( 150 ) and a second part ( 160 ) where the first part ( 150 ) extends from the first end ( 130 ) toward the second end ( 140 ) and terminates intermediate the first end ( 130 ) and the second end ( 140 ); the second part ( 160 ) extends from the second end ( 140 ) toward the first end ( 130 ) and terminates intermediate the first end ( 130 ) and the second end ( 140 ).
[0016] Also illustrated in FIGS. 1 , 2 , 4 , 5 and 6 , when the apparatus is composed of a first part ( 150 ) and a second part ( 160 ), is a hinge ( 410 ) joining the first part ( 150 ) and the second part ( 160 ) intermediate the first end ( 130 ) and the second end ( 140 ). The hinge may be comprised of flexible, semi-flexible and rigid materials including canvas and metal and or plastic hinges. Included in hinges, but not limited thereby, will be the piano hinge. It is seen that the hinge ( 410 ) is orthogonal to the longitudinal axis ( 400 ). It is also seen that the hinge ( 410 ) is affixed to the first part ( 150 ) and the second part ( 160 ) to enable the folding of the first part ( 150 ) relative to the second part ( 160 ) to cause the bottom side ( 600 ) of the first part ( 150 ) to be rotated to face the bottom side ( 600 ) of the second part ( 160 ) and to prevent the folding of the first part ( 150 ) relative to the second part ( 160 ) to cause the top side ( 100 ) of the first part ( 150 ) to be rotated to face the top side ( 100 ) of the second part ( 160 ); the hinge ( 410 ) is formed to prevent the apparatus ( 1 ) from folding when the apparatus ( 1 ) is unfolded and in use. Of concern is the possibility that the hinge ( 410 ) may be installed to allow the apparatus ( 1 ) to fold upwardly when a workman steps in the vicinity of the hinge. Hence the hinge mechanism will limit movement that would allow the first part ( 150 ) and the second part ( 160 ) to fold so as to allow the top side ( 100 ) of the first part ( 150 ) to face the top side ( 100 ) of the second part ( 160 ). Such will be managed by having a hinge ( 410 ) limited in rotation so that rotation can only occur to cause the bottom side ( 600 ) of the first part ( 150 ) and of the second part ( 160 ) to face each other. The hinge movement can be controlled by installation such that the respective first part ( 150 ) and second part ( 160 ) will be limited in rotation upwardly by physical limitation through contract of the first part ( 150 ) with the second part ( 160 ) when rotational forces are applied that would urge the top sides ( 100 ) toward each other.
[0017] FIG. 1 illustrates at least one magnet ( 500 ) at the top side ( 100 ) and or at the bottom side ( 600 ).
[0018] FIG. 2 shows a bottom side structural support ( 610 ) comprised of stiffeners. The apparatus may be formed of rigid materials including metals and plastics. Stiffeners will be commonly recognized by those of ordinary skills in the plastic and metal arts and may be in many different arrangements.
[0019] FIG. 6 shows at least one joist notch ( 700 ) at the bottom side ( 600 ). It will be appreciated that the at least one joist notch ( 700 ) is orthogonal to the axis ( 400 ), extends from the first side ( 110 ) to the second side ( 120 ) and fulfills the purpose of receiving an upstanding structure thereby anchoring and giving greater stability to the apparatus ( 1 ) when in use. In the preferred embodiment the joist notch ( 700 ) is shaped to receive an upstanding ceiling joist. In standard ceiling construction in the United States the ceiling joists will be spaced 24″ apart with this spacing preferred.
[0020] While a preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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The support apparatus is principally directed to a planar structure which will support a workman when working above a ceiling with steps provided only by joists. The support apparatus is planar having handles at each side and each end. The apparatus folds about a hinge which is intermediate the ends. Notches at the bottom side are spaced to standard residential construction for joists to give the support apparatus greater stability when in use.
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BACKGROUND OF THE INVENTION
Many microfilm storage and retrieval systems in the prior art use old analog technology and accordingly have a number of problems. Cartridge retrieval is done using theoretical values which do not work because of the mechanical variations and tolerances inherent within the alignment of the hardware elements used in the system. The prior art systems are only capable of fixed resolution and fixed window size image scanning. Very primitive fixed thresholding techniques are sometimes used to convert grey levels into binary data. The systems generally have no built-in intelligence for error recovery or self-diagnostics. The reliability of present systems is a main problem. The breakdown of such systems appears to be nearly an everyday affair. Most of the motors are driven using analog logic without any feedback and nearly always employ open loop controls. Primitive belt-driven motion control techniques are commonly used. No velocity profiles are generated or motions monitored. Using existing systems, no optimization is possible for the motion (based on distance to be moved). Inherently, compromised speeds must be picked for both short and long moves. Furthermore, the performance of existing systems appears very poor with limited band width.
Most existing systems accept only particular types of film (24X, 32X) with many restrictions. Image quality is generally governed by primitive thresholding techniques. Using the prior systems, it is not possible to extract information from the noisy data. There exists no provision for loading the cartridges using software without jeopardizing safety requirements.
The storage capacity of the present invention, known as the MegaSAR-420, is twice the storage capacity of the original MegaSAR. The retrieval unit taught in U.S. Pat. No. 5,367,382 which significantly advanced the art. The apparatus disclosed in that patent had completely re-engineered electronics. Digital technology was used throughout along with brand new algorithms and theory. State-of-the-art technology for that time was used, thus adding many capabilities. The present invention improves the apparatus disclosed in U.S. Pat. No. 5,367,382. Most notably, the storage capacity is doubled. Storage capacity is doubled by complete redesign of cassette and also film reel as well as adding eight more spoked hubs (spiders). This is achieved by adding eight spoked hubs, also known as spider assemblies. In conjunction, the cartridges used in the present invention also have an increased storage capacity. In addition, the latest hardware technologies are employed. Software is completely redone in "Windows."™ Many of the mechanical subsystems are improved to increase system reliability and function. The system architecture also allows for future expansion or additions. Hardware and software subsystem designs are modular. The system, in sum, is developed with state-of-the-art technology and has double the capacity of the largest known existing system, which is disclosed in U.S. Pat. No. 5,367,382.
SUMMARY OF THE INVENTION
The improved microfilm storage and retrieval system (MegaSAR-420) of the present invention puts 2.4 million microfilm images at 24× on-line in a document imaging system. The MegaSAR-420 could be connected to a PC LAN based document imaging system with specialized software. A remote user then has the ability to retrieve images of the stored microfilm. MegaSAR-420 doubles storage capacity of current MegaSAR by redesigning cassette and film reel as well as adding eight more spiders.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective cut-away view of the storage and retrieval unit of the present invention.
FIG. 2 illustrates the pick plate mechanism of the present invention.
FIGS. 3A and 3B are a top view and a side view of the spider assembly of the present invention.
FIG. 4 is a perspective cut-away view of the storage and retrieval unit of the present invention.
FIG. 5 is a side view of the film handling unit of the present invention.
FIG. 6 is a cut-away view of the suppression tree locking mechanism of the present invention.
FIG. 7 is an exploded view of the component of the spider arm/column locking mechanism of the present invention.
FIG. 8 is a side view of the solenoid control dipstick utilized in the present invention.
FIGS. 9A and 9B illustrate the knife motor assembly of the present invention.
FIG. 10 is an exploded view of the components utilized in the optical path of the present invention.
FIG. 11 is a side view of the film gate assembly of the present invention.
FIGS. 12A, 12B and 12C depict the break bridge assembly of the present invention.
FIGS. 13A and 13B depict the take-up reel assembly of the present invention.
FIG. 14 is a flowchart which functionally describes the elevator calibration process of the present invention.
FIG. 15 is a flowchart which functionally describes the column calibration process of the present invention.
FIGS. 16A and 16B depict the overall operation of the storage and retrieval process of the present invention.
FIG. 17 depicts the steps involved in the load cartridge phase of the present invention.
FIG. 18 depicts the steps involved in the put-away phase of the present invention.
FIG. 19 depicts the steps involved in the get image phase of the present invention.
FIG. 20 depicts the steps involved in the process frame phase of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the improved on-line microfilm storage and retrieval system of the present invention, hereinafter referred to as MegaSAR-420, will be best understood in light of the detailed description below, in association with the accompanying drawings, wherein like reference numerals identify like elements.
From a functional standpoint, the preferred embodiment of the present invention includes three main subsystems which together constitute the storage and retrieval system. These three subsystems include 1) a cartridge handling subsystem, 2) a microfilm handling subsystem and 3) a video image processing subsystem. Each of these subsystems are discussed individually below to define the configuration and operation of the many components which operate together within each subsystem.
The first of the subsystems to be discussed is the cartridge handling subsystem. The MegaSAR-420 is approximately the size of a large washing machine. Most of the area occupied by the MegaSAR-420 system of the present invention is devoted to the accessible storage of various microfilm cartridges onto which image information has previously been stored. The objective of the cartridge handling subsystem is to respond to a request by selecting the desired microfilm cartridge, loading the selected cartridge into the film handling subsystem (discussed in detail below) and restoring the desired microfilm cartridge to that cartridge's assigned position within the unit.
The particular details for the cartridge handling subsystem of the present invention are precisely depicted in FIG. 1. The illustrated configuration is capable of holding up to 420 individual cartridges. The number of images that a particular cartridge MegaSAR-420 contains is a function of: the reduction ratio, the size of the original image compared to its size on the film, the number of images per blip, typically simplex or duplex, and the number of blips per roll of film. As used herein, the term blip refers to the markings or tags sometimes placed on each individual frame or a series of frames of the film contained within the film cartridge. The MegaSAR-420 preferably uses a redesigned cartridge in which the images stored on each cartridge varies from about 6000 images at 24× per cartridge (2.52 per MegaSAR-420) to about 20,000 images at 48× D40 per cartridge (8.4 million per MegaSAR-420).
The structural arrangement of the cartridge handling subsystem utilized by the MegaSAR system of the present invention revolves around a center column assembly 20. As illustrated in FIG. 1, the center column assembly 20 includes a center column 22 which is vertically positioned in the middle portion of the housing of the MegaSAR system. The center column 22 is connected to the shaft of a motor (not shown) which is located on the base of the MegaSAR housing. The motor is electrically controlled, so as to rotate the center column assembly in the appropriate direction an arc distance necessary to position the entire center column assembly 20 in the desired rotational orientation with regard to the housing of MegaSAR system 10. The direction and amount of rotation is determined by the processing unit of the MegaSAR system based upon the storage location of the particular cartridge.
As depicted in FIG. 1, the center column assembly 20 further includes a plurality of spider assemblies (i.e., spoked hubs) 24 which each include a series of spider arms (i.e., spokes) 26 arranged to extend outward in a plane which is perpendicular to the axis of the center column 22. The plurality of spider assemblies 24 are not directly connected to the center column 22, but instead each of the spider assemblies 24 incorporates a center ring 28, as illustrated in FIG. 3, from which each of the spider arms 26 extend. The diameter of the center rings 28 is slightly larger than the center column 22. Therefore, each of the spider assemblies 24 are sequentially positioned so that each of the center rings 28 fits around the center column 22. This sequential positioning of the plurality of spider assemblies allows the spider assemblies 24 to be stacked along the height of the center column 22 with each of the spider arms 26 radiating horizontally from the vertical center column 22.
In the preferred embodiment, twenty-eight (28) spider assemblies 24 are stacked on top of each other, thereby establishing twenty-eight (28) rows of spider assemblies 24 capable of holding a series of microfilm cartridges. Each of the spider assemblies 24 are manufactured of lightweight aluminum or a similar material to allow efficient maneuvering of each assembly. Furthermore, a collection of hard metal spacers (not shown) are positioned between each of the rows of spider assemblies 24 to prevent the softer metal (aluminum) used to make the spider assemblies 24 from rubbing together when being rotated and thus possibly deforming one of the spider assemblies 24.
The individual spider arms 26 are uniformly separated, except for the elevator path which will be discussed in greater detail below, around the arc of the center column 22, such that each of the pair of spider arms 26 adjacent to one another form a cradle 30, as shown in FIG. 3. The dimensions of the cradle 30 are approximately equivalent to the dimensions of the microfilm cartridges being used in the MegaSAR system. The particular size and shape of the cartridge and the specific spacing and arrangement of the spider arms may be coordinated so that a variety of known cartridge shapes and sizes may be used in the system of the present invention. Furthermore, the film itself may be converted to the particular cartridge shape chosen. However, the specific construction of the spider rods 26 and the microfilm cartridges allows each cartridge to be supported by a corresponding cradle 30 whenever the cartridge is lowered into the cradle 30. The above stated design and construction allows any cartridge to be easily lifted out of its cradle 30 by applying an upward force from below the cartridge, but in the absence of such upward force gravity maintains the cartridge in its proper position in the cradle 30 created between each of the spider arms 26.
In the preferred embodiment of the present invention, the spider arms 26 are radially spaced so as to create fifteen (15) cradles 30, as depicted in FIG. 3, or positions for storing cartridges within each spider assembly 24. Therefore, given that there are twenty-eight (28) rows of spider assemblies with each of these twenty-eight (28) rows having fifteen (15) cradles for holding cartridges, the previously described architecture will allow the MegaSAR-420 system of the present invention to store and provide access from up to 420 microfilm cartridges.
Each of the spider assemblies 24 includes two spider arms 26 which are intentionally spaced far enough apart to allow the film cartridges to pass through vertically without being impeded. Therefore, since the microfilm cartridges can easily pass between these two spider arms 26, no cradle 30 is created between these two particular arms. The present invention utilizes this wide spacing 36 to designate a home position for each of the twenty-eight spider assemblies 24. Therefore, when each of the spider assemblies 24 are oriented in their home position, the wider gaps 36 or home positions of each spider assembly 24 are vertically aligned, thereby establishing a vertical column 32, the height of the center column 22 wherein microfilm cartridges can pass through the complete height of the stacked assemblies.
In the preferred embodiment of the present invention, the film handling subsystem is located at the top of the center column 22. To effectuate the maneuvering of the various cartridges from their designated row up to the top of the center column 22, the MegaSAR system of the present invention employs an elevator 34, which moves vertically, within this vertical column 32. The elevator 34 is horizontally oriented and shaped so as to be capable of freely moving between each of the cradles 30. The elevator 34 is moved vertically along two vertical shafts 38 and 40, shown in FIGS. 1 and 4, positioned near the periphery of the spider arm assemblies.
During the operation, the vertical movement of elevator 34 is coordinated with the rotational movement of the individual spider assemblies 24 such that the elevator 34 is positioned below the row occupied by the particular spider assembly 24 holding the cartridge determined to contain the image information requested by the operator. Before any rotational movement of the spider assemblies 24 or vertical movement of the elevator 34, the MegaSAR system of the present invention verifies that the particular cradle 30 which contains the cartridge storing the requested image information is in the only spider assembly 26 rotated out of its home position and that the elevator 34 is positioned in the vertical column 32 at a point lower than the spider holding the chosen cartridge. To obtain the desired cartridge, the spider then containing that cartridge is rotated such that the vertical column 32 is unobstructed except for the particular cradle 30 supporting the chosen cartridge.
To effectuate the vertical motion of the elevator 34 within vertical column 32, the present MegaSAR system utilizes an electric elevator motor 42, preferably secured to the base of the MegaSAR housing frame. The output shaft of the motor 42 is connected to a chain or belt 44 via a sprocket 46 to coordinate precisely the movement of the motor shaft to the movement of the chain or belt 44.
The chain or belt 44 is oriented around an upper pulley assembly (not shown), located at the top for the cartridge handling subsystem near the upper end of vertical shafts 38 and 40, and a lower pulley assembly 48, as illustrated in FIG. 1, preferably located near the output shaft of electric motor 42 and the lower end vertical shafts 38 and 40. The upper and lower pulley assemblies are positioned such that the chain or belt 44 is vertically oriented adjacent to the vertical shafts 38 and 40 along the entire height of the cartridge handling subsystem. By securely attaching the elevator 34 to one point along the chain or belt 44, the particular arrangement of the pulley assemblies, belt 44 and elevator motor 42 effectively transfers the rotational motion of the output shaft of elevator motor 42 into the vertical movement of elevator 34 within vertical column 32. The direction in which the elevator motor 42 is rotated controls whether the elevator 34 moves upward or downward.
In order to accurately control the rotational movement of each spider assembly 24 and ensure that only one spider assembly is rotated out of its home position at a time, the present MegaSAR system incorporates a suppression tree assembly 50. The suppression tree assembly 50 operates in coordination with the center column assembly 20 to selectively lock and unlock particular spider assemblies 26 to the rotatable center column 22. The control aspects of the locking and unlocking procedure will be discussed in greater detail below.
From the standpoint of mechanical structure, the suppression tree assembly 50 incorporates a series of vertically stacked solenoids 52 which are electrically connected to and controlled by the microprocessor unit which will be discussed in greater detail below. The number of solenoids 52 corresponds directly to the number of spider assemblies 24, with a solenoid 52 being physically oriented at the outer end of each spider assembly 24. A detailed cut-away view of one solenoid 52 within the suppression tree assembly 50 in relation to the spider arm 26 of the corresponding spider assembly 24 is shown in FIG. 6.
The particular mechanical mechanism utilized in the preferred embodiment of the present invention to lock and unlock the suppression tree assembly 50 to the center column 22 is illustrated in an expanded arrangement in FIG. 7. As illustrated in FIG. 7, various mechanical elements are incorporated to lock or unlock the selected spider assembly 24. The main component utilized to actually lock and unlock the suppression tree assembly 50 to the center column assembly 20 is a locking rod 54. The locking rod 54 is a cylindrical rod with a relatively small diameter with specific machining at both ends and approximately the length of the spider arms 26. The present MegaSAR system includes one locking rod 54 for each spider rod assembly 24, wherein each of the locking rods 54 are horizontally oriented and positioned directly underneath their corresponding spider arm 26. The remaining mechanical elements, which will be discussed in greater detail below, act in conjunction with their corresponding locking rod 54 to move or hold that locking rod 54 in its proper position for that stage in the cartridge handling process.
As part of the mechanism used selectively to lock a particular spider assembly 24 to the center column, the center column assembly 20 includes a teardrop dipstick 56. The dipstick 56 is a thin rectangular strip of metal approximately the length of the center column 22. The dipstick 56 is vertically secured to the side of the center column 22 which faces the suppression tree assembly when the center column 22 is in its home position. The dipstick 56 is constructed with a series of teardrop-shaped holes 58 arranged vertically one on top of the other along the height of the dipstick 56. The teardrop-shaped holes 58 are oriented so that the smaller end of each hole 58 is above the larger end of that hole 58. The dipstick 56 is operated by a mechanism as illustrated in FIG. 8 for raising and lowering the dipstick 56 at the appropriate times to assist further in securely locking and unlocking of spider. The configuration of the dipstick 56 of the present MegaSAR system allows the locking rod 54 to be shifted inward toward the center column 22 and partially through the larger portion of that locking rod's corresponding hole 58. However, after the locking rod 54 is inserted through the largest section of the appropriate hole 58, the dipstick 56 is moved vertically downward, thereby moving the locking rod 56 from the larger section of hole 58 where the fit was loose, to the smaller position of hole 58, where a more secure fit between the locking rod 56 and the hole 58 may be achieved.
To assist further in securing a particular locking rod 54 to the center column 22 via dipstick 56, a pick plate 60 is attached to the center column 22 between each pair of holes 58. Each pick plate 60 is a rectangular piece of metal with small rectangular notches 62 and 64 cut out of both the top and bottom edge of the pick plate respectively. The notches 62 and 64 are sized and oriented such that when a locking rod 54 is inserted through a hole 58 and the dipstick 56 moved vertically to secure a tighter fit, the locking rod 54 is positioned into the appropriate notch 62 or 64 of the corresponding pick plate 60, thus allowing the structurally strong pick plate 60 to receive the majority of forces directed toward pulling the locking rod 54 away from the center column 22.
When the locking and unlocking mechanism of the present invention is in its relaxed or nonenergized state, the locking rod 54 is resting in the suppression tree assembly 50, in line with the appropriate solenoid 52, with no connection existing between the locking rod 54 and the center column 22. Therefore, in normal operation, when a cartridge is selected, only the solenoid 52 corresponding to the spider assembly 24 containing that cartridge is energized. By energizing that solenoid 52, the corresponding locking rod is connected to the center column 22. The center column 22 with selected spider assembly 24 attached by the locking means is then rotated as needed to align the desired cartridge within the vertical column 32.
Normally, to bias the locking rods 54 outward--toward the suppression tree assembly 50 and away from the center column assembly 20--a return spring 66 is incorporated into the overall locking and unlocking mechanism used by each spider assembly 24. The return spring 66 has a diameter slightly larger than the locking rod 54 and is positioned over the end of the locking rod 54 nearest the center column 22. The return spring 66 is held in its desired position (within the spider assembly 24) along the locking rod by retaining rings 68 and 82. One end of the return spring 66 applies a force against a surface within spider arm 26. Given that retaining ring 68 provides a point along the locking rod 54 for the other end of return spring 66 to apply its forces, return spring 66 acts to force the locking rod 54 away from the center column and thereby prohibiting engagement or locking between a locking rod 54 and the corresponding pick plate 60 without the appropriate solenoid 52 being sufficiently energized to overcome the potential force of the return spring 66.
The end of the locking rod 54 located nearest the suppression tree assembly 50 interacts with the corresponding solenoid 52 in such a manner that when the solenoid 52 is energized, a solenoid plunger 70 moves within the solenoid 52 to force that particular locking rod 54 inward toward the center column 22 against the potential pressures of return spring 66. In addition to the solenoid plunger 70, each solenoid 52 includes a plunger return spring 72. The plunger return spring 72 encircles the solenoid plunger 70. The solenoid plunger 70 is supported by spring 72 in a ready state outward, and applies a constant biasing force against the solenoid plunger 70. This constant biasing force applied to the solenoid plunger 70 by the plunger return spring 72 pushes the solenoid plunger 70 outward, away from the center column 22. Therefore, to lock a particular locking rod 54 into the center column assembly 20, the inward force applied when the appropriate solenoid 52 is energized must overcome the outward forces exhibited by the return spring 66 and the plunger return spring 72.
However, once the previously energized solenoid 52 is de-energized, the plunger return spring 72 moves the solenoid plunger 70 outward, back to its ready state. The mechanism which unlocks or disengages the spider assembly 24 associated with that locking rod 54 from the center column assembly 20 is illustrated in FIG. 8. On command, a solenoid coil 69 is energized, moving dipstick 56 vertically upward so as to permit the large portion of teardrop hole 58 to disengage itself from locking rod 54, thus allowing the return spring 66 to move the locking rod 54 outward, there by unlocking or disengaging the assembly 24 associated with that locking rod 54 from the center column assembly 20.
Various other preferred elements are within the locking and unlocking mechanism of the present invention, as illustrated in FIG. 7, include a solenoid cable 74, a solenoid connector 76, a pilot bushing 78, as well as a stop bushing 80 and a retaining ring 82 for the outer end of locking rod 54. Each of these elements cooperate with the other elements included in the locking and unlocking mechanism for each spider assembly 24 to manipulate effectively and to hold the locking rod 54 and associated spider assembly in the desired position based upon the specific instructions received.
The knife assembly, as illustrated in FIGS. 9A and 9B, is a mechanism utilized by the present invention to hold the film cartridge (after having been selected and transported through the cartridge handling subsystem previously described) in a fixed position within the film handling subsystem. The knife assembly incorporates the use of photo sensors (which are described in further detail below). The knife assembly consists of a motor gearbox device 84. The motor gearbox device 84 has a locking cam 86 attached to the output shaft of the motor. These components are supported in a frame type housing 88 which permits the assembly of the unit into the film deck. Upon command (detection of the presents of a film cartridge in the film handling subsystem) the motor 84 is energized causing the locking cam 86 to rotate and pass between two rollers attached to the side of elevator 34. These rollers are spaced so as to equal the thickness of the cam 86. After a rotation of 180 degrees, the motor is de-energized and comes to rest in a position whereby the elevator 34 (with selected cartridge) is locked into the film deck to begin the film handling process. Upon completion of the film handling process, the motor 84 is again energized causing locking cam 86 to rotate 180 degrees, thereby disengaging with elevator 34, thus allowing elevator 34 to transport and store the selected cartridge into its designated position within the cartridge handling subsystem.
In summary, the overall operation of the cartridge handling subsystem provides an efficient and effective on-line method of locating the particular cartridge containing the requested image information out of 420 cartridges or possibly more resting in the various cradles of the system and maneuvering that cartridge into the proper position within the film handling subsystem, discussed immediately below, for further processing.
As detailed above, initially an elevator 34 is positioned below the spider assembly 24 containing the desired cartridge. The spider assembly 24 with the desired cartridge is then rotated until the cradle with the cartridge is aligned above the elevator 34 in the vertical column. Only the one spider assembly 24 containing the desired cartridge is rotated, all of the other spider assemblies 24 remain in the home position. The elevator 34 then moves vertically upward and lifts the cartridge out of the cradle. The elevator 34, continues to rise, carrying the desired cartridge upward until the cartridge is properly positioned in the film handling subsystem. The rotated spider assembly 24 remains in its rotated position until all desired processing of that cartridge is completed. The elevator 34 then descends to a position below the rotated spider assembly 24. As the elevator 34 drops through the rotated spider assembly 24 the cartridge gently releases itself from the elevator 34 and rests in its designated cradle. The spider assembly 24 then rotates back into its home position, and the cycle is complete. The preferred embodiment of the present invention is able to complete one complete cycle of returning a cartridge and presenting a new cartridge to the film handling subsystem. The movement of the elevator may be concurrent with the spider assembly 24 rotation in order to optimize the speed of cartridge retrieval.
FILM HANDLING SUBSYSTEM
The second functional subsystem of the preferred embodiment of the present invention is the film handling subsystem. The film handling subsystem incorporates various elements necessary actually to wind and to unwind the film in the loaded cartridge, as well as a mechanism for identifying the particular frame containing the desired image information and appropriately centering the identified frame within the optical path of the MegaSAR-420 system.
Once the cartridge containing the requested image information is properly loaded into the film handling subsystem from the cartridge handling subsystem, the film within the cartridge must be unwound to the particular frame which contains the desired image. As illustrated in FIG. 5, attached to the outermost end of the roll of film within the cartridge is pin 90. The ends of this pin extend above and below the cartridge. A take-up reel 92 contains take-up fingers 94 which, when properly positioned, grab the ends of the pin 90 and as the take-up reel 92 rotates, pull the film from the cartridge and begins winding the film onto the take-up reel 92, as shown in FIGS. 13A and 13B. To further facilitate the exchange of the film from the cartridge over to the take-up reel 92, the take-up reel 92 has a spiral groove 96 cut into each of the sides of the take-up reel 92. In addition, once the pin 90 is directed to the center core of the take-up reel 92, the pin 90 drops into a groove 98 along the center core of the take-up reel 92 to allow the film to wrap around the center core in a smooth manner.
As the film is exchanged from the cartridge to the take-up reel 92, it passes across the optical path of the MegaSAR-420 system. The optical path shown in FIG. 10 of the MegaSAR-420 system begins with a light source 100. In the preferred embodiment of the present invention the light source 100 is a projection bulb. The light emitted by projection bulb 100 is focused on the microfilm 102 by a condenser lens 104. The condenser lens incorporates the use of a green filter 106 and an IR filter 108 for optimum spectral performance.
There are two separate activities which occur while the film is illuminated in the optical path. The first, dealing with accurate identification of the desired frame, will be discussed immediately below whereas the second, dealing with the actual image scanning and processing performed after the proper frame has been identified, will be discussed in detail in the next section of this disclosure.
The manner in which the preferred embodiment accurately identifies the desired frame is by blip counting. There are a variety of methods employed to put image information onto microfilm, and a variety of formats which the image information may appear on the film. At present, the key method of tagging or marking frames is the use of blips. Blips are rectangular sections of completely exposed film outside of the actual stored image used to mark the position on the film at which one or more images have been exposed. By monitoring the blips located on the particular frames of the film as it passes through the optical path, a particular frame can be identified. The present invention includes a photocell array to monitor the blips. Any one of cells within the photocell array 110 may be used to detect blips. Furthermore, by selecting a photocell from the array, the relationships between the blips and the frame such as leading edge, centered and trailing edge can be controlled. Furthermore, on selecting different photocells, the relationships between the blip an the frame such as leading edge, centered and so on, can be controlled.
After the blip monitoring process described above has identified and properly aligned the frame containing the desired image information, the arm 112 of a film gate assembly as illustrated in FIG. 11 are moved to the closed position. The film gate is shown in FIG. 11 in both its open and its closed positions. When in the closed position, the film gate holds the film located between the cartridge and take-up reel in the proper plane required for the subsequent image processing to be performed accurately.
Being a component of the film handling subsystem as illustrated in FIG. 5, the brake assembly, as illustrated in FIG. 12, functions as a means of holding take-up reel 92 in a motionless state during the operation of the arm 112 (as shown in FIG. 10), thus allowing the 16 mm film 102 to remain stationary during the video image processing procedure. This is achieved through an electromagnet 114 attached to a support bar 116 and a photo sensor (described in greater detail below) which detects proper positioning of the take-up reel 92 prior to activation of the electromagnet 114.
The objective of the film handling subsystem is achieved once the desired frame is identified and securely held in its proper position within the optical path, as illustrated in FIG. 10, of the MegaSAR-420 system. With the completion of the duties performed by the film handling subsystem, the image information contained on the selected frame is ready for image processing steps, as discussed in the next section of this disclosure
VIDEO IMAGE PROCESSING SUBSYSTEM
The third functional subsystem of the preferred embodiment of the present invention is the video image processing subsystem. Once the cartridge handling subsystem has located the particular cartridge containing the selected image information and loaded that cartridge into the film handling subsystem, which locates the specific frame depicting the selected image and precisely positions it within the optical path, the video image processing subsystem begins its duties, which include image illumination, projection and focusing, as well as image scanning, digitizing and processing.
As stated earlier and illustrated in FIG. 10, the optical path of the present MegaSAR-420 system begins with a light source 100 which emits light through a condenser lens 104. In the next step of the optical path, the light passes through the film, and more specifically the desired frame, which is being held motionless by the film gate 112. Next, the light which now includes the image, passes through a lens 118 which optically amplifies the image on the microfilm. In order to conserve physical space, the present invention then turns the light ninety degrees (90°) by a mirror 120. The previous manipulation of the image focuses the image in the focal plane.
In the preferred embodiment, as depicted in FIG. 4, a scanner board 122 is positioned within the focal plane and mounted to a vertical scanner 124. The vertical scanner 124 may be maneuvered vertically within the focal plane by a direct-drive screw arrangement 126. Vertical posts 128 are used to constrain the motion of the vertical scanner 124. In the configuration of the present invention, the vertical scanner 124 can move from any position to any other position within the focal plane with a completely smooth and regular motion, at a speed sufficient to keep up with the fastest scanning electronics presently existing.
As shown in FIG. 4, the scanner board is a charge couple device or CCD (not shown). The CCD is a device which converts various light intensifies to proportional electrical voltages. The CCD contains a horizontal array of cells which may be configured to include either 2048 or 3456 or 5000 individual cells depending on the resolution requirement of the film being processed.
The CCD captures a linear array of pixels in order to create a scan line with each of the pixels representing a tiny square of light intensity. The scanner board 122 may be moved in such a manner as to produce the appropriate number of scan lines needed to properly reproduce the desired image on either a display screen or a printer. The speed of the scanning motion depends on the resolution requirement.
The CCD may have a width of 1728 or 3456 elements. The MegaSAR-420 system of the present invention can be commanded to produce exactly the desired number of scan lines, but the number of pixels/line is fixed.
From the CCD, the image passes through a number of stages of processing prior to being presented to the user. The analog signals produced by the CCD are first amplified and cleaned during a pre-processing phase. The signals are then converted to a binary value by an A-to-D converter, which in the present invention produces eight bits per pixel. Eight bits produce 256 different combinations, which means that 256 shades of grey can be represented. Processing of the digitized image may be done using one of the two techniques described in detail below.
First, a particular eight-bit value may be used as a threshold to convert the grey scale image to a binary image (black-and-white), containing just one bit per pixel. The image may be inverted at this time to accommodate clear images on a black background. A binary image typically consists of a half million or a million bytes, and may be compressed by the controlling computer to about one tenth that size.
Second, the gray scale may be fed to an integral image enhancement processor, which uses sophisticated algorithms in a context-sensitive way to determine for each pixel whether it is foreground or background. The output of the image enhancement processor is a binary image. The operation of the enhancer is in real time.
All sensors in the MegaSAR-420 are implemented using infra-red beams of light which are either broken or bounced back. The use of infra-red avoids interference with ambient light. An LED shows whether the sensor is on or off, thus providing a simple way to verify sensor operation.
OPERATIONAL CONTROL SYSTEM
Maintenance is aided by the fact that the MegaSAR-420 includes an integral 486-based or "Pentium"™ PC including a hard disk. A connection on the control panel permits service personnel to plug in an ASCII terminal, a PC with terminal emulation or a modem for remote diagnosis and monitoring. Diagnostic and monitoring programs may be run while the MegaSAR-420 is in normal operation, thus permitting intermittent problems to be caught.
THEORY OF OPERATION
Prior to beginning the actual storage and retrieval process, the MegaSAR-420 system of the present invention may initiate one or both of the calibration phases of operation available. In the two calibration phases of the present invention, the physical location and operability of the elements involved in the movement of both the elevator and the individual columns are verified.
The flowcharts set forth in FIGS. 14 and 15 provide a functional description of the manner in which the microprocessor of the present invention is programmed in order to carry out either one of the two calibration phases of the present invention. FIG. 14 depicts the steps employed to calibrate the motion of the elevator within the present invention. In the preferred embodiment, the elevator calibration phase is followed by a phase which calibrates the various columns of each level. The particular steps performed to calibrate the columns are depicted in FIG. 15. Implementation of the flowcharts 14 and 15 in terms of specific programming steps will vary somewhat, depending on the particular microprocessor hardware chosen.
Referring first to FIG. 14, an elevator calibration sequence is commenced by enabling the microprocessor with an elevator calibrate command signal may be generated as a result of electrical power being supplied to the MegaSAR-420 unit or by directly activating the calibrate command signal during operation to provide further system verification. As represented by block 200, the microprocessor responds to the elevator calibrate command signal by opening a calibration file or memory within the unit and reading in data indicative of the positional values of the elevator and columns. The position data may be obtained from a number of different types of well-know sensors positioned at particular points of interest throughout the MegaSAR-420 unit of the present invention. In the preferred embodiment, the positional data may reflect the vertical position of the elevator as well as the rotational alignment of each column.
The next operation executed by the microprocessor, as represented by block 202, is to initialize each of the motors utilized to raise and lower the elevator. Upon completion of the motor initialization process, a check is made to verify that all of the individual film cartridges are properly stored in their appropriate carriages, as illustrated by decision block 204. If not, then the out of place cartridge is restored as indicated by block 206. The microprocessor then proceeds to block 208, where the system generates the necessary commands to move the elevator and all of the columns to their home position.
Once the elevator and columns are positioned in what is believed to be the home position, and all cartridges properly restored, a verification that the elevator is indeed in its home position is made, as indicated by decision block 210. Should the data returned from the sensors indicate that the elevator is actually not in its proper home position, an error message is printed in accordance with block 212 and then the calibration phase of the present invention is terminated.
However, upon verification that the elevator is indeed in its proper home position, a current level value is set to equal the number of levels or spider assemblies present within that particular storage and retrieval unit in the preferred embodiment, this number is twenty-eight (28), as depicted by block 214. The current level value is used within the microprocessor to keep track of the particular column level to which the elevator position is being calibrated to at any given time during the elevator calibration process. Next, in accordance with decision block 216, the microprocessor makes a determination as to whether the elevator has been calibrated to all of the levels. If all levels have been processed, then the elevator is moved up to the film deck for further calibration, as will be discussed in greater detail later. However, if all levels have not been processed, then as depicted by block 218, the particular spider assembly associated with the current level to which the elevator is being calibrated is then locked into the center column as set forth earlier.
Once the proper spider assembly is locked into the center column, the center column is rotated clockwise until the closet spider arm has been moved into the path of the elevator, in accordance with block 220. Then as indicated by block 222, the elevator is raised at a very slow speed and low torque until the elevator makes contact with the rotated spider arm. To record the desired alignment of the elevator when positioned adjacent to that particular level, an offset value of a predetermined amount is added to the detected position of the elevator and then stored in the calibration file of the MegaSAR-420 unit, as depicted by block 224. Upon recording the desired elevator position relative to the level in question, the elevator is lowered to a height which will allow an unobstructed return of the rotated spider arm to its home position as illustrated in block 226. The center column and rotated spider arm are then repositioned to their home position as depicted in block 228.
After the particular level which has just been calibrated has been returned to its home position, the current level value is decreased by 1 in accordance with block 230. The microprocessor then returns to decision block 216 where once again it is determined whether all of the levels have been calibrated. As long as there remains any levels which have not been calibrated, the steps of blocks 218 through 230 are repeated.
However, once block 216 makes the determination that all of the levels have been calibrated via the steps of block 218 through 230, the microprocessor generates commands to move the elevator up to the film deck as set forth in block 232. Then, as illustrated by block 234, the elevator is positioned very close to the film deck, so as to allow the knife to rotate freely. Such positioning of the elevator allows the knife to properly remove a cartridge from the elevator and place this cartridge into the film deck. The desired position of the elevator for the cartridge transfer from elevator to film deck is then recorded in the calibration file, as depicted by block 236. Upon recording this position, the microprocessor may close its calibration file and thus complete the elevator calibration phase of the present invention as illustrated by block 238.
A second phase of calibration which may be performed by the MegaSAR II unit of the present invention performs the precise measurement and alignment of each of the columns within the unit. The particular procedures performed to properly calibrate the various columns are functionally described in the flowchart of FIG. 15. The beginning steps involved by the microprocessor are nearly identical to those performed during the initial stages of the elevator calibration phase. That is, the calibration file is opened and the value indicative of the position of the elevator is read into the calibration file as represented by block 240. Then the appropriate motors are initialized as illustrated by block 242. However, a slight deviation from the previously described elevator calibration phase, the loop involving determining if the cartridges are all properly stored, and accordingly, restoring any out-of-place cartridges is not repeated in the column calibration phase. Instead, after initializing the motors in accordance with block 242, the elevator and column are moved to their home position as depicted by block 244.
Upon positioning the elevator and columns in their home position, a verification is made in accordance with decision block 246 determining whether the elevator is indeed in its proper home position. If the elevator is indicated as not being in its home position, an error message is reported to the operator and the column calibration phase terminated or depicted in block 248. However, as in the elevator calibration phase, a current level value is set equal to the number of levels or spider assemblies present within the particular storage and retrieval unit in the preferred embodiment, this value is twenty-eight (28) as depicted by block 250.
Since each of the cradles within each level of the storage and retrieval unit must be calibrated, decision block 252 represents the means by which the system determines whether each level has had its associated cradles calibrated. Upon determining that each of the cradles of all of the levels have been calibrated, the calibration file is closed and the column calibration phase terminated as depicted by block 254.
However, as long as decision block 252 indicates that all of the levels have not been calibrated, the microprocessor proceeds to set a value representative of the current column position equal to zero as set forth by block 256. Decision block 258 represents the next step performed by the microprocessor in that the column calibration process been performed on each of the column or cradles present on that level or spider assembly.
As long as there remain columns on the chosen level which have not been calibrated, the microprocessor then uses the data collected during the elevator calibration stages to precisely move the elevator into the path of the spider assembly at the current level, as depicted in block 260. Then, in accordance with block 262, the center column is rotated clockwise until the spider arm makes contact with the elevator. The precise location of this position is then stored for use in later calculations. As depicted in block 264, the center column is then rotated counter clockwise until the appropriate spider arm again makes contact with the elevator. Likewise, the precise location of this position is stored.
The microprocessor then uses the two stored values, representative of the position of contact between the elevator and spider arms described above, to calculate the appropriate position for that cradle or column which allows the elevator to be precisely centered between the two spider arms creating the cradle in question as depicted by block 266. The center column is then moved to the calculated centering position so that the desired centering position may be recorded into the calibration file in accordance with block 268.
Once that cradle or column has been calibrated, the elevator is moved out of that column path, as illustrated by block 270. Then in accordance with block 272, the microprocessor increments the value representing the current column position by one and proceeds back to the step depicted by decision block 258. At this point of the column calibration phase, it is once again determined whether the column calibration process described above has been performed on all of the columns or cradles in the particular level being checked. As long as there remain columns which have not be calibrated, the steps depicted in blocks 260 through 272 are repeated.
However, once all of the columns on the current level have been calibrated, the microprocessor decreases the value representing the current level being calibrated by one, as depicted by block 274, and returns to decision block 252. Decision block 252 then, once again, determines if all of the levels within the storage and retrieval unit have had their columns calibrated by the procedure of the present invention as described above; if not, the steps set forth in blocks 256 through 274 are repeated.
As stated above, each column or cradle of the level being processed is calibrated according to the step depicted in blocks 260 through 272. Then the microprocessor generates commands which initiate the column calibration process for the various columns associated with the next level. This repetitive procedure is sequentially performed on each column or cradle of each level present in the storage and retrieval unit being calibrated. In the preferred embodiment of the present invention, the column calibration phase will include the calibration of 420 columns or cradles since the preferred embodiment employs twenty-eight (28) levels or spider assemblies, each level having 15 columns or cradles. As stated earlier, the column calibration phase of the present invention is completed only after it is determined by decision block 252 that each level has had its associated columns calibrated. Then, in accordance with block 254, the calibration file is closed and the column calibration phase terminated.
After the MegaSAR-420 system of the present invention has completed the selected calibration phases, the system is ready to enter its normal mode of operation. FIG. 16 is a functional description of the positional procedures involved in the standard method used by the present invention to use an on-line personal computer to activate and control a multiple cartridge storage and retrieval system.
The first step, as depicted by block 276, is for the microprocessor to initialize the system. The initialization of the system includes, among other things, placing the elevator and columns in their home position and activating communication link between the personal computers and the storage and retrieval unit. Following system initialization, the microprocessor continually monitors any incoming signal from the operator to determine when a command has been received as depicted by decision block 278 and the associated loop. As illustrated, the new command monitoring continues until a command has been received. Upon receipt, the command is decoded by the microprocessor, as indicated by block 280.
As stated earlier, there are a variety of commands which may be requested by an operator. As depicted by decision block 282, should the HOME command be received, it, once again, initializes the system and the proceeds to continue monitoring for subsequent commands from the operator. However, as illustrated in blocks 284 and 286, should the decoded command not be a HOME command but is instead a LOAD command, the microprocessor performs the steps as set forth in FIG. 17.
The LOAD command is only used by the operator when he desires to load a cartridge into the storage and retrieval unit for the first time. Thus, the LOAD command may be used to add new cartridges to the unit or reposition within the unit cartridges which had to be physically removed from the storage and retrieval unit for one reason or another. Some such reasons may include repairing a damaged cartridge or updating the data on a particular cartridge.
As illustrated in block 288 of FIG. 17, upon the command of the operator, the microprocessor gets the desired cartridge address from the command decoder. In the preferred embodiment of the present invention, the cartridge address contains a two-digit valve representative of the level the cartridge is to be loaded into (referred to herein as LL) in combination with another two-digit value representing the column position where the cartridge is to be placed (referred to herein as PP). Therefore, the cartridge address may be represented as (LL, PP). The operator then selects level LL, in accordance with block 290. Following the selection of the desired level, that level is rotated so that position PP is aligned within the elevator path as depicted by block 292. The microprocessor then generates commands to move the elevator in its position closet to the door located in the front panel of the MegaSAR-420 unit, in accordance with block 294. As illustrated by blocks 296 and 298, the operator then opens the loading door and physically loads the new cartridge onto the elevator. In accordance with block 300, the operator may close the loading door by pressing any key on the keyboard associated with the personal computer. After the door is closed, the elevator is then moved so as to be aligned with a cartridge sensor, as depicted by block 302. The cartridge sensor is used to verify that a cartridge was indeed loaded into the elevator. As illustrated by decision block 304, should a cartridge not be detailed on the elevator, an error message in accordance with block 306 is conveyed to the operator and the load cartridge phase is terminated. However, should decision block 304 indicate that a cartridge is present on the elevator, then as depicted by block 308, the new cartridge is stored into the selected location (LL, PP) and the load cartridge phase is successfully completed.
Now referring back to FIG. 16A again, should the operator wish to request a particular image for viewing, he may generate the image request command through the microprocessor. Upon decoding of an image request command by block 280 and recognition of the command as an image request, in accordance with decision block 310, the microprocessor proceeds to decision block 312. Decision block 312 determines whether a cartridge is properly positioned within the film deck. If there is a determination that a cartridge is located in the film deck, the microprocessor, in accordance with decision block 314, determines whether the next image requested is located on the cartridge presently located in the film deck. Then if it is determined via decision block 314 that the next image requested is not located on the particular cartridge, already located in the film deck, the cartridge presently in the film deck is removed from the film deck and restored in its proper cradle position with the storage and retrieval unit as depicted by block 316 and further illustrated in FIG. 18.
The present invention utilizes a Put-Away phase to remove an undesired cartridge from the film deck and return that particular cartridge to its appropriate position within the unit. The steps involved in the Put-Away phase of the present invention is depicted in the flowchart of FIG. 18. To begin the Put-Away phase, a verification, as illustrated by decision block 318 is made to assure that the loading door on the front panel of the MegaSAR-420 unit is closed. If the loading door is determined to be open, the microprocessor may send a signal, causing the door to be closed in accordance with block 320.
Once the loading is determined to be properly closed via decision block 318, the film present in the undesired cartridge is rewound, as depicted by block 322. As depicted by decision block 324 and the associated loop back to block 322, attempts are made to rewind the film until acknowledgement is received at a proper PIN detection. After the film in the cartridge to be restored has been properly rewound, the elevator is lowered slowly, as illustrated by block 326. Since the cartridge to be replaced is fully supported by the elevator plate and the level from which this cartridge was removed is still rotated into the elevator path, the lowering of the elevator through the proper cradle allows the cartridge to softly come to rest within the appropriate cradle. As illustrated by block 328, the elevator may then be positioned immediately below the level containing the next requested image. Simultaneously, the present invention causes the level holding the cartridge previously removed from the film deck to be returned to its home position by engaging the proper spider assembly and rotating the center column. Such rotation removes all cartridges from the elevator path and sets the storage and retrieval unit in a ready position to process the next image, thereby completing the Put-Away phase of the present invention.
However, now referring once again to decision block 312 of FIG. 16A, once it is determined that there is not a cartridge present in the film deck, either because a cartridge has not been located in the film deck or that the Put-Away phase described above has been completed, then the microprocessor generates the appropriate signals to carry out the Get Image phase of the present invention. The Get Image phase of the present invention is functionally described in the flowchart of FIG. 19.
The initial step involved in the Get Image phase of the present inventions is to acquire the appropriate cartridge address from the command decoder as depicted by block 330. As stated earlier, the preferred embodiment represents the cartridge address, as a level volume, LL, and a column position value, PP. Once the proper cartridge address is identified, the associated level or spider assembly is selected and engaged with the center column as depicted by block 332. Then in accordance with block 334, the selected level is rotated so that the identified column or cradle position PP is aligned within the elevator path at a position above the elevator plate. In the preferred embodiment, such a positioning of elements may be referred to as the elevator pickup position. Next, as depicted by block 336, the elevator is raised thereby passing through the rotated cradle and picking up the chosen cartridge and delivering this cartridge to the film deck.
Upon properly positioning the cartridge in association with the film deck, decision block 338 represents the determination made as to whether the status of the cartridge sensor is acceptable. Should the cartridge sensor status be acceptable, the microprocessor proceeds to determine if the status of the PIN detection sensor is satisfactory as depicted by decision block 340. However, should either the status of either the cartridge sensor or the PIN detection sensor be outside the predetermined tolerances, a error message is generated and sent to the operator as illustrated by block 342.
Once the cartridge and PIN detection sensors are verified acceptable, the microprocessor proceeds to obtain the particular frame address, FFFFF, of the requested image as depicted by block 344. To actually locate the desired frame, the film deck begins unwinding the film and counting the frames as they pass in accordance with block 346. As stated earlier, the counting of the individual frames may be accomplished by using a variety of the blip counting methods, including single and double blip configurations. As illustrated by the loop connecting block 348 and decision block 350, the frames are continually incremented until verification via decision block 350 indicates that the current frame number being counted is the same as the frame number associated with the requested image. After the proper frame number containing the requested image is identified, the image is centered within the film deck for later processing as represented by block 352. In the preferred embodiment of the present invention, this later processing is carried out via a Process Frame phase which is functionally described in the flowchart of FIG. 20 and will be discussed in greater detail later.
After the Put-Away phase has been used to clear the film deck of an undesired cartridge, and the Get Image phase has been employed to properly locate and center the frame containing the requested image, the operator may generate a SCAN command to allow him to view the data stored or the requested frame. In the preferred embodiment, as indicated by decision block 354 and associated block 356, the receipt of a SCAN command by the microprocessor, activates a Process Frame phase which, as stated earlier, is functionally depicted in the flowchart of FIG. 20.
Now referring to FIG. 20, to begin the processing associated with the Process Frame phase of the present invention, the microprocessor generates a signal which activates the closing of the film gate as depicted by block 358. The closing of the film gate secures the film in the proper position for subsequent image processing. Next, the microprocessor utilizes the particular window size and resolution requirements of the system as selected by the operator to relocate the most appropriate scanner speed, in accordance with block 360. Based upon the calculated scanner speed, the image is then scanned, as depicted by block 362. Following scanning of the image, the image is digitized as represented by block 364 and manipulated via well-known image processing methods as represented by block 366. In conclusion, the digitized data corresponding to the requested image, as well as a status code are delivered to the operator, as represented by block 368, thereby completing the Process Frame phase of the present invention.
Now referring to FIG. 16B, a determination represented by decision block 370 is made to verify that the operation requested was indeed completed in a successful manner. If it is determined that the operation was a success, then the storage and retrieval system is once again initialized, in accordance with block 276 and prepared to receive, evaluate and carry out the next command generated by the operator. However, if for some reason the requested operation was not appropriately completed, then the microprocessor makes another determination, in accordance with decision block 372 to determine if the particular error detected is of such a nature that it may be classified as a recoverable error. If the detected is classified recoverable, then the present invention initiates an internal error recovery logic as represented by block 374. The error recovery logic allows the system to detect certain minor errors, possibly make minor adjustments so that when the command is retransmitted, the operation may be successfully completed. However, as indicated by block 376, should the detected error be determined to be non-recoverable, then the entire storage and retrieval unit is shutdown.
Motion control is done using microprocessor based hardware and software techniques. All the essential variables of motion control: acceleration, optimum maximum concise speed, deceleration, torques tolerances allowed, etc. are digitally selectable. All the motion control systems are reduced to the mathematical transfer functions which can be manipulated depending on requirements. Depending on the short or long distance to be moved, velocity profile is generated by the system. This profile tries to move the object at the fastest possible smooth speed. Smooth speed refers to proper acceleration and deceleration profile which includes step size and time. While in motion, the system samples actual positions and compares against the expected position. Depending on results of the comparison, appropriate changes are made in the profile. When an object reaches its destination, it is positioned with pre-defined accuracy. Positions of all the objects ever moved by the system are sampled at regular intervals and appropriate actions are taken. This process always goes on when the system is in operation.
`Self-Learn` Feature
`Self-learn` feature is an effective and important capability of the system microfilm jukebox in a storage and retrieval system. So when a request for any image is received, it is one of the millions of images stored in the jukebox. Any request consists of the three following address information:
Level address of the cartridge storing the request image;
Position address of the cartridge storing the requested image;
Frame address of the requested image.
The preferred embodiment of the present invention has twenty-eight (28) levels, and every level can store up to fifteen (15) cartridges. For each requested image retrieval, level address is decoded first and appropriate level is selected. Then the position address is decoded using an encoded rotational address, and that particular level is rotated to position the cartridge in the elevator path. The elevator has to pick up this cartridge and move it up to the reader for scanning the image. The `self learn` feature deals with rotational motion of the column and linear motion of the elevator.
The system learns by itself about rotational positions of all the cartridges stored as well as about park positions of the elevator (for all twenty-eight levels) for gentle pick up and drop off of the cartridge. It is very difficult to find out these addresses mathematically because of the mechanical variations and tolerances. In a manufacturing environment, it is a nightmare when these numbers vary from unit to unit. For reliable storage and retrieval operation, it is essential to have accurate information. Because of all these reasons, a self-learn technique was developed. The system learns to live with all the variations by self-teaching about all the necessary information. This technique also makes manufacturing of such a complex electro-mechanical system easy. It lets all the variables vary (within tolerance limit) from unit to unit and the system learns to live with it. In spite of all the variations, it ensures reliable storage and retrieval operation.
State of the art sensor technology is used. Reflected- and through-beam type are the two types of the sensors used. Sensors-flag system is used to detect the position and/or presence of the object to be detected. Sensors are throughout the system to keep track of the status of all the subsystems at all times. Sensor technology is also used to check health of the system from time to time. For error detection and error recovery, sensor technology is the heart of the technique. Sensors are ultra-high precision sensors.
Very sophisticated image processing techniques are developed to enhance image quality. Analog information on film is digitized to 256 grey levels. Convolution theory is used to bring information out from the noisy data. The grey level of each pixel is read and compared with the expected value. The expected value is calculated based on the grey level information of the neighboring pixels. Trends are taken into account for calculating expected values. When actual value and expected value is compared and the difference is greater than the tolerance allowed, then proper adjustments are made. Advanced filtering techniques are used. As a result of image processing, grey level data is converted to binary data. An alternate on-board enhancement option is also available using look up tables. Grey level output, if required for external image processing, is also available.
Image manipulation techniques are developed for addressing wider market need. Hardware and software is developed to scan the entire image or part of the image. Multiple scan windows per image can also be defined. Top and bottom of the image or only a middle section of the image can be scanned. Depending on the requirements, a window or multiple windows can be scanned at different resolutions. Depending on the scan window and resolution required, scan speed is calculated on-the-fly. Resolution is a very important factor of the image quality.
Information processing is another novel feature of this system. Information processing is the state-of-the-art concept in data processing and reduces drastically the amount of data to be handled as well as improving access time.
The present invention, with help of sensors and intelligent software, can recognize many of the errors and take proper corrective action without any intervention. It has, built in, three different levels of error recovery. The first level of recovery only affects the subsystem having an error condition. The second level of error recovery affects other subsystems also. The third and final level deals with fatal error conditions and stops the system operation. Operator intervention is required for third level of error recovery. The first two levels of error recovery is transparent to the user because the system recovers by itself by taking proper corrective actions.
A running error log of all the recoverable errors is kept. The log can be accessed using a utility program. The running log has a wrap-around capability which can be sorted for getting different kinds of information using the options of the utility program. Examples include a summary section of the log, types of errors occurred with error message, and error code and frequency of accuracy. The log provides vital information to the service engineer because it logs all the sequence of events leading to the error condition. If the system is functioning flawlessly, then at the time of 90 days preventive maintenance period, the log would give valuable information about recoverable errors. Proper action could be taken to take care of those errors. Without the log, those errors would have gone unnoticed because they are transparent to the user.
At power up, the system performs a very important self-diagnostic operation. It checks the health of different subsystems, sensors and basic key operations. Functioning of the hardware and sensors is checked thoroughly. If any malfunctioning is detected, the system tries to recover using error recovery logic. If the system recovers, then a log of all the events is recorded and then the system is put on-line. If the system cannot recover, then the proper error information is posted and system shuts itself down. Similar checks can also be performed using the system reset command. The objective of self-diagnostics is early detection of any malfunctions of hardware of any subsystem.
The system communicates with the outside world via a server and via a front panel LCD display. There is a two-line LCD display on the front panel. The first line displays the command the system has received. The second line displays status or error messages. Thus the server engineer knows exactly the status of the operation being performed. Error messages inform about the type of error condition that has occurred. Status or error information is also communicated to the server for every communication received. Some of these messages are displayed at the workstation for informing user about the status of the request made.
The following is a list of sensors used in the MegaSAR-420:
i. Elevator Home Sensor
ii. Knife In Sensor
iii. Knife Out Sensor
iv. Cartridge Detection Sensor
v. Take-up Reel Sensor
vi. Scanner Limit Sensors
vii. Pin-Home Sensors
The sensors are used to detect the presence of the individual components in their home position at the start up of the system and monitor these components during the progression of events during a cycle.
DIAGNOSTICS
Since the MegaSAR-420 is controlled by an embedded 486 PC, the diagnostics are the same full-screen programs that are used during design and manufacturing.
The controller PC includes a hard disk and is run as a normal DOS operating machine, preferably using "Windows"™. One of the programs that can be run is the normal MegaSAR-420 controller program, which accepts formatted commands on a serial port and executes them.
The command program always displays its status on a 2-line, 24 character LCD display. The first line of the display shows the command the MegaSAR II is currently executing, or the most recent command it executed. The second line displays the internal state of the MegaSAR-420 in real time. The state is one of the following:
Done, waiting for command
Error number and message
Current action, e.g.:
Rewinding film
Elevator returns cart
Column to home
Other programs may be run on the controller PC. These programs are a suite of exerciser/diagnostic programs that are full-screen oriented and menu driven. It is possible to execute these programs by one of the following methods.
Connect a normal keyboard and monitor to the controller PC
Load a program like CloseUp into the controller PC, direct connect to the controller PC via one of the serial ports with a diagnostic PC and operate the controller as though with a directly connected monitor and keyboard.
Do the same as the previous step, except put a pair of modems and a phone line between the controller PC and the diagnostic PC. This enables all the diagnostics to be executed remotely.
The controller PC displays its detailed internal status to a monitor in additional to the two-line control panel display. If CloseUp is run during normal MegaSAR-420 operation, remote, real-time display of the MegaSAR-420's activity can be achieved.
While this invention has been described in detail with particular reference to the preferred embodiment thereof, it will be understood that variations and modifications can be effected with the spirit and scope of the invention as previously described and as defined in the claims.
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The microfilm storage and retrieval (MegaSAR-420) system of the present invention puts microfilm images on line in a document imaging system. A MegaSAR-420 could be connected to a PC LAN base document imaging system with specialized software. A remote user then has the ability to retrieve images of the stored microfilm. The MegaSAR-420 doubles the capacity of devices in the prior art, specifically including at least twenty-eight spoked hub units and using cartridges having greater storage capacity.
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FIELD OF THE INVENTION
The present invention relates to the field of computerized search and retrieval systems. More particularly, this invention relates to a method and apparatus for characterizing and retrieving information based on the affect content of the information.
BACKGROUND OF THE INVENTION
Advances in electronic storage technology have resulted in the creation of vast databases of documents stored in electronic form. These databases can be accessed from remote locations around the world. Moreover, information is not only stored in electronic form but it is created in electronic form and disseminated throughout the world. Sources for the electronic creation of such information includes news and periodicals, as well as radio, television and Internet services. All of this information is also made available to the world through computer networks, such as the worldwide web, on a real time basis. As a result, vast amounts of information are available to a wide variety of individuals. The problem with this proliferation of electronic information, however, is the difficulty of accessing useful information in a timely manner. More particularly, how can these vast sources of information be personalized and used in decision support.
To assist in this effort, an analysis of the characteristics of textual information and an intuitive presentation to the user of those characteristics become increasingly important. For example, to match an individual user's interest profile on the worldwide web, it would be particularly useful to understand how the user felt about various topics. The information from which this judgment is made, however, is simply text (or associated voice or video signals converted to a text format) without an associated characterization. We can, however, introduce a human emotional dimension into textual understanding and representation. The analysis of the human emotional dimension of the textual information is referred to as affect analysis. Affect analysis of a text, however, has two sources of ambiguity: i) human emotions themselves and ii) words used in the natural language. The results of the analysis must be conveyed to the user in a form that allows the user to visualize the text affect quickly. In this way, responses to a web user's interest profile may be personalized on a real-time basis.
OBJECTS OF THE PRESENT INVENTION
It is an object of the present invention to provide a method and apparatus for extracting information from data sources.
It is another object of the present invention to extract information from data sources by analyzing the affect of the information.
It is still another object of the present invention to extract information from data sources by analyzing the affect of information and creating a graphical representation of that affect.
It is still a further object of the present invention to analyze the affect of information by quantifying the ambiguity in human emotions and the ambiguity in the natural language.
It is still another object of the present invention to combine affect analysis with other characteristics of textual information to improve the characterization of the information.
SUMMARY OF THE INVENTION
The present invention is a technique for analyzing affect in which ambiguity in both emotion and natural language is explicitly represented and processed through fuzzy logic. In particular, textual information is processed to i) isolate a vocabulary of words belonging to one or more emotions, ii) using multiple emotion categories and scalar metrics to represent the meaning of various words, iii) compute profiles for text documents based on the categories and scores of their component words, and iv) manipulate the profiles to visualize the texts. Lexical ambiguity is dealt with by allowing a single lexicon entry (domain word) to belong to multiple semantic categories. Imprecision is handled, not only via multiple category assignments, but also by allowing degrees of relatedness (centrality) between lexicon entries and their various categories. In addition to centralities, lexicon entries are also assigned numerical intensities, which represent the strength of the affect level described by that word.
After the affect words in a document are tagged, the fuzzy logic part of the system handles them by using fuzzy combination operators, set extension operators and a fuzzy thesaurus to analyze fuzzy sets representing affects. Instead of narrowing down or even eliminating the ambiguity and imprecision pervasive in the words of a natural language, fuzzy techniques provide an excellent framework for the computational management of ambiguity.
The representation vehicle in the system is a set of fuzzy semantic categories (affect categories) followed by their respective centralities and intensities, called an affect set. An affect set with attached centralities is always treated as a pure fuzzy set, and all fuzzy techniques applicable to fuzzy sets are applied to affect sets. Intensities are handled differently, in a more statistical way, since they involve less ambiguity and imprecision and more quantitative aspects of the text. Graphical representation of the affect set is used as a tool for decision making.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram that illustrates a computer system for performing affect analysis according to one embodiment of the present invention.
FIG. 2 is a flow chart for carrying out affect analysis according to one embodiment of the present invention.
FIG. 3 is a flow chart illustrating a process for query expansion according to one embodiment of the present invention.
FIG. 4 is a flow chart for carrying out classification analysis according to one embodiment of the present invention.
FIG. 5 is a diagram illustrating visualization of the affect analysis according to one embodiment of the present invention.
FIG. 6 is a diagram illustrating visualization of the affect analysis according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram of a computer system used for retrieving information from a database. Computer 20 comprises a central processing unit (CPU) 30 and main memory 40 . Computer 20 is connected to an Input/Output (I/O) system 10 and disk storage unit 50 . The I/O system 10 includes a display 5 , a keyboard 7 and a mouse 9 . Furthermore, this computer system is connected to a variety of networks for communicating with other computers and obtaining access to remote databases. Among the networks connected to this computer system is the worldwide web 55 , an intranet 57 , private external network 59 . In general, the disk storage unit 50 stores the program for operating the computer system and it stores the documents of the database. The computer 20 interacts with the IO system 10 and the disk storage unit 50 . The computer 20 executes operations according to instructions contained in a program that is retrieved from the disk storage unit 50 . This program causes the computer 20 to retrieve the text of documents, or parts thereof, which are stored in a database located either in disk storage 50 or in a storage location accessible over a network. These instructions also cause information received over a network to be distributed to specific individuals over a network based on the content of the information.
The process of analyzing the affect of any document in a database according to the present invention requires the generation of an affect set for a document. FIG. 2 illustrates the process for creating a document affect set. An affect set is simply a set of affect categories for a text document with associated centralities and intensities (discussed below). As illustrated in FIG. 2, a document 100 is initially tagged 102 . Tagging the document involves parsing the document into individual words and normalizing the words according to the English language using the grammar rules 110 . This would involve converting inflected word forms into base forms (e.g., “goes” to “go”) by rule or by a listing or look up table. The normalized words are then tagged—that is, associated with category designations and numerical representations. Once the document has been tagged 112 , the normalized words are looked up in an affect lexicon 104 . If a word has a lexicon entry, that entry and its associated centrality and intensity scores are also selected, tagged and added to the initial affect set 114 .
The affect lexicon 104 is a list of words (and associated parameters) that pertain to emotion. The affect lexicon contains entries of the form:
<lexical_entry> <part_of_speech_tag>
<affect_category> <centrality>
<intensity>
as in
“arrogance” sn superiority 0.7 0.9.
A lexical entry is a word that has an affectual connotation or denotes affect directly. An affect lexicon is simply a table correlating words with affect entries and having an assigned centrality and intensity. An affect lexicon may be added to directly or from processing documents. An affect lexicon may have 5,000 or more entries.
Since ambiguity sometimes depends on a word's part of speech (POS)—and since NLP processing allows us to differentiate parts of speech in documents—we have included POS information 102 for lexicon entries. For example, the word alert has different category assignments associated with different POS values:
“alert” adj intelligence
“alert” vb warning
That is, the adjective alert means quick to perceive and act—a kind of intelligence—while the verb alert means to call to a state of readiness—a kind of warning.
A word's POS can affect its centrality or intensity values as well as its category assignment. For example, lexicon entries with POS, categories, and centrality degrees for the word craze include:
“craze” vb insanity 0.8
“craze” sn insanity 0.5
That is, the verb craze belongs to affect category insanity with a degree of 0.8; the singular noun craze belongs to the same category with a degree of 0.5. This reflects the fact that the verb craze means to make insane or as if insane—very central to the insanity category; while the noun craze means an exaggerated and often transient enthusiasm—i.e., it belongs to insanity only in a less central, more metaphorical sense.
Many affect categories may not strictly involve only affect: for example, deprivation, health, and intelligence are only marginally affects, and death, destruction and justice are not affects at all. Such categories have been created in cases where (a) some significant portion of an affect word's meaning cannot be captured using pure affect categories; and (b) the same meaning component recurred again and again in the vocabulary at issue. For example, a word like corpse certainly entails some affect, and can plausibly be assigned to categories sadness and horror; at the same time, a part of its meaning is obviously being missed by those categorizations. Moreover, words like assassination, cyanide, execute, funeral, genocide, and homicidal share this missing meaning component. In the present invention, there are not-strictly-affect categories to handle such words.
At present, there are 83 affect categories. Each affect category has an explicit opposite, with three exceptions.
1. Centrality degrees range from 0 to 1 by increments of 0.1. A word which belongs to several affect categories will generally have different centralities from category to category, as in this example:
“emasculate” vb weakness 0.7
“emasculate” vb lack 0.4
“emasculate” vb violence 0.3
That is, the element of weakness is fairly central in the word emasculate (a rating of 0.7); the notion of a specific lack is also present but less central (rating of 0.4); and an additional element of violence is possible but not really necessary (rating of 0.3).
In assigning centrality, typical questions the developer should answer for each entry/affect category include: To what extent is affect X related to category C? To what extent does affect X co-occur with category C? To what extent can affect X be replaced with category C in the text, without changing the meaning?
Since centralities indicate the presence of a certain quality (represented by the appropriate affect category) for a given lexicon entry, centralities are handled as fuzzy membership degrees.
2. In addition to centralities, lexicon entries are also assigned numerical intensities, which represent the strength of the affect level described by that entry. Intensity degrees, like centrality degrees, range from 0 to 1 by increments of 0.1. Here are some examples (the second number represents the intensity):
“abhor” vb repulsion 1.0 1.0
“contempt” sn repulsion 0.6 0.7
“aversion” sn repulsion 0.9 0.5
“displeasure” sn repulsion 0.3 0.3
“fat” adj repulsion 0.2 0.1
All of these words have some element or connotation of repulsion. A word like abhor expresses very intense repulsion (as well as being very central to the concept of repulsion); contempt, aversion, and displeasure are progressively less intense on the repulsion scale. A word like fat—which is not at all central to the repulsion concept, as expressed by its low centrality of 0.2, but which has some slight overtones of repulsion to many Americans—is an objective description, hence hardly an affect word at all. This is reflected in its low intensity score of 0.1. In general, scores below 0.4 on both scales tend to be the most subjective and notional.
A word that belongs to several affect categories will generally have different intensities from category to category, as in this example:
“avenge” vb conflict 0.1 0.8
“avenge” vb violence 0.8 0.5
“avenge” vb justice 0.4 0.7
That is, avenge is a high-intensity conflict word, but only a moderate-intensity word with respect to violence; its intensity rating for justice is somewhere in between.
Assigning category labels and membership degrees to lexicon entries is a very subjective process. In the present invention, the assignments have been made by a single linguist. They are obviously influenced by the linguist's own experience, reading background, and (since affects are in question) personal/emotional background and prejudices. Repeated iterations and use of additional profiles or personal lexicons will allow the individual user to fine-tune membership degrees and accommodate his or her own subjective criteria.
The affect lexicon can be expanded through the use of a fuzzy thesaurus. The fuzzy thesaurus is generated by the system from the affect lexicon. It is generated using max-min combination: R ( A C i , A C j ) = A ∈ AffectLexicon { C A ( A C i ) C A ( A C j ) }
where AC i , AC j are affect categories whose relationship degree R(AC i , AC j ) we want to compute, and C A (AC i , C A (AC j ) are the centralities of affect categories AC i , AC j with respect to affect A. C A (AC i ), C A (AC j ) is taken directly from the affect lexicon.
The fuzzy thesaurus establishes relationships between pairs of affect categories, based on the centralities of lexical items assigned to both categories in the lexicon. It contains entries of the form:
<affect_category — 1>,
<affect_category — 2>,
<relationship_degree>
as in
attraction, love, 0.8
arranged in a matrix. When the relationship degree is equal to 0, no entry is recorded in the fuzzy thesaurus. When the relationship degree is equal to 1.0, we say that we have discovered affectual synonyms, as in
conflict, violence, 1.0
pain, harm, 1.0
Non-synonymous pairs having entries in the matrix are related to some specified degree.
The fuzzy thesaurus is primarily used for expansion of affect sets. For example, if an affect set consists of love/0.7, and the user opts to expand it using the fuzzy thesaurus, related categories such as attraction will be added to the set automatically.
Affect category groups are generated automatically by clustering the fuzzy thesaurus. In this process, affect categories with high similarity degrees (as defined in the fuzzy thesaurus) are grouped together. For example, we might find that love, attraction, happiness, desire and pleasure formed one affect category group, while repulsion, horror, inferiority and pain formed another. If the automatically-created groups are not so intuitively natural as this example, the user can edit them.
In FIG. 2, the initial affect set 114 for the following sentence:
His first film, Un Chien Andalou (1928), co-directed by Salvador Dali, caused an uproar (he filled his pockets with stones, he wrote in his autobiography, so he would have something to throw if the audience attacked him).
could be for example,
“uproar” sn violence 0.6 0.6
“attack” vb violence 0.9 0.8
“attack” vb conflict 0.8 0.7
According to FIG. 2, once the initial affect set has been created 114 , the centralities and intensities are combined in step 106 .
The following algorithm describes how to reduce the initial affect set by combining the centralities and intensities of recurring categories.
1. For each affect category that appears in the tagging set:
a) Compute the maximal centrality (fuzzy union) of all centralities attached to that affect category in the tagged document. The result is the centrality of that category for the document as a whole.
b) Compute the average intensity of all intensities attached to that affect category in the tagged document. The result is the intensity of that category for the document as a whole.
2. Combine the counts of each affect category with its intensities using simple averaging, to yield the overall intensity score for the document.
As an example, consider the following document:
Luis Bunuel's The Exterminating Angel (1962) is a macabre comedy, a mordant view of human nature that suggests we harbor savage instincts and unspeakable secrets. Take a group of prosperous dinner guests and pen them up long enough, he suggests, and they'll turn on one another like rats in an overpopulation study. Bunuel begins with small, alarming portents. The cook and the servants suddenly put on their coats and escape, just as the dinner guests are arriving. The hostess is furious; she planned an after-dinner entertainment involving a bear and two sheep. Now it will have to be canceled. It is typical of Bunuel that such surrealistic touches are dropped in without comment. The dinner party is a success. The guests whisper slanders about each other, their eyes playing across the faces of their fellow guests with greed, lust and envy. After dinner, they stroll into the drawing room, where we glimpse a woman's purse, filled with chicken feathers and rooster claws.
After fuzzy semantic tagging, the following output is produced:
macabre, adj, death, 0.50, 0.60
macabre, adj, horror, 0.90, 0.60
comedy, sn, humor, 1.00, 0.60
mordant, adj, pain, 0.3, 0.5
mordant, adj, clarity, 0.4, 0.8
savage, adj, violence, 1.00, 1.00
instinct, sn, intelligence, 0.50, 0.20
instinct, sn, innocence, 0.40, 0.60
secret, sn, slyness, 0.50, 0.50
secret, sn, deception, 0.50, 0.50
prosperous, adj, surfeit, 0.50, 0.50
rat, sn, disloyalty, 0.30, 0.90
rat, sn, horror, 0.20, 0.60
rat, sn, repulsion, 0.60, 0.70
alarm, vb, fear, 0.60, 0.50
alarm, vb, warning, 0.70, 0.70
alarm, vb, excitement, 0.80, 0.80
portent, sn, promise, 0.70, 0.90
portent, sn, warning, 1.00, 0.80
escape, vb, aversion, 0.90, 0.60
furious, adj, violence, 0.80, 0.90
furious, adj, anger, 1.00, 0.80
entertainment, sn, pleasure, 0.7, 0.6
cancel, vb, failure, 0.30, 0.50
cancel, vb, lack, 0.50, 0.40
surrealistic, adj, absurdity, 0.80, 0.50
surrealistic, adj, creation, 0.30, 0.40
surrealistic, adj, insanity, 0.50, 0.30
surrealistic, adj, surprise, 0.30, 0.30
success, sn, success, 1.00, 0.60
whisper, vb, slyness, 0.40, 0.50
whisper, vb, slander, 0.40, 0.40
slander, vb, slander, 1.0, 0.9
play, vb, creation, 0.30, 0.30
play, vb, pleasure, 0.70, 0.50
play, vb, innocence, 0.20, 0.40
greed, sn, desire, 0.60, 1.00
greed, sn, greed, 1.00, 0.70
lust, vb, desire, 0.80, 0.90
envy, sn, desire, 0.7, 0.6
envy, sn, greed, 0.7, 0.6
envy, sn, inferiority, 0.4, 0.4
envy, sn, lack, 0.5, 0.5
envy, sn, slyness, 0.5, 0.6
fill, sn, surfeit, 0.70, 0.40
After tagging, recurring affect categories are combined into a set of unique tags, with centralities and intensities that accurately reflect the overall document content. For that purpose, the original affect words and the POS information are discarded, and the intensities and centralities of the remaining affect categories are combined.
Intensities and centralities are handled differently, since they represent different types of information. Centrality indicates the purity of a quality represented by an affect category. Intensity indicates the strength of that quality. Thus the number of occurrences of a particular affect category in a document does not affect its centrality, but does affect its intensity. Centrality, as the purity of a quality, depends on the maximal centrality over all instances of that affect category in a particular document. That is to say, the maximal purity of the quality in the document already implies vaguer or more diluted degrees of that quality, and is therefore appropriate as the combined centrality/purity for that category. The appropriate operation here is thus fuzzy union. On the other hand, the more times an affect category is present in the document, and the higher the intensities of its instances, the higher will be the combined intensity/strength attached to it. The intensity attached to an affect category is computed as a simple average of all the intensities attached to the affect category's instances.
After computing centralities using fuzzy union, and arranging elements so that the elements with higher membership degrees (centralities) are at the front of the fuzzy set, the fuzzy set is represented by: violence 1.0 + humor 1.0 + warning 1.0 + anger 1.0 + success 1.0 + slander 1.0 + greed 1.0 + horror 0.90 + aversion 0.90 + absurity 0.80 + excitement 0.80 + desire 0.80 + pleasure 0.70 + promise 0.70 + surfeit 0.70 + repulsion 0.60 + fear 0.60 + lack 0.50 + death 0.50 + slyness 0.50 + intelligence 0.50 + deception 0.50 + insanity 0.50 + clarity 0.40 + innocence 0.40 + inferiority 0.40 pain 0.30 + disloyalty 0.30 + failure 0.30 + creation 0.30 + surprise 0.30
This form of representation for the fuzzy set of affect categories enables us easily to spot predominant affects in the document. The meaning of this affect category set is that the document has a high degree of violence, humor, warning, anger, success, slander, greed, horror, aversion, absurdity, excitement, desire, pleasure, promise and surfeit; a medium degree of repulsion, fear, lack, death, slyness, intelligence, deception, insanity, clarity, innocence and inferiority; and a low degree of pain, disloyalty, failure, creation and surprise.
Other metrics for the document can also be computed. For example, a simple weighted average over all affect category instances and their respective intensities may be used to compute overall intensity: I ( D ) = ∑ j = 1 N I ( A C I j ) N ,
where I(D) is overall intensity of a document D, N is the total number of affect category instances in the document D, and I(ACI j ) is the intensity of an affect category instance ACI j . For a given document, overall intensity is 0.597. Overall intensity is used to detect documents with offensive content. For example, high overall intensity (over 0.7) in combination with a specific centrality profile ( distaste 0.8 + violence 0.9 + pain 0.8 )
may indicate offensive and undesirable content.
Also, the affect quotient shows the percentage of the document that contains affect words, with respect to the whole document. The whole document is considered to be the total number of words that normalize to a singular noun, verb or adjective (i.e., the set of content words).
Still further, the cardinality of an affect set is computed as the sum of all centralities of the affect categories composing that affect set: card ( D i ) = ∑ j = 1 N i C ( A C i , j ) .
For a document affect set, this number can give us a measure of the abundance of particular feelings for comparison with the cardinalities of other documents. Depending on the content, it may indicate sophistication of expression on the part of the document's author, depth and intricacy of feelings, detail of description, etc.
Additionally, the fuzziness of an affect set indicates how balanced the centralities or intensities of the affect categories are. It is computed using: F ( D i ) = card ( A ⋂ A _ ) card ( A ⋃ A _ ) ,
where A denotes an affect set, and {overscore (A)} denotes its complement. The affect set is assumed to be normalized, which means that maximal centrality of a set is 1.0. The more centralities are close to 0.5, the higher the fuzziness of the affect set. When all centralities are 1.0, the affect set is crisp, and therefore its fuzziness is 0.
Fuzziness shows how balanced the feelings are in an affect set. Fuzziness of 0.0 indicates the same degree of quality for the various feelings in the affect set. It may indicate direct, unambiguous expression of emotion. Fuzziness of 1.0 may indicate a highly ambiguous expression of emotion from a conflicted or uncommitted person.
As illustrated in FIG. 2, once the centralities and intensities have been combined, a complete document affect set 108 has been created. A document affect set is then generated for each document in the database. Specific affect related information extraction can then be performed on the database. In particular, extraction is performed by computing the similarity between the affect set (for each document in the database) and affect profile for a query.
A query, like any other document, can be represented as a set of affect categories with attached centralities and intensities. A complex query may also contain an overall intensity, combined centralities and intensities for each affect category, only a centrality for each affect category, or only an intensity for each affect category.
A query can be composed of any number of affect categories, with associated centralities and intensities. Complex affect categories must be defined using the already available affect categories. An example of a query is: attractiveness 0.7 + happiness 0.8 + confusion 0.9
Raw affects (i.e., not affect categories but ordinary affect words) can be used in queries, with centralities. When an affect word is in neither the personal lexicon nor the general lexicon, the user is asked to define it by using existing affect categories.
Any affect set (query, document affect set, profile) can be expanded using the fuzzy thesaurus at the level of affect categories. The typical operation for expansion is min-max composition, although other composition operations can be used. Query expansion is a particular case of more general affect set expansion. The same method can be applied to any affect set: one representing a document, a profile, or a group of documents. Query expansion is performed using the min-max composition rule for expanding fuzzy queries with a fuzzy thesaurus. FIG. 3 represents this process graphically. As an example, let the relevant part of the fuzzy thesaurus be humor excitement attractiveness intelligence [ humor excitement attractiveness intelligence 1.0 0.6 0.0 0.8 0.6 1.0 0.9 0.7 0.0 0.9 1.0 0.8 0.8 0.7 0.8 1.0 ]
Assuming that a user wants to get documents containing humor with a degree of about 0.7: humor 0.7
From the fuzzy thesaurus, using mini-max composition, we expand this query as follows: humor 0.7 o humor excitement attractiveness intelligence [ humor excitement attractiveness intelligence 1.0 0.6 0.0 0.8 0.6 1.0 0.9 0.7 0.0 0.9 1.0 0.8 0.8 0.7 0.8 1.0 ] = humor 0.7 ohumor [ humor excitement attractiveness intelligence 1.0 0.6 0.0 0.8 ] = humor 0.7 + excitement 0.6 + intelligence 0.7
The resulting fuzzy set represents our expanded query.
This procedure can be represented with a formula:
Q
E
=QoT,
where Q represents the fuzzy query, T the fuzzy thesaurus, Q E the expanded fuzzy query, and o the composition operation, in this case min-max composition: C Q E = A C x ∈ X { C Q ( A C x ) R D T ( A C x , A C y ) } .
In addition to performing information extraction based on centrality, extraction can be performed using intensity as well. An intensity-based query will return documents with intensities greater than or equal to the respective intensities of the affect categories in the query. Only those documents satisfying all intensity constraints are returned. Intensity-based information extraction can be combined with centrality-based extraction. In such a case, intensity-based extraction is carried out first. Then centrality-based extraction is carried out on the returned document set. In other words, the requested intensity acts as a constraint in the second extraction step. Yet another possibility is to extract documents with overall intensity above or below some stated threshold value.
The purpose of fuzzy retrieval is to return all documents that contain affect categories with centrality profiles similar to the centrality profile of the document. Given the expanded query from the previous section, Q = humor 0.7 + excitement 0.6 + intelligence 0.7 ,
and this document affect set, D 1 = humor 1.0 + superiority 1.0 + crime 1.0 + intelligence 0.90 + violence 0.90 + excitement 0.80 + conflict 0.80 + warning 0.70 + failure 0.50 + attractiveness 0.50 + security 0.50 + distaste 0.40 + justice 0.20 + fear 0.20 + pain 0.10
the document would be returned by the query.
The degree to which a query is satisfied is computed by using a pair of measures: Π ( Q , D i ) = Π i = sup min j ( Q ( a j ) , D i ( a j ) ) , and N ( Q , D i ) = N i = inf max j ( Q ( a j ) , 1 - D i ( a j ) ) ,
where Π i denotes the possibility measure and N i denotes the necessity measure that document D i matches the query Q. Using our example, we have Π ( Q , D i ) = Π i = sup [ min j ( 0.7 , 1.0 ) , min ( 0.6 , 0.80 ) , min ( 0.7 , 0.9 ) ) = sup [ 0.7 , 0.6 , 0.7 ] = 0.7 , and N ( Q , D i ) = N i = inf [ max j ( 0.7 , 1 - 1.0 ) , max ( 0.6 , 1 - 0.80 ) , max ( 0.7 , 1 - 0.9 ) ) = inf [ 0.7 , 0.6 , 0.7 ] = 0.6
A pair of threshold values is defined for which a query is satisfied with the formula:
(Π t ,N t )=(0.6,0.4).
And, since (Π i ,N i )>(Π t ,N t ) (where>is the “pairwise greater than” operator), the document will be returned.
Fuzzy classification (or filtering) is a process as shown in FIG. 4 in which affect sets from documents 150 are matched 155 with predefined affect profiles 160 containing affect category tags to yield document groupings into different categories. Profiles are described as a list of affect categories with attached centralities and intensities (an affect set). In the process of classification, a single document is matched with a profile using the same method (scoring 165 and thresholding 170) as in fuzzy retrieval. Depending on the goal of classification, a profile can be expanded prior to matching using the query expansion feature. After matching, if the matching criterion described in fuzzy retrieval is satisfied, the document becomes a member of the category (through routing 175 and group 180) described by the current profile.
This classification approach has the following implications.
A document can be routed to multiple categories, and the thresholding mechanism can be fine-tuned to pass documents having different affect structures.
Profiles can be automatically adjusted to reflect the current content of the class represented by that profile.
Clustering can be performed based on:
1. User-defined classification categories (profiles)
2. Centralities for a specific category or a group of categories
3. Intensity degrees for a specific category or group of categories, or overall intensity degrees for the documents
Documents containing many affect categories with high intensities may be documents with offensive content, inappropriate for certain groups. Documents with high centralities attached to some affect categories can be also grouped and filtered out, for example documents with a high centrality score for affect category violence.
Information Extraction, Classification and Clustering using affect analysis are particularly applicable to network, internet or multimedia (including audio and video) data sources. For example, using affect analysis on information returned from an internet search engine, that information can be analyzed for its violence affect. To the extent information has a violence centrality and intensity above a defined threshold, that information may be specially routed or not delivered or the source of the information itself tagged for special treatment (i.e., not accessed). This same process is applicable to audio and video files that are tagged or analyzed for their language content.
Additionally, affect analysis can be combined with other information to further improve document characterization. In particular, document structure from punctuation marks can be combined with affect analysis to indicate affect characteristics of different parts of a document. For example, sentences (marked by periods) can be analyzed for affect and then combined. The affect of a plurality of sentences can be combined into an affect for a paragraph (marked by indentations). Paragraph affect can be further combined to section affect wherein each section is defined by topic headings. Furthermore, section affect can be combined to create a document affect and document affects can be combined to describe affect for a database of documents. Other types of document structures such as extracted entities (persons, places, things), typed fields (using pre-existing analysis), quotes, or indices may have assigned affect or affect generated by analysis on the individual structure. These affect characteristics can then be combined with sentence or document affect to further characterize the information being analyzed.
Assigning centralities to affect categories in a query can be carried out using visualization with polygons, which is the same as visual query definition. For example, a query humor 0.7 + excitement 0.6 + intelligence 0.7 + fear 0.4 + love 0.8
would be represented as a pentagon, as shown in FIG. 5 . Affect category space with attached centralities can be visualized in a number of ways because, among other reasons, centrality and intensity have been quantified. For example, each affect category can be represented as a point on the perimeter of a circle and opposite affect categories placed on opposite sides of the circle with respect to the center point. Since each document is tagged with one or more affect categories, and since centralities are between 0 and 1, each document can be represented as an n-sided polygon. As noted above, FIG. 5 illustrates how the query {humor/0.7+excitement/0.6+intelligence/0.7+fear/0.4+love/0.8} would be represented. Other types of visualization tools include grouping opposite emotional categories according to average values using two or three dimensional maps or a linear arrangement. In particular, FIG. 6 illustrates a visualization of five different personal affect category profiles resulting from a movie preference list. This visualization of the affect categories illustrates how different persons react to the same information. Radar charts are particularly useful for this visualization although other types of charts may be used. From the radar chart of FIG. 6, affects with higher centrality are easily visible. Such a chart is useful for observing individual affect categories for a certain person or comparison of affect categories for different persons.
While this invention has been particularly described and illustrated with reference to a preferred embodiment, it will be understood by one of skill in the art that changes in the above description or illustrations may be made with respect to form or detail without departing from the spirit and scope of the invention.
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A technique for analyzing affect in which ambiguity in both emotion and natural language is explicitly represented and processed through fuzzy logic. In particular, textual information is processed to i) isolate a vocabulary of words belonging to an emotion, ii) represent the meaning of each word belonging to that emotion using multiple categories and scalar metrics, iii) compute profiles for text documents based on the categories and scores of their component words, and iv) manipulate the profiles to visualize the texts. The representation vehicle in the system is a set of fuzzy semantic categories (affect categories) followed by their respective centralities (degrees of relatedness between lexicon entries and their various categories) and intensities (representative of the strength of the affect level described by that word) called an affect set. A graphical representation of the affect set can also be used as a tool for decision making.
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This invention relates to methods and apparatus for sealing and insulating roofs and more particularly to systems employing inexpensive waterproof membranes and insulating materials to repair leaky and poorly insulated roofs of house trailers and other habitations with simple tools requiring minimal skills.
BACKGROUND OF THE INVENTION
House trailers and other inexpensive residential structures are often manufactured with inadequate roofs and roof insulation. The costs of heating and cooling these structures are excessive. Furthermore, in cold weather the moisture generated internally condenses on the ceiling, or within the insulation if the insulation is not sealed from the inside. The problems are compounded by leaks in the roof which may allow rain water to saturate the insulation. Water destroys its insulating properties. Access to the insulating space between roof and ceiling is generally not feasible to replace or add insulation. Consequently, repair of leaky roofs and provision of adequate insulation are expensive problems for people who can least afford them.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the invention to provide a system of waterproof sealing and insulating of a roof that is external to the original roof for ease of application.
It is a further object to provide a system that can be applied by individuals without special skills such as a do-it-yourself kit and process.
It is a further object to provide a system that includes at least three layers to the existing roof: (a) a first, complete waterproof sealing layer against the roof; (b) a second, insulating layer covering the roof; and (c) a third, complete waterproof sealing layer over the insulation tha seals the insulation completely between the two waterproof layers so that moisture cannot enter the insulation from above or below.
The invention includes a unique edge-sealing means that fastens to the upper walls, continuously encircling the structure below the roof. This edge sealing means enables the unskilled operator to use inexpensive membranes and roll insulation to fix the membranes and insulation in place and seal them together with ordinary tools. An optional cover means can be applied to further secure the sealing means and provide a drip strip so that water does not run down the walls. The invention provides means for securing the edge sealing means to the trailer. And the edge sealing means is so arranged that any leakage at the points of securing to the trailer will not result in moisture leaking into the insulation or into the residential structure.
These objects and advantages and others will become apparent to those skilled in the art from the following disclosure of the preferred embodiment of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of a house trailer with the invention in place with various portions broken away to illustrate the layered application to a leaky roof.
FIG. 2 is a perspective view in partial cross section of the cover element for the sealing strip.
FIG. 3 is a perspective view in partial cross section of the sealing strip.
FIG. 4 is a cross section view through plane 4--4 of FIG. 1.
FIG. 5 is a cross section view through plane 5--5 of FIG. 1.
FIG. 6 is a cross section view through plane 6--6 of FIG. 1.
FIG. 7 is a cross section view through plane 7--7 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 3 wherein is illustrated a short length of the sealing strip 1, which is a profile extrusion of a corrosion resistant metal such as aluminum or a plastic such as polyvinyl chloride that can be inexpensively produced in quantity. A v-shaped groove 2 provides a guide for drilling periodic holes 3 through the strip for securing the strip to the upper wall 16 of trailer 13 (FIG. 1) by screws, bolts, blind rivets or other fastening means. The groove 2 countersinks the head of the rivet below the surface of the strip 1. Phantom lines 4 (FIG. 3) indicate the path of a hole that might be drilled at the level of the cross section. These fastener holes may be drilled at various locations along the length of the strip at the discretion of the user to best anchor the strip to the structure, such as at vertical studs. Resilient elements 5 and 6 may seal the strip tightly against the structure when fasteners are secured to stop the entry of water. The sealing surface 7 may include adhesive or an adhesive caulking material may be used in conjunction with or in place of elements 5 and 6. The elements 5 and 6 may alternatively be of the same material as the strip itself. An effective adhesive on surface 7 may eliminate the need for fasteners and fastener holes in strip and structure. Three receiving channels 8,9 and 10 are shown in the strip for receiving webs of material to be sealed in place by resilient splines in a manner well known in the art of window screens. Webs may be replaced without disturbing the strip.
Each channel has a gently curving upper edge 12 to prevent accidental cutting of the web secured in the channel. A screw-receiving slot 11 has longitudinal internal ridges 36 that provide easy insertion and holding of self-tapping machine screws without requiring hole drilling that might penetrate the strip.
Referring now to FIG. 1, a typical house trailer 13 has a roof 14 with leaking holes 15. These leaks not only allow water to enter the living space, but also to penetrate the roof insulation, rendering it ineffective. Because the insulation is inaccessible, it is costly to replace when repairing the roof by conventional methods.
The process of installing new insulation and waterproofing using the instant invention is illustrated by breaking away successive layers. The sealing strip 1 is first secured permanently continuously all around the upper wall 16 of trailer 13. This may include drilling holes 3 through strip 1 at groove 2 and use of adhesive sealant. The hole may be drilled into or through the trailer wall to receive screws or rivets. Next a web of waterproof material is drawn completely over the roof. This is a seamless membrane large enough to cover the entire roof and extend down over the strip on all sides. Since this first membrane will be covered by other materials, it need not provide great resistance to external trauma. Polyethylene films of this size, often used as construction and agricultural covers because of the low cost, are readily available and are relatively permanent in this application. At the corners 18, they may be folded over much like the "hospital corner" for bedsheets to make a snug, seamless corner. As shown in the detail of FIG. 4, a spline 19 is forced into channel 8 over the membrane to continuously seal the membrane water tight into the channel. Blind rivet 20, countersunk in groove 2 secures the strip 1 to wall 16. For clarity of illustration, the strip is not shown tight against the wall with resilient elements 5 and 6 deformed to a weatherstrip seal as they would be in actual use. Furthermore, the channels 8,9 and 10 would preferably be closer together than herein illustrated. After sealing membrane 17 water tight into channel 8 with spline 19, the membrane is trimmed off just below the spline to expose channel 9. It can be seen that this process provides a complete continuous seamless watertight cap for the roof that extends down below any holes 3 drilled for fasteners as well as any roof leaks.
Next, a layer of thermal insulation is applied to the roof. This may be in the form of fiberglass insulation three inches thick supplied in rolls four feet wide. To facilitate installation, this is cut into lengths that extend transversely across the roof from edge 22 to edge 23. These strips of insulation are fastened with tape or adhesive to strips of plastic 24 that are long enough to extend over strip 1 and be reached from ground level. Alternatively, the plastic strip may be cut to twice the width of the insulation and folded over it to envelop the insulation. The plastic strip 24 holds the insulation 21 firmly down on the roof (FIG. 5) and it is inserted into the second channel 9 of sealing strip 1 and secured by spline 25. The strips of insulation are butted tightly against each other along their length to ensure a complete layer of insulation over the roof. To seal all of these seams water-tight would be a difficult task. Instead, an additional waterproof membrane 26 without seams is now placed over the insulation and sealed in place in the continuous third channel 10 by spline 27, thereby forming a complete waterproof chamber enclosing all insulation top and bottom without seams and sealed water-tight continuously along its edges by sealing strip 1 (FIG. 6). Furthermore, the water-tight assembly caps the entire roof and securing holes. This outer membrane 26 may be of a more sturdy composition to resist damage from external forces. It may be formed of fiber reinforced polyethylene or vinyl coated nylon. In an alternative embodiment, not shown, the membrane 26 may also be an inexpensive polyethylene film and an additional layer of heavy fabric may be applied to the surface and sealed into a fourth channel in strip 1. This fabric need not be seamless or waterproof since it acts only as a protection for the waterproof membrane 26.
It may be desirable to protectively cover the sealing splines after the membranes have been installed with cover strip 28 (FIGS. 2,7,1). Cover strip 28 includes top and bottom resilient weatherstrips 33 and 34 and a groove 29 that serves as a guide for drilling holes 30 as indicated by phantom lines 31 at the level of the cross section in FIG. 2. The drilled hole receives a self-tapping screw 32 which engages the serrated slot 11 in sealing strip 1, while the groove provides a countersink for the head of the screw 32. A downward projection 35 may be provided to serve as a drip strip to help keep rainwater off the wall. Caulking sealant may also be applied to the finished assembly to further enclose the seals.
The above disclosed invention has a number of particular features which should preferably be employed in combination although each is useful separately without departure from the scope of the invention. While I have shown and described the preferred embodiments of my invention, it will be understood that the invention may be embodied otherwise than as herein specifically illustrated or described, and that certain changes in the form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea of principles of the invention within the scope of the appended claims.
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A process and a system for applying insulation and water sealing to roofs such as house trailers includes a sealing strip that fastens completely around the upper wall. This strip seals the edges of successive layers of a first waterproof membrane, a layer of thermal insulation and a second waterproof membrane. The combination provides a layer of thermal insulation completely enclosed in waterproof membranes. This maintains the effectiveness of the insulation by preventing the entry of moisture. The system permits use of readily available, inexpensive materials. The system may be applied by the owner because it requires no special tools or skills.
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TECHNICAL FIELD
[0001] The present technology relates to adjusting features on a head-up display. More specifically, the technology relates to adjusting features on a head-up display based on contextual inputs to allow an enhanced user experience.
BACKGROUND
[0002] A head-up display, or HUD, is a display that presents data in a partially transparent manner and at a position allowing a user to see it without having to look away from his/her usual viewpoint (e.g., directly in front of him/her). Although developed for military use, HUDs are now used in commercial aircraft, automobiles, computer gaming, and other applications.
[0003] HUD images presented from virtual image forming systems are typically located in front of a windshield of the vehicle, e.g., 1 to 3 meters from the driver's eye. Alternately, HUD images presented from transparent display technology appear at the location of the transparent display, typically at the windshield.
[0004] Within vehicles, HUDs can be used to project virtual images or vehicle parameter data in front of the vehicle windshield or surface so that the image is in or immediately adjacent to the operator's line of sight. Vehicle HUD systems can project data based on information received from operating components (e.g., sensors) internal to the vehicle to, for example, notify users of lane markings, identify proximity of another vehicle, or provide nearby landmark information.
[0005] HUDs may also receive and project information from information systems external to the vehicle, such as navigational system on a smartphone. Navigational information presented by the HUD may include, for example, projecting distance to a next turn and current speed of the vehicle as compared to a speed limit, including an alert if the speed limit is exceeded. External system information advising what lane to be in for an upcoming maneuver or warning the user of potential traffic delays can also be presented on the HUD.
[0006] One issue with present HUD technology for vehicles is that the HUD systems typically contain fixed system parameters. These system parameters are almost always preset (e.g., from the factory). Additionally, the HUD system parameters are typically fixed, offering the user few, if any, options to adjust to changing conditions.
[0007] Some HUDs automatically adjust a brightness level associated with the display, so projections are clearly visible in direct sunlight or at night. The ability to adjust brightness is typically based only on the existence of an ambient light sensor that is sensitive to diffuse light sources. However, other forms of light, e.g., from spatially directed sources in the forward field, may not prompt a change in the brightness level of the HUD and the displayed image may not be clearly visible.
[0008] Furthermore, present HUD technology does not allow adjustment of other preset system parameters, except specific adjustments in the brightness level. Specifically, the preset system parameters do not have the ability to adjust based on changing conditions internal or external to the vehicle.
SUMMARY
[0009] The need exists for systems and methods to adjust a HUD based on environmental and user-physiological inputs. The proposed systems and methods identify features of the HUD that can be adjusted to provide an enhanced user experience.
[0010] It is an objective of the present technology to create customized projections to the user based on changing environmental conditions and user behavior conditions. User attributes (e.g., height or eye level), prior user actions and preferences of the user are considered in customizing the display. Customized projections can thus create an experience that is appropriate for environmental conditions and personalized for the user within the vehicle based on previous user interaction with the vehicle.
[0011] The present disclosure relates to systems that adapt and adjust information present, such as how it is displayed (e.g., projected) onto the HUD, based on context, e.g., driver attributes (e.g., height), driver state, external environment, vehicle state. The systems can, e.g., adjust how information is displayed on the basis of attributes of the HUD background image, such as chromaticity, luminance. Output, or output-feature characteristics for adjustment include, e.g., display brightness, texture, contrast, coloring, or light-quality related characteristics, size, and positioning or location within a display area, for example.
[0012] The systems include a processor for implementing a computer-readable storage device comprising instructions that cause the processor to perform operations for providing assistance to a vehicle user.
[0013] The operations include, in part, the system parsing a wide variety of information from vehicle systems and subsystems that can be projected on the HUD and selecting information relevant to current driving context (e.g., environment and/or user behavior conditions). The data derived from the parsing and selecting operations is referred to as context data.
[0014] Additionally, based on the context data, operations of the system dynamically adjust or adapt optical attributes (e.g., image background optical attributes such as chromaticity and luminance of the forward scene) of the HUD.
[0015] Finally, the context data is in some embodiments presented at an appropriate position in a field of view of the user.
[0016] The present disclosure also relates to methods and systems for context awareness and for HUD image compensation. The methods are similar to the above described operations of the system.
[0017] Other aspects of the present invention will be in part apparent and in part pointed out hereinafter.
DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates schematically an adjustable head-up display system in accordance with an exemplary embodiment.
[0019] FIG. 2 is a block diagram of a controller of the HUD system in FIG. 1 .
[0020] FIG. 3 is a flow chart illustrating an exemplary sequence of the controller of FIG. 2 .
DETAILED DESCRIPTION
[0021] As required, detailed embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof. As used herein, for example, exemplary, illustrative, and similar terms, refer expansively to embodiments that serve as an illustration, specimen, model or pattern.
[0022] Descriptions are to be considered broadly, within the spirit of the description. For example, references to connections between any two parts herein are intended to encompass the two parts being connected directly or indirectly to each other. As another example, a single component described herein, such as in connection with one or more functions, is to be interpreted to cover embodiments in which more than one component is used instead to perform the function(s). And vice versa—i.e., descriptions of multiple components herein in connection with one or more functions is to be interpreted to cover embodiments in which a single component performs the function(s).
[0023] In some instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present disclosure. Specific structural and functional details disclosed herein are therefore not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present disclosure.
[0024] While the present technology is described primarily in connection with a vehicle in the form of an automobile, it is contemplated that the technology can be implemented in connection with other vehicles such as, but not limited to, marine craft, aircraft, machinery, and commercial vehicles (e.g., buses and trucks).
I. OVERVIEW OF THE DISCLOSURE
FIGS. 1 and 2
[0025] Now turning to the figures, and more particularly to the first figure, FIG. 1 shows an adjustable head-up display (HUD) system 100 including a context recognizer 150 and a controller 200 . In some embodiments, the context recognizer 150 can be constructed as part of the controller 200 .
[0026] Received into the context recognizer 150 , are a plurality of inputs 105 . Based on its programming and one or more inputs, the HUD system 100 generates or controls (e.g., adjusts) an image to be presented, which is projected onto an output display 90 .
[0027] The inputs 105 may include data perceived by sensors providing information about conditions internal to the vehicle and external to the vehicle. Conditions perceived internal to the vehicle include user-psychological conditions (e.g., user state 10 ), among others. Environmental conditions external to the vehicle include, e.g., weather conditions 20 , luminance conditions 30 , chromaticity conditions 40 , traffic conditions 50 , and navigation conditions 60 , among others. The system 100 may take into consideration the inputs 105 to adjust features on the output display 90 ultimately presented to the user.
[0028] The user state conditions 10 in one embodiment represents information received by one or more human-machine interfaces within the vehicle. The user state conditions 10 could also include user settings or preferences, such as preferred seat position, steering angle, or radio station. Sensors within the vehicle may sense user attributes, such as driver height of eye level, and/or physiological behavior of the user while in the vehicle. For example, sensors may monitor blink rate of the driver, which may indicate drowsiness. As another example, sensors may capture vehicle positioning with reference to road lanes or with respect to surrounding vehicles to monitor erratic lane changing of the driver. The system 100 may take into consideration such user settings, attributes, and information from user-vehicle interfaces, such as physiological behavior, when adjusting user state features to ultimately present to the user.
[0029] The weather conditions 20 represents information associated with the conditions outside of the vehicle. Sensors internal and/or external to the vehicle may perceive weather conditions that affect the vehicle operation such as, temperature, moisture, ice, among others. The system 100 may take these characteristics into consideration when adjusting HUD display weather condition features to present to the user.
[0030] The luminance conditions 30 represents information associated with lighting characteristics that would affect the display, such as brightness (e.g., amount of background or foreground light) in and/or surrounding the vehicle. Adjustments in HUD image luminance can be made to account for changes in ambient lighting (e.g., reduced ambient light when entering a tunnel, increased ambient light when there exists a glare due to bright clouds). Adjustments in luminance can also be made to account for other forms of lighting such as florescent or incandescent (e.g., in a parking garage or building). For example, when lighting conditions within the vehicle change, e.g. an interior dome light is activated, the HUD image luminance can be accordingly adjusted.
[0031] The chromaticity conditions 40 represents information associated with characteristics of the background e.g., as seen through the vehicle windshield. Chromaticity assesses attributes of a color, regardless of luminance of the color, based on hue and colorfulness (saturation). Chromaticity characteristics can include color, texture, brightness, contrast, and size, among others of a particular object. The system 100 may take these characteristics into consideration when adjusting HUD display chromaticity features to present to the user.
[0032] The traffic conditions 50 represents information associated with movement, of vehicles and/or pedestrians, through an area. Specifically, the traffic conditions perceive congestion of vehicles through the area. For example, the system 100 may receive information that future road traffic will likely increase (e.g., rush hour or mass exodus from a sporting event). The system 100 may take traffic into consideration when adjusting traffic condition features to present to the user.
[0033] The navigation conditions 60 represents information associated with a process of accurately ascertaining positioning of the vehicle. The navigation conditions 60 also represents information associated with planning and following a particular route for the vehicle. For example, a vehicle may be given turn-by-turn directions to a tourist attraction. The system 100 may take into consideration GPS when adjusting navigation features to present to the user.
[0034] In addition to user-psychological conditions and environmental conditions, the inputs 105 may include vehicle conditions (not illustrated). Vehicle conditions are different than environmental conditions, and may include sensor readings pertaining to vehicle data, for example, fluid level indicators (e.g., fuel, oil, brake, and transmission) and wheel speed, among others. Readings associated with vehicle conditions typically provide warnings (e.g., lighting a low fuel indicator) or potential failure of a vehicle system (e.g., lighting a “check engine” indicator) to the user for a future response (e.g., add fuel to vehicle or obtain service for the engine).
[0035] In some situations vehicle conditions may be combined with user-psychological conditions, environmental conditions, or both, and presented as information into the context recognizer 150 . As an example, when a vehicle has a low fuel level (e.g., as recognized by a fuel gauge indicator) and the user is near a gas station (e.g., as recognized from information on a GPS), a vehicle condition and an environmental condition concurrently exist. In this situation, the system 100 may present a change in color of the fuel gauge indicator (e.g., from of amber to red) as a response inform the user of the low fuel level and proximity of the gas station.
[0036] In one embodiment, the system 100 can use one or more vehicle conditions, user-psychological conditions, and/or environmental conditions to determine another user-psychological condition or an environmental condition. For example, the system 100 could use a coordinate location and/or direction of travel (e.g., from a GPS) combined with a time of day (e.g., from an in-vehicle clock display) to determine a potential luminance condition. Thus, when a vehicle is heading in an east direction during a time of sunrise, the HUD image luminance can be accordingly adjusted.
[0037] The context recognizer 150 includes adaptive agent software configured to, when executed by a processor, perform recognition and adjustment functions associated with the inputs 105 . The context recognizer 150 serves as an agent for the output display 90 , and determines how and where to display the information received by the inputs 105 .
[0038] The context recognizer 150 may recognize user input such as, information received by one or more human-machine interfaces within the vehicle, including, specific inputs into a center stack console of the vehicle made by the user, a number of times the user executes a specific task, how often the user fails to execute a specific task, or any other sequence of actions captured by the system in relation to the user interaction with an in-vehicle system. For example, the context recognizer 150 can recognize that the user has set the pixilation of text and/or graphics displayed on the output display 90 to a specific color. As later described in association with FIG. 3 , the system 100 can adjust (e.g., outline, increase brightness of, change color of) the text and/or graphics to emphasize features.
[0039] The context recognizer 150 may also process external inputs received by sensors internal and external to the vehicle. Data received by the context recognizer 150 can include vehicle system and subsystem data, e.g., data indicative of cruise control function. As an example, the context recognizer 150 can recognize when the luminance of the background has changed (e.g., sunset). As later described in association with FIG. 3 , the system 100 can adjust the luminance of the output display 90 to be more clearly seen by the user in dim conditions, for example.
[0040] Both internal and external inputs are in some embodiments processed according to code of the context recognizer 150 to generate a set of context data to be used in setting or adjusting the HUD.
[0041] The context data generated by the context recognizer 150 can be constructed by the system 100 and optionally stored to a repository 70 , e.g., a remote database, remote to the vehicle and system 100 . The context data received into the context recognizer 150 may be stored to the repository 70 by transmitting a context recognizer signal 115 . The repository 70 can be internal or external to the system 100 .
[0042] The data stored to the repository 70 can be used to provide personalized services and recommendations based on the specific behavior of the user (e.g., inform the user about road construction). Stored data can include actual behavior of a specific user, sequences of behavior of the specific user, and the meaning of the sequences for the specific user, among others.
[0043] The data is stored within the repository 70 as computer-readable code by any known computer-usable medium including semiconductor, magnetic disk, optical disk (such as CD-ROM, DVD-ROM) and can be transmitted by any computer data signal embodied in a computer usable (e.g., readable) transmission medium (such as a carrier wave or any other medium including digital, optical, or analog-based medium).
[0044] The repository 70 may also transmit the stored data to and from the controller 200 by a controller transmission signal 125 . Additionally, the repository 70 may be used to facilitate reuse of certified code fragments that might be applicable to a range of applications internal and external to the monitoring 100 .
[0045] In embodiments where the context recognizer 150 is constructed as part of the controller 200 , the controller transmission signal 125 may transmit data associated with both the context recognizer 150 and the controller 200 , thus making the context recognizer signal 115 unnecessary.
[0046] In some embodiments, the repository 70 aggregates data across multiple users. Aggregated data can be derived from a community of users whose behaviors are being monitored by the system 100 and may be stored within the repository 70 . Having a community of users allows the repository 70 to be constantly updated with the aggregated queries, which can be communicated to the controller 200 via the signal 125 . The queries stored to the repository 70 can be used to provide personalized services and recommendations based on large data logged from multiple users.
[0047] FIG. 2 illustrates the controller 200 , which is an adjustable hardware. The controller 200 may be a microcontroller, microprocessor, programmable logic controller (PLC), complex programmable logic device (CPLD), field-programmable gate array (FPGA), or the like. The controller may be developed through the use of code libraries, static analysis tools, software, hardware, firmware, or the like. Any use of hardware or firmware includes a degree of flexibility and high-performance available from an FPGA, combining the benefits of single-purpose and general-purpose systems.
[0048] The controller 200 includes a memory 210 . The memory 210 may include several categories of software and data used in the controller 200 , including, applications 220 , a database 230 , an operating system (OS) 240 , and I/O device drivers 250 .
[0049] As will be appreciated by those skilled in the art, the OS 240 may be any operating system for use with a data processing system. The I/O device drivers 250 may include various routines accessed through the OS 240 by the applications 220 to communicate with devices and certain memory components.
[0050] The applications 220 can be stored in the memory 210 and/or in a firmware (not shown) as executable instructions and can be executed by a processor 260 .
[0051] The applications 220 include various programs, such as a context recognizer sequence 300 (shown in FIG. 3 ) described below that, when executed by the processor 260 , process data received into the context recognizer 150 .
[0052] The applications 220 may be applied to data stored in the database 230 , such as the specified parameters, along with data, e.g., received via the I/O data ports 270 . The database 230 represents the static and dynamic data used by the applications 220 , the OS 240 , the I/O device drivers 250 and other software programs that may reside in the memory 210 .
[0053] While the memory 210 is illustrated as residing proximate the processor 260 , it should be understood that at least a portion of the memory 210 can be a remotely accessed storage system, for example, a server on a communication network, a remote hard disk drive, a removable storage medium, combinations thereof, and the like. Thus, any of the data, applications, and/or software described above can be stored within the memory 210 and/or accessed via network connections to other data processing systems (not shown) that may include a local area network (LAN), a metropolitan area network (MAN), or a wide area network (WAN), for example.
[0054] It should be understood that FIG. 2 and the description above are intended to provide a brief, general description of a suitable environment in which the various aspects of some embodiments of the present disclosure can be implemented. While the description refers to computer-readable instructions, embodiments of the present disclosure can also be implemented in combination with other program modules and/or as a combination of hardware and software in addition to, or instead of, computer readable instructions.
[0055] The term “application,” or variants thereof, is used expansively herein to include routines, program modules, programs, components, data structures, algorithms, and the like. Applications can be implemented on various system configurations including single-processor or multiprocessor systems, minicomputers, mainframe computers, personal computers, hand-held computing devices, microprocessor-based, programmable consumer electronics, combinations thereof, and the like.
[0056] One or more output displays 90 are used to communicate the adjusted feature to the user. For example, the output display 90 can be a HUD built into the vehicle or a HUD add-on system, projecting the display onto a glass combiner mounted on the windshield.
[0057] The output display 90 provides visual information to a vehicle occupant about changing features (e.g., changing position of objects detected in a surrounding environment). For example, the output display 90 may display text, images, or video within the vehicle (e.g., front windshield).
[0058] The output display 90 may be combined with auditory or tactile interfaces to provide additional information to the user. As another example, the output component may provide audio speaking from components within the vehicle (e.g., speakers).
[0059] The system 100 can include one or more other devices and components within the system 100 or in support of the system 100 . For example, multiple controllers may be used to recognize context and produce adjustment sequences.
[0060] The system 100 has been described in the context of a visual HUD. However, the principles of the system 100 can be applied to one or more other sensory modes (e.g., haptic and auditory) in addition to or alternative to the visual mode. For example, software of the system 100 can be configured to generate or control communications to a user (e.g., haptic or auditory communications) in a manner, or by characteristics tailored to context such as the user (e.g., user attributes, actions, or state) and/or environmental conditions.
[0061] Auditory output features include, e.g., tones or verbal notifications. Adjustable output-feature characteristics regarding auditory features include, e.g., tone, volume, pattern, and location (e.g., which speakers to output from or at what volume speakers are to output).
[0062] Adjustable haptic output features include, e.g., vibration, temperature, and other appropriate haptic feedback. Adjustable output-feature characteristics regarding haptic features, such as vibration and temperature, include location (e.g., steering wheel and/or seat), timing or pattern (e.g., direction) for the output at the appropriate part(s) or location(s), harshness of haptic output, or other appropriate haptic or auditory characteristics).
II. METHODS OF OPERATION
FIG. 3
[0063] FIG. 3 is a flow chart illustrating methods for performing a context recognizer sequence 300 .
[0064] It should be understood that the steps of the methods are not necessarily presented in any particular order and that performance of some or all the steps in an alternative order, including across these figures, is possible and is contemplated.
[0065] The steps have been presented in the demonstrated order for ease of description and illustration. Steps can be added, omitted and/or performed simultaneously without departing from the scope of the appended claims. It should also be understood that the illustrated method or sub-methods can be ended at any time.
[0066] In certain embodiments, some or all steps of this process, and/or substantially equivalent steps are performed by a processor, e.g., computer processor, executing computer-executable instructions, corresponding to one or more corresponding algorithms, and associated supporting data stored or included on a computer-readable medium, such as any of the computer-readable memories described above, including the remote server and vehicles.
[0067] The sequence 300 begins by receiving inputs 105 by the system 100 at step 310 . The software may be initiated through the controller 200 . The inputs 105 may be received into the system 100 according to any of various timing protocols, such as continuously or almost continuously, or at specific time intervals (e.g., every ten seconds), for example. The inputs 105 may, alternately, be received based on a predetermined occurrence of events (e.g., activation of the output display 90 or a predetermined condition, such as a threshold level of extra-vehicle brightness being sensed.
[0068] Next, at step 320 , the system 100 receives one or more of the inputs 105 into the context receiver 150 . In some embodiments, the inputs 105 may contain an original feature which can be displayed to the user at the output display 90 . In other embodiments, the original feature can be generated within the context receiver 150 . The inputs 105 are in some embodiments processed (e.g., stored and used) based on the type of input.
[0069] For example, data from vehicle motion sensors (e.g., speed, acceleration, and GPS sensors) can be received into a portion of the context recognizer 150 that recognizes vehicle state data. Specialized sensors (e.g., radar sensors) would be received into a portion of the context recognizer that recognizes the specific characterization of the camera. For example, a radar sensor information could be received into a system such as an advanced driver assistance system (ADAS).
[0070] Physiological sensors (e.g., blink rate sensors) would be received into a portion of the context recognizer 150 that recognizes user state data.
[0071] Information from external vehicle sensors (e.g., traffic sensors, weather sensors, visual editor sensors) would be received into a portion of the context recognizer 150 that recognizes external environmental data.
[0072] Information from scene cameras (e.g., front and/or rear mounted cameras) would be received into a portion of the context recognizer 150 that recognizes external environmental data, image data, and/or scene data. Information from specialized cameras (e.g., infrared cameras) would be received into a portion of the context recognizer 150 that recognizes the specific characterization of the camera. For example, an infrared camera can have information received into night vision imaging system (NVIS).
[0073] Next, at step 330 , the system 100 according to the sequence 300 determines whether the original feature received into and/or generated by the context receiver 150 should be adjusted based on the context data. The original feature may need to be adjusted based on any of the inputs 105 . For example, the original feature may need to be adjusted based on the user state conditions 10 .
[0074] If adjustment of the original feature is not necessary (e.g., path 332 ), the assistance of the system 100 is not required. For example, if the user is decelerating to turn into a gas station (e.g., as recognized from information on a GPS), there may not be a need for the system 100 to present an alert to the user regarding a low fuel level.
[0075] When adjustment of the original feature is not necessary (e.g., path 332 ), the original feature is presented to the user without edit. In one embodiment, however, first the system 100 , at step 350 , or another point in the sequence 300 , determines if an intended display location (e.g., a position on the driver's side of a windshield) is impaired. The display location may be impaired if the user cannot easily view the information. For example, the front driver side of the windshield may be impaired when the driving in an east direction during sunrise.
[0076] If adjustment of the original feature is determined needed (e.g., path 334 ), the original feature is adjusted based on the context data at step 340 . Adjustment of the original feature can occur by the controller 200 executing a set of code instructions stored within the controller 200 or the repository 70 , for example.
[0077] The code instructions are a set of predetermined rules that, when executed by the controller 200 , produce an adjusted feature which can be presented to the user. The adjusted feature may be based on context data from the user state conditions 10 , the weather conditions 20 , the luminance conditions 30 , the chromaticity conditions 40 , the traffic conditions 50 , and the navigation conditions 60 .
[0078] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the user state conditions 10 . As an example, when the user turns on the left signal of the vehicle, the system 100 can emphasize (e.g., visually highlight, audibly speak) businesses (e.g., restaurants, gas stations) that will appear when the turn is executed. As another example, when the user is distracted by a secondary task (e.g., phone call, radio tuning, menu browsing, conversation with a passenger), the system 100 can enlarge fonts or change the display to get the attention of the user.
[0079] Additionally, the system 100 assesses the user state conditions 10 within the forward scene for threats and highlights these threats if the system 100 determines that the user has not perceived and acted upon the threats in the same manner as an automated system. As an example, if the user does not begin to apply the brakes when a ball rolls into the street, the system 100 may highlight the ball to bring the object into a perceptual field of the user when displayed by the output display 90 .
[0080] The HUD can include components associated with virtual or augmented reality (AR) in some embodiments. When the system 100 perceives user state conditions 10 , the system 100 can change the AR to provide adjusted features to the user. For example, if the user does not decelerate (e.g., near 0 miles per hour) when approaching a stop sign, the system 100 may highlight the stop sign to make it noticeable to the driver. Conversely, if the user decelerates the vehicle, the system 100 may not decides not to highlight the stop sign. As another example, when the user turns on the left signal of the vehicle, the system 100 can emphasize businesses (e.g., restaurants, gas stations) that will appear when the turn is executed. The HUD can include an arrow pointing to the left wherein the arrow tip points actually to the actual building from the driver's perspective.
[0081] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the weather conditions 20 . As an example, on wet roads, an indicator of safe speeds, wheel slip, and non-use of cruise control systems may be adjusted within the system 100 and displayed on the output display 90 .
[0082] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the luminance conditions 30 . For example, upon entering a tunnel, luminance of the output display 90 may dim and tunnel safety information may be indicated. Safety information such as, appropriate distance for following a vehicle ahead, no horn sounding, and no lane changes may be adjusted within the system 100 and displayed as indicators on the output display 90 . Additionally, if the usual location of the output information is impaired (e.g., driving into a sunset), the system 100 may present the information an alternate position.
[0083] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the chromaticity conditions 40 . Displayed information (e.g., text and/or graphics) may be adjusted and/or outlined with a chromaticity that is distinguishable from the chromaticity of the ambient background. As an illustrative example, where snow covers the road, displayed information (e.g., text and/or graphics) on the output display 90 information normally presented in white may be adjusted to a more visible color (e.g., green). Similarly, where green trees appear the background, displayed information that is normally presented in green may be adjusted to white or another more visible color.
[0084] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the traffic conditions 50 . For example, if the system 100 determines that road traffic will likely increase (e.g., rush hour or mass exodus from a sporting event), they system 100 may adjust a traffic change strategic indictor and display on the indicator on the output display 90 to enable the driver to take actions to avoid a sudden onset of traffic.
[0085] In some embodiments, the set of code instructions executed by the controller 200 may produce the adjusted feature based on the navigation conditions 60 . For example, a bus may have a tourist attraction presented as the bus gets within a certain range of the attraction. To this point, the code instructions executed by the controller 200 can also produce the adjusted feature based on timing or occurrence of a specific task, such as proximity to the attraction.
[0086] The set of code instructions within the system 100 can be determined by a relevant domain. For example, where the system 100 is associated with a marine environment, the relevant domain may include adjusted features associated with e.g., maximum heading control parameters. As another example, where the system 100 is associated with a construction machinery, the relevant domain may include adjusted features associated with e.g., equipment and/or markings of utility service companies.
[0087] Once any adjusting has occurred, the adjusted feature is then ready to be presented to the user. As stated above, at step 350 , the system 100 determines if an intended display location (e.g., driver's side of a windshield) is impaired.
[0088] When no impairment exists (e.g., path 352 ), the original feature or the adjusted feature, if necessary, is displayed at the original display location at step 360 .
[0089] When an impairment exists (e.g., path 354 ), the original feature or the adjusted feature is displayed at an alternate display location at step 370 . The alternate display location may be a location that is easily viewed by the driver. The alternate display location should allow the content of the presented information to be readily viewed by the user. For example, in a transparent display HUD, where the driver's side of the windshield is impaired when driving east during sunrise, the system 100 may choose to have the projection on the passenger side of the windshield.
[0090] Displaying in the alternate location can also include changes in characteristics of the projection including, font of display, colors used within the display, among others.
[0091] The presentation of the original feature or the adjusted feature can occur on one or more output devices (e.g., output display 90 for a HUD).
[0092] In one embodiment, determining the intended display location (e.g., step 350 ) is not present. In another embodiment, the display location is an adjustable characteristic of the feature (e.g., color and/or brightness), and the operation of determining whether the original feature should be modified (e.g., step 330 ) includes determining whether a display location for the feature should be modified. In this implementation, adjusting the feature at step 340 would include changing a display location for the feature if determined appropriate or needed in step 330 . Once the original feature is adjusted, if necessary, at step 340 , the adjusted feature will be presented to the user at an output location as explained above.
III. SELECT FEATURES
[0093] Many features of the present technology are described herein above. The present section presents in summary some selected features of the present technology. It is to be understood that the present section highlights only a few of the many features of the technology and the following paragraphs are not meant to be limiting.
[0094] One benefit of the present technology is the system present information relevant to current driving context. In prior systems, static format image projections are possible, but not context-based information. Presenting contextual information (e.g., context data) can add significantly utility (e.g., relevance, reduced clutter) to the HUD system.
[0095] Another benefit of the present technology is the system dynamically adjust/adapt optical attributes of the HUD. Adjustment/adaptation compensates for contextual information and may increase visual comprehension, by the user, of the presented images, resulting in streamlined HUD usability.
IV. CONCLUSION
[0096] Various embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof.
[0097] The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the disclosure.
[0098] Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.
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The present disclosure relates to systems that adapt information displayed onto a head-up display (HUD) based on context. The present disclosure also relates, generally, to methods for context awareness and methods for HUD image compensation. In one embodiment, the systems include a processor and a computer-readable storage device comprising instructions that cause the processor to perform operations for providing context-based assistance to a vehicle user. The operations include, in part, the system parsing information that can be projected on the HUD and selecting therefrom information relevant to current context indicating an environmental condition and/or a user-physiological condition. For example, based on contextual information, operations of the system dynamically adjust optical attributes of the HUD.
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BACKGROUND OF THE INVENTION
a) Field of the Invention
The invention relates to a swivel lever closure for the door, side wall, or the like, of a switch cabinet, machine enclosure or the like, with an actuating shaft which extends through the door leaf, with locking devices, such as a sash lock and/or bar lock, which are drivable by the actuating shaft, with a dish or cavity that can be placed on the door leaf or the like, with an actuating lever which is articulated at the actuating shaft so as to be swivelable about an axis extending vertical to the axis of the actuating shaft and which can be secured in a swiveled in position in the cavity by means of a locking device and can be swiveled out of the cavity, wherein the actuating shaft can be rotated by means of the actuating lever into the position which is swiveled out from the cavity.
b) Description of the Related Art
A swivel lever closure of the type mentioned above is known, for example, from page 2-105 of a catalog from DIRAK GmbH und Co. KG, Kaiserstr. 55-59, 58332 Schwelm. Further, reference is had to EP 0 054 225 B1 and U.S. Pat. No. 5,450,735.
All of the cited references show swivel lever shapes which extend in a straight line parallel to the surface of the door or the like when swiveled in. Therefore, when the lever is swiveled out, it extends at a sharply acute angle to this surface of the door leaf or the like, which is inconvenient on the one hand and, on the other hand, reduces the effective lever arm length by which the lever projects in the swiveled out state on the door leaf surface and accordingly increases the forces required for rotation. In this respect, a swivel lever closure described in DE 297 05 778 U1 has a slight inclination, but its cavity has a very long constructional length in comparison to the length of the fastening lever.
Further, with the exception of the first swivel lever from the catalog cited above, none of the swivel lever closures provides the possibility of locking with a padlock.
In contrast to the prior art, it is the object of the invention to shape the swivel lever closure in such a way that the cavity has only a slightly larger constructional length than the actuating lever and such that the swivel lever closure can be conveniently handled in the swung out state and nevertheless offers the possibility of locking with a padlock, wherein provisional locking should also be possible without a padlock.
This object is met first in that the actuating lever has a first shorter portion which proceeds from the axis of articulation at the actuating shaft and which is directed at an inclination away from the plane of the door leaf or the like when the lever is swiveled into the cavity, and a second, longer portion following the first portion which is directed at an inclination toward the plane of the door leaf when the swivel lever is positioned so as to be swiveled into the cavity.
As a result of these features, it is possible for the user when swiveling out the handle to move this handle into a position such that a substantial portion of the swivel lever extends either parallel to or at a smaller angle to the door leaf plane, which facilitates handling.
This lever shape is also advantageous in that particularly favorable relationships result when, according to another feature, the cavity has, in its area receiving the free end of the lever, a shoulder such as an eyelet which projects through a notch or slit of the lever end when the lever is in its swiveled in position. That is, in a surprisingly advantageous manner, the inclined shape creates space for this eyelet without increasing the constructional height.
In this connection, it is noted that the swivel lever actuation according to page 2-105 of the catalog from DIRAK GmbH & Co. KG also has an eyelet whose purpose, according to this reference, is to secure the swivel lever by means of a padlock. A disadvantage in this known arrangement is that the shoulder projects far over the surface of the swiveled in swivel lever and accordingly not only increases the constructional height, but also presents an obstacle to persons passing by it. Due to the fact that the shoulder in the center of the cavity projects out very far, this shoulder also impedes the user's hand when the lever is swiveled out. In contrast to this known arrangement, the shoulder or eyelet according to the invention through which the padlock can be inserted presents less of an obstacle. This is achieved primarily in that the cavity carries the shoulder, such as an eyelet, in its area receiving the free end of the lever rather than in the center, wherein the shoulder projects through the notch or slot of the lever end when the lever is in the swiveled in position. Due to the special shape of the lever, in which the area of the junction between the two inclined areas is the area located farthest away from the door leaf surface, the eyelet does not project out as far as the farthest projecting area of the swivel lever and therefore no longer presents an obstacle. In addition to this, the eyelet is located below the projecting area of the lever when the latter is arranged vertically, as is usually the case, and also presents less of an obstacle.
As a result of the arrangement of the eyelet, it is possible for the shoulder or the eyelet to be mounted so as to be swivelable against spring force and to form a protuberance or offset which secures the swivel lever in the swiveled in state. A disadvantage of the known arrangement, wherein the swivel lever is prevented from swiveling out only when a padlock is actually inserted, is avoided by means of this feature. However, there are also cases in which a padlock of this type will not be provided at least at certain times, in which case the known arrangement is not protected against an unintentional swiveling out of the swivel lever. This swiveling out can occur when, as a result of shaking movement such as can occur during earthquakes or during operation of a vibrating machine, the swivel lever exits from its cavity, in which case there is a risk that it will rotate with the driving shaft to the extent that the locking device opens and, e.g., the door leaf of the switching cabinet secured by the closure will stand open. Switching cabinets which are located, e.g., on crane installations where there are often a plurality of, e.g., as many as 30, switching installations which are enclosed by a switch room are subject to especially strong shaking movements. It is unacceptable for switch cabinet doors of this type to be able to open unintentionally due to shaking movements, even if they do not all have padlocks.
EP 0 054 225 B1, U.S. Pat. No. 5,450,735, and DE 297 05 778 U1, but also the arrangement known from the catalog (see the note on the possibility of combination with a profile cylinder), offer the possibility of providing a profile cylinder which can likewise secure the actuating lever irrespective of a padlock. However, combining a swivel lever closure with a padlock as well as a profile cylinder complicates the arrangement because two keys are then necessary, a first key for the padlock and a second key for the profile cylinder.
OBJECT AND SUMMARY OF THE INVENTION
Obviously, it is not possible in the known arrangements according to the above-cited references to simply press in and lock the actuating lever. When a key-actuated arrangement is provided, it must—at least in the European and U.S. patents—first be locked by means of a key, e.g., as in the case of a cylinder lock, or a padlock must be inserted in order to lock as in the catalog reference.
Therefore, the invention also has the primary object of further developing the known arrangement in such a way that the actuating lever can be pressed into its locked position and securely held in this position also without the use of a padlock and without using a cylinder which is actuated by key.
Further, it should be possible to move the actuating lever out of this pressed in secured position without special tools.
These additional objectives are met in that the above-mentioned shoulder or eyelet is mounted so as to be swivelable against spring force and a protuberance or offset is formed by the eyelet which secures the swivel lever in the swiveled in state. In this connection, it is advantageous that the eyelet performs two functions simultaneously, namely, it provides a bore hole for receiving the shackle of a padlock which, when inserted, prevents the lever from swiveling out and also provides a protuberance or offset which brings about a locking by means of simply pressing in when the padlock is not used.
It is particularly advantageous in this respect when the spring loading of this protuberance or eyelet is carried out in such a way that it acts in the same direction as the weight of an inserted padlock.
Further, it should be possible to release the actuating lever from this pressed in, locked position without needing special tools. This is achieved in that the eyelet head can be moved out of its locking position against the spring force simply by exerting a pressing force with the thumb.
It may be advantageous when the actuating lever also has an additional lock which can be actuated by means of a tool. This provides a security which, while inferior in degree to the security afforded by a padlock, makes it possible to lock when there is no padlock present in such a way that the locking cannot be canceled without a tool. In order to meet this object, a locking device can be provided in the area of the driving shaft, which locking device can only be actuated by a tool such as a wrench, screwdriver, or the like and which prevents rotation of the actuating shaft by the swivel lever.
There are various possible embodiment forms for this additional locking device which will be described more fully in the following.
With respect to design, it is advantageous when the cavity has two projections, preferably with the same dimensions, which project through the door leaf or the like, wherein one projection forms a locking shaft bearing and the other projection is formed by the fastening for the shoulder or eyelet. On the one hand, this secures the cavity against rotation on the door leaf; on the other hand, fastening can be carried out by means of parts which are present in any case and accordingly certain elements of the closure can serve a dual purpose.
It is advantageous when the fastening is carried out in such a way that the closure is constructed such that it can be used in a right-handed manner as well as in a left-handed manner, i.e., such that its actuation projections advantageously require through-openings in the door leaf which are identical and symmetric to the center of the door and the connection between the lever arm and driving shaft can be switched in such a way that turning to the right and turning to the left can both lead to a desired function.
The projections can form circumferential threads on which fastening screw nuts can be screwed, so that the door leaf is clamped between the latter and the cavity. This results in a particularly simple assembly of the arrangement.
The actuation used for the swivel lever closure according to the invention is suitable for actuating a sash lock or also a flat bar lock or a round bar lock.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described more fully in the following with reference to embodiment examples shown in the drawings.
FIG. 1 shows a side view of a swivel lever closure, constructed according to the invention, for a door of a switch cabinet, wherein locking can be carried out by a padlock, additional locking is provided by means of an eyelet offset, and additional locking is provided in the area of the lock shaft;
FIG. 2 is a top view of the arrangement according to FIG. 1;
FIG. 3 is a sectional view along line A—A in FIG. 1;
FIG. 4 shows a side view of the actuation device (cavity with handle) for the swivel lever closure;
FIG. 5 is a top view of the arrangement according to FIG. 4;
FIG. 6 is a view similar to FIG. 1, in which the locking in the area of the driving shaft is modified;
FIG. 7 is a top view of the arrangement according to FIG. 6;
FIG. 8 is a sectional view along line A—A of FIG. 6 for describing the locking in the area oft lock shaft; and
FIGS. 9 and 10 show two additional embodiment forms of a swivel lever closure according to the invention in a side view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a side view of a closure 12 for a switch cabinet 14 or machine housing wall or the like, wherein the closure 12 comprises a swivel lever actuation 10 with a cavity 18 which is arranged on the outer surface 16 of the switch cabinet door 14 or the like. A locking shaft or actuating shaft 20 which in this case drives a sash 22 and locking bars 24 , 26 extending along the door leaf 14 is arranged in the cavity 18 . The bars 24 , 26 are articulated at a disk 27 which also carries or forms the sash'tongue 22 and which is fastened to the actuating shaft 20 by means of a screw 29 . When the actuating shaft 20 is rotated, the disk 27 and, with it, the sash 22 , are also rotated; moreover, the locking bars 24 , 26 articulated at the disk 27 are displaced upward or downward. According to FIG. 1, the locking bar 24 is mounted in a bar guide 31 which may be made of plastic and may be held by a Stub bolt 33 which is spot-welded to the door leaf 14 . A holder 35 which carries a run-up roller 37 is arranged and clamped on the lower end of the bar 24 . When the bar 24 is displaced downward,-the roller 37 runs up on an angled surface 17 formed by the cabinet frame 15 and in so doing presses the door leaf 14 via the bar guide 31 against the frame angle 19 , wherein the inner surface of the door leaf 14 carries a U-shaped holding web 21 for a sealing strip 23 against which the front edge of the angle 19 presses in a sealing manner. The locking bar 24 can be constructed as a flat strip or as a solid round bar or, as is shown here, as a tubular arrangement that is pressed flat at its articulated end.
The actuating shaft 20 is rotatably mounted inside a corresponding bearing bore hole of the cavity 18 and is axially fixed at its end facing the sash 22 by a disk 25 that is held by disk 27 and by the associated screw 29 , wherein an O-ring seal 37 is also advisably provided. For torsion bar support of the disk 27 , the shaft 20 advisably forms a polygon, such as a rectangle, on which a corresponding polygonal opening or rectangular opening of the disk 25 or 27 is mounted so as to be rigid with respect to rotation. At its opposite end, the actuating shaft 20 has a head 39 which, in itself, contacts the shoulder 41 of the bearing area of the cavity 18 , possibly so as to be sealed by means of an O-ring seat 43 . The head 39 carries at its outer end a half-cylinder projection 45 on which a handle or actuating lever 28 is articulated about an axis 30 extending transverse to the shaft axis 32 of the shaft 20 , wherein the half-cylinder projection 45 is received so as to fit in a corresponding recess 47 of the lever in such a way that the lever 28 can be swiveled out of the position in which it is inserted into the cavity 18 to the extent that it is freely rotatable about the axis 32 together with the shaft 20 .
The actuating lever 28 shown in FIG. 1 is enclosed on the sides in the swiveled in position by edges formed by the cavity 18 , so that the actuating lever is prevented by this enclosure from being rotated out of its position oriented to the cavity. Therefore, it is not possible to open the door in this position of the lever 28 . When the actuating lever 28 is directed vertically downward in its locking position, its own gravitational force or friction can suffice in itself to keep it in this position. However, during shaking movements such as those which can occur, for example, in crane installations, there is a risk that the actuating lever 28 will move out of its swiveled in position and be released from the cavity 18 and that, as a result of further shaking movement, a rotation will be carried out about axis 32 , so that the closure 12 opens in certain cases and therefore exposes the interior of the switch cabinet in an unwanted manner. It is also possible that an unauthorized person will swivel out the actuating lever 28 and move the closure out of its closed position into an open position by rotating about the axis 32 and will accordingly be able to open the door 14 of the switch cabinet 15 .
In order to prevent this, the cavity 18 can have a shoulder 40 , wherein an eyelet 42 is arranged at the free end of the shoulder 40 in such a way that, when the actuating lever 28 is swiveled into the cavity 18 , this eyelet 42 projects through an opening 44 in the actuating lever 28 and the shackle 46 of a padlock 48 can be inserted through the eyelet 42 , so that the actuating lever 28 is prevented from being swiveled out.
As is clear from FIG. 1, the actuating lever 28 is outfitted in the area of the opening 44 for the shoulder 40 with an edge 50 which can be engaged by an offset formed by the eyelet 40 , wherein this engagement is brought about on the one hand by the weight of an inserted padlock 48 , but, on the other hand, also by a pressure spring 54 which presses the shoulder 40 in the clockwise direction, this shoulder 40 being supported in the cavity 18 so as to be rotatable about an axis 55 . The pressure spring 54 is constructed as a spiral spring which, on the one hand, is received in a pocket 56 formed by the cavity and, on the other hand, is held at the other end by a projection 58 proceeding from the shoulder 40 . Therefore, in the rest position or inactive position, the eyelet 40 secures the hand lever 28 in the swiveled in position by its offset protuberance 52 . However, when the padlock 48 is removed from the eyelet 42 , the shoulder 40 can be pressed upward with the eyelet 42 in the counterclockwise direction about the axis 55 against the force of the spring 54 by the user's thumb, so that the surface 52 releases surface 50 and allows the hand lever 28 to be swiveled outward out of the position shown in the drawing until it is prevented from a further swiveling movement about the axis 30 in that the lever surface 60 strikes against the head surface 62 . The geometric relationships are advisably selected in such a way that the swivel limiting action takes effect when the hand lever 28 whose area 49 extends at an inclination to the plane of the door leaf 16 in the swiveled in position, as can be seen from FIG. 1, is then oriented, with respect to this surface 49 , substantially parallel and at a distance to the door plane 16 or is swiveled out somewhat farther, as is shown, e.g., in FIG. 4 . This is a position in which the hand lever 28 is disengaged from the edges of the cavity 18 on the one hand and from the shoulder 40 on the other hand and it is therefore possible for the hand lever 28 to rotate about axis 32 .
For this purpose, the actuating lever 28 has a first portion 64 proceeding from the articulation axis 30 at the actuating shaft 20 , which first portion 64 (as is shown) is directed at an inclination away from the plane of the door leaf 16 when the lever 28 is swiveled into the cavity 18 and which causes the distance of the lever from the door leaf when this lever is swiveled out, followed by a second portion 48 which is directed at an inclination toward the plane of the door leaf 16 in the position of the swivel lever 28 in which the swivel lever 28 is swiveled into the cavity; this second portion 49 forms the handle area. Accordingly, as viewed from the side, the two portions 64 , 49 form a roof which is set on the plane of the door leaf 16 with a roof ridge area 66 that projects over all other parts of the closure actuating arrangement, including the shoulder 40 . The ridge area is advisably rounded so as to interfere as little as possible with persons passing by it.
When the lever is swiveled out, the lever area 49 achieves, e.g., an approximately parallel position with respect to the door leaf 16 .
At the same time, the lever area 64 achieves an almost perpendicular position, for example. This arrangement of the swivel lever facilitates the rotating movement. The construction according to the invention provides space below the lever allowing the uses hand a firm grip without this position of the lever being excessively inclined to the door leaf.
The transitional area between the two portions 64 and 49 , that is, the roof ridge 66 , forms a (rounded) angle which may range between 90° and 150°. In the embodiment form shown in the drawing, this ridge angle 68 is approximately 125°.
The great advantage in securing by means of a padlock 48 , as is shown in FIG. 1, consists in that an individual padlock 58 belonging to a certain person can be used, for example, at certain times and for certain reasons, so that it is possible for this person to secure a door against unauthorized opening. Only this person can open the padlock again by means of the appropriate key, remove the padlock, and then open the respective door closure 12 by swinging out and then turning the actuating lever 28 . When a special locking of this kind is not required at certain times, a padlock can also be advantageously omitted. In order for the actuating lever to be secured in the swiveled in position nevertheless in this case, there is provided the above-described hook device which is formed by the surface 52 of the shoulder 40 and the surface 50 of the cavity 18 and which snaps into the end position so as to lock when the actuating lever is swiveled in. Therefore, the lever can be locked without the need to insert a lock simply by swiveling in such that an unintentional opening, e.g., due to shaking movements, cannot take place. On the other hand, the locking can be canceled again without great effort in that the shoulder 40 is displaced upward with the thumb in order to be able to move the lever 28 out of its swiveled in position again.
The actuating lever 28 can be provided in the area of its articulation axis 30 with another spring device, not shown, so that it can also be moved out of its swiveled in position automatically when needed. When the shoulder 40 is pressed with the thumb in this case, the hook formed by the surface 50 is freed and the spring action presses the actuating lever 28 out of its swiveled in position provided it is not impeded by an inserted padlock 48 .
As is shown in FIG. 1, another (third) locking possibility can also be provided, wherein a spring-loaded pin 68 is arranged in the head 39 of the shaft 20 . In the position shown in the drawing, this pin projects into a slot 70 formed by the shaft bearing bore hole of the cavity 18 . The pin secures the shaft 20 against rotation in the position shown. In order to enable rotation out of the shown position, the pin 68 must be pressed back against the force of the spring 72 until it is entirely pulled back out of the slot 70 . This is achieved, for example, by means of a ball 74 which can be forced in the direction of the pin by a slotted screw 76 . This slotted screw 76 can be actuated, e.g., against the force of a spring 78 , by means of a tool such as a screwdriver and the screw is automatically forced back into its initial position, e.g., after the tool is removed. This means that in order to swivel the lever out of its shown position into an open position for the door closure, a tool such as a screwdriver must turn the slotted head screw 76 out of the shown position until the ball 74 has forced the pin 68 back against the force of the spring 70 , whereupon the hand lever 23 can be swiveled. When the tool is removed from the slotted head screw 76 , the latter returns to its initial position due to the spring force 78 and, when the lever is swiveled back into its shown position, allows the pin 68 to slide back into its locking position and accordingly lock the hand lever 28 .
According to FIG. 4, the cavity 18 has a projection 38 which projects through the door leaf, where it is part of a lock shaft bearing and, e.g., supports the shaft 20 with a rectangle 86 which proceeds therefrom and supports the disk 27 so as to be fixed with respect to rotation relative to it. A second projection 90 is provided at the lower end of the cavity 18 and contains, for example, the swivelable eyelet 40 which was described in connection with FIG. 1 .
Both shoulders have the same outer diameter, for example, and have, e.g., an external thread so that a union nut can be screwed on. When the door leaf has corresponding openings that can receive the projections 88 , 90 , the cavity can be arranged on the door leaf and secured by means of the two union nuts.
Alternatively, however, the fastening can also be carried out by means of special head screws 80 , 82 which are guided through appropriate bore holes in the door leaf 16 and can be screwed into corresponding threaded bore holes inside the cavity 18 , not shown.
The openings are advisably arranged in the door leaf 16 in such a way that they are symmetric with respect to an axis 82 representing the center dividing line of the door leaf. In this case, the closure can be installed so as to be rotated by 180° so that a door can be converted from left-hand to right-hand. In this case, the door is rotated by 18°.
In order to be able to adapt the actuating direction of the swivel lever 28 , for example, to open in the rotating direction away from the edge of the door, a coupling element 25 is advisably provided according to FIG. 3, wherein the coupling element 25 is arranged on the rectangle 86 and can move between projections 92 (FIG. 4) formed by the cavity 18 . The movement path between stops formed by the projections 92 is, e.g., exactly 90°.
FIG. 4 shows that the end of the lever 28 has the shape of a nose-shaped projection 84 which is concealed and protected by the shackle of the padlock 48 when a padlock 48 is inserted. When the padlock 48 is removed, the projection 84 can be grasped by a finger after the eyelet 40 is displaced upward and the swivel lever 28 can be swiveled downward as is shown in dashed lines in FIG. 4 . The extent to which the lever can be swiveled out depends on the corresponding play or clearance formed between surface 45 and surface 62 according to FIG. 1 and can be selected as needed. In order to create additional space for the shackle 46 , the end of the lever 28 also has a depression or indentation 96 .
FIG. 6 shows an embodiment form in which the head 139 of the actuating shaft 120 has a somewhat different construction than that shown in FIG. 1. A locking pin 168 is displaced by means of an eccentric screw 176 inside a bore hole 94 in such a way that the pin 168 is either pulled back in the shaft area until it does not project into a slot 96 arranged axially in the shaft bore hole for the shaft 120 . Depending on the position of the screw 176 , the shaft 120 can accordingly be rotated in the cavity bore hole or not.
The advantage of the additional locking in the area of the actuating shaft 20 , 120 is that the closure is locked even before the lever has reached the fully swiveled in position, that is, when it has not yet reached its end position. An arrangement of this kind is particularly important for the U.S. market, where this type of lock is known as a “defeater.” In the known devices, for example, in U.S. Pat. No. 5,450,735, it is not possible to lock the closure until the lever is in its end position inside the cavity. This is disadvantageous in that it allows the closure to open in an unwanted manner in case of a rotational movement in the event that the user forgets to swivel in the lever. Therefore, the arrangement according to the invention offers greater security.
FIG. 9 shows a swivel lever arrangement 210 similar to that shown in FIG. 4, wherein the inclination of the second portion 249 of the hand lever 228 in its swiveled in position is reduced with respect to the fastening surface 53 of the cavity 218 , which results in a somewhat smaller constructional height. Further, the cavity 218 encloses the actuating lever 228 completely at its end provided with the countersink 296 . Moreover, the first portion 264 located in the area of the actuating shaft 220 is oriented at a steeper inclination relative to the run-up surface 53 .
FIG. 10 shows a swivel lever arrangement 310 with an even flatter second portion 349 , so that the overall height H is further reduced. It can also be seen that the free end of the actuating lever 328 is more securely enclosed by the cavity 318 , which offers greater protection for the actuating lever against unauthorized tampering than is the case, e.g., in the embodiment form shown in FIG. 1 .
COMMERCIAL APPLICABILITY OF THE INVENTION
While the foregoing description and drawings represent the present invention, it will be obvious to those skilled in the art that various changes may be made therein without departing from the true spirit and scope of the present invention.
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A pivoting lever closure is disclosed for the door, the sidewall or the like of an electrical control cabinet, a machine casing or the like, comprising an actuation shaft traversing the door leaf or the like, locking devices driven by the actuating shaft such as a sash lock and/or a bar lock, a cavity that can be placed on the door leaf or the like, an actuating lever which can be pivotally actuated on the actuating shaft around an axis which is perpendicular to the axis of the actuating shaft and which can be blocked in a pivoting position in the cavity by a locking device (i.e. a padlock) and can be swung out of the cavity. The actuating shaft can be rotated by the actuating lever from the cavity in the pivoting position.
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BACKGROUND OF THE INVENTION
The present invention relates generally to the control of the speed of electrical motors, and more particularly, to a system for digitally controlling the speed of a D.C. motor.
In present-day high-speed carriage drive matrix printing devices, the voltage requirements of the motor driving the carriage vary due to the number of printing elements that are firing and other load conditions. In addition, the torque on the motor changes due to the stopping and starting of the carriage as the printing mechanism completes a line of printing. Thus, the motor is subject to varying supply voltages and torque loads which affect the speed of the motor and the operation of the printing mechanism. In those printing mechanisms in which a printing carriage is operated to move the print mechanism across the printing medium, high current loads are encountered which require speed control circuits employing high-cost power transistors and other high-cost circuit elements. It is therefore a principal object of this invention to provide a speed control circuit which allows a high current D.C. motor to maintain a constant speed over a varying supply voltage and varying torque loads. It is another object of this invention to provide a low-cost speed control circuit for a high current D.C. motor which can function under the aforementioned operating conditions.
SUMMARY OF THE INVENTION
In order to carry out these objects, there is provided a pulse generator coupled to the output of the motor drive shaft for generating pulses representing each dot column of a character printed by the printing mechanism. The pulses are applied to a logic circuit which, upon the occurrence of each dot column pulse, will clear a counter which has been counting pulses generated by an oscillator and latch the output of the counter into a holding register. The count represents the number of oscillator pulses which occur during the time of duration of each dot column pulse. The output count of the holding register is transmitted to a digital-to-analog converter comprising a network of resistors which converts the digital count into an analog reference voltage. The reference voltage is applied to the non-inverting input of a comparator whose inverting input receives a ramp voltage having a slope based on the level of the motor supply voltage. The output of the comparator controls the time a power pulse is applied to the motor, thereby controlling the speed of the motor. Upon the value of the ramp voltage developed reaching the level of the reference voltage, the output of the comparator is switched, controlling the length of time the power pulse is applied to the motor and thereby controlling the speed of the motor. The generation of each pulse will trigger a one-shot network which disables the supplying of the power pulses to the motor in the case of a motor stall condition.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a motor control circuit incorporating the principles of the invention.
FIGS. 2A-2H are waveform diagrams with signals appearing at several places in the circuit of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A schematic diagram of the motor control circuit in accordance with the principles of the present invention is shown in FIG. 1. The circuit provides a voltage waveform upon the output lines 20, 22 for driving a D.C. motor 24, which waveform is in the form of pulses which varies in width depending on the speed of the motor 24 in order to provide a constant motor speed under varying torque and/or motor supply voltage conditions. The D.C. motor disclosed can be employed in many applications such as tape and document transport systems, but the circuit of the present invention is particularly well-suited for driving a motor employed in a high-speed printing apparatus in which the print mechanism is mounted on a carriage driven by the D.C. motor across a printing medium during a printing operation.
The circuit of FIG. 1 includes a pair of standard linear integrated voltage comparators 26 and 28 which may be of any well-known type such as part no. LM339 sold by the National Semiconductor Corporation of Santa Clara, California. The comparator 26 functions as a buffer with hysteresis for noise immunity and has applied to its non-inverting input an analog waveform 30 (FIG. 2A) representing a dot column pulse generated by a tachometer strobe assembly generally indicated as 32 (FIG. 1) and which is mounted on the drive shaft of the motor 24 in a manner that is well-known in the art. The tachometer strobe 32 may be composed of an infrared optical sensor sensing reference elements located on a wheel 31 secured to the drive shaft of the motor 24. The waveform 30 (FIG. 2A) generated by the strobe assembly 32 is selected to represent the time during which one character is printed by the printing mechanism (not shown) driven by the motor 24. The waveform 30 is shaped by the amplifier 26 to output the squared waveform 34 (FIG. 2B) whose leading edge will clock a D-type flip-flop 36 resulting in the appearance on its Q output of a high signal which is applied to the D input of a second D-type flip-flop 38. Flip-flop 38 is clocked by signals 40 (FIG. 2C) received over line 46 and generated by a free-running oscillator 44 which, in the present example, generates pulses at a frequency of 9 Khz. The flip-flops 36 and 38 may be of any well-known type such as part no. LM4013 manufactured by the previously-mentioned National Semiconductor Corporation.
The Q output of flip-flop 38 is coupled to the clear input of a binary counter 42 whose clock input is coupled to the oscillator 44 over the line 46. The counter 42 is a standard presettable binary counter wired to keep all outputs high when an overflow occurs. The counter 42 counts the oscillator pulses 40 received until cleared by a pulse 48 (FIG. 2E) appearing on the Q output of flip-flop 38. The pulse 48 will clear the counter 42 enabling the counter 42 to initiate another count representing the time of occurrence of the next dot column pulse waveforms 30 (FIG. 2A) and 34 (FIG. 2B). Thus, the count appearing on the output of the counter 42 at the time the pulse 48 is generated represents the actual speed of the motor 24.
As shown in FIG. 2B, upon the occurrence of the leading edge of the dot column pulse waveform 34, a pulse 50 (FIG. 2D) is generated on the output of a NOR gate 52 (FIG. 1), which pulse functions as a clock pulse and is transmitted to a holding register 56 latching the binary count appearing on output lines 54 of the counter 42 into the holding register 56. Upon the occurrence of the trailing edge of a pulse 50, the pulse 48 (FIG. 2E) appears on the Q output of flip-flop 38 clearing the counter 42. The output lines 58a-58d inclusive of the register 56 are coupled to a D/A converter which comprises a network of resistors 60-68 inclusive. Resistors 60-66 inclusive are wired in parallel with each resistor representing a binary weight. The resistor 60 has a value eight times that of resistor 66 and which in the present embodiment represents a binary weight of one. Correspondingly, the resistors 60-66 inclusive are wired in series with resistor 68 having a value which is a binary multiple of resistor 66. In the present embodiment, the value of resistor 68 is the same as that of resistor 60. The voltage level appearing at the node 70 will be proportional to the binary count appearing on the output lines 58a-58d inclusive of the register 56. Thus, if the motor 24 is rotating faster than some prescribed nominal speed, the binary count appearing on the output of the counter 42 and the register 56 will be small compared to the count representing the nominal speed. When the motor 24 is turning at a speed slower than normal, the binary count will be large. The voltage level appearing at the node 70 (waveform 72 of FIG. 2F) will reflect this relationship.
Thus, assuming that the voltage level for a nominal speed of the motor is 2.5 volts, the voltage level of the waveform 72 (FIG. 2F) appearing at the node 70 (FIG. 1) will swing between 0 volts and 5.0 volts as the speed of the motor varies with respect to the prescribed nominal speed of the motor 24. The counter 42 and the register 56 may be of any type that is commercially available at present. Examples of a counter 42 that is presently available is part no. LM40193B while register 56 may be part no. LM4035, both also manufactured by the previously-mentioned National Semiconductor Corporation.
The voltage appearing at the node 70 and which will be referred to as a reference voltage V R hereinafter, is transmitted over line 73 to the non-inverting input of the comparator 28 having an open collector output and is biased for noise immunity. As is well-known in the art, the output of the amplifier 28 will go from high to low upon the level of the voltage appearing at the inverting input of the amplifier 28 equalling the voltage V R appearing at the non-inverting input of the amplifier 28. The voltage applied to the inverting input of amplifier 28 is a ramp voltage whose waveform 74 (FIG. 2G) is developed by an RC network comprising resistor 76 coupled to the motor voltage supply V s , which in the present application is 28 volts, and the capacitor 78. A NPN transistor 80 is connected to the RC network at point A with its base element coupled to the output of the oscillator 44 through a base limiting resistor 82.
Upon the generation of each oscillator pulse 40 (FIG. 2C), transistor 80 will conduct thereby shorting the capacitor 78 to ground. As soon as the pulse is removed from point A, the capacitor 78 is charged through the resistor 76 producing the waveform 74 (FIG. 2G) of the ramp voltage V rm which voltage is applied to the inverting input of the comparator 28. This ramp voltage V rm rises until it equals the reference voltage V R present at the non-inverting input at which time the output signal of the comparator 28 goes low.
The output of the comparator 28 is coupled through a wired AND gate 120 to a power amplifier 88 which amplifies the motor supply voltage V received over line 90. The output voltage pulses 92 (FIG. 2H) of the amplifier 88 is applied over the lines 20 and 22 to the motor 24. It will be seen from this arrangement that upon the discharge of the capacitor 78 the ramp voltage signal V rm appearing at the inverting input of the comparator 28 will be lower than the voltage signal V R appearing at the non-inverting input of comparator 28, resulting in the output signal of comparator 28 going high. This output signal enables the power amplifier 88 to supply the voltage pulse 92 (FIG. 2H) to the motor 24, thereby increasing the speed of the motor during the time the ramp voltage V rm stays below the reference voltage V R . When the ramp voltage V rm meets the reference voltage V R , the output signal of comparator 28 will go low turning off the voltage pulses 92 (FIG. 2H) being applied to the motor 24. Thus, the width of the pulse 92 is determined by the time required for the ramp voltage V rm to equal the reference voltage V R . The power amplifier 88 may be part no. 2N3055 manufactured by Motorola, Inc. of Phoenix, Arizona.
As described previously, the speed of the motor 24 may be affected by variations in the torque applied to the motor and the motor supply voltage V s . Slowing down of the motor 24 due to an increase in torque applied to the motor will increase the binary count output of the register 56 in a manner previously described. This condition will increase the value of the reference voltage V R and therefore increase the time for the ramp voltages V rm to reach the reference voltage V R resulting in an increase in the width of the pulse 92 (FIG. 2H) together with a corresponding increase in the speed of the motor 24. When the motor speeds up due to a decrease in the applied torque, the reference voltage V R is decreased due to the generation of a lower binary count by the counter 42 resulting in a decrease in the width of the pulse 92 together with a corresponding decrease in the speed of the motor 24.
In the case where the motor 24 is running at a nominal speed and its supply voltage V s increases, the slope of the ramp voltage waveform 74 (FIG. 2G) is increased resulting in the ramp voltage V rm reaching the reference voltage V R in a shorter time. This action results in a decrease in the width of the voltage pulse 92, thereby maintaining constant speed of the motor 24. A decrease in the supply voltage V s produces an increase in the pulse width and again results in maintaining a constant motor speed. Thus, the circuit provides an efficient speed control of the motor 24 where either the torque or the supply voltage applied to the motor varies with operating conditions.
There will now be described a more detailed operation of the circuit shown in FIG. 1. At the start of the operation of the motor 24, the output of the counter 42 will have been preloaded with all "ones" by a carry signal appearing on line 94. This condition produces the maximum width of the pulse 92 (FIG. 2H) to bring the motor to operational speed in the shortest time possible. To initiate a print operation, a MOTOR ON logical one control signal will appear on line 96 and is transmitted over line 98 to one input of the NOR gate 100, enabling the gate to invert the oscillator pulses 40 (FIG. 2C) received from the oscillator 44 over line 46, which pulses are outputted through NOR gate 100 to one input of the NOR gate 52. The other input to the NOR gate 52 is coupled over line 102 to the Q output of the flip-flop 36 whose output signal is a logical one at this time. When this output signal goes low in a manner to be described hereinafter, a high signal is gated by the NOR gate 52 to the clock input of the register 56 enabling the register to store the output count of the counter 42 which at this time is at the maximum count. As the result of the loading of this count into the register 56, the maximum reference voltage V R is established at the non-inverting input of comparator 28 resulting in the maximum width of the pulse 92 (FIG. 2H) being generated to initiate the operation of the motor 24. For purposes of this description, positive logic is assumed for all logical elements disclosed.
Once the motor 24 is in operation, the analog voltage signal 30 (FIG. 2A) representing a dot column pulse generated by the tachometer strobe assembly 32 and developed over resistor 104 is applied to the non-inverting input of the comparator 26. A voltage developed across the voltage divider network of resistors 106 and 108 is applied to the inverting input of comparator 26 resulting in the comparator 26 outputting the squared dot column pulse 34 (FIG. 2B) to the clock input of the flip-flop 36. Thus, the analog signal 30 is buffered and shaped by the comparator 26.
The flip-flops 36 and 38 comprise a control circuit for generating a clock signal upon the sensing of the rising edge of the dot column pulse 34 (FIG. 2B. The D input of flip-flop 36 is always high being coupled to the 5 volt logic supply voltage V cc . When the leading edge of the pulse 34 goes high, the Q output of flip-flop 36 goes high, which signal is transmitted over line 111 to the D input of flip-flop 38. Simultaneously with this occurrence, the Q output of flip-flop 36 goes low, which signal is transmitted over line 102 to the NOR gate 52, enabling the NOR gate to output a logical one or high signal to the clock input of the register 56, thereby latching the output of the counter 42 in the manner described previously.
Upon the D input of the flip-flop 38 going high, the Q output of the flip-flop 38 will go high at the time the next oscillator pulse is received over line 46 at the clock input of the flip-flop 38. The high signal appearing at the Q output of the flip-flop 38 will be transmitted over line 110 to the clear input of the counter 42, thereby clearing the counter 42 and initiating a new count in the counter 42. The high signal appearing at the Q output will also reset the flip-flop 36 over line 112. The 9 Khz. frequency of the oscillator 44 was selected to provide the occurrence of 8 oscillator pulses 40 (FIG. 2C) during the generation of each dot column pulse 34 (FIG. 2B) to constitute the nominal speed of the motor 24 (FIG. 1). Any variation from this value occurring in the output of the counter 42 will produce a variation in the width of the pulse 92 (FIG. 2H) to return the motor to its nominal speed in the manner described previously. Thus, upon the occurrence of each dot column pulse 34 the output of the counter 42 is latched into the holding register 56 and the counter 42 is cleared to initiate a new count.
The clocking of the flip-flop 38 upon the occurrence of the leading edge of the dot column pulse 34 (FIG. 2B) will produce a logical zero or low signal at the Q output, which signal is transmitted over line 114 to a standard retriggerable one-shot network 116, thereby triggering the one-shot network 116 for a predetermined time period. In this case the time period is 100 milliseconds developed by the RC circuit comprising resistor 115 and capacitor 117 (FIG. 1) coupled to the 5 volt logic supply voltage V cc . If the one-shot 116 is not retriggered during this time period, which in most instances would indicate a motor jam condition, the one-shot 116 will time out and output a low signal over line 118 to the wired AND gate 120 resulting in the wired AND gate 120 outputting a low signal to the power amplifier 88, thereby turning off the amplifier. As shown in FIG. 1, the motor 24 is restarted by the generation of the high MOTOR ON signal over line 96, which signal is inverted by an inverting buffer 122 and transmitted over line 124 to the reset input of flip-flop 38. Upon the occurrence of the trailing edge of the MOTOR ON signal, the output signal of the inverting buffer 122 will go high, thus resetting the flip-flop 38 and enabling the Q output of the flip-flop 38 to retrigger the one-shot 116 upon the occurrence of the next dot column pulse 34. The inverting buffer 122 may be any standard inverter which is commercially available.
The output of the inverting buffer 122 is also coupled over line 126 through a limiting resistor 128 to the base of a transistor 130, enabling the transistor 130 to disable the wired AND gate 120 and the power amplifier 88 by shorting the inputs to the AND gate 120 to ground during the generation of the MOTOR ON signal. The transistors 130 and 80 may be part no. 2N3904 manufactured by the RCA Corporation.
A feature of the circuit shown in FIG. 1 is the D/A converter comprising the resistors 60-68 inclusive in which the most significant bit of the count latched in the holding register 56 would have the most binary weight. In this case a larger voltage drop across resistor 68 would be required while in the case of the least significant bit, a smaller voltage drop would have to occur. Thus the resistor 66 located in the output line 58d of the register 56 in which the most significant bit appears would have a value 1/8 of the value of the resistor 60 located in the output line 58a in which there is the least significant bit of the count latched in the register 56. The value of the resistors 62 and 64 would have values representing the corresponding binary weight of two and four respectively. As the binary count increases, the analog voltage output appearing at the node 70 will increase proportionately. The resistor 68 in series with the resistors 60-66 inclusive and having a value equal to the resistor 60 provides the proper output analog voltage. Thus, as shown in FIG. 2F, the level of the reference voltage V R appearing at the node 70 (FIG. 1) may vary between 5.0 volts and 0 volts depending on the speed of the motor 24.
The reference voltage V R appearing at the node 70 over line 73 is transmitted through a bias resistor 130 to the non-inverting input of the comparator 28. The ramp voltage V rm developed at the junction A in the manner described previously is applied to the inverting input of the comparator 28 in the manner described previously. Upon the occurrence of the ramp voltage equalling the reference voltage, the output signal of the comparator 28 will switch from high to low, which signal disables the wired AND gate 120, whose output will go low, thereby turning off the power supply 88 and the motor drive pulse 92 (FIG. 2H). Since the ramp voltage is generated upon the occurrence of each oscillator pulse 40 (FIG. 2C), the power level supplied to the motor 24 is changing at a much faster rate than the generation of the dot column pulse 30 (FIG. 2A). Thus the D.C. motor 24 is seeing some average voltage and thereby provides no noticeable change of speed of movement of the printing carriage.
The supply voltage V s applied to the power amplifier 88 over line 90 and to the RC network of resistors 76 and capacitor 78 is arbitrarily selected to be much larger than the supply voltage V cc applied to the integrated chip network in the circuit so as to provide a linear ramp waveform at the inverting input of the comparator 28 in order to maintain a linear change in the output of the comparator 28. The supply voltage V s in the present embodiment is an unregulated 28 volts.
Typical values of the components of the circuit can be as follows:
______________________________________Resistor Value______________________________________60 80K62 40K64 20K66 10K68 80K76 220K82 56K106 33K108 22K115 1.2 Meg128 10K130 120K______________________________________Capacitor Value______________________________________78 470 pf117 .1 uf______________________________________
Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the details of construction and the combination of arrangements of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.
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A speed control circuit for a motor is responsive to variations in motor supply voltage and torque wherein a digital output indication of the actual speed of the motor is generated. The digital output is converted to an analog value and applied to a comparator which also receives the output voltage of a ramp circuit based on the motor supply voltage. The output of the comparator controls the width of the motor voltage pulses applied from a power amplifier to the motor in which the voltage pulses applied have proportionally larger width for a smaller level of motor supply voltages or decrease in the amount of motor shaft speed and proportionally narrow width pulses for increased levels of motor supply voltage or an increase in the amount of motor shaft speed. A one-shot network is provided for motor stall protection.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/005,113 filed Dec. 5, 2001, now U.S. Pat. No. 7,346,783 entitled, “Network Security Device and Method”, which has been allowed. The aforementioned related patent application is herein incorporated by reference.
TECHNICAL FIELD
This invention relates to a technique for achieving a high level of physical security in a network security device such as would be used with a portable computer, a computer terminal or a Personal Digital Assistant (PDA) to connect to a network and obtain secure service from that network.
BACKGROUND ART
The power of a computing device, such as a personal computer, data terminal or even a Personal Data Assistant (collectively referred hereinafter as “a network peripheral device”) improves dramatically when such device is connected to other devices across a network to allow information sharing. Such a network may take the form of a simple Local Area Network (LAN), Wide Area Network, Corporate Intranet, the Intranet or combination of such networks. In many instances, the services, resources and/or data accessed or transmitted through this network are sensitive in that a breech of authenticity or privacy of the services, resources or information would have economic or other undesirable consequences for the users of the network.
Security is achieved by the use of a combination of software and hardware measures. Software employing a variety of cryptographic techniques is used to encrypt and/or authenticate the information exchanged through the network while hardware-based physical security measures guarantee that the cryptographic keys and the software using these keys remain uncorrupted, private and trustworthy. The software and cryptographic techniques used depend on the services, resources and information accessed through the network; for example, a network security device that supports Virtual Private Networking (VPN) functionality will have software that implements IPsec, Point-to-Point Tunneling Protocol (PPTP) or some other VPN protocol. This software will use cryptographic keys in the way specified by the VPN protocol in use to encrypt and/or authenticate all information flowing to and from the network.
Physical security can be achieved in different ways. Two approaches to physical security are common: physical access control and tamper-proofing. In the first approach, no specific physical security measures are included in the device; the physical security depends entirely on the fact that only authorized and trustworthy users have physical access to the device. In the second approach, the casing of the device is hardened to make its penetration difficult and detectors are placed inside the device to detect any attempt to break through the casing; if a penetration attempt is detected, the device erases all sensitive information from its memory and renders itself useless. The level of security afforded by the first approach depends on the inaccessibility of the device and is limited by the fact that there will be no way to detect a compromise of the device if the physical access controls fail. In most settings the second approach affords a much higher level of security. However, tamper-proofing by itself is not enough to guard against substitution attacks. In a substitution attack, the attacker replaces the security device of the user by another similar device that was prepared specially so that it uses keys known to the attacker, thereby nullifying the security provided by the device for the user. Tamper-proofing a device is also expensive: the device has to be augmented to include intrusion detectors, circuitry that continuously monitors the detectors and some power source to keep the intrusion detection system active when the device is not in use.
Thus, a need exists for a physical security mechanism that guarantees the integrity of software and keys used by the device and that protects against substitution attacks while keeping the cost of the security measures low.
BRIEF SUMMARY OF THE INVENTION
Briefly, in accordance with a preferred embodiment, the present invention provides a combination of physical security mechanisms and restrictions on the software placed in the device that together provide a high level of security, protecting the device's user (or users) against tampering of the device and against substitution attacks. Because of the restrictions on the software, not all network security devices can benefit from this invention; only those whose software can be modified to fit the imposed restrictions. In practice this does not restrict the types of services that can be offered by the device, only the specific cryptographic protocols that can be used to secure these services. For example, a VPN card implementing PPTP cannot make use of this invention because PPTP does not have the ‘perfect forward secrecy’ property. On the other hand, a VPN card implementing IPsec can. The security mechanism of the invention includes at least one immutable memory element (e.g., a read-only memory element) that contains information that remains immutable (unchanged) prior to and after each session (except for any upgrades). In practice, the immutable memory element contains security application code that “boot straps” (initiates the operation of) the security mechanism itself as well as initiating execution of application code that provides the security services (i.e., user and security mechanism authentication). The security mechanism also includes a persistent memory element that contains files that may undergo a change between sessions. For example, the persistent memory element may contain configuration information that permits the user to gain network access in different environments. Lastly, the security mechanism includes a volatile memory element for retaining data for only the length of a current session. For example, the volatile memory element typically contains critical security data (e.g., a user password or session specific cryptographic keys) to permit connection to the network as well as provide authentication data that authenticates the user and the security mechanism itself. At the end of the session, all of the information in the volatile memory element is erased, thereby preventing re-use of such information by unauthorized users. A tamper-evident enclosure contains the memory elements. The tamper-evident enclosure, when tampered with, will reflect such tampering, thereby allowing the user to know if an attempt was made to physically compromise the security mechanism.
The security mechanism of the invention affords a high level of security if the software of the device can be made to meet the requirements for ‘perfect forward security’ and if the device obtains all security critical data from its user at the beginning of each session. In the context of this invention, we define perfect forward security as the property of software whereby a future compromise of the device will not compromise past or present sessions protected by that device. At the beginning of a session, the security mechanism executes a ‘key exchange’ with the remote gateway. In this exchange, a session key is generated at random, encrypted using the device's private key and sent to the gateway. An attacker who intercepts this encrypted message and later gets access to the device could extract the device's private key and use that to decrypt the session key. In this manner, the attacker breaks the security of a past session. Perfect forward secrecy refers to esoteric cryptographic techniques that render this type of attack impossible. This definition is an extension of the concept of ‘perfect forward secrecy’ that is a property of cryptographic key exchange protocols that has been much discussed in the cryptographic research community. A consequence of the perfect forward security requirement for the device's software is that any key exchange protocol it uses must have the perfect forward secrecy property. As discussed, the volatile memory that holds the authentication information for the current session is erased at the end of a current session, preventing its re-use. Thus, if someone were to misappropriate the security mechanism, no authentication information remains to allow for unauthorized network entry and no information remains that could be used to decrypt a past session. Moreover, since a tamper-evident enclosure surrounds the various memory elements of the security mechanism, any attempt to physically gain access would become apparent to the legitimate holder of the security mechanism. The security critical data that the device obtains from the user at the beginning of a session must be sufficient to unambiguously determine the security services expected by the user.
The perfect forward security requirement guarantees that a compromise of the device will not compromise the security of past sessions. The tamper-evident properties of the enclosure guarantee that the user will not entrust sensitive information to a device that was compromised. Finally, the requirement that the device collects security critical data at the beginning of each session guarantees that an uncompromised device will provide the expected security services thereby guarding against substitution attacks.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates partially cut-away perspective view of a security device in accordance with a preferred embodiment of the present invention;
DETAILED DESCRIPTION
FIG. 1 illustrates a security mechanism 10 in accordance with a preferred embodiment of the invention for permitting a user (not shown) to establish a secure communications session between a network peripheral device 12 and a communications network 14 via a security gateway 15 . The network peripheral device 12 can take the form of a computer terminal, personal computer or a Personal Data Assistant (PDA), while the network 14 may comprise Virtual Private Network (VPN) accessed directly, or through an intermediate network (not shown). In the illustrated embodiment, the security mechanism 10 is a network card that provides VPN functionality and that has the configuration of a Personal Computer Memory Card International Association (PCMCIA) package for receipt in a PCMCIA slot 16 within the network peripheral device 12 . Alternatively, the security mechanism 10 could take on other configurations and could offer different functionality without departing from the spirit and scope of the invention.
To facilitate the establishment of a secure session, the security mechanism 10 includes at least one immutable memory element 18 in the form of a Read Only Memory (ROM) element that stores information (software and support files) that remains fixed for all times (i.e., for each and every communications session). In the illustrated embodiment, the memory element 18 bears the designation “Security ROM” because it stores security application software (including bootstrap) code that initiates the operation of the security mechanism 10 . Further, the security ROM 18 also generates at random the private key(s) required by the security mechanism 10 to perform its security functions including user and device authentication. (This ensures that the private keys used by different network peripheral devices remain independent from each other and that the security device cannot be forced to use keys known to an attacker.)
As an adjunct to Security ROM 18 , the security mechanism 10 may also include a write-once ROM 20 for storing information written into the ROM during manufacture of the security mechanism. Such information may include additional bootstrap code as well as any upgrade that occurred subsequent to the manufacture of the Security ROM 18 . (To the extent that either of the ROMs 18 and 20 have an upgrade capability, only the upgrade management software should have the capability of modifying the software in each ROM. Further, any application that loads either ROM should be signed by the manufacturer and the signature verified prior to writing any data.)
In addition to the security ROM 18 (and the write-once ROM 20 if present), the security mechanism 10 of FIG. 1 also includes at least one “persistent” memory element 24 , in the form of a Complementary Metal Oxide Semiconductor Random Access Memory (CMOSRAM) or a Programmable Read Only Memory (PROM) for receiving data prior to or during a communications session and for retaining such data for use during a subsequent session. In FIG. 1 , the memory element 24 bears the designation “Configuration Memory” because this memory element stores configuration data that enables the security mechanism 10 to facilitate a connection with different networks. Thus, the contents of the Configuration memory element 24 can change upon an application executed by the network peripheral 12 that requires new or updated configuration information. To maintain security, only the application requiring new or updated configuration information should have the ability to write data to the configuration memory element 24 and the data written to this area must not be of a nature that could compromise the security afforded to the user. In other words, security critical data (i.e., data identifying the user and the device) must be excluded. The application executed by the network peripheral device 12 that seeks to write data to the Configuration Memory Element 24 should require signing and that such signing should be verified by the information in the Security ROM 18 .
In addition to the previously described memory elements, the security mechanism 10 also includes at least one volatile memory element 26 in the form of a Random Access (RAM) memory or the like. The RAM 26 holds session-specific data, including user-entered verification data, such as a password or Personal Identification Number (PIN), as well as authentication data generated by the security mechanism 10 itself. The data held within the RAM 26 remains only for the duration of a session. At the end of each session, as well as upon a power-down condition, the bootstrap code within the Security ROM 18 (or the bootstrap code in the Write-Once ROM 20 ) causes the RAM 26 to erase all of its data (or at least its sensitive security data) if such data has not already been erased. In this way, the memory element 26 loses all user-entered verification data, as well as all security mechanism-generated authentication data associated with a given session upon its completion, or upon a power-down condition.
An interconnection medium 28 in the form of a circuit board or the like, supports and interconnects the Security ROM 18 , the Write-once ROM 20 , the Configuration 24 memory and the volatile memory 26 , as well as other chips (not shown) such as a central processing unit. The circuit board 28 couples the memory elements and other components mounted thereon to a connector 30 , which mates with a complementary connector (not shown) in the PCMCIA slot 16 of the network peripheral device 12 . A tamper-evident enclosure 32 surrounds the circuit board 28 and the components mounted thereon to prevent access to such components, thus preventing tampering therewith. The effective level of the physical security of the security mechanism 10 depends the selection of the materials and fabrication technology employed. In addition to preventing access to the components on the circuit board 28 , the tamper-evident enclosure 32 has the property that it readily exhibits any attempt to gain access there through to the circuit board and the components mounted thereon. In this way, a user who inspects the tamper-evident enclosure 32 can easily observe whether anyone has attempted to gain access to any of the Security ROM 18 , the Write-once ROM 20 , the Configuration 24 memory and the volatile memory 26 , thereby compromising the integrity of the security mechanism 10 . In addition to employing the tamper-evident enclosure 32 , the components of the security mechanism 10 are strengthened against extreme environmental conditions, including, but not limited to under/over voltage conditions, fast/slow clock speeds, temperature variations and electromagnetic radiation.
In the illustrated preferred embodiment, the network security mechanism 10 implements VPN functionality using IPsec. At the beginning of each network connection session, the security mechanism 10 will obtain from the user the security critical data that describes the security services to be provided. This data should specify which security gateway to connect to, which cryptographic algorithms and which key sizes are acceptable, the username by which the user is known to the security gateway and the password that the security gateway will use to authenticate the user. Using this security critical data, the security mechanism 10 establishes a secure connection to the indicated gateway, establishing encryption and authentication keys to be used for the remainder of the session as well as performing any authentication steps that are required by the security gateway to gain access to the resources it controls. The specifics of authentication and key establishment depend on the specific protocols in use. The details for the IPsec VPN protocol, for example, can be obtained from the definition of the protocol itself.
The above-described embodiments merely illustrate the principles of the invention. Those skilled in the art may make various modifications and changes that will embody the principles of the invention and fall within the spirit and scope thereof.
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The invention describes a method for hardening a security mechanism against physical intrusion and substitution attacks. A user establishes a connection between a network peripheral device and a network via a security mechanism. The security mechanism includes read only memory (ROM) that contains code that initiates operation of the mechanism and performs authentication functions. A persistent memory contains configuration information. A volatile memory stores user and device identification information that remains valid only for a given session and is erased thereafter to prevent a future security breach. A tamper-evident enclosure surrounds the memory elements, which if breached, becomes readily apparent to the user.
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The present application is a continuation-in-part of my earlier copending application Ser. No. 482,092, filed June 24, 1974, and now U.S. Pat. No. 3,952,724.
The present invention relates to solar energy collectors. More specifically, the invention provides a relatively inexpensive and efficient unit for installation as a module or unit in a solar energy converter system.
SUMMARY OF THE INVENTION
The basic components of the energy collector unit for the system are made of glass of known tubular manufacture such as are prevalent today in the manufacture of glass tubing products, e.g. process glass pipe, or the like.
The tubular glass solar energy collectors are assembled onto a manifold such that the tubular collectors are detachably connected into a manifold. The manifold may be constructed for disposition of the collectors on either side thereof so as to extend laterally in rows along the manifold and provide an energy collecting system connected for either cooling or heating uses.
OBJECTS OF THE INVENTION
One of the important objects of the present invention is to provide a collector unit of low cost of manufacture and of operation. The collector unit may be mass produced of relatively inexpensive raw materials, the bulk of which is glass, and may be maintained in use or replaced easily.
Another important feature of the invention is the construction of the collector wherein the components comprised of three concentric tubes are made of glass. The two outermost tubes are constructed from glass tubing to resemble oversized test tubes in that their one end is closed. The outer tube is sealed to the intermediate inner tube and the space therebetween evacuated to a practical and efficient degree of vacuum to prevent heat loss through the space by convection and conduction heat loss. The intermediate inner tube is coated with an energy absorbing coating of high absorptance and low emittance. The third tube is placed inside the intermediate tube and is used to carry the fluid medium to the interior, closed end of the latter. The parts thus described, aside from the coatings, are of the same or similar composition of glass. The thermal expansion characteristics are similar and allow a glass-to-glass flame seal rather than a glass-to-metal gradient seal used in this type of collector heretofore, thereby avoiding failure from thermal expansion differences during operation. Additionally, the glass parts may be sealed one to the other more readily and with less cost in manufacture.
A further object of the invention is to provide a manifold for the fluid medium flow into and out of a plurality of the collector units connected thereto, and the collector units are provided with a quick disconnect and O-ring seal in a socket of the manifold for each collector unit.
Another object of the invention is to provide a spring support means connected to the interior end of the coated, intermediate absorber tube holding that end of the tube in concentric position in the outer tube, the other end of the absorber tube being sealed to the wall of the outer tube for support.
Other objects and advantages will become apparent from the following description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the invention in use on the roof slope of a dwelling.
FIG. 2 is a side view, partly broken away and in section, of collector unit of the invention.
FIG. 3 is an exploded, perspective view, partly broken away and in section, showing a solar energy converter system module of the double manifold embodiment, wherein collector units extend on either side of the manifold.
FIG. 4 is a sectional plan view of a portion of the manifold of FIG. 3.
FIG. 5 is a perspective view of the end cap providing an inner end support means for the coated absorber tube of the collector inside the outer jacket tube.
FIG. 6 is a staggered sectional end view of the collector taken along line 6--6 on FIG. 2. FIG. 7 is a side elevational view, partly broken away and in section, of a second embodiment of collector unit of the invention.
FIG. 8 is a fragmentary, enlarged sectional view of the fusion assembly of the glass absorber tube and the glass outer tube of the collector unit of FIG. 7.
DESCRIPTION
Shown on FIG. 1 is a typical in-use setting for the invention. The dwelling 10, such as a residence, has its roof section 11 located nearest the sun or most accessible to the sun, provided with plural modules 12 of the solar energy converter of the invention. The area selected for coverage by modules 12 may be left to the skill of the engineer and architect providing for the heating or cooling for the dwelling.
The Manifold
The module of the solar energy converter is shown in detail on FIG. 3. Module 12 which appears in part on the exploded view, comprises a central longitudinal manifold section 13 that extends down the roof section (FIG. 1). Extending outwardly from either side of the manifold 13 are plural collector units 14, to be presently described. The collectors 14 are of a plug-in type of connection into the side ports 15 spaced along the opposite vertical side walls 16 and 17 of manifold 13. Internally of manifold 13 are longitudinal passageways 18 and 19 running along the ports 15 on either side of the manifold. Sandwiched between passageways 18 and 19 is a central passageway 20 defined by the longitudinal interior vertical walls 21 and 22. Along walls 21 and 22 there are spaced apart ports 23. The ports 15 and 23 are matched as sets on the same central axis, i.e., the ports are coaxial.
The manifold 13 connects into a fluid handling system illustrated by the duct 24 having an upper conduit passage 25 and a lower conduit passage 26. The duct 24 extends between the heating or cooling system (labelled "Fluid Heat Exchanger" on FIG. 3) and the solar converter module 12. The passage 25 carries the relatively cool fluid medium, such as water, air or the like, and inroduces it through the matching aperture connection 39 in the vertical wall 24a of duct 24 and aperture 27 in the vertical end wall 28 of manifold 13. The aperture 27 connects into the central passageway 20 of manifold 13. The duct 24 and manifold 13 are connected and sealed together by the gasketed facing 29 held by cap screws 30 threaded into end wall 28 at 31. Gasket 29 may be any suitable compressible gasket material that will withstand elevated temperature service. Matching lower apertures 32 and 33 in wall 24a and 34 and 35 in wall 28 connect the respective passages 18 and 19 with the duct passage 26 for carrying the heated fluid medium coming from the collectors 14.
Manifold 13 is enclosed by top and bottom walls 36 and 37, respectively, and at its outer end by vertical wall 38.
The Collector Unit -- First Embodiment
The collectors 14 shown on FIGS. 2 and 3 are all constructed alike, and each comprises an outer glass tube 40 that is of convenient length, say from 4 to 7 feet and of standard diameter, e.g. 2 inches O.D. A lower mirrored surface 45 may be employed to reflect radiant energy onto a portion of the absorber tube 41 of the collector.
The interior tube 41 is made of glass and is of somewhat lesser diameter and of slightly greater length. Tube 41 has its exterior surface precoated with an energy absorbing coating 42 having a high absorptance and low emittance. Examples of such wave length selective coatings are metallic undercoatings such as aluminum or silver deposited upon the glass surface, and a semi-conductor type coating is next deposited over the metallic surface coating to provide the wave length sensitivity desired. A high performance wave length selective coating is preferred having 0.8 or greater absorptance and 0.1 or lower infra red emittance.
Inside tube 41 there is a fluid delivery glass tube 43 for conveying relatively cool fluid medium into the collector interiorly of tube 41 and adjacent the closed end wall 41a thereof. The inner end 43a of delivery tube 43 is open (FIG. 2).
In assembly, the absorbing tube 41 already coated on the exterior with the wave length selective coating 42, is further provided with the snap-on end support cap 46 (FIG. 5) which provides inner end support means for tube 41 in tube 40. Cap 46 comprises a semispherical shell and multiple (either 3 or 4) legs 47. The cap 46 is made of metal or plastic having some resiliency to maintain its force fit on the inner end of tube 41. Tube 41 is then inserted into the outer tube 40 and in this first embodiment of the invention is fastened to outer tube 40 by fusing its open end onto tube 41 at the juncture 40a (FIG. 2). Thereafter, a vacuum is pulled through the opposite end of tube 40 at a tubulation and sealed off at the tip 48 in the manner known to those skilled in the art, the resultant sealed space 49 between the outer tube 40 and absorber tube 41 being highly evacuated; viz on the order of 10 -4 torr of vacuum. Next the delivery tube is inserted interiorly of the absorber tube 41. Each of the collector units 14 is detachably assembled into the manifold 13 as follows. The free end 43b of the delivery tube 43 is approximately the same O.D. as the diameter of the ports 23 in the interior walls 20 and 21 of the manifold. A rubber O-ring 50 is provided on free end 43b of the delivery tube to seal the latter in port 23. Similarly, free end 41b of the absorber tube is approximately the same O.D. as the port 15 in either of vertical side walls 16 or 17. A rubber O-ring 51 is provided on free end 41b of the absorber tube to seal it in port 15. The ports 15 and 23 are each provided with recess grooves 51a and 50a respectively, to receive the gasket O-rings 51 and 50 therein.
The Collector Unit -- Second Embodiment
The collector construction shown on FIGS. 7 and 8 has similar parts labelled with corresponding numerals marked by a prime designation.
The collector 14' is comprised of a glass outer tube 40' that is transparent or clear and is closed at its one outer end in a sealed tubulation 48'. The opposite end of tube 40' is open. The interior tube 41' is made of glass tubing of somewhat lesser diameter and length. The interior glass tube 41' has its exterior surface precoated over substantially its length and periphery with the high absorptance and low emittance wave length selective coating 42' as described earlier herein under the first embodiment. Before the coating 42' is applied, preferably, the open end of glass tube 41' is worked to an outwardly flared end opening of the contour of the flared end 60 shown on FIGS. 7 and 8. The coating 42' is applied on the tube adjacent the flared end 60 to and inclusive of the closed end of tube 41'. Next, tube 41' is inserted into glass outer tube 40', a simple coil spring 61 being first assembled to fit on the closed end of tube 41' and bear against the closed end on the inside of outer tube 40'. At this stage of assembly, the tubulation at 48' is still open. With the tubes 40', 41' in place, as shown on FIG. 7, and spring 61 being somewhat compressed, the flared end 60 of tube 41' and the open end portion of tube 40' are heated and the glass fused together to form the integral end connection of the two tubes 40', 41', such as shown on FIG. 8. Thereafter, a vacuum is pulled through the opposite end tubulation at 48' of the outer tube 40' and sealed off at the tip 48' shown, which seals the space 49' between the outer tube 40' and the inner absorber tube 41' at a vacuum, preferably on the order of 10 -4 torr or greater of vacuum. The coating 42' is thus contained within the vacuum of space 49'. A delivery tube 43' is inserted through a wall member 62 and annular rubber grommet 63 in a port 15' or 23' on one side or the other of the manifold 13, as described earlier herein. A rubber O-ring 51' is seated in a groove 51a'of the port 15' and compressed against the outer wall surface of tube 40' near the open end of the collector. The O-ring 51' forms the primary seal for the collector 14' in the manifold port.
Manifold 13 includes a layer of foamed insulation 64 around its exterior, exposed surfaces, and at locations corresponding to the collector ports in the manifold, the insulation layer includes formed ports 65 registering with the manifold ports. A thin washer-like seal 66 of flexible material is imbedded in the insulation within the bore of each of the ports 65 which annularly engage the periphery of the tube 40' thereby providing an outer seal in the ports.
The outer tube 40' is made of high transmittance and preferably low iron transparent glass. The inner absorber tube 41' is preferably of substantially the same glass composition as tube 40' for ease in the joining process and to reduce the residual stress at the fusion seal between the outer and inner tubes near their open ends.
Regarding the wave length selective coating layer 42' on glass tube 41', the coating comprises a substance having 0.80 or greater absorptance and a sub-coat having 0.1 or less emittance. For high absorptance as indicated, metallic compounds such as oxides or sulphides of chrome, nickel, copper or the like can be used with success. Sometimes a combination of metal and its compounds is best for the solar energy absorption. For low emittance as indicated, aluminum, silver, copper and gold are preferred as the sub-coat, the high absorption coating substances being superimposed thereover.
Any method of deposition of the coating substances selected must be capable of applying a controllable think film. Such methods used with success are vacuum deposition, chemical vapor deposition, ion-plating and sputtering.
In the invention, energy absorbing coatings not suitable in other types of collectors, such as flat plate collectors, may now be used because the coating is protected in the space 49' between the tubes at hard vacuum environment. Chemical attack by air and moisture or lack of bonding integrality are alleviated and no longer detrimental factors in the tubular solar energy collector herein disclosed.
The spacing means used between the closed ends of the inner and outer tubes 41', 40' of the collector can be of any design or material. The design criterion is that it must provide a firm support of the inner tube end to minimize the stress created at the opposite fused ends, or open ends of the tubes. It must allow the inner tube to expand or shrink according to its temperature without developing undue stress at the mentioned fused joint. Also, it must have preferably a minimum contact surface between the tubes and the spacing means to minimize heat loss by conduction, and it must also serve as a support during the sealing operation. As is disclosed herein, the spacing means may take the form of the snap-on clip 46 (FIG. 5) or the coil spring 61 (FIG. 7).
Because the spacer means is in the space to be evacuated to a hard vacuum, the material thereof used should not release gases after bake-out and tip-off of the outer tube 40 or 40' in the evacuating process. Also, the material of the spacer must be free of oily substance and organic bonding material, which would be be eliminated at a bake-out temperature for evacuation. Stainless steel properly cleaned is the preferred material.
Operation of the Collector Module
Utilizing the assembly shown on FIG. 3, and described earlier herein, a fluid medium, for example air, is pumped in duct 25 into central passage 20 of the manifold. The free ends 43b of the several collectors 14 communicate with passage 20 and are sealed therein so that the air flows lengthwise of the delivery tube 43 and exits at inner end 43a. Solar rays penetrate the upper glass of tube 40 and energy therefrom is absorbed by coating 42 of the absorber tube 41. The air circulated on the interior of tube 41 traverses the passage defined by helical baffle 44 and heat exchange therewith increases the temperature of the air as it travels toward the free end 41b of tube 41.
When heated air reaches the free end 41b of the tube connected thereat into either passageway 18 or 19, as the case may be, the heated fluid media flows into the lower duct 26 and is utilized to either heat or cool dwelling 10, or service hot water heating, or both.
One of the significant advantages of the system is experienced in the collector units 14 or 14' of the invention. Should any one of the collectors be damaged, break or malfunction, a replacement may be readily inserted and the defective unit removed, thereby maintaining the efficiency of the system.
The glass tubes of the unit are fabricated from known and standard glass shapes of either a soda-lime glass composition or a borosilicate glass composition. Both glasses are relatively inexpensive. The system and modules thereof may be assembled on the site of installation and need not be prefabricated at the factory and delivered to the site. The solar energy collector of this invention is simple to manufacture and assemble. Furthermore, it is lightweight; therefore, there is no need to further structure or reinforce the roof of the building where it is installed.
In use of the invention, the working fluid is deliverable from the collectors at a temperature in excess of 250° F. The energy absorbing coating 42 or 42' is totally protected and will last the lifetime of usage of the collector unit.
The module concept illustrated herein includes the preferred embodiment whereby collectors extend on both sides of the manifold -- a "double acting" system. It is also within the scope of the invention to fabricate a "single acting" system wherein collectors extend only along the one side of the manifold. This may have some specialized uses, but, as stated, the double acting system is the preferred embodiment.
Other and further modifications may be resorted to without departing from the spirit and scope of the appended claims.
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The disclosed invention relates to a solar energy collector in a conversion system. The collector is made from common glass tubing lengths of different diameters and comprises a first outer clear glass cylindrical tube closed at one end, and a glass absorber tube inside the first tube having an energy absorbing coating on its exterior surface. The absorber tube resembles an over-sized test tube in that one end is closed. The absorber tube is held in place inside the outer tube by a spacer-support means engaging the closed end of the absorber tube. The open end of the absorber tube is sealed to the inside of the wall of the outer tube, which is the longer of the two, and the space is evacuated. An open-ended fluid handling tube of glass is inserted into the absorber tube to guide working fluid issuing into the absorber tube near its closed end along the wall thereof and extract collected heat. Several of the energy collectors are detachably connected into a manifold for circulation of working fluid (air or water or the like) into the handling tube and receive working fluid flowing from the absorber tube. The manifold provides for collector tubes to depend on opposite sides as a module covering predetermined area of rooftop or like solar exposure. The working fluid carrying the energy is utilized in a heating or cooling system.
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BACKGROUND OF THE INVENTION
The invention relates to a locking system having a lock unit and a key unit between which power and data can be transmitted, with the lock unit having a lock body on which a coil carrier with a lock side induction coil is provided for the transmission of power and date, and with a key side induction coil being provided in the key unit for the transmission of power and data.
A locking system of this kind is known from DE 42 07 161. The locking system described there has a key unit with an induction coil on the key side and a lock unit with an induction coil on the lock side. Data in the form of encoding information can be transmitted from one induction coil to the other, data transmission taking place to control the operation of a latching arrangement contained in the lock unit. The induction coil on the lock side is mounted on a lock body of the lock unit by means of a coil carrier and, when the key unit is inserted in the lock unit, is in direct proximity of the induction coil on the key side fitted in a key bit on the key unit.
In order to allow the induction coils to locate closely together, the area of the induction coil on the lock side directed towards the induction coil on the key side is open. The interference immunity of the data transmission can therefore be adversely affected to a considerable extent as a result of environmental factors such as the ingress of moisture to the induction coil on the lock side. Furthermore, the labor and the costs involved in the manufacture of the lock unit are high owing to the close proximity of the induction coils.
Also, the figure of merit of the induction coil on the lock side and therefore the interference immunity of the data transmission after mounting the induction coil on the lock side to the lock body is reduced by the material properties of the lock body. The cause of this reduction is a ring current induced in the lock body by a magnetic field arising at the time of data transmission. Since the magnetic field is a high-frequency alternating field, this ring current can only flow through a thin layer on the surface of the lock body because of what is known as the skin effect. The resistance of this layer, the thickness of which depends on the depth to which the magnetic field penetrates the lock body, depends on the conductivity and the magnetic permeability of the lock body. Since the thin layer and the induction coil on the lock side represent a transformer with the induction coil on the lock side as primary coil and the thin layer as short-circuited secondary coil, the resistance of this thin layer conducting the ring current is stepped up to the primary coil, i.e., to the induction coil on the lock side, and thus causes the resistance of the induction coil on the lock side to increase. Consequently, the figure of merit of the induction coil on the lock side is reduced by mounting the induction coil on the lock side onto the lock body.
SUMMARY OF THE INVENTION
The object of the invention is to provide a locking system that can be manufactured at low cost and with little labor and which allows interference-free data transmission that is hardly affected by environmental factors.
This object is solved in accordance with the invention by a locking system including a lock unit and a key unit between which power and data can be transmitted, wherein the lock unit has a lock body on which a coil carrier is located with a first induction coil provided for the transmission of power and data, and wherein a second induction coil provided in the key unit for the transmission of power and data, and wherein the lock unit has a screening body located between the first induction coil and the lock body to screen off magnetic fields. Advantageous variations and further developments are disclosed and discussed.
In accordance with the invention, the lock unit has a screening body that screens off magnetic fields and which is situated between the induction coil on the lock side and the lock body. The lock body is screened magnetically from the induction coils provided for the transmission of power and data by the screening body such that any magnetic field arising at the time of power and data transmission is unable to find penetrate the lock body. Consequently, the figure of merit of the induction coil on the lock side is not related to the material of the lock body. For the same reason, the inductance of the induction coil on the lock side is not related to the distance between lock body and induction coil on the lock side and consequently it is not related to any assembly tolerances there might be when mounting the coil carrier on the lock body. The power transmission and the interference immunity of data transmission, both of which depend on the figure of merit and inductance of the induction coils, are therefore improved by the screening body.
The screening body is made preferably of a material with good electrical conductivity and advantageously of a non-ferromagnetic material such as copper.
The locking system can be used wherever, together with a mechanical lock, the use of an additional electrical security system or identification system is required or advisable for checking the right of entry or access.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in further detail with reference to the drawing FIGURE which shows, as an example of application, a locking system for operating an ignition system and an electronic immobilizer in a motor vehicle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The lock body 10 as shown in the FIGURE is a conventionally designed lock cylinder with a cylinder core that can be rotated in a housing and locked by means of mechanical tumblers. It is made of a ferromagnetic material, steel for instance, in order to provide a low-cost locking device that is difficult to damage.
The induction coil 11 on the lock side is fitted on the lock body 10 by means of a coil carrier 12 made of plastic. The coil carrier 12 has a keyhole 14 through which the key bit 20 of key unit 2 can be introduced into the lock body 10 in order to unlock the lock unit 1.
By introducing the key bit 20 into the lock body 10, the induction coil 21 on the key side of transponder 23 located in the grip 22 of key unit 2 is brought into the proximity of the induction coil 11 on the lock side. Inductive power and data transmission then takes place between the induction coils 11 and 21. Transponder 23 is thus supplied with power from the power transmission and hence activated to output data. Transponder 23 can also be activated to output data by data transmitted from the induction coil 11 on the lock side to the induction coil 21 on the key side. The key unit 2 is identified from the data transmitted from the induction coil 21 on the key side to the induction coil 11 on the lock side and, if there is a right of access for the vehicle, the vehicle immobilizer is deactivated.
The induction coil 11 on the lock side has no ferrite core as field conducting element and is wound around the keyhole 14 of the coil carrier 12, i.e., around the axis of rotation 15 of the lock body 10 and the key unit 2. Consequently, data transmission is possible irrespective of the position of the key unit 2 inserted in the lock body 10. This means that data transmission occurs even when the key unit 2 is turned in the lock body 10. The key unit 2 can therefore also be designed as a reversible key.
The screening body 13 is located between the induction coil 11 on the lock side and the lock body 10. It is made of copper, i.e., of a non-ferromagnetic material with high conductivity. Its purpose is to screen the lock body 10 from the induction coil 11 on the lock side and thus prevents the magnetic field created by the transmission of power and data from penetrating the lock body 10. The thickness of the screening body 13 is at least sufficient to prevent the magnetic field from passing it. Since the magnetic field in the present example is an alternating field with a frequency of 125 kHz, and since the depth of penetration of this magnetic field is approximately 0.2 mm in copper, the design thickness is therefore greater than this 0.2 mm. Furthermore, it has a wide area and covers as large a part as possible of the side of the lock body 10 facing the induction coil 11 on the lock side. In the present example, in order to keep the dimensions of the lock unit 1, and in particular the distance between the side of the coil carrier 12 facing the key unit 2 and the lock body 10, it is designed as a disk 13 with a thickness of approximately 0.5 mm. This disk 13 has an opening through which the key bit 20 of the key unit 2 can be introduced into the lock body 10.
Due to the magnetic field created during the transmission of power and data, a ring current is induced which, however, on account of the skin effect, flows through only a thin layer on the side of the screening body 13 facing the induction coil 11 on the lock side. If there were no screening body 13, this ring current would flow through a thin layer on the surface of the lock body 10. This ring current produces a reduction in the figure of merit of the induction coil 11 on the lock side, and this reduction increases with the magnitude of the resistance of the layer conducting the ring current. Since, because of the materials used, the magnetic field can penetrate to a greater depth in the screening body 13 than in the lock body 10, and since furthermore the electrical conductivity of the screening body 13 is greater than that of the lock body 10, the layer of the screening body 13 conducting the ring current has a lower resistance than the corresponding layer of the lock body 10 through which the ring current would flow in the absence of screening body 13. The figure of merit of the induction coil on the lock side is therefore reduced to a considerably lesser extent by the ring current flowing through the screening body 13 than by the ring current that would flow in the absence of the screening body 13 in the lock body 10. This means that with the screening body 13 the figure of merit of the induction coil 11 on the lock side is reduced, but this reduction is considerably less than the reduction obtained by assembling coil carrier 12 without screening body 13 on lock body 10.
The induction coil 11 on the lock side and the screening body 13 are securely joined to one another at the time of manufacture of the coil carrier 12, advantageously in one working step, for instance by injection molding. A definable distance, of approximately 1 mm for example, between the induction coil 11 on the lock side and the screening body 13 can be obtained with high accuracy. Since the inductance of the induction coil 11 on the lock side varies in accordance with this distance, the inductances of induction coils joined in this way with screening bodies vary only slightly from one another.
By screening, one also obtains a reduction of the influence of the lock body 10 on the inductance of the induction coil 11 on the lock side so that, when the coil carrier 12 is assembled to the lock body 10, no tight specifications are given with respect to maintaining a particular distance between the lock body 10 and the induction coil 11 on the lock side.
Vehicles with conventional ignition locks can thus be retrofitted with little effort and at low cost with an induction coil on the lock side for operating an immobilizer.
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In a locking system comprising a lock unit and a key unit, each of which has an induction coil for transmitting power and data, the induction coil on the lock side is mounted by via a coil carrier on a lock body in the lock unit. Between the induction coil on the lock side and the lock body, there is a screening body which magnetically screens off the lock body from the induction coil on the lock side.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of German application no. 10 2006 051 104.2, filed Oct. 25, 2006, and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a device for extruding hollow strands from thermoplastic material.
BACKGROUND OF THE INVENTION
In DE 697 13 645 T2, a device for cooling the interior of a hollow profile, in this case a plastic pipe, by means of cooling air is described. For this purpose, a hollow cylinder that is closed at the front is pushed into the hollow mandrel of an extruder head and protrudes into the following calibrating unit, an annular gap remaining between the outer wall of the hollow cylinder and the inner wall of the extruded pipe. The hollow cylinder is double-walled and is supplied with cooling water through a central feed line, which opens out into the front end wall of the hollow cylinder. This cooling water flows from its inlet point in the front end wall of the hollow cylinder radially outwards and then back through the cylindrical double casing to the extruder head. In the region of the mandrel, the double casing is bent conically inwards and comes to lie against the circumference of the central cooling water feed line. The cooling air is blown into the hollow cylinder in the direction of extrusion and deflected outwards at the cone formed by the double casing onto the wall of the hollow cylinder. Provided there are through-openings, through which the cooling air flows into the annular gap. There it passes over the inner wall of the extruded pipe and cools it down. The heat taken up by the cooling air is removed again, at least partially, by the cooling water flowing in counterflow in the double casing, so that the cooling air can remove heat from the extruded pipe over the entire length of the annular gap.
In U.S. Pat. No. 4,545,751, a device for cooling the interior of a corrugated tubing produced on an extrusion line is described. Screwed as an extension onto the mandrel of the extruder head of this device is a housing, which reaches into a peripheral mould for creating the corrugation of the tubing to be produced. Arranged in the housing is a Ranque vortex chamber, the cooling air outlet of which opens out into the housing. The latter has in turn radial outlet openings, through which the cooling air flows into the extruded hollow strand lying against the mould and cools it from the inside.
For some years, equipment that makes it possible to change the dimensions of an extruded plastic profile while the production process is in progress has been available. This includes calibrating sleeves, the cross section of which can be changed within relatively wide limits and which have an inlet that can is radially adjustable to match the changing cross section. Such a calibrating sleeve is described in DE 10 2005 002 820 B3.
In particular on account of their radial dimensions, the prior-art devices for cooling the interior of extruded hollow strands in a calibrating device described at the beginning cannot be used in calibrating devices designed for making a dimensional change while operation is in progress, in particular in the case of small cross sections of the hollow strands.
This also applies to a device for extruding hollow strands from thermoplastic material that is disclosed in the subsequently published DE 10 2005 031 747 A1. This has, inter alia, an extruder head with a mandrel and also a calibrating device. Formed in the mandrel is a least one Ranque vortex chamber, the cooling air outlet of which leads into the interior space of the extruded hollow profile.
OBJECTS AND SUMMARY OF THE INVENTION
The object of the present invention is to remedy this situation and provide a device with which effective interior cooling is achieved in calibrating devices designed for making a dimensional change while operation is in progress.
This object is achieved according to the invention by a device for extruding hollow strands from thermoplastic material, including an extruder head having a mandrel, and a calibrating device, for making a dimensional change while production is in progress, and with a radially adjustable inlet. At least one Ranque vortex chamber being formed in the mandrel, a cooling air outlet of which chamber leads into a cooling tube, which extends as an axial extension of the mandrel through the inlet of the calibrating device and has a cooling air outlet opening out into the calibrating device.
The present invention uses the known phenomenon of the Ranque vortex tube to provide a simple way of producing a cooling gas which is used for cooling the interior of an extruded hollow strand. In this case, the vortex tube does not require any additional space ahead of the extrusion die, since it is situated in its mandrel. There, the hot air generated in the vortex tube can also be meaningfully used, for example by the mandrel being additionally heated. Cooling gas produced in the vortex tube is transferred via the cooling tube, to a certain extent as with an injection needle, into the calibrating device and is available there for effective interior cooling. Since the cooling tube only has to be designed in its cross section for the amount of cooling gas to be transported, its radial dimensions can be kept small, so that it does not hinder the radial adjustment displacements of the calibrating device that are required in the case of a dimensional change, or make them impossible.
Further advantageous refinements of the invention are provided as set forth in detail herein, such as below, and in the claims and abstract.
The invention is explained in more detail below on the basis of exemplary embodiments of a pipe extrusion line.
Relative terms, such as left, right, up, and down, are for convenience only, and are not intended to be limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic side view of an extrusion line,
FIG. 2 shows an enlarged schematic detail A according to FIG. 1 in a sectional representation, in the case of a device in a first operating state,
FIG. 3 shows an enlarged detail from FIG. 2 ,
FIG. 4 shows a representation according to FIG. 3 in the case of a device in another operating state,
FIG. 5 shows a schematic cross section through the mandrel of an extruder head in a first embodiment of a Ranque vortex chamber, and
FIG. 6 shows a representation according to FIG. 5 in a second embodiment of the Ranque vortex chamber.
DETAILED DESCRIPTION OF THE INVENTION
The extrusion line for producing pipes that is represented in FIG. 1 comprises an extruder unit 1 with a feed hopper 2 , an extruder screw, which cannot be seen in the drawing, and a pipe extrusion head 3 . A thermoplastic material 4 in the form of granules or powder is fed to the extruder unit 1 via the feed hopper 2 . In this extruder unit, the granules or powder is/are heated, kneaded and plasticated. Subsequently, the plastic 4 is conveyed as a mouldable compound by the extruder screw into the pipe extrusion head 3 and forced there through an annular gap 15 (see FIGS. 2 to 4 ).
After emerging from the annular gap 15 , the hot, still deformable pipe 5 is drawn by means of a tracked take-off unit 6 , arranged at the end of the extrusion line, through a calibrating and cooling unit 7 , which has a vacuum tank 8 with a calibrating sleeve 9 arranged at its inlet. The calibrating sleeve 9 is infinitely variable in diameter, so that the extruded, still mouldable pipe 5 can be fixed to the desired outer diameter. After leaving the calibrating and cooling unit 7 , the pipe 5 enters a cooling zone 10 , in which it is cooled down to room temperature. Arranged between the cooling zone 10 and the tracked take-off unit 6 is an ultrasonic scanner 11 , with which the diameter and the wall thickness of the extruded pipe 5 are recorded. The tracked take-off unit 6 is adjoined by a separating saw 12 , in which the pipe 5 is cut to length. To maintain a negative pressure in the calibrating and cooling unit 7 , the cooling zone 10 and the ultrasonic scanner 11 , seals 13 are provided, enclosing the pipe 5 running through with a sealing effect.
Since the extruded pipe 5 is only cured, i.e. becomes dimensionally stable, after it leaves the cooling zone 10 , before that it must be supported to avoid it sagging and thereby deforming. For this purpose, two pipe supports 14 are provided in the cooling zone 10 and one is provided in the calibrating and cooling unit 7 .
The calibrating sleeve 9 has an annular inlet head 16 and an annular outlet head 17 . While the inlet head 16 is arranged outside the vacuum tank 8 , the outlet head 17 is in the vacuum tank 8 ( FIG. 1 ). The outlet head 17 has a fixed inner diameter, which corresponds at least to the greatest pipe diameter to be handled in the extrusion installation. It can be displaced with respect to the fixed inlet head 16 in the axial direction of the calibrating sleeve 9 , in order to change its diameter. For this purpose, at least two spindle units 18 are provided, the threaded spindles of which are motor-driven.
The inlet head 16 has radially adjustable segments 19 ( FIGS. 2 to 9 ), which are arranged uniformly over the circumference of the pipe 5 to be calibrated and form a conical inlet of the calibrating sleeve 9 . For the further construction of the calibrating sleeve 9 , reference is made to DE 2005 002 820 B3, the relevant disclosure of which is hereby made the subject matter of these exemplary embodiments. This calibrating sleeve 9 , in the same way as the other equipment of the extrusion line too, is suitable for making a dimensional change while production is in progress.
In the front end of the pipe extrusion head 3 that is shown in FIGS. 2 to 4 , the polymer melt 41 conveyed by the extruder screw is divided in an annular manner. Provided for this purpose is a mandrel support tip 20 , which protrudes conically into the stream of polymer melt 41 . The mandrel support tip 20 is adjoined by a mandrel support spider plate 21 , by means of which a mandrel 22 of the pipe extrusion head 3 is connected to the mandrel support tip 20 by screwing. The mandrel 22 goes over at its front end into a hollow cylinder 23 , in the region of which the mandrel 22 is surrounded by a hollow-cylindrical die ring 24 while leaving the annular gap 15 , said die ring being connected to the mandrel 22 by screwing. The annular gap 15 continues through the mandrel 22 to the mandrel support tip 20 . In the mandrel support spider plate 21 , the annular gap 15 is interrupted every 90 degrees by webs of material (not represented), which however do not disturb the flow of the polymer melt 41 .
The hollow cylinder 23 is closed at its front end by a diaphragm 39 , which has a central outlet opening 25 , which opens out into a collecting chamber 26 . At the opposite extreme end of the hollow cylinder 23 , a diaphragm 27 is likewise provided, leaving an annular outlet opening 28 at its circumference. Arranged in the mandrel support spider plate 21 is an air supply bore 29 , which is angled away at right angles in relation to the mandrel 22 in the vicinity of the centre axis of the mandrel 22 , and is continued in the latter to the front end of the hollow cylinder 23 . There, the air supply bore 29 opens out tangentially into the hollow cylinder 23 . On account of this tangential introduction of air and the outlets 25 and 28 , the hollow cylinder 23 acts as a Ranque vortex tube. This is supplied with compressed air at a pressure of approximately 7 bar and a temperature of about 20° C. by means of the air supply bore 29 .
On account of this air supply into the hollow cylinder 23 , two air flows form in the latter: a hot air flow 30 at the wall of the hollow cylinder 23 and a cold air flow 31 in the vicinity of the centre axis of the mandrel 22 . The hot air flow 30 leaves the hollow cylinder 23 via the outlet opening 28 and flows from there via an air discharge bore 32 , which continues in the mandrel support spider plate 21 . The hot air flow 30 has a temperature of up to 110° C. The temperature of the cold air flow 31 is approximately 0° C. to 5° C. and flows via the outlet opening 25 into the collecting chamber 26 . From the collecting chamber 26 , the cooling air flows into a cooling tube 33 , which extends as an axial extension of the mandrel 22 through the segments 19 , i.e. through the inlet of the calibrating sleeve 9 , and has a cooling air outlet 34 opening out into the calibrating sleeve 9 . The cooling air 31 flowing out from the cooling tube 33 cools the extruded pipe 5 on its inner side in a very effective way in addition to the exterior cooling taking place in the vacuum tank 8 . In order to prevent heating of the cooling air 31 on its way into the calibrating sleeve 9 , the collecting chamber 26 and the cooling tube 33 are insulated.
To make the cooling more intensive, water is mixed with the cooling air 31 flowing out from the cooling tube 33 . For this purpose, a water supply bore 35 is provided, extending through the mandrel support spider plate 21 and the mandrel 22 into the front diaphragm 39 of the hollow cylinder 23 and going over there into a thin pipeline 36 , which runs centrally through the collecting chamber 26 and the cooling tube 33 and ends at the cooling air outlet 34 .
In order to bring the moist cooling air flow effectively into the region of the inner wall of the extruded pipe 5 , a corresponding air directing device 37 is provided ahead of the cooling air outlet 34 , and in this exemplary embodiment is configured as a cone.
FIG. 3 shows the production of a pipe 5 with a large diameter, FIG. 4 shows the production of a pipe 5 with a small diameter. A comparison of the two representations shows that the cooling tube 33 and the collecting chamber 26 neither hinder the segments 19 in their radial adjustability nor adversely affect the melt cone 40 formed between the pipe extrusion head 3 and the calibrating sleeve 19 .
In FIGS. 5 and 6 , two exemplary embodiments of how Ranque vortex tubes are formed in the mandrel 22 are shown. The example shown in FIG. 5 corresponds to the exemplary embodiment explained above according to FIGS. 2 to 4 . Here the mandrel 22 has been drilled with a bore of large diameter, so that the hollow cylinder 23 formed as a result acts as the one and only Ranque vortex tube. In this case, the collecting chamber 26 represented in FIGS. 2 to 4 is not absolutely necessary, i.e. the cooling tube 33 may directly adjoin the outlet opening 25 .
In the exemplary embodiment according to FIG. 6 , seven bores 38 of smaller diameter have been made in the front region of the mandrel 22 and each of the seven bores 38 acts independently as a Ranque vortex tube. In other words, there is a plurality of vortex tubes. Each vortex tube then has of course its own tangential air supply and its own outlet openings for the cold and warm air flows, the outlets for the cold air opening out into the collecting chamber 26 .
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.
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Device for extruding hollow strands from thermoplastic material, with an extruder head, having a mandrel, and a calibrating device, for making a dimensional change while production is in progress, and with a radially adjustable inlet, at least one Ranque vortex chamber being formed in the mandrel, the cooling air outlet of which chamber leads into a cooling tube, which extends as an axial extension of the mandrel through the inlet of the calibrating device and has a cooling air outlet opening out into the calibrating device. This device achieves the object of providing a device with which effective interior cooling is achieved in calibrating devices designed for making a dimensional change while operation is in progress.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/381,189, filed Sep. 9, 2010, entitled PROCESS FOR PREPARATION OF SILVER NANOWIRES, which is hereby incorporated by reference in its entirety.
BACKGROUND
The general preparation of silver nanowires (10-200 aspect ratio) from silver ions is known. See, for example, Y. Xia, et al., Angew. Chem. Int. Ed. 2009, 48, 60, and J. Jiu, et al., Mat. Chem . & Phys., 2009, 114, 333, each of which is hereby incorporated by reference in its entirety. These include the “polyol” process, in which a silver salt is heated in a polyol (typically ethylene glycol (EG)) in the presence of polyvinylpyrrolidinone (PVP, also known as polyvinylpyrrolidone), yielding a suspension of AgNW in EG, from which the wires can be isolated and/or purified as desired.
H. Takada describes in U.S. Patent Application Publication 2009/0130433 a process for preparing metal nanowires by forming a nucleus metal particle.
Y. Sun, B. Mayers, T. Herricks, and Y. Xia ( Nano Letters, 2003, 3(7), 955-960) proposed that AgNW are the result of the growth of multiply twinned particles (MTP) of silver metal.
P.-Y. Silvert et al. ( J. Mater. Chem., 1996, 6(4), 573-577 and J. Mater. Chem., 1997, 7, 293-299), each of which is hereby incorporated by reference in its entirety, described the formation of colloidal silver dispersions in EG in the presence of PVP.
Previous methods of preparing silver nanowires tend to produce products with non-uniform morphologies. Such variability has been seen to increase as such methods are scaled-up.
SUMMARY
At least some embodiments provide methods comprising reducing at least one first portion of at least one first reducible metal ion in the presence of at least one protecting agent to form at least one first composition, and reducing at least one second portion of the at least one first reducible metal ion in the presence of the at least one first composition to form at least one first metal product.
In some cases, the at least one first metal ion may comprise at least one coinage metal ion or at least one ion from IUPAC Group 11. An exemplary first metal ion is a silver ion.
The at least one protecting agent may, in some embodiments, comprise one or more polymer, surfactant, or acid. An exemplary protecting agent is polyvinylpyrrolidinone, also known as polyvinylpyrrolidone or PVP.
In at least some embodiments, the at least one first composition may comprise silver particles, such as, for example, silver particles having a largest dimension less than about 50 nm, or less than 50 nm. Such silver particles may, in some cases, comprise multiply-twinned particles. For example, at least about 75 number percent or at least 75 percent of such silver particles may be multiply-twinned particles.
In at least some embodiments, such methods may further comprise combining the at least one first composition with at least one polyol. In at least some cases, the at least one polyol may comprise one or more of ethylene glycol or propylene glycol.
In at least some embodiments, the reducing the at least one second portion may be performed in the presence of at least one second metal ion. In at least some cases, the at least one second metal ion may, for example, comprise at least one iron ion.
In at least some embodiments, the reducing the at least one second portion may be performed in the presence of at least one chloride ion.
Other embodiments provide the at least one metal product produced according to such methods. In some cases, the at least one metal product may, for example, comprise at least one silver nanowire.
Still other embodiments provide articles comprising such metal products.
These and other embodiments may be understood from the description, exemplary embodiments, examples, and claims that follow.
DESCRIPTION
All publications, patents, and patent documents referred to in this document are incorporated by reference herein in there entirety, as though individually incorporated by reference.
U.S. Provisional Application No. 61/381,189, filed Sep. 9, 2010, is hereby incorporated by reference in its entirety.
Introduction
Silver nanowires (AgNW) are a unique and useful wire-like form of the metal in which the two short dimensions (the thickness dimensions) are less than 300 nm, while the third dimension (the length dimension) is greater than 1 micron, preferably greater than 10 microns, and the aspect ratio (ratio of the length dimension to the larger of the two thickness dimensions) is greater than five. They are being examined as conductors in electronic devices or as elements in optical devices, among other possible uses.
A number of procedures have been presented for the preparation of AgNW. See, for example, Y. Xia, et al. ( Angew. Chem. Int. Ed. 2009, 48, 60), which is hereby incorporated by reference in its entirety. These include the “polyol” process, in which a silver salt is heated in a polyol (typically ethylene glycol (EG)) in the presence of polyvinylpyrrolidinone (PVP, also known as polyvinylpyrrolidone), yielding a suspension of AgNW in EG, from which the wires can be isolated and/or purified as desired.
While small scale preparations of AgNW have been reported, replication of these procedures is often difficult and scaling up these procedures to produce larger quantities of wires (as needed for some of the envisioned applications) typically results in inferior material.
Among the traits of this inferior material are: higher levels of metal particles with an aspect ratio below five (non-wire-shaped particles herein referred to simply as particles), AgNW which are shorter on average than desired, and AgNW which are thicker on average than desired. A scalable process is clearly desirable.
Applicants have recognized that colloidal silver dispersions, prepared, for example, by the procedures of Silvert et al. can be excellent templates or seeds from which to grow AgNW. Silver seeds prepared by such methods have been isolated and characterized by transmission electron microscopy (TEM), and have been found to comprise predominately multiply twinned particles (MTPs). While not wishing to be bound by theory, such MTPs may influence the shape of the final nanowire product. See, for example, B. Wiley, et al., Chem. Eur. J., 2005, 11, 454-464, and Y. Sun, et al., Nano Letters, 2003, 3, 955-960, each of which is hereby incorporated by reference in its entirety.
AgNW have been prepared by adding such seeds to hot ethylene glycol, followed simultaneously by solutions of silver nitrate and PVP in ethylene glycol. After holding such mixtures at elevated temperature, suspensions of AgNW in ethylene glycol have been obtained. Such AgNW have been isolated by standard methods, including centrifugation and filtration.
Previous AgNW preparations such as those disclosed by Takada employ an in situ approach to preparing seeds (e.g., the addition of silver nitrate to hot EG, just prior to the main addition of the silver nitrate and the PVP solutions), or they employ no separate seeding step at all (see, for example, Y. Sun and Y. Xia, Adv. Mater. 2002, 14(11), 833-837). While these previous methods may yield AgNW, their morphological purity is highly variable. High and/or variable levels of non-wire particles may also be formed, decreasing the yield of the desired nanowires and requiring additional purification steps.
Applicants have also observed that this morphological variability is exacerbated as the scale of the procedure is increased. In contrast, the addition of silver “seeds” results in AgNW preparations with reproducibly low levels of non-wire particles, even as the production scale is increased.
Some embodiments provide methods to prepare silver nanowires comprising at least two stages:
In a first stage or stages, preparation of a colloidal silver dispersion in which said dispersed silver particles have a largest dimension less than 50 nm and more than 75 number % of said silver particles are multiply twinned particles,
In a second stage or stages, adding said colloidal silver dispersion to a heated polyol under an inert atmosphere, followed by addition of a solution or solutions of a silver salt and PVP in a polyol under conditions which grow nanowires from the colloidal silver dispersion particles, and holding the mixture at an elevated temperature to complete the nanowire growth. Such processes can provide nanowire products that retain uniformity as the processes are scaled-up to larger production volumes.
Reducible Metal Ions and Metal Products
Some embodiments provide methods comprising reducing at least one reducible metal ion to at least one metal. A reducible metal ion is a cation that is capable of being reduced to a metal under some set of reaction conditions. In such methods, the at least one first reducible metal ion may, for example, comprise at least one coinage metal ion. A coinage metal ion is an ion of one of the coinage metals, which include copper, silver, and gold. Or such a reducible metal ion may, for example, comprise at least one ion of an IUPAC Group 11 element. An exemplary reducible metal ion is a silver cation. Such reducible metal ions may, in some cases, be provided as salts. For example, silver cations might, in some cases, be provided as silver nitrate.
In such embodiments, the at least one metal is that metal to which the at least one reducible metal ion is capable of being reduced. For example, silver would be the metal to which a silver cation would be capable of being reduced.
Preparation Methods and Materials
A common method of preparing nanostructures, such as, for example, nanowires, is the “polyol” process. Such a process is described in, for example, Angew. Chem. Int. Ed. 2009, 48, 60, Y. Xia, Y. Xiong, B. Lim, S. E. Skrabalak, which is hereby incorporated by reference in its entirety. Such processes typically reduce a metal cation, such as, for example, a silver cation, to the desired metal nanostructure product, such as, for example, a silver nanowire. Applicants have observed that reproducibility can be improved and variability reduced if such metal cation reduction is carried out in at least two stages.
In the first stage or stages, a first reduction of a first portion of at least one first metal ion is carried out in the presence of at least one protecting agent, such as, for example, polyvinylpyrrolidinone (PVP, also known as polyvinylpyrrolidone), other polar polymers or copolymers, surfactants, acids, and the like, to form at least one first composition. In at least some embodiments, such a first composition may comprise colloidal silver dispersions, prepared, for example, by the procedures of Silvert et al. Such silver dispersions may comprise silver particles having a largest dimension less than about 50 nm. In some cases, at least about 75 number percent of such silver particles may be multiply-twinned particles. Such a reduction may be carried out in a reaction mixture that may, for example, comprise one or more polyols, such as, for example, ethylene glycol (EG), propylene glycol, butanediol, glycerol, sugars, carbohydrates, and the like. These and other components may be used in such reaction mixtures, as is known in the art. The reduction may, for example, be carried out at one or more temperatures from about 80° C. to about 190° C., or from about 120° C. to about 190° C.
In the second stage or stages, a second reduction of a second portion of the at least one first metal ion is carried out in the presence of the at least one first composition. Such a reduction may be carried out in the presence of at least one second metal ion, such as, for example, at least one iron ion. The reduction may be carried out in the presence of at least one chloride ion. Such chloride ions may, for example, be provided by salts, such as sodium chloride, tetraalkylammonium chloride, ammonium chloride, and the like. Or, in other cases, the at least one metal ion and the at least one chloride ion may be provided by metal chlorides, such as chlorides of iron (II), iron(III), copper(II), copper (III), tin (II), and the like. Such reductions may be carried out in the presence of one or more protecting agents or polyols, such as those described for use in the first stage or stages. These and other components may be used in such reaction mixtures, as is known in the art. The reduction may, for example, be carried out at one or more temperatures from about 120° C. to about 190° C.
Nanostructures and Nanowires
In some embodiments, the metal product formed by such methods is a nanostructure, such as, for example, a one-dimensional nanostructure. Nanostructures are structures having at least one “nanoscale” dimension less than 300 nm, and at least one other dimension being much larger than the nanoscale dimension, such as, for example, at least about 10 or at least about 100 or at least about 200 or at least about 1000 times larger. Examples of such nanostructures are nanorods, nanowires, nanotubes, nanopyramids, nanoprisms, nanoplates, and the like. “One-dimensional” nanostructures have one dimension that is much larger than the other two dimensions, such as, for example, at least about 10 or at least about 100 or at least about 200 or at least about 1000 times larger.
Such one-dimensional nanostructures may, in some cases, comprise nanowires. Nanowires are one-dimensional nanostructures in which the two short dimensions (the thickness dimensions) are less than 300 nm, preferably less than 100 nm, while the third dimension (the length dimension) is greater than 1 micron, preferably greater than 10 microns, and the aspect ratio (ratio of the length dimension to the larger of the two thickness dimensions) is greater than five. Nanowires are being employed as conductors in electronic devices or as elements in optical devices, among other possible uses. Silver nanowires are preferred in some such applications.
Such methods may be used to prepare nanostructures other than nanowires, such as, for example, nanocubes, nanorods, nanopyramids, nanotubes, and the like. Nanowires and other nanostructure products may be incorporated into articles, such as, for example, electronic displays, touch screens, portable telephones, cellular telephones, computer displays, laptop computers, tablet computers, point-of-purchase kiosks, music players, televisions, electronic games, electronic book readers, transparent electrodes, solar cells, light emitting diodes, other electronic devices, medical imaging devices, medical imaging media, and the like.
Exemplary Embodiments
The following eleven non-limiting exemplary embodiments were disclosed in U.S. Provisional Application No. 61/381,189, filed Sep. 9, 2010, which is hereby incorporated by reference in its entirety.
A. The polyol may, in some cases, be ethylene glycol or propylene glycol. B. The amount of silver in the colloidal silver dispersion may, in some cases, be between 0.001 and 1 mole % of the total silver. C. The silver salt may, for example, be silver nitrate. D. An iron salt may be added to the heated polyol. Examples of such iron salts include iron(II) chloride and iron acetonylacetate. E. A chloride salt may be added to the heated polyol. Examples of such chloride salts include iron(II) chloride or sodium chloride. F. The PVP and silver salt solutions may, in some cases, be added as separate solutions at substantially the same rate. G. The mole ratio of PVP to silver nitrate may, in some cases, be 1:1 to 10:1. H. The reaction temperature may, in some cases, be between about 130° C. and about 170° C., or, for example, between about 135° C. and about 150° C. I. The reaction may be stirred throughout. J. The nanowires may be isolated or purified, for example, by centrifugation, removal of the supernatant, addition of solvent(s), and re-dispersion. K. The nanowires so produced may have an average diameter of about 50 to about 150 nm, or about 60 to about 110 nm, or about 80 to about 100 nm.
EXAMPLES
Example 1 (Comparative)
To 100 mL of stirred ethylene glycol (EG) at 164° C. was added 10 mL of 1.5×10 −4 M silver nitrate in EG over 10 sec. After 6 min, a solution of 5.583 g of polyvinylpyrrolidone (PVP) (55,000 molecular weight) and 1.695 g of silver nitrate in 200 mL of ethylene glycol was added dropwise over 199 min while the temperature was held at 159 to 165° C. Examination of the product solution by optical microscopy at 400× showed only non-wire shaped particles of silver metal, none larger than 3 microns.
Example 2 (Comparative)
This example demonstrates variability at smaller scale. Two identical reactions were run at smaller scale as follows: To a mixture of 200 mL of EG and 1.28 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added simultaneously in two streams 60 mL each of 0.094 M silver nitrate in EG and 0.282 M PVP in EG over 25 min. After an additional 90 min at 145° C., each reaction was sampled and examined by optical microscopy at 400×. The first reaction produced predominately 1 micron and smaller non-wire particles, containing only a few short (under 10 microns) wires, while the second reaction produced myriad wires, some as long as 100 microns, many 10 to 30 microns long, and only a few non-wire particles.
Example 3 (Comparative)
This example demonstrates variability at larger scale. Five identical reactions were run at larger scale as follows: To a mixture of 3003 mL of EG and 19.2 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added simultaneously in two streams a solution of 14.47 g of silver nitrate in 905 mL of EG and a solution of 83.76 g of PVP in 905 mL of EG over 25 min. All solutions were sparged with nitrogen for at least 1 hr before use. After holding an additional 90 min at 145° C., each mixture was cooled in an ice/water bath, diluted with an equal volume of acetone and centrifuged at 200 G for 45 min. Each supernatant was decanted and discarded, the residue redispersed in isopropanol by shaking, and the mixture centrifuged again as above. Three more cycles of supernatant removal, redispersion in isopropanol, and centrifugation were repeated to give the final products. Results: The first and second reactions produced many wires of length 30-100 microns, a few shorter wires, and few particles. The third reaction produced wires less than 40 microns long and a few wires up to 60 microns in length, as well as many particles. The fourth reaction produced 20 micron wires with a few wires up to 80 microns in length, as well as many particles. The fifth reaction produced many 20-40 micron wires with many particles.
Example 4 (Comparative)
This example demonstrates difficulty in scaling-up methods employing in situ formed silver seeds. In this example, a procedure which gave a good yield of AgNW without significant non-wire particle formation, gave much shorter, heavily particle-contaminated wires on scaling it up by a factor of 15. All solutions were sparged with nitrogen before use.
To a mixture of 200 mL of EG and 1.28 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added 0.06 mL of 0.282 M (based on polymer repeat units) PVP in EG followed 1 min later by the addition of 0.06 mL of 0.094 M AgNO3 in EG. The mixture was held at 145° C. for 30 min, and then were added simultaneously in two streams 60 mL each of 0.094 M silver nitrate in EG and 0.282 M PVP in EG over 25 min. After an additional 90 min at 145° C., the reaction was cooled and worked up as in Example 3 to give a product with wires predominately 20-40 microns in length, with very few particles.
An attempt was made to scale-up this procedure. To a mixture of 3003 mL of EG and 19.2 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added sequentially 9 mL of 0.282 M (based on polymer repeat units) PVP in EG and 9 mL of 0.094 M AgNO3 in EG. The mixture was held at 145° C. for 31 min, and then were added simultaneously in two streams a solution of 14.47 g of silver nitrate in 905 mL of EG and a solution of 83.76 g of PVP in 905 mL of EG over 25 min. All solutions were sparged with nitrogen for at least 1 hr before use. After holding an additional 90 min at 145° C., the reaction was cooled and worked up as in Example 3 to give the product: wires mostly 2-20 microns in length, with few longer, with a significant level of non-wire particles.
Example 5
Silver Seeds Preparation
Silver seeds were prepared similarly to the process of Silvert (P.-Y. Silvert et al., J. Mater. Chem., 1996, 6(4), 573-577), experiment 1. Thus, to a solution of 1.5 g of PVP (10,000 molecular weight) in 75 mL of EG, was added 50.1 mg of silver nitrate, stirred 12 min at 22° C. to dissolve, then heated to 120° C. over 2 hr, and held at 120° C. for 39 min to yield the Silver Seed solution. To characterize material, 11.47 g were diluted with 28.3 g of acetone, and centrifuged at 2548 rpm for 8 min. The supernatant was decanted and discarded, isopropanol added to the residue, which was redispersed by immersion in an ultrasonic bath for 5 min. An evaporated droplet of this dispersion was examined by TEM. Spheroidal particles with multiple twin planes were observed, average diameter 19.8±/−5.4 nm.
Silver Nanowire Preparation
All solutions were sparged with nitrogen before use. To a mixture of 200 mL of EG and 1.28 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added 0.29 mL of the Silver Seed solution, and then were added simultaneously in two streams 60 mL each of 0.094 M silver nitrate in EG and 0.282 M PVP in EG over 25 min. After an additional 90 min at 145° C., the reaction was cooled and worked up as in Example 3 to give the product: AgNW with lengths 5-60 microns and very few particles.
Example 6
Silver Seeds Preparation
Silver seeds were prepared using the procedure of Example 5.
Silver Nanowire Preparation
All solutions were sparged with nitrogen before use. To a mixture of 3003 mL of EG and 19.2 mL of 0.006 M iron(II) chloride tetrahydrate in EG under a nitrogen atmosphere, heated and stirred at 145° C., was added 4.35 mL of the Silver Seed solution, and then were added simultaneously in two streams a solution of 14.47 g of silver nitrate in 905 mL of EG and a solution of 83.76 g of PVP in 905 mL of EG over 25 min. After holding an additional 90 min at 145° C., the reaction was cooled and worked up as in Example 3 to give the product: AgNW with lengths 5-150 microns and only a few particles. Repetition of this reaction gave similar results.
The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.
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Preparation methods, compositions, and articles are disclosed and claimed. Methods for reducing metal ions to metals, the metal products, and articles comprising the metal products are claimed. Such methods show improved reproducibility upon scale-up than previous methods, resulting in products that exhibit reduced variability. The claimed inventions are useful for electronic and optical applications.
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BACKGROUND OF THE INVENTION
[0001] Asphalt is inexpensive, has a relatively high penetration value when applied to most porous surfaces, and is relatively weather-resistant and water-impermeable. As a result, asphalt has traditionally been used as a major component of protective coatings, films, and membranes. Water-based asphalt emulsions has been used for a wide array of products including waterproofing membranes, paving and roofing products, joint sealants, specialty paints, electrical laminates and hot melt adhesives. In addition, water-based asphalt emulsions have been used as diluents in the manufacture of low-grade rubber products, as diluents for the disposal of radioactive waste, for hot-dip coatings, and for water-retention barriers. For many of these applications, the water based asphalt emulsion is modified by inclusion of a hydrocarbon polymer such as natural rubber. The coating that results when such a modified product is applied to a substrate and allowed to dry has improved performance properties.
[0002] Asphalt emulsions, in their most basic form, are made by melting solid asphalt, typically at a temperature between 210-300° F., and then mixing the molten asphalt with water and a dispersant system. Such mixing, typically, is done in a colloid mill under high shear and high speed. If the emulsion is to be used as a waterproofing coating, hydrocarbon polymer emulsions/latexes such as natural rubber, styrene butadiene rubber (SBR), acrylic, etc., typically, are then added to these emulsions to give the properties that are desired. Since the resulting blend (asphalt emulsion plus hydrocarbon polymer emulsion/latex) typically requires an alkaline stabilizer such as ammonium hydroxide, the coating compositions are often neutral to alkaline in nature. Although, it is also possible to add the desired hydrocarbon polymer emulsion to the asphalt emulsion in situ, this is more difficult and rarely done.
[0003] Water-based asphalt emulsions, including those that comprise a hydrocarbon polymer emulsion or suspension such as a rubber latex, cure through moisture evaporation and subsequent coalescence of the dispersed particles. Even though these materials skin over in a relatively short period of time, the skin, generally, is not tough enough to withstand contact with water as in rainfall for exterior applications. Rain erodes the skin and washes out the uncured material underneath. Accordingly, application instructions for such materials generally suggest not applying the emulsion to a substrate if rain is a possibility within several hours of application. Moreover, the time required to cure through the entire coating composition may be unacceptably long or not occur at all. Such difficulties limit the thickness of the asphalt based coating compositions that can be applied to the underlying substrate. Because of the long drying time, the standard practice in the industry is to add a salt, such as calcium chloride during application to “break” the emulsions. The salt reacts with the ionic groups in the emulsion, causing the emulsion to destabilize and coagulate faster.
[0004] Non-water-based weather resistant coatings may also be prepared by combining polyurethane extenders and isocyanates to an asphalt material. However, the blend has to be heated, generally, from 80° C. to 120° C. Such methods are cumbersome and require special equipment on the job site.
[0005] Accordingly, it is desirable to have new systems and methods for preparing water based asphalt-containing coatings, films, and membranes Methods and systems that provide water-based asphalt coating compositions that dry more quickly, and thus achieve more rapid wash out resistance are desirable. Methods and systems that provide water-based asphalt-containing coating compositions with a relatively rapid cure through are also desirable. A rapid cure through of the coating compositions allows for reduced time on a job site, weight bearing loads sooner, pedestrian traffic sooner without detrimental effects to the physical integrity of the coating. In addition, a rapid cure through also enables a thicker layer of the coating composition to be applied as a single (i.e., in one step) as opposed to multiple layers to achieve the same thickness.
SUMMARY OF THE INVENTION
[0006] The present invention provides systems and methods for preparing a water-based, asphalt-containing coating, membrane, or film. The system comprises a first composition (referred to hereinafter as “Part A”) and a second composition (referred to hereinafter as “Part B”) for producing a water-based asphalt coating composition that can be applied to a vertical or horizontal substrate and cured relatively quickly without application of heat. The first composition of the system is an emulsion comprising asphalt, water and a dispersant system. The asphalt emulsion may further comprise other emulsions of organic polymers such as natural rubber, styrene-butadiene rubber, acrylic resins, polyvinyl acetate, and similar materials, or any combinations thereof. These organic polymers are added to the asphalt emulsion to provide desired performance properties, including strength, adhesion, elasticity, and/or water vapor permeance. In certain embodiments, the solids ratio of the asphalt emulsion is from 35 to 65%. The second composition (Part B) is a viscous liquid that can be blended with Part A. Part B comprises a non-emulsion, liquid polymer composition that lacks water. The system is based, at least in part, on inventors' discovery that the addition of a relatively small amount of such a liquid polymer composition to a water-based asphalt emulsion in situ produces a coating composition that dries more quickly than water-based asphalt emulsions to which such a liquid polymer composition has not been added. As a result, such coatings have increased wash-out resistance. Inventors have also discovered that addition of a relatively small amount of such a liquid polymer composition to a water-based asphalt emulsion in situ provides a coating with faster cure through. Thus, when the present system is used a thicker layer of such coating can be applied to a substrate.
[0007] The present invention also relates to methods of coating a substrate by combining Part A of the present system with Part B of the present system, and applying the resulting emulsion or blend to the substrate. The present system can be used to coat a variety of substrates including, but not limited to concrete, wood, or metal. The resulting emulsion or blend can be applied to the substrate by spraying, dipping, rolling, painting, or spreading. Depending upon the solids content and the amount and type of hydrocarbon polymer emulsion in Part A, Part A and Part B are combined at ratio of from 3:1 or greater, preferably at a ratio of 17:1 to 3:1 The ratio is adjusted based on the desired skin and cure-through time. The method can be used to form a coating of varying thicknesses, including, but not limited to, a single layer coating that is more than 250 mils, on a substrate.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention can, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0009] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.
[0010] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the following specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention.
[0011] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0012] Provided herein is a system for producing a weather-resistant coating or membrane with a fast cure-through rate. The system comprises a water-based asphalt emulsion system (Part A) and a liquid polymer composition that lacks water (Part B) for forming a waterproofing coating, and methods of making such coating by combining Part A and Part B of the present system. Part A of the composition may further comprise a hydrocarbon polymer emulsion such as a natural rubber, styrene-butadiene rubber, acrylic resin, polyvinyl acetate, and similar materials or any combinations thereof. In certain embodiments, the ratio of Part A to Part B in the system ranges from 17:1 to 3:1. Thus, depending upon the solids content and the amount and type of hydrocarbon polymer emulsion in Part A, or the pH of the emulsion system of Part A, the ratio of Part A to Part B in the system can be 17:1, 16:1, 15:1, 14:1, 13:1, 12:1, 11:1, 10:1, 9:1, 8:1, 7:1, 6:1, 5:1, 4:1, 3:1 15:2, 13:2, 11:2, 9:2, 7:2, etc. Optimum ratios can be determined by the skilled artisan using standard techniques.
Part A
Water-Based Asphalt Emulsion
[0013] Part A of the present system is an emulsion comprising water, asphalt, and a dispersion system. The asphalt may be a polymer-modified asphalt, an oxidized asphalt, or an unoxidized asphalt. The asphalt emulsion may further comprise a hydrocarbon polymer emulsion/latex such as a natural rubber, a synthetic rubber like styrene butadiene, an acrylic resin, polyvinyl acetate, and similar materials, or any combinations thereof. One example of a suitable synthetic polymer emulsion is a styrene-butadiene rubber (SBR) emulsion. The SBR may also be cross-linked, for example, with carboxylate groups resulting from treatment with methacrylic acid, or the like. Another example of a suitable synthetic polymer emulsion is a polyacrylate emulsion. Polymer emulsions may be made prior to mixing, or polymerized in the asphalt during the emulsification process.
[0014] The dispersion system comprises one or more asphalt emulsifiers. The asphalt emulsifier can be nonionic, anionic, or cationic. Examples of nonionic emulsifiers are mono- and di-glycerides, polysorbates, and glycerol esters. Examples of anionic emulsifiers are soaps, sulfated oils, and sulfated alcohols. Cationic emulsifiers are typically some type of amine compound.
[0015] The asphalt emulsion may further comprise other optional ingredients such as defoamers, rheology modifiers, fillers, antifreeze agents, plasticizers, cross-linkers, solvents etc.
Part B
[0016] Part B of the present multi-part system is a liquid polymer composition that lacks water. Such composition is liquid at room temperature and has a viscosity that allows part B to be mixed with part A to provide a coating composition that can be applied to the surface of a substrate by spraying or pouring. Thus, in certain embodiments, Part B has a viscosity of between 3000 and 60,000 cps. In certain embodiments, Part B comprises an organic solvent. In other embodiments, Part B lacks an organic solvent, i.e., is solventless.
[0000] Liquid Polymer
[0017] Part B of the present system can comprise one or more of the following non-emulsion, liquid polymers: polyurethane polymers, acrylic polymers, sytrene butadiene, styrene block polymers, including but not limited to, styrene (ethylene-butylene)-styrene (SEBS) block polymer, styrene-(isoprene)-styrene (SIS) block polymer, styrene-(butylene)-styrene (SBS) block polymer, styrene-(ethylene-propylene)-styrene (SEPS) block polymer, and styrene-(ethylene-propylene) (SEP) block polymer, silicone polymers, i.e. organopolysiloxanes, or any combinations thereof.
[0018] The polyurethane polymer is formed by reacting a hydroxy-terminated polymeric material with an aromatic or an aliphatic isocyanate to provide a polyurethane polymer. The polyurethane polymer may comprise uncapped or end-capped NCO groups or both. In certain embodiments, the polyurethane polymer composition comprises from about 1.2 to 3.5% by weight of NCO groups.
[0019] Suitable hydroxy-terminated polymeric materials for preparing the present polyurethane polymer include, but are not limited to di, tri, and tetra functional polyols, including polyether polyols, polyester polyols, acrylic polyols, and polyols comprising two or more hydroxyl groups and a straight or branched chain hydrocarbon.
[0020] Suitable polyether diols and triols include polyethylene ether diols or triols, polypropylene ether diols or triols, polybutylene ether diols or triols, polytetramethylene ether diols or triols, and block copolymers of such diols and triols.
[0021] Suitable hydroxy-terminated polyesters include any hydroxy-terminated polyester prepared from poly-basic acids or anhydrides (for example, adipic acid and phthalic anhydride). Polylactone containing hydroxyl groups are also suitable for making the polymer, particularly polycaprolactone diol and triol.
[0022] Suitable acrylic polyols include hydroxyl-terminated polyacrylate. Acrylates include, but are not limited to, butylacrylate, methylacrylate, methylmethacrylate, ethyl acrylate, 2-ethylhexyl acrylate or the mixture of above. Suitable polyols comprising two or more hydroxyl groups and a straight or branched hydrocarbon chain include hydroxyl functionalized polybutadiene. Other suitable polyols include polycarbonates having hydroxyl groups.
[0023] In certain embodiments, the polyol has a weight average molecular weight of from 500 to 18,000.
[0024] The isocyanates that are reacted with the hydroxy-terminated backbone polymer are organic isocyanates having 2 or more isocyanate groups or a mixture of such organic isocyanates. The isocyanates are aromatic or aliphatic isocyanates. Examples of suitable aromatic di- or triisocyanates include p,p′,p″-triisocyanato triphenyl methane, p,p′-diisocyanato diphenyl methane, naphthalene-1,5-diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, and mixtures thereof. Examples of preferred aliphatic isocyantes are isophorone diisocyanate, dicyclohexyl methane-4,4′-diisocyanate, and mixtures thereof.
[0025] The polyurethane polymer may be prepared by mixing the hydroxy-terminated polymer and organic isocyanate together at ambient temperature and pressure, although the speed of the reaction is significantly increased if the temperature of the reaction mixture is raised to a higher temperature, for example, a temperature between 60°-100° C. A molar excess of the isocyanate is used to ensure that the substantially all the polyurethane prepolymer chains have NCO terminal groups. A catalyst such as a tin catalyst may be added to the mixture to accelerate formation of the polymer.
[0026] In certain embodiments, the % by weight of NCO groups on the polyurethane polymer ranges from 1.9 up to 3.0.
[0027] Part B may comprise polyurethane polymers that are uncapped or end-capped or combinations thereof. The end capped polyurethane polymers may be end-capped with silane capping agents, alcohol end capping agents, or epoxies Examples of suitable silane capping agents include, but are not limited to, silanes corresponding to the formula I.
H—NR 1 —R 2 —Si(OR 3 ) 2 (R 4 ) I
[0028] wherein R 1 represents hydrogen, a substituted aliphatic, cycloaliphatic, and/or aromatic hydrocarbon radical containing 1 to 10 carbon atoms, a second —R 2 —Si(OR 3 ) 2 (R 4 ), or —CHR 5 —CHR 6 COOR 7 where R 5 and R 6 are H or C 1-6 organic moiety, and R 7 is C 1-10 organic moiety.
[0029] R 2 represents a linear or branched alkylene radical containing 1 to 8 carbon atoms.
[0030] R 3 represents a C 1-6 alkyl group.
[0031] R 4 =—CH 3 , —CH 2 CH 3 , or OR 3 .
[0032] Examples of suitable aminosilanes corresponding to formula I include N-phenylaminopropyltrimethoxysilane, N-ethylaminoisobutyltrimethoxysilane, gamma-aminopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane, and the reaction product of an aminosilane (such as gamma-aminopropyltrimethoxysilane, gamma-aminopropyltriethoxysilane, gamma-aminopropylmethyldimethoxysilane) with an acrylaic monomer (such as ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methyl acrylate, methyl methacrylate, and glycidal acrylate).
[0033] Examples of other suitable silanes include mercaptosilane, the reaction product of a mercaptosilane with a monoepoxide, and the reaction product of an epoxysilane with a secondary amine.
[0034] The silicone polymer or organopolysiloxane used in the present composition may be a non-reactive organopolysiloxane, i.e., a polysiloxane that contains no reactive functional groups. In other embodiments, the organopolysiloxane is a reactive organopolysiloxane that contains reactive functional groups, preferably two reactive functional groups on the polymer chain, preferably at the terminal portion thereof, i.e., preferably the reactive functional groups are end-groups. Organopolysiloxanes useful in this invention include, but are not limited to, those which contain a condensable functional group which can be an hydroxyl group, or hydrolyzable group such as a silicon-bonded alkoxy group, acyloxy group, ketoximo group, amino group, amido group, aminoxy group, an alkenoxy group, and so forth. The reactive functional groups may be hydroxyl, alkoxy, silicone alkoxy, acyloxy, ketoximo, amino, amido, aminoxy, alkenoxy, alkenyl, or enoxy groups or any combination thereof. The reactive functional groups are end groups, pendant groups, or a combination thereof. In certain embodiments, the organopolysiloxanes used in the present invention preferably have a molecular weight in the range from 20,000 to 100,000 grams/mole.
[0035] In one embodiment, the reactive organopolysiloxane polymer is of the formula:
where R 1 and R 2 , independently, are an alkyl having from 1 to 8 carbon atoms, desirably from 1 to 4 carbon atoms with methyl being preferred, or is an aromatic group or substituted aromatic group having from 6 to 10 carbon atoms with phenyl being preferred, and “n” is such that the weight average molecular weight of the organopolysiloxane is from about 10,000 to about 200,000 and desirably from about 20,000 to about 100,000 grams/mole. It is to be understood that the above polymers also contain, as noted above, two or more reactive functional groups (X) therein. The functional groups, independently, can be OH, or OR 3 , or N(R 4 ) 2 , enoxy, acyloxy, oximo, or aminoxy, wherein these functional groups may have substituents at any substitutable location. For example,
wherein R 3 through R 14 are, independently, an alkyl or cycloalkyl having from about 1 to about 8 carbon atoms.
[0036] In one embodiment, the reactive organopolysiloxane of the present polymer composition may be depicted as
The one or more R groups, independently, is an alkyl having from 1 to 8 carbon atoms or an aromatic or an alkyl-aromatic having from 6 to 20 carbon atoms and optionally containing one or more functional groups thereon, such as amine, hydroxyl, alkene, alkoxy, and so forth. The amount of the functional groups, i.e., m, is 1, 2 or 3.
[0037] The reactive functional group (X), can be OH, or OR′, or N(R′), or enoxy, or acyloxy, or oximo, or aminoxy, or amido, wherein the reactive functional group may have substitutions, R′, at any substitutable C or N, and which is selected from the group consisting of an alkyl having from about 1 to about 8 carbon atoms, an aromatic, an alkyl-aromatic having from 6 to 20 carbon atoms, and wherein R′ may optionally contain one or more functional groups thereon such as amine, hydroxyl, and so forth. An organopolysiloxane fluid can furthermore contain a blend of two or more different polysiloxanes and/or organopolysiloxanes having different molecular weights. The polysiloxanes are generally a viscous liquid and are commercially available from several silicone manufacturers such as Wacker Corporation, General Electric, Dow Corning and Rhone-Poulenc.
[0038] In another embodiment, the present polymer composition comprises a non-reactive organopolysiloxane, i.e., the organopolysiloxane lacks functional groups. The non-reactive organopolysiloxane may be depicted as
where R 1 , R 2 , and R 3 independently, are an alkyl having from 1 to 8 carbon atoms, desirably from 1 to 4 carbon atoms with methyl being preferred, or is an aromatic group or substituted aromatic group having from 6 to 10 carbon atoms with phenyl being preferred, and “n” is such that the weight average molecular weight of the organopolysiloxane is from about 100 to about 100,000 and desirably from about 3,000 to about 50,000 grams/mole.
Optional Ingredients
[0039] Optionally, part B of the present system comprises a plasticizer, which may be used to control or reduce the viscosity of Part B. Examples of suitable plasticizers for use in part B include, but are not limited to phthalates, benzoate esters, and mineral oil. Part B may also comprise fillers such as calcium oxide, calcium carbonate, fume silica, clay, talc. Such fillers may be added to control the viscosity, rheology, or reduce cost of Part B. Optionally, Part B comprises one or more of, a moisture scavenger and a UV stabilizer.
[0000] Solvent
[0040] In certain embodiments, Part B of the present invention does not include a solvent, i.e., the polymer composition is solventless. In other embodiments, Part B comprises a solvent, which may be used for solubilizing the polyurethane polymers. Examples of suitable solvents for use in the present system include but are not limited to, mineral spirits, xylene, and toluene.
[0000] Preparation of the Polyurethane Asphalt Coating.
[0041] Depending upon the type of coating that is desired, various ratios of part A may be combined with Part B, to provide the water-based asphalt-containing coating composition of the present invention. In certain embodiments, the ratio of part A to part B ranges from 17:1 to 3:1 parts by weight. The ratio selected depends, at least in part, on the solids content of the asphalt emulsion, the absence or presence of additional ingredients such as natural rubber, styrene butadiene, acrylic or PVA emulsions or combinations thereof in the asphalt emulsion. Part A is combined with Part B at ambient temperature and the resulting emulsion or blend applied to one or more horizontal or vertical surfaces of an underlying substrate. Thereafter, the resulting emulsion or blend is allowed to cure or dry under ambient conditions. When such conditions include temperatures of 50° F. or less, it may be desirable to add a curing catalyst to the resulting emulsion or blend before application. Examples of suitable curing catalysts include dibutyltin diacetate, dibutyltin dilaurate, and dibutyltin bis(acetylacetonate). The catalyst may also be pre-added to Part A, i.e., the asphalt emulsion.
[0042] The present method does not require heating of any part of the present multi part system, and therefore overcomes some of the disadvantages of the previous methods that have been used to make polyurethane asphalt coatings.
[0000] Properties of Coating
[0043] The coatings that are produced in accordance with the present method have increased wash out resistance as compared to coatings that result from applying Part A alone to an underlying substrate. In addition, the coatings that are produced in accordance with the present method cure more rapidly that coatings that result from applying Part A alone to an underlying substrate. Thus, in certain embodiments, the present method can be used to make a single layer coating that is thicker than a single layer coating that results from applying Part A alone to an underlying substrate.
EXAMPLES
[0044] The following examples are for purposes of illustration only and are not intended to limit the scope of the claims which are appended hereto. All references cited herein are specifically incorporated in their entirety herein.
Materials
[0000] Part A: Asphalt Emulsion
[0045] Asphalt emulsion (˜50% solids) or a polymer modified asphalt emulsion such as an SBR-asphalt emulsion (˜60% solids), natural rubber-asphalt emulsions, or acrylic-asphalt emulsions are available from commercially and can be used in the present system as described below.
[0000] Part B: Liquid Polymer
[0046] Part B, i.e., the liquid polymer system can comprise different polyurethanes, acrylics, Kraton, styrene butadiene, silicone polymers or any combinations thereof.
[0047] In Examples 1-4 below, the polyurethane polymer composition was made by reacting polyol and MDI in the presence of a tin catalyst to achieve a % NCO of 2.6 and a viscosity of 14,000 cps at 25° C. with spindle 52 at 20 rpm using a cone and plate viscometer.
Example 1
[0048] In this example, 1 part of Part B, a polyurethane polymer, was mixed with 10 parts of Part A, a rubberized asphalt emulsion, and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 1a and 1b below.
TABLE 1a Part A Parts Latex Composition per 100 Parts Asphalt Latex (64% solids) 76.5 Styrene Butadiene Rubber Latex (68% 9.1 solids) Natural Rubber Latex (61.5% solids) 14.4 TOTAL 100.00
[0049]
TABLE 1b
Part B
Composition
Weight Percent
Polyurethane Polymer
100
TOTAL
100.00
[0050] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 1c below.
TABLE 1c 16 hour Composition cure through Water wash out at 30 PSI Parts A + B 4 mm Passed after 4 hours Part A 1 mm Passed after 10 hours
Example 2
[0051] In this example, 1 part of Part B, a polyurethane polymer, was mixed with 6 parts of Part A, a rubberized asphalt emulsion, and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 2a and 2b below.
TABLE 2a Part A Parts Latex per Composition 100 Parts Asphalt Latex (64% solids) 76.5 Styrene Butadiene Rubber Latex (68% solids) 9.1 Natural Rubber Latex (61.5% solids) 14.4 TOTAL 100.00
[0052]
TABLE 2b
Part B
Composition
Weight Percent
Polyurethane Polymer
60
Calcium Carbonate
15
Calcium Oxide
7
Plasticizer
17
Pigment Package
1
TOTAL
100.00
[0053] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 2c below.
TABLE 2c 16 hour Composition cure through Water wash out at 30 PSI Parts A + B 4 mm Passed after 4 hours Part A 1 mm Passes after 10 hours
Example 3
[0054] In this example, 1 part of Part B, a polyurethane polymer, was mixed with 7 parts of Part A, a rubberized asphalt emulsion, and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 3a and 3b below.
TABLE 3a Part A Parts Latex per Composition 100 Parts Asphalt Latex (64% solids) 55.4 Natural Rubber Latex (61.5% solids) 44.6 TOTAL 100.00
[0055]
TABLE 3b
Part B
Composition
Weight Percent
Polyurethane Polymer
60
Calcium Carbonate
15
Calcium Oxide
7
Plasticizer
17
Pigment Package
1
TOTAL
100.00
[0056] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 3c below.
TABLE 3c 16 hour Composition cure through Water wash out at 30 PSI Parts A + B 5 mm Passed after 3 hours Part A 3 mm Passed after 6 hours
Example 4
[0057] In this example, 1 part of Part B, a polyurethane polymer, was mixed with 7 parts of Part A, a rubberized asphalt emulsion, and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 4a and 4b below.
TABLE 4a Part A Parts Latex per Composition 100 Parts Asphalt Latex (64% solids) 86.3 Styrene Butadiene Rubber Latex (68% solids) 13.7 TOTAL 100.00
[0058]
TABLE 4b
Part B
Composition
Weight Percent
Polyurethane Polymer
60
Calcium Carbonate
15
Calcium Oxide
7
Plasticizer
17
Pigment Package
1
TOTAL
100.00
[0059] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 4c below.
TABLE 4c Composition 16 hour cure through Water wash out at 30 PSI Parts A + B 5 mm Passed after 2 hours Part A 0 mm Failed after 16 hours
Example 5
[0060] In this example, 1 part of Part B, a silicone polymer, was mixed with 6 parts of Part A, a rubberized asphalt emulsion and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 5a and 5b below.
TABLE 5a Part A Composition Parts Latex per 100 Parts Asphalt Latex (64% solids) 76.5 Styrene Butadiene Rubber Latex (68% solids) 9.1 Natural Rubber Latex (61.5% solids) 14.4 TOTAL 100.00
[0061]
TABLE 5b
Part b
Composition
Parts Latex per 100 Parts
Silicone polymer
69.64
Plasticizer
11.8
Fumed Silica
10.5
Crosslinker
5.4
Adhesion promoter
2.64
Catalyst
.02
TOTAL
100.00
[0062] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 5c below.
TABLE 5c Composition 16 hour cure through Water wash out at 30 PSI Parts A + B 5 mm Passed after 4 hours Part A 1 mm Passed after 10 hours
Example 6
[0063] In this example, 1 part of Part B, a acrylic polymer, was mixed with 6 parts of Part A, a rubberized asphalt emulsion and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 6a and 6b below.
TABLE 6a Part A Composition Parts Latex per 100 Parts Asphalt Latex (64% solids) 76.5 Styrene Butadiene Rubber Latex (68% solids) 9.1 Natural Rubber Latex (61.5% solids) 14.4 TOTAL 100.00
[0064]
TABLE 6b
Part B
Parts
Composition
Latex per 100 Parts
Calcium carbonate
34
Ethylacrylate-acrylonitrile-acrylic acid terpolymer
33
Xylene
11.5
Talc
5.2
ceramic fibers
4.2
Oxydipropyl dibenzoate
4
Ethylbenzene
2.5
Amorphous silica
2
Titanium dioxide
1.2
Nonylphenol branched polyurethane
1
Hydrogenated castor oil
1
Titanium dioxide
1.2
Dolomite
.4
TOTAL
100.00
[0065] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 6c below.
TABLE 6c Composition 16 hour cure through Water wash out at 30 PSI Parts A + B 3 mm Passed after 6 hours Part A 1 mm Passes after 10 hours
Example 7
[0066] In this example, 1 part of Part B, a SEBS blocked co-polymer, was mixed with 6 parts of Part A, a rubberized asphalt emulsion and a 125 mm coating of the mixture applied to a substrate. The amounts are listed in Table 7a and 7b below.
TABLE 7a Part A Composition Parts Latex per 100 Parts Asphalt Latex (64% solids) 76.5 Styrene Butadiene Rubber Latex (68% solids) 9.1 Natural Rubber Latex (61.5% solids) 14.4 TOTAL 100.00
[0067]
TABLE 7b
Part B
Composition
Weight Percent
Xylene
25.5
Hydrogenated hydrocarbons
14
Styrene-(ethylene-butylene)-styren block polymer
13.5
Aluminum silicates
8.3
Polybutene
8.2
Titanium dioxide
8
Aromatic hydrocarbon resin
7.4
Ethylbenzene
6.1
Styrene-isoprene rubber
5.3
Hydrocarbon resin
3.3
(3-Mercaptopropyl) trimethoxysilane
.4
TOTAL
100.00
[0068] The mixture of Parts A and B was compared to Part A in the following two ways, wash out resistance and 24 hour cure depth. The results are listed in Table 3c below.
TABLE 7c Composition 16 hour cure through Water wash out at 30 PSI Parts A + B 3 mm Passed after 6 hours Part A 1 mm Passed after 10 hours
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The present invention relates to multi-part coating compositions that comprise a first part which is an asphalt emulsion comprising water, asphalt, and a dispersion system and a second part which is a liquid polymer composition that lacks water. The asphalt emulsion and liquid polymer composition are combined in situ to provide a coating that has fast dry characteristics, and that quickly develops good water-resistance. Such compositions are useful as coatings on metal, wood, and other surfaces, where fast drying characteristics are important. Such compositions are particularly useful as coatings on substrates where early water-resistance of the coating is important, such as those surfaces which are routinely exposed to the outdoors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/505,874, filed Jul. 8, 2011, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a new media art form, and more particularly to an interactive media art form, which displays visually changing color patterns in response to one or more supplied data streams, either in real time or as playback of stored data on a woven, threaded surface of fiber optic threads.
[0003] Throughout the ages, and continuing to present times, weaving has and continues to epitomize social interaction. Textiles have a shared history throughout the world's cultures and are common throughout time. In European culture, medieval tapestries told narratives, and in the 21st century, we find our stories threaded and networked throughout the web.
[0004] Electronic optical art technologies, such as a liquid crystal displays (LCDs), field-emission displays (FEDs), and plasma display panels (PDPs) have been heretofore described for displaying various images in a form embodying a relatively thin profile, such that such displays are suitable for wall mounting or portable applications.
[0005] However, traditional woven crafts have not heretofore been employed for display of dynamically changing patterns.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the invention to provide a new media art form that synergistically blends traditional textile arts with contemporary communication materials and processes to redefine the role of a tapestry in contemporary culture, and provide a visual “weaving” of information, which can function as a dynamic data visualization screen or mural.
[0007] It is a still a further object to create a computer controlled fiber optic tapestry which fuses traditional arts, digital electronics, interactivity, and data scraping with contemporary art.
[0008] These and other objects of the invention are achieved by utilizing one or more meshes of woven fiber optic threads that each comprise a woven fiber optic panel of the present invention. Each panel is lightable by arrayed light sources optically coupled at a peripheral border of the panel, all of which is enclosed within a housing.
[0009] The fiber optic panel serves as a new media canvas for display of images “woven” from optically converted information, using fiberoptic filaments to carry and display the optically converted information and data from a suitable source, for example, the Internet, in the form of changing light patterns and/or colors, which can be programmed to change with variable speeds and durations. The fiber optic panels are woven to create a tapestry capable of emitting light. It is noted that the term “tapestry” is being used to refer to a woven mural design made up of woven fiber optic threads, since not all weaves meet the literal requirement of the term “tapestry.”
[0010] When the fiber optic panels are woven on a handloom, the weaving process automatically etches or abrades the fiber optic surface of the individual fibers, allowing light to be emitted along the length of the fibers. The light sources are controlled by a computer responsive to information collected from a selected external source, for example, as in this invention, the Internet, which is converted to light emission data for displaying emitted light as a changing color pattern on the surface expanse of the tapestry. Other external sources may be used to trigger the light patterns, such as sound, video or audio or movement detected through various sensors.
[0011] The fiber optic woven “tapestry” functions as a data visualization canvas, which displays information on its surface as woven light. The surface is animated and dynamic based on various data sources and sets including, but not limited to, TWITTER. It can also read flight information from airport arrivals and departures, scraping a database that supplies this real time information. The tapestry according to an embodiment of the invention has further potential to read and display, in abstract dynamic light patterns, other exemplary data sets, such as stock market quotes, or energy usage/or energy efficiency in a green building so as to create a visual thermostat.
[0012] The optical tapestry according to the invention could optionally serve as a sonically or visually interactive surface, using sound to trigger the surface patterning or a video camera to interact with movement from an exterior real time source in order to provide such patterning. Additionally, the tapestry can respond to data from a customized website, or other types of data.
[0013] The tapestry is also optionally addressable by smart phones. The tapestry can also be controlled with commands to display specific pre-programmed patterns. It can be conceivably programmed using TWITTER TWEETS to panel display particular colors and patterns.
[0014] The patterns and light variations that are displayed on the panel's surface are all predetermined and predefined, and their timing and transitional rates are assigned. As such, these are not randomly blinking lights. However, they also could be such.
[0015] In a particularly advantageous embodiment, the woven optical fiber panels are optically coupled at a periphery thereof to suitable color controllable light sources, for example, RGB LEDs to illuminate the warp and the weft. The LEDs are computer controlled and programmed to change color and pattern so as to be responsive to the conversion of the aforementioned collected information.
[0016] In accordance with an embodiment of the invention, the computer controlling the display on the tapestry parses information from TWITTER and other data sources to display color, light and pattern onto multiple fiber optic panels according to the invention using the color variable light sources, for example, the RGB LEDs mentioned above. The resulting real-time animation is an abstract, data visualization that continually updates as data changes.
[0017] The tapestry display, and assembly thereof, comprises one or more woven fiber optic panels that are created, for example, by conventional weaving techniques, using plastic fiber optic thread. The fiber optic threads are optionally woven in a weft faced 20 four-harness satin weave, known as a “satin weave construction.” Other weave structures can be used as well. As in all woven textiles, the panels have warp and weft threads.
[0018] As mentioned above, a natural etching of the fiber optic threads occurs as a result of abrasion from the weaver's shuttle on the surface of the plastic fiber optic threads and the thread's contact with the loom's sand bar. The surface of the threads may be further advantageously etched or scratched by hand so as to allow for an enhanced diffusion of light therethrough. Each fiber optic mesh also has warp and weft end threads. All sides are free, allowing them to connect to the RGB LEDs.
[0019] A portion of the electronics enabling controlling of the LEDs are housed conveniently on electronic circuit boards, each board consisting, for example, of four integrated circuits (IC). Each IC controls a time manageable number of LEDs, for example, ten. There is a transreceiver chip on each board that sends commands to all four ICs. Each board, in such example, has forty RGB LEDs. This allows programming and control of each LED individually for color and luminosity.
[0020] A housing is provided, conveniently in the form of a four (4) sided, optionally metal or plastic box, with a window cut in the front. The box houses four of the aforementioned circuit boards on inner walls of the box, one on each of four sides thereof. The woven fiber optic panel described above is sandwiched between two clear Plexiglass plates and this sandwich is then attached to the inside of the front window of the housing. This sandwich is advantageously locked into place within and to the housing a conventional type, or custom designed, locking tab.
[0021] The end threads of the woven panels are attached to the RGB LEDs through light guides in the form of coupling plugs, made conveniently from black, heat shrink tubing, and each is advantageously fitted with a mirror MYLAR inner lining, which enhances the reflection of light. This entire construction is advantageously designed to be non-adhesive, so as to allow the assembly to be broken down into its basic components of circuit boards, fiber optic panel, light-guides (plugs) and housing.
[0022] An example of suitable configuration software for implementation of the invention is MAX MSP. MAX may be used to program RGB values for the LEDs, and can make pattern animations by programming fades. The boards are programmed using suitable software, such as, for example, MAX. All of this information is stored in the nonvolatile memory of the ICs of the circuit boards.
[0023] As a particular display embodiment in accordance with the invention is developed, a combination of programming languages is generally used. For example, PYTHON to use data from the Internet to control and trigger patterns on the fiber optic panels, MAX for testing and perhaps for standalone visualization pieces that are not triggered by Internet data. The program PURE DATA can also optionally be used to trigger the panels with sound. Both PYTHON and PURE DATA are open source software. MAX is an open license for use with APPLE products.
[0024] In practice, the warp and weft ends of the woven fiber optic meshes are connected to the RGB LEDs that are electrically connected (e.g., soldered) to the circuit boards. The boards are connected to and controlled by a computer which is, for example, on-line, on the Internet, scraping databases for specific information. These programs are also designed to operate from the computer hard drive as files. It will therefore run live from the Internet and/or as a file stored on the computer's hard drive. As will be understood, one or more of the IC boards and the computer comprise a data interpretation device for implementing the invention, and in which the term “computer” comprises, optionally, a conventional desktop or laptop computer, a smartphone or any other device capable of digital processing, transmission and/or reception of a digital signal; in which the data interpretation device is contemplated to be communicable with the tapestry of the present invention through a wired connection, though a wireless connection is also contemplated.
[0025] A search is carried out for pre-determined language using, for example, PYTHON, for data scraping. In accordance with an example of the invention, words are pre-assigned a numeric value such that the words comprise a specific data that is receivable by the data interpetation device and correlated with the pre-assigned value, for example, so as to define a color and pattern that is translated onto the surface of the woven fiber optic canvas. For example, the word “people” is assigned an RGB value of 255-255-0 (Pure yellow), and triggers the first group of 20 LEDs on to the weft of the fabric, depending on the frequency by which the word is said. The display of the pattern is pre-defined by the number of times the word is said in a given time frame, which frequency is also optionally a specific data. The colors are RGB, and transition rates vary from on/off to an imperceptible transition that can last for hours. Each of these aspects including, optionally, the aforementioned pattern, colors and transition rates are combinable so as to provide and correlate to a specific representation of the specific data. As provided for herein, other types of specific data may also optionally comprise sound, relative information between one or more predetermined items and/or interactive information.
[0026] All activity on the surface of the fiber optic canvas is prompted by either real time information (i.e., received as data input live from the Internet or other inputs), or by recorded information (i.e., information drawn from a prerecorded archive of data implemented in playback mode).
[0027] A working example of the tapestry called “50 Different Minds” debuted prior to the filing of Applicant's U.S. Provisional Patent Application No. 61/505,874 at the San Jose Museum of Quilts and Textiles as part of the Zer01 Festival in San Jose, Calif. The piece measured 50 by 50 inches. It displayed patterns and colors that related to TWITTER TWEETS of color words. It also used air traffic data from the nine busiest airports in the U.S. Horizontal and vertical lines on the tapestry's surface moved in real-time, and were synchronized with the longitude and latitude of arriving and departing flights.
[0028] Visitors could also interact with the tapestry by tweeting additive and subtractive color names. The tapestry is programmed to display colors in response to TWEETS written using the expression “#optictapestry,” and then primary and secondary color words, like “blue,” “red,” “yellow,” “magenta,” “cyan,” etc.
[0029] In San Jose at Zer01, the tapestry consisted of nine (9) individual woven fiber optic panels, measuring a total of 50×50 inches, see FIG. 9 . The inspiration for the patterns and colors derived from the color theory of painter Josef Albers and his wife Anni Albers' work in textiles.
[0030] While on display in San Jose, the tapestry was connected to the Internet and scraped data in real time. There are four routines for 50 Different Minds. Two computer programs drive the surface animation, one of which listens for TWITTER TWEETS, and the other of which follows flight arrivals and departures at the nine busiest airports in the U.S. Specific search terms are associated with patterns and color frequencies. When queried, information is parsed and assigned a pattern, which triggers a display of changing pattern and/or color. The animated effect looks like illuminated silk.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a partial plan view of a woven fiber optic thread panel according to an embodiment of the invention;
[0032] FIG. 2 is perspective view of a fiber optic panel housing according to an embodiment of the invention;
[0033] FIG. 3 is an explanatory view depicting a manner of coupling light sources with the fiber optic threads via light-guides (plugs);
[0034] FIG. 4 is a partial cross-sectional view of the light-guide (plug) and LED of FIG. 3 ;
[0035] FIG. 5 is an illustration of a particular illumination of the tapestry according to the invention;
[0036] FIG. 6 is a perspective view of an interior side of a fiber optic panel housing according to the invention; and
[0037] FIG. 7 is a perspective view of an assembly of a plurality of fiber optic panels according to the invention shown adjacently arranged, and in which a portion of the housing is removed to illustrate at least the panel contained respectively therein.
[0038] FIG. 8 is an illustration of the wall mounting system for use with a tapestry module of the present invention.
[0039] FIG. 9 is an illustration of the tapestry of the present invention comprising nine (9) modules and woven fiber optic panels thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0040] A representative example of the invention, and its manner of construction and use, is embodied in the following description, and is directed to an operational system which has actually been constructed and operated. It is noted, that while serving as a concrete example of the structural configurations, hardware and software for implementing a working model of the media art form according to embodiment of the invention, the specific details are intended merely as being representative of one possible approach to construction, as well as just a few examples of various operational modes (routines). Many other alternative structural components and operating modalities (software and routines) are contemplated within the scope of the invention.
[0041] In accordance with the example, and as partially depicted in FIG. 1 , fiber optic threads 1 woven in a pattern forming a fiber optic woven mesh 10 and comprising a woven fiber optic panel of the present invention is shown in a weft faced 4-harness satin weave with a stitching 2 , see FIG. 4 , sewn around all four sides to restrain the individual threads 1 . The hem 2 is sewn with a polyester thread, but could alternatively be sewn with a monofilament or thin thread as well. The fiber optic woven panel 10 of the example measures 12×12 inches and is woven on a hand loom.
[0042] When weaving of the panel is complete, it is subsequently flattened using a heat-set press for 3-5 minutes at a temperature of 250 degrees.
[0043] A natural etching of the fiber optic threads 1 occurs as a result of abrasion from the weaver's shuttle on the surface of the plastic fiber optic threads 1 and the sand bar, which is part of a hand loom. The surface of the threads 1 are further advantageously scratched using a light sand paper and/or a scapel knife to scrape the surface allowing more light to leak along the length of each of the fiber threads 1 , which would otherwise remain within each of the threads 1 over its length.
[0044] In looking to FIG. 2 , a lighting module 20 defines a panel housing 21 comprising, optionally a metal or plastic frame having approximately a 15.5″ outer dimension and a rim thickness of approximately ⅛″. Housing 21 encloses the woven panel 10 , which optionally comprises etched fiber optic thread (Mitsubishi CK-20 Eska 5 mm). Portions of the housing 21 are conveniently cut on a laser cutter and joined using, a suitable bonding material, for example, Weld-On 3 solvent. On the inside of the housing, an inner 1/16″ thick Plexiglass window 22 comprising two plates 25 of museum non-reflective Plexiglass each measuring 12×12 inches are provided and held in place with Plexiglass locking tabs (not shown) in each corner of the housing 21 . The fiber optic panel 10 is sandwiched between the plates 25 .
[0045] As depicted in FIGS. 3 and 4 , groups 31 of four to five fiber optic thread ends are fed, as at “A,” perpendicularly from the panel 10 edges into a reflective connector, referred to herein as a light-guide (plug) 32 , as at “B,” which is made, for example, from 5 mm heat shrink tubing (3:1 polyolefin, HS3-0188, black). The fiber optic threads 1 measure ⅞ inch to 1 inch in length from the end of the weave structure to the end of the thread.
[0046] The light-guides (plugs) 32 are conveniently handmade by heat shrinking them using a silicon mold which has multiple conical forms customized to the size of the RGB LEDs and baked at a temperature of 220 degrees in an oven. They are lined with a square of reflective MYLAR measuring ⅝ inch square. The MYLAR squares are inserted by handrolling them into the light-guide's (plugs) 32 heat-shrink casing.
[0047] The light-guides (plugs) 32 are attached to lights, as at “C” and “D,” by sliding them over the tip of a Red-Green-Blue (RGB) light emitting diode (LED) 34 (for example, Superbright RGB 599R2GBC-CA) mounted on a printed circuit board (PCB) 35 . The placement of the fiber optic thread ends in relation to the tip of the RGB LEDs varies ¼″ to 1/16″ from the end of the thread to the front tip of the LED surface when fully assembled, as shown at “E.”
[0048] The PCB (12 inches×1 inch) spans the edge of the panel 10 and secures forty RGB LEDs, four microcontrollers (Motorola PIC18F4620-I/P), supporting power circuitry (including capacitors, crystals, transistors and resistors), and a serial data transceiver circuit (MAX483 RS-485). There is one board 35 on each side of the four-sided housing 21 .
[0049] The module 20 is designed so that the fiber optic mesh, above electronics and PCBs, and the housing can be assembled and disassembled with respect thereto so as to be containable within the housing, as shown in FIG. 6 .
[0050] Therein, the circuit boards 35 are held in place by with 6/32 nylon screws, ¾″ in length. Each microcontroller controls ten RGB LEDs and applies independent pulse width modulated (PWM) signals to the red, green, and blue terminals of the LEDs and holds a unique chip identification number (ID) in nonvolatile memory space.
[0051] Four identical PCBs, one per side of the module 20 , are attached to the woven panel 10 and are supplied with remote power and serial data. A 5V 50 amp power supply and 4 power jumpers per module 20 , and multiples thereof, are contemplated for use in providing sufficient power.
[0052] Data is transmitted from a Lantronix XPort Direct Plus (XPD100100S-01 ethernet-to-serial converter). There is one ethernet to serial converter per three panels in a tapestry construction comprising nine (9) modules 20 , see FIG. 9 , in which a set of three modules 20 is operatively connected mechanically in series and to data lines in order to receive and display information that is the same or similar. The data lines are connected in parallel to the three modules 20 using flat flex cables. Additionally, there are three flat flex cables per module 20 .
[0053] Each data converter is assigned a static Internet protocol (IP) address, connected to an Internet switcher (Cisco SD205 Switch—5 ports), and receives formatted display data from a computer program. The number of identical lighting modules connected to the data converter is limited only by electrical factors and the microcontroller ID space.
[0054] The formatted display data is a standard UDP packet transmitted to the static IP address of the data converter and containing standard 8 bit RGB color data, the ID of the target microcontroller, and specifying the affected LEDs. This packet is received by the data converter and the color and target data is transmitted on a wired serial data line.
[0055] Each connected microcontroller checks the ID in the serial data and parses that data if that ID matches the number stored in memory. The RGB color data is converted to three PWM signals which are fed to the specified LEDs. These signals affect the power each basic color in the LEDs receives and thus the perceived color is displayed in the attached fiber optics. The microcontroller maintains this output until another serial packet is parsed. The entire system is updated by scanning through each microcontroller with display data.
[0056] The software for the fiberoptic tapestry installation consists of several layers of code written in the PYTHON language. The lowest level sends raw binary commands to the device over UDP (User Datagram Protocol) which the Lantronix UDP UART (Universal Asynchronous Receiver/Transmitter) device translates into serial commands to the hardware. The next highest level, the API (Application Programmer's Interface), translates drawing commands into low level binary commands. Examples of such commands allow the programmer to set the color of columns and rows, or change colors. Next, individual routines execute specific sequences of drawing commands to create the different content “programs,” e.g., air traffic data. The final layer, the “harness,” executes the different content programs in a rotating sequence.
[0057] Each of the computers or computer used in conjunction with the tapestry of the present invention, and supporting apparatus including, for example, the aforementioned power supply, UDP, and converter are, optionally, housed in a separate equipment box (not shown).
[0058] The following describes examples of routines (referred to by the names “Comings and Goings,” “Prelude,” “Fifty Different Minds” and “Tweet Suite”) to assist in an understanding of the versatility of the invention in practice.
[0059] It is to be understood that the tapestry comprising the invention may comprise a single module 20 or multiples thereof.
Comings and Goings
[0060] Comings and Goings is an air traffic routine that visualizes the incoming and outgoing air traffic at major airports around the U.S. In the aforementioned invention, the program module scrapes flight data from nine (9) of the busiest American airports. Each square panel in the tapestry represents a single airport while the warp and weft encode incoming and outgoing air traffic. A single LED that illuminates a bundle of four to five threads represents a flight and its distance from the airport is encoded in the position within the panel 10 . Incoming flights are drawn as horizontal threads where the bottom of the panel 10 represents the airport. As flights land and get closer, the lines move from top to bottom. As flights take off and get farther from the airport, the lines move from left to right on the panel 10 . The bottom and left represent a distance of zero miles from the airport, while the extreme top and right represent distances of 30 nautical miles from the airport.
[0061] For each airport under consideration, the latitude, longitude, and airport code are encoded in the software. It periodically loops through the list of airports and makes a query to a public API at flightstats.com requesting flights in the airspace of each airport. Using a PYTHON module called “mechanize,” it retrieves the data which is returned in an XML format and contains the flight number, source, destination, and current position coordinates. The software then filters the list by removing any flight that is outside a 30 mile radius from the airport. The distance for filtering is the euclidean distance, i.e., sqrt[(longitude[airport] longitude[airplane])̂2−(latitude[airport]−latitude[airplane])̂2]. The incoming flights are then drawn as individual rows and the outgoing flights are drawn as individual columns. The position is determined by linear interpolation, mapping the range of 0-30 miles to the 160 threads in each direction. A flight 0 miles from the airport would be drawn at thread 0, a flight 15 miles would be drawn on thread 80, and so on.
[0062] In order to optimize the visual continuity of the drawing and give the illusion that the visualization is running in real time, the updated positions are slowly drawn over a period of time rather than all at once despite representing a snapshot in time. To accomplish this, an internal database is maintained with all the current flights. As the flight list is updated with each iteration, each flight is compared with the database and is determined to have changed or not. If the position has not changed since the last update, it will not be drawn. The average period of time required to draw the flights is then divided by the number of updated flights to determine the spacing between updates. So if the display is intended to last for 60 seconds, and there were 10 flights with new positions, each of the 10 updated positions are drawn every 6 seconds. To eliminate the need to update the entire display for each drawing operation, an internal double buffer is maintained in software. Each time a drawing operation occurs, it is drawn into the buffer first and compared with what has been sent to the hardware. Only changes are sent to hardware to minimize bandwidth requirements and more importantly, to prevent flickering as slow updates are sent out.
Prelude
[0063] The prelude routine uses colors mentioned on TWITTER's global timeline to drive an animation stepping through the three primary color groups red, yellow, and blue, in that order. The array of nine panels is arranged in a square, having three rows and three columns. Each of these nine squares is in turn divided into four horizontal stripes. Colors mentioned are drawn on each of these stripes and then slowly consolidated until all nine panels share the same color using a sort of “tournament bracket” algorithm. The first consolidation makes each of the nine panels the dominant color of its four stripes, the second consolidation makes each row the dominant color of its three panels, and the last consolidation makes all nine panels the dominant color of its three rows.
[0064] For each of the three primary colors, there are four variants enumerated in a data file, each with a search term and a RGB (Red Green Blue) color definition. For example, the primary color red may consist of the search terms “crimson,” “blood,” “fire,” and “pink,” each bearing a unique color definition. If the search term is used anywhere in a TWEET, one “hit” is counted for that color. To balance the unequal number of results each term may generate, each of the four variants constituting a primary color receives an equal representation by searching back as far as possible to obtain 36 hits (one stripe for each of nine panels). Next, they are sorted by time of mention to create an ordered list generating the variations in the animation.
[0065] After downloading the data from the Internet, one of the nine panels is selected at random to animate. For this panel, the row stripes are “painted” in order from top to bottom by selecting its color from the top of the ordered list. After drawing the four horizontal stripes, the most common color is determined. Ties are broken randomly. The panel is then slowly faded to the most common color.
[0066] After drawing all four horizontal stripes and fading to the dominant shade, another panel is selected at random from the remaining un-painted nine panels and the procedure repeats.
[0067] Once all nine panels have been striped and faded to the dominant color, consolidation occurs row-wise. For each of the three rows top to bottom, the dominant color is determined and then the row fades to that color.
[0068] Lastly, the dominant color of the three rows is determined and the entire array of nine panels fades to that color. Once this occurs, the striping and consolidation routine occurs for the next of the three primary colors.
Fifty Different Minds
[0069] In the Fifty Different Minds routine, the following keywords (one, people, name, listening, red, different, color, minds, fifty) are used to create pseudo-random numbers which determine the size of various zones. To generate a pseudo-random number within a given range, the timestamp of a TWEET (a large, unique integer) containing one of the keywords is divided by the maximum of such given range and the remainder is returned—i.e. the modulus.
[0070] With reference to FIG. 5 , respective Zones 1 , 2 and 3 are provided and enable an illustration of exemplary LEDs 34 denoting each of the zones. In the routine, once every three seconds, Zone 1 is updated; every 5 seconds, Zone 2 is updated; every 7 seconds, Zone 3 is updated. Each update entails changing the color and the size of the zone with an approximately 5-second fade. Each zone is assigned a preprogrammed, looping sequence of three colors and the next in the sequence is used each time the zone is updated. Some zones may grow slightly from their nominal size—e.g. zone 1 , nominally the center panel of the nine-panel array, may grow vertically by one row of 10 LED's above and below, to two (2) rows above and below, creating a vertically-oriented rectangle. The color of the area taken by the expanded zone takes precedence over the color of the next nominally-larger zone.
[0071] If a zone is allowed to expand n steps above the nominal size, a random number of maximum value n is determined by the algorithm given above. A number of 0 corresponds to drawing the zone in its nominal size; a number of 1 corresponds to drawing the nominal area plus the area of the first defined expansion, and so on.
[0072] This sequence continues for a set number of seconds before rotating to the next program in the harness.
Tweet Suite
[0073] The final routine example, “Tweet Suite,” responds to TWEETS containing color words and the hash tag “#optictapestry” by creating outwardly-expanding concentric circles of color. Ripples is an interactive component of the invention. A person can send a TWITTER TWEET from their personal computer or smart phone from anywhere in the world using this hashtag command and the invention responds by displaying a color or pattern. The first color in the sequence is drawn on the smallest, innermost ring and slowly faded in over a random period of time ranging from 0.2 to 4 seconds. After the fade-in period, it is faded into the next larger ring as the next color in the sequence is faded in to the smaller ring, and so on. Black is added as the last color in the sequence to ensure the tapestry is completely off before moving to the next TWEET.
[0074] A database of color words and their RGB definitions is used to translate the colors found in a TWEET. If a color is not recognized, or is misspelled, it simply does not appear in the sequence. The routine does not run if there are no new TWEETS in the last fifteen minutes.
[0075] It is to be understood that the present invention contemplates a panel display comprising two or more adjacent modules arranged relative to one another, as shown in FIG. 7 . In such arrangement, the modules are shown from a backside of the tapestry with a backside of their housings 21 removed in order to show that one or more may be connected to one another, optionally through use of screws or other fasteners.
[0076] In this way, one or more of the modules of the modular display comprising a tapestry of the invention may receive information from an information source or device that is different than an information source or device supplying information to an adjacent module. This is the case as each individual module of the modular display can be specifically programmed and connected with its own information source or device.
[0077] In a particular configuration, the tapestry may be programmed to execute and exhibit one or more combinations of the aforementioned routines in a predetermined order thereof.
[0078] When displaying one or more combinations of the aforementioned routines, or other information which the tapestry is adapted to exhibit, it is further contemplated that instead of the sandwiched configuration of the woven fiber optic panel described herein, that such a panel, measuring, optionally, 12″ by 30″ be tacked with monofilament onto a Plexiglass frame. In this way, the woven fiber optic panel and illuminated surface provided thereby is exposed to the environment whereby the woven fiber optic panel is sewn to the Plexiglass frame in which the sewing material is passed through the woven fiber optic panel and then through the Plexiglass frame.
[0079] As such, each of the several modules of the modular display comprising a tapestry of the present invention may further be useable to display one or more types or categories of information. Each component of information may, for instance, be displayed by one or more of the modules whereby illumination of a particular panel may be faded and patterned according to programming, as discussed hereinabove, which is used to interpret the information.
[0080] It is to be further understood that the module display comprising several of the aforementioned modules so as to comprise a tapestry of the present invention is mountable on a wall surface through, as shown in FIG. 8 , use of a mounting system 38 comprising a first wall plate 39 that is attachable to a wall surface, and which provides cleats 40 to which a second wall plate 41 , and specifically a back surface 42 thereof with cleats 43 carried thereon, matingly engage. A front surface 44 of second wall plate 41 carries rails 45 onto which carriages (not shown) carried on a back surface of a modular housing 21 ride so as to comprise the tapestry of the invention when mounted to a wall surface. Each of the rails and carriage are contemplated to comprise a construction commensurate with an IGUS rail and carriage system. In this way, the display provides an informative and aesthetically pleasing device able to be easily incorporated within a household or office environment.
[0081] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A woven fiber optic tapestry for conveying a specific representation of data on a woven fiber optic threaded surface. The tapestry is provided in a particular system including fiber optic threads threadedly arranged together to form a woven fiber optic panel, in which each of the threads is operatively connected to a light source, and a data interpretation device operatively connected to the light sources so as to provide a transfer of a pre-assigned value of data from the data interpretation device to the light sources and the threads, the transfer of the pre-assigned value causing an illumination of the light sources so as to correlate to a specific representation of the data.
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CROSS REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
This application claims the benefit, under 35 U.S.C. §119(e), of U.S. Provisional Patent Application No. 61/219,498, filed 23 Jun. 2009, the entire contents and substance of which is incorporated herein by reference in its entirety as if fully set forth below.
TECHNICAL FIELD
Embodiments of the present invention relate generally to containing and removing accumulated moisture. More particularly, embodiments of the present invention relate to temporary systems for removing water that can be installed quickly. The systems can be operational at least until permanent measures can be put into place, and can be removed with minimal effort.
BACKGROUND
Foundations and exterior walls of buildings often experience water problems due to a variety of causes. When exterior walls that are below grade are constructed, the surrounding soil must be removed prior to construction. The soil is then replaced after the foundation and walls are complete. As a result, the exterior walls can become damaged as soil settles outside of the foundation. A negative grade sloping toward the exterior walls can also be formed due to such settling. With the negative grade, the force of gravity causes water and soil to move toward the walls, which can create positive hydrostatic pressure. This pressure can cause cracking of, and seepage through, the exterior walls and floor allowing moisture to enter the building.
Additional water problems can be caused by water accumulating around and under walls and foundations. This can be caused by, for example, rising ground water during rainy parts of the year. All of these sources are especially prevalent in basements and crawl spaces. When water enters a dwelling, regardless of source, many problems arise, including, among other things, damage to the physical structure of the dwelling and a decrease in indoor air quality.
Conventional systems exist to control or direct water seepage thorough the interior walls of a structure. These systems often require extensive time and/or extensive modification of the structure to install. A rainy season, flooding, and other factors can create a backlog for service providers attempting to provide water mitigation services. This can create a situation in which water sits inside the dwelling for extended periods until the service provider can affect the necessary repairs.
Standing water inside a dwelling can create health problems related to, for example, mold, mildew, bacteria, viruses, and insects (e.g., mosquitoes). Water inside the structure can also cause structural problems. The problems can include, among other things, wood rot and fastener corrosion. Owners may spend thousands of dollars drying structures to prevent such damage, only to have the structure flooded again before a service provider can affect a permanent repair.
BRIEF SUMMARY OF EXEMPLARY EMBODIMENTS
A system for removing water from areas where water is undesirable is disclosed. The system can be installed quickly, without modification to the installation area. The system can provide a temporary water removal solution until a more permanent solution can be installed in the area. The system can be useful, for example and not limitation, during periods of heavy rain, when service providers may encounter backlogs due to high demand. The system can provide ease of installation and can be removed from a structure without making permanent modifications to the structure.
In accordance with some embodiments, the system can comprise a dam, in watertight communication with a substrate, for sequestering water in a retention area. In some embodiments, the dam can comprise a substantially rigid material. In this configuration, the dam can further comprise a sealer for forming a substantially watertight seal between the dam and one or more of the substrate and one or more walls.
The system can further comprise a water collection system, in fluid connection with the retention area, for removing water from the retention area to a reservoir. A water removal system can be provided for removing the water from the reservoir to a disposal location. In some embodiments, the dam can be in watertight communication with the substrate and one or more walls to form a retention area.
In some embodiments, the water collection system can comprise a first conduit in fluid communication with the retention area and the reservoir. The first conduit can provide communication between a vacuum and the reservoir. The first conduit can enable the vacuum to draw water out of the retention area and into the reservoir. The system can be equipped with a sensor for activating and deactivating the vacuum motor based on the water level in the retention area.
In accordance with some embodiments, the water removal system can comprise a pump for removing water from the reservoir. The pump can be in communication with a disposal area via a second conduit. The system can be equipped with a second sensor for activating and deactivating the pump based on the water level in the reservoir. In some embodiments, the second conduit can be in fluid communication with a drain disposed inside the structure and the drain can be in fluid communication with the disposal location.
In some embodiments, the first sensor can activate the vacuum motor when the water level in the retention area reaches a first predetermined level and can deactivate the vacuum motor when the water level in the retention area reaches a second predetermined level. In still other embodiments, the second sensor can activate the pump when the water level in the reservoir reaches a first predetermined level and can deactivate the pump when the water level in the reservoir reaches a second predetermined level.
The system can also include additional features. For example, the first conduit can further comprise a first valve to prevent water from draining out of the first conduit and back into the retention area when the vacuum motor is deactivated. Similarly, the second conduit can comprise a second valve to prevent water from draining out of the second conduit and back into the reservoir when the pump is deactivated. The first conduit can further comprise a nozzle comprising a plurality of channels to channel water into the first conduit. Similarly, the second conduit can further comprise a baffle for smoothing the flow of water out of the second end of the second conduit.
Embodiments of the present invention can also comprise a method for removing water from unwanted areas. The method can comprise installing a dam to create a retention area. An additional feature of the method can comprise placing a water collection and removal system in fluid communication with the retention area. In some embodiments, the water collection and removal system can be placed in fluid communication with a disposal location. When possible, the disposal location can be an existing drain. The water collection and removal system can be provided with a power source or can have an internal power source.
To install the dam and create a retention area, a portion of the bottom and/or the sides of the dam can be covered with sealant. When the desired sealant has been placed on the dam, the dam can be placed in communication with a substrate and/or one or more walls to form a substantially watertight retention area. In some installations, it may be desirable to adjust the height of a first conduit within the retention area such that the first conduit is in close proximity to the substrate.
Additional repairs may be necessary if the walls and/or floor of the installation area are cracked or damaged. In some embodiments, the method can further comprise drilling a hole in a crack in one or more of the substrate and one or more walls where the dam will span the crack after installation. After drilling, the hole can be filled with a sealant prior to installing the dam to create a water tight seal between the dam and one or more of the substrate and the one or more walls after installation.
The foregoing and other objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a side view of a water collection and removal system embodiment in accordance with some embodiments of the present invention.
FIG. 2A depicts a schematic view of two water collection and removal system embodiments in accordance with some embodiments of the present invention.
FIG. 2B depicts another schematic view of two water collection and removal systems embodiments, including a baffle, installed in a structure, in accordance with some embodiments of the present invention.
FIG. 3 depicts various cross-sectional configurations for a dam for use with the water collection and removal system embodiment, in accordance with some embodiments of the present invention.
FIG. 4 depicts a nozzle for use with the water collection and removal system in accordance with some embodiments of the present invention.
FIG. 5 depicts a detailed, side view of the water collection and removal system of FIG. 1 in accordance with some embodiments of the present invention.
FIG. 6 depicts a perspective view of an embodiment of a dam of a water collection and removal system embodiment in accordance with some embodiments of the present invention.
FIG. 7 is a flow chart depicting a method of use for the water collection and removal system embodiment in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION
Embodiments of the present invention are directed to a temporary waterproofing system. The system can be installed quickly to remove unwanted water. In some embodiments the system can comprise a dam for sequestering, or pooling, water in a retention area. The water can be removed from the retention area, using a vacuum or other suitable means, to a reservoir. The water can then be removed to a drain, or other safe area, using a pump, or other suitable means. The system can maintain a relatively dry environment until a more permanent solution can be installed.
To facilitate an understanding of the principles and features of the invention, it is explained with reference to its implementation in an illustrative embodiment. Embodiments of the present invention can be quickly installed in a basement, crawlspace, or other area with water infiltration and provide removal of the water until a permanent waterproofing repair can be put in place. Additionally, because embodiments of the present invention can be installed quickly, in times of high demand, service providers can provide a temporary waterproofing solution to prevent additional structural damage due to backlogs.
Embodiments of the invention, however, are not limited to use in basements or crawl spaces. Rather, embodiments of the invention can be used in any location where water accumulation is undesirable. These locations can include, for example and not limitation, parking garages, overpasses, storage areas, and the bilges of ships.
The materials described as making up the various elements of the system of the invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described can include, but are not limited to, materials that are developed after the time of the development of the invention, for example.
Referring now to the figures, FIG. 1 depicts a side view of a water collection and removal system embodiment in accordance with some embodiments of the present invention. Embodiments of the present invention can comprise a water collection and removal system 100 for removing water from, for example, a structure 105 . The structure 105 can be of a conventional design comprising a footing 115 onto which a wall 110 and a floor 120 are constructed, though other configurations are contemplated. Water seeping into the structure 105 can be caused by, among other things, excessive hydrostatic pressure, wall 110 and/or floor 120 cracks, and flooding.
In some embodiments, the system 100 can comprise a water collection system 145 , a water removal system 165 , and a dam 125 . The dam 125 can be used to confine water to a portion 135 , or retention area, of the structure 105 . In other words, the dam 125 can prevent the water from spreading across the surface of the floor 120 . The dam 125 can cause the water to pool in the retention area 135 for removal.
In some embodiments, one or more dams 125 can be installed to create a retention area 135 . The dam 125 can be installed in multiple configurations depending on, among other things, room layout and location of water infiltration. The dam 125 can be installed, for example, from one wall 110 to another wall to trap water between the two walls 110 and the floor 120 . This can form a substantially triangular retention area 135 . In other embodiments, the dam 125 can be flexible and can create a substantially semicircular retention area 135 between a single wall 110 and the floor 120 . Alternatively, the dam 125 can be formed into a substantially circular retention area 135 on a particular portion of the floor 120 .
The dam 125 can be in watertight communication with the wall 110 and/or the floor 120 . In other words, the dam 125 can be capable of forming a substantially watertight seal between the wall 110 and or the floor 120 . The dam 125 can sequester water between the dam 125 and wall 110 and/or floor 120 . In some embodiments, the dam 125 can comprise a soft, flexible material that enables it to conform to many different shapes and textures. The dam 125 can be self-adhesive, or can be affixed using, for example, an adhesive, sealant, or caulk. The dam 125 is preferably attached using an adhesive that can provide a secure, watertight seal between varieties of surfaces, yet can be easily removed with a minimum of cleanup and/or damage to the underlying substrate.
In some embodiments, the dam 125 can comprise a rigid material such as, for example and not limitation, plastic, metal, or wood. The dam 125 can be treated with a waterproofer. The dam 125 can be installed using, for example, a caulk or adhesive suitable to attach the dam 125 to the floor 120 and/or wall 110 and creating a watertight seal therebetween. In some embodiments, it may be desired to provide additional support for the dam 125 . This can be achieved by affixing it to the floor 120 and/or wall 110 using, for example and not limitation, ballistic fasteners, epoxy, or lag bolts.
In some embodiments, the dam 125 can be of composite construction. In other words, the dam 125 can comprise two or more layers. One layer of the dam 125 can comprise a rigid material such as, for example and not limitation, plastic, metal, or wood. Another layer of the dam 125 can comprise a pliable material on sealing surfaces, i.e., where it meets the wall 110 and/or floor 120 . This can enable the dam 125 to self-seal so that it can be wedged into place. This can obviate the need for adhesives or caulks and can expedite removal and cleanup.
In some embodiments, the water collection system 145 can further comprise a first conduit 140 . The first conduit 140 can be in fluid communication with the retention area 135 and the collection system 145 . The first conduit 140 can be, for example and not limitation, a length of rubber or plastic hose (e.g., garden hose). In some embodiments, the first conduit 140 can comprise, for example and not limitation, a plastic vacuum hose or a rigid PVC pipe.
In some embodiments, the end 142 of the first conduit 140 can comprise a nozzle 142 . In some embodiments, the nozzle 142 can have multiple holes to enable the collection system 145 to remove water through 360 degrees around the first conduit 140 . The nozzle 142 can further comprise, for example and not limitation, a screen or filter to prevent debris from clogging the first conduit 140 .
The collection system 145 can further comprise a sensor 155 located at or near the end 142 of the conduit. The sensor 155 can detect the presence of water and can provide a signal to activate the collection system 145 . The sensor 155 can be, for example and not limitation, a float switch, a resistance-based switch, or an optical switch (e.g., an infrared laser). The sensor 155 can be set to trip, or close, when the height of the water in the retention area 135 reaches a specific height (the “removal height”). In some embodiments, this can be achieved by mounting the sensor 155 at the desired height on the first conduit 140 . In other embodiments, the sensor 155 can have an integral means for setting the removal height (e.g., an adjustable float).
When the sensor 155 detects that the water level has reached the removal height, the sensor 155 activates the collection system 145 . In some embodiments, the sensor 155 can simply complete the circuit between the collection system 145 and power or ground to activate a motor in the collection system 145 . In other embodiments, the sensor 155 can be connected to, for example, a relay, controller, or microprocessor capable of activating the collection system 145 .
In some embodiments, the sensor 155 can also detect when the water level has dropped to a suitable level and can deactivate the collection system 145 . So, for example, the sensor 155 can be a float switch and can activate the collection system 145 when the float rises to a first predetermined height. The sensor 155 can then deactivate the collection system 145 when the float drops to a second predetermined height. Deactivation can be accomplished, for example and not limitation, by opening the ground or power circuit to the collection system 145 . In other embodiments, the collection system 145 can be controlled by a timer and can simply run for a predetermined time.
The collection system 145 can be a vacuum or a pump capable of removing the water from the retention area 135 and collecting it in a reservoir 130 . It is preferable for the collection system 145 to remove as much water as possible from the retention area 135 . This minimizes the amount of standing water in the structure 105 . In an exemplary embodiment, the collection system 145 can be a vacuum and the reservoir 130 can be the canister of the vacuum.
The system 100 can further comprise a water removal system 165 . The water removal system 165 can be in fluid communication with the reservoir 130 of the collection system 145 . In some embodiments, the water removal system 165 can be inside the reservoir 130 . The water removal system 165 can comprise, for example, a pump 162 and a sensor 160 . In some embodiments, the pump 162 can comprise, for example and not limitation, a centrifugal or reciprocating pump. In a preferred embodiment, the design of the pump 162 can enable the pump to operate when dry without damage. In other words, the pump 162 does not “burn-out” if run without fluid.
The water removal system 165 can further comprise a sensor 160 located at or near the pump 162 . The sensor 160 can detect the presence of water and can provide a signal to activate the pump 162 . The sensor 160 can be, for example and not limitation, a float switch, a resistance-based switch, or an optical switch (e.g., and infrared laser). The sensor 160 can be set to trip, or close, when the height of the water in the reservoir 130 reaches a specific height. This can be achieved by mounting the sensor 160 at the desired height on the pump 162 . In some embodiments, the sensor 160 can have an integral means for setting the height (e.g., an adjustable float).
When the sensor 160 detects that the water level has reached a certain height, the sensor 160 can activate the pump 162 . In some embodiments, the sensor 160 can simply complete the circuit between the pump 162 and power or ground. In other embodiments, the sensor 160 can be connected to, for example, a relay, controller, or microprocessor capable of activating the pump 162 .
In an exemplary embodiment, the pump 162 can be a sump pump and the sensor 160 can be a float switch. When the water inside the reservoir 130 reaches the set height, the pump 162 activates and substantially empties the reservoir 130 . In some embodiments, the pump 162 can be connected to a second conduit 150 . The second conduit 150 can be, for example and not limitation, PVC pipe, garden hose, or clear plastic tubing. The second conduit 150 can be connected to, among other things, a drain or sink inside the structure 105 . In some embodiments, the second conduit can simply exit the structure 105 .
In some embodiments, the structure 105 may not be equipped with a drain or the drain may not be accessible. If the portion of the structure with water infiltration is located below ground, it can also be difficult or impossible to remove the water from the structure via a second conduit 150 . In this situation, therefore, it can be necessary for the reservoir 130 to be larger. In other words, when no convenient route exists for water removal, it can be necessary to increase the size of the reservoir 130 . This minimizes the number of times the reservoir 130 must be emptied in a given period. In some embodiments, therefore, the system 100 can simply collect the water in the reservoir 130 to be emptied periodically.
FIG. 2A depicts a schematic view of two water collection and removal systems in accordance with some embodiments of the present invention. In some embodiments, based on the volume of water that must be removed, it can be desirable to install two water collection and removal systems 230 , 235 . If water is infiltrating all four walls 205 , 210 , 215 , 220 of a room, for example, it can be necessary to install a dam 240 around the perimeter of the room 200 . This can substantially create a moat, or retention area 222 , around the room 200 . The moat can collect water and prevent water from covering substantially the entire floor 202 . In this way, a majority of the room 200 can be kept dry. This can prevent, for example, damage to items stored in the room 200 or the flooring installed over the floor surface 202 .
The systems 230 , 235 can be in fluid communication with the retention area 222 via conduits 245 , 250 . The systems 230 , 235 can remove water from the retention area 222 when the water level reaches the removal height, e.g., one-quarter of an inch. In this way, the retention area 222 can be kept substantially dry. This can substantially reduce problems arising from the presence of standing water.
Each of the systems 230 , 235 can be in fluid communication with a tube 255 a , 255 b . The tube 255 a , 255 b can be in fluid communication with, for example, a drain 254 . In some embodiments, the systems 230 , 235 can be connected to a hose 254 , or other means, that simply exits the building to a suitable location. In some embodiments, the systems 230 , 235 may have separate drains (not shown).
Many configurations of the present invention can be employed based on the needs presented by a particular situation. FIG. 2B depicts another schematic view of two water collection and removal systems embodiments. The system 100 can be deployed in a room 204 in which water infiltration affects substantially all of one wall 260 , but only a corner of another wall 266 . Multiple dams 255 , 265 can be used to create multiple retention areas 257 , 267 , as needed.
In this embodiment, a dam 255 can be placed along substantially the entire first wall 260 and continue partially along the adjoining walls 262 , 264 . The dam 255 , therefore, can be sealed along the surface of the floor 206 and can be sealed against the walls 262 , 264 to contain water in a retention area 257 . When the water level reaches the removal level, e.g., one-quarter of an inch, the system 270 can remove the water. When the water level inside the system 270 , i.e., in the reservoir 130 , reaches a set height, the water can then be pumped out to a suitable location 285 for removal, e.g. a drain. The drain 285 can be, for example and not limitation, a tub drain, a sink, a floor drain, or a washing machine drain. If no drain is available, the system can simply use a hose or conduit that exits the building.
A second system 275 can service a second retention area 267 formed by the dam 265 in the corner of the room 204 . In some embodiments, the second system 275 can share a common drain 285 with the first system 270 . In some embodiments, the second system 275 can have a separate drain 285 from the first system 270 . More or less systems 270 , 275 can be employed, as necessary, to meet the water removal demands in a given room 204 .
In some embodiments, a baffle 280 can be employed. The baffle 280 can be disposed on the end of the first conduit 140 . The baffle 280 can prevent large debris from being sucked into and clogging the first conduit 140 . The baffle 280 can also be disposed on the end of the second conduit 150 . In this configuration, the baffle 280 can slow and smooth water flow exiting the second conduit 150 into the drain 285 . This can prevent, for example, exceeding the removal capacity of the drain 285 . The baffle 280 can also prevent splashing and water damage to areas surrounding the drain 285 .
FIG. 3 depicts various cross-sectional configurations for a dam for use with the water collection and removal system embodiment, in accordance with some embodiments of the present invention. The dam 125 can be many shapes and materials and can provide a water tight seal at the floor 120 and/or wall 110 . In some embodiments, the dam 305 can be substantially L-shaped. In this configuration, the dam 305 can be attached to the floor 120 using, for example and not limitation, a nail 307 , screw, or adhesive. The dam 305 can then be made watertight by placing a bead of caulk or adhesive 309 at the base of the dam 305 . In some embodiments, the caulk or adhesive 309 can be disposed between the dam 305 and the floor 120 and/or wall 110 . The use of caulk or adhesive 309 can obviate or mitigate the need for additional fasteners 307 .
In some embodiments, the dam 310 can comprise a firm but flexible material. The dam 310 can form a half pipe shape with a pliable bulb 312 attached on one side. The bulb 312 can comprise a material suitable for creating a water tight seal with the floor 120 and/or wall 110 such as, for example and not limitation, rubber or silicone. In some embodiments, the dam 310 can be placed against the floor 120 in tension and fastened to the floor with a suitable fastener 314 . The tension can force the pliable bulb 312 against the floor 120 creating a water tight seal. The fastener 314 can be, for example and not limitation, a nail or screw suitable for fastening the dam 310 to the floor 120 .
In some embodiments, the dam 315 can comprise a solid, but pliable material suitable for creating a watertight seal with the floor 120 . The dam 315 can comprise, for example, a block of soft, jelly-like rubber. In some embodiments, the dam 315 can comprise a material that can be cut to length. This can enable the dam 315 to be wedged between, for example, two walls 110 . The dam 315 can also be affixed to the floor 120 and/or wall 110 using a suitable adhesive or caulk. In some embodiments, the dam 315 can also be affixed to the floor 120 and/or walls 110 using a suitable fastener (e.g., nail, screw, bolt, etc.).
FIG. 4 depicts a nozzle for use with the water collection and removal system 100 in accordance with some embodiments of the present invention. The nozzle 400 can comprise a plurality of slots 410 . The nozzle 400 can increase the surface area of the first conduit 140 , which can increase the efficiency of water removal and prevent clogging of the first conduit 140 . In some embodiments, the conduit can further comprise a screen or filter (not shown) to prevent clogging of the first conduit 140 .
In some embodiments, the nozzle 400 can further comprise a valve 415 . In some embodiments, the valve 415 can be a simple on/off valve such as, for example, a ball valve. This type of valve can be useful when installing or removing the system 100 to prevent water dripping from the first conduit 140 . In some embodiments, the valve 415 can comprise a one-way, or backflow, valve. This can prevent water that has been sucked into the first conduit 140 draining back into the retention area 135 when the water collection system 145 is deactivated. The valve 415 can minimize the amount of standing water in the retention area 135 .
The nozzle 400 can further comprise a fixed or adjustable sensor 155 . In some embodiments, the sensor 155 can be mounted on the inside of the nozzle 400 to protect it from damage. As described above, the sensor 155 can detect the level of the water in the retention area 135 and activate the water collection system 145 . In some embodiments, the sensor 155 can also deactivate the water collection system 145 when the water level drops sufficiently. In some embodiments, the sensor 155 can be disposed on the outside of the nozzle 400 . In some embodiments, the mounting height of the nozzle 400 can determine when the water collection system 145 is activated and/or deactivated.
FIG. 5 depicts a detailed, side view of the water collection and removal system of FIG. 1 in accordance with some embodiments of the present invention. The system 100 can comprise a water collection system 145 and a water removal system 165 . The water collection system 145 can comprise a first conduit 140 in fluid communication with a retention area 135 . The retention area 135 can be created between the dam 305 , the floor 120 , and the wall 110 . In some embodiments, as shown in FIG. 5 , the dam 305 can be substantially L-shaped. This can enable the dam 305 to be attached to the floor using a suitable fastener 307 . A watertight seal can be formed between the base of the dam 305 , for example, a bead of caulk or adhesive 309 .
The first conduit 140 can further comprise a sensor 155 . The sensor can detect the water level in the retention area 135 . The water collection system 145 can further comprise a vacuum motor 505 and a reservoir 130 . In some embodiments, the first conduit 140 can be supported using a brace 515 to retain the first conduit 140 in the reservoir 130 . The brace 515 can prevent, for example, vibration, flexing, and cracking of the first conduit 140 . In some embodiments, the brace 515 can enable the height of the first conduit 140 to be adjusted. The height of the first conduit 140 can be adjusted to account for, among other things, varying water levels or uneven floors 120 .
When the water level in the retention area 135 reaches the level set by the sensor 155 , the sensor 155 can activate the vacuum motor 505 on the water collection system 145 . In some embodiments, the sensor 155 can be connected to a controller 510 . The controller 510 can be for example a relay, which can enable a small switching current from the sensor to activate a large current for the vacuum motor 505 . In other embodiments, the sensor 155 can be a float switch, or similar, that completes the power or ground circuit for the vacuum motor 505 .
When the vacuum motor 505 is activated, water is drawn up the first conduit 140 into the reservoir 130 . In some embodiments, the vacuum motor can run for a pre-determined amount of time (e.g., based on the size of the retention area 135 ). In other embodiments, the sensor 155 can provide a signal, or interrupt power to the motor 505 , when the water drops to a certain level.
In some embodiments, the first conduit 140 can further comprise a valve 415 . In some embodiments, the valve 415 can be a simple on/off valve such as, for example, a ball valve. This type of valve can be useful when installing or removing the system 100 to prevent water dripping from the first conduit 140 . In some embodiments, the valve 415 can comprise a one-way, or backflow, valve. This can prevent water that has been sucked into the first conduit 140 from draining back into the retention area 135 when the water collection system 145 cycles off. The water collection system 145 , therefore, removes the water from the retention area 135 to the enclosed reservoir 130 . This minimizes the volume of standing water in the retention area 135 .
The system 100 can further comprise a water removal system 165 . The water removal system 165 can comprise a pump 525 in fluid communication with a second conduit 150 . The water removal system 165 can further comprise a sensor 160 . The sensor 160 can detect the water level in the reservoir 130 . In some embodiments, pictured, the sensor 160 can be a float switch that activates and deactivates the pump 525 . When the water level in the reservoir 130 reaches a first predetermined height in the reservoir 130 , the switch can activate the pump 525 . Similarly, when the water level in the reservoir reaches a second predetermined height, the switch can deactivate the pump 525 .
The pump 525 can be in fluid communication with the second conduit 150 via a pipe 535 . In some embodiments, the pipe 535 can be inside the reservoir 130 . In some embodiments, the pipe 535 can be, for example and not limitation, PVC pipe, clear plastic tubing, or garden hose. The pipe 535 can be connected to a fitting 537 on the reservoir 130 . The fitting 537 can enable the second conduit 150 to be detachably coupled to the pipe 535 . In some embodiments, the fitting 537 can be a hose fitting (e.g., a garden hose fitting) and the second conduit 150 can be a hose (e.g., a garden hose). The second conduit 150 can be in fluid communication with a suitable means for removing the water from the structure 105 . The second conduit 150 can be in fluid communication with, for example, a drain or the outside of the structure 105 .
In some embodiments, the pipe 535 can further comprise a valve 530 . In some embodiments, the valve 530 can comprise a one-way or backflow valve. This can prevent water that has been pumped into the pipe 535 from draining back into the reservoir 130 when the pump 525 is deactivated.
Based on size and electrical current requirements, it may be desirable for the vacuum motor 505 and pump 525 to be powered on separate circuits. The current requirements of the vacuum motor 505 and pump 525 may be higher than can be safely accommodated on a single residential circuit breaker. It may be desirable for the vacuum motor 505 and pump 525 to have separate power cords 540 A, 540 B so that they can be connected to outlets 550 A, 550 B on separate circuits. In some embodiments, the vacuum motor 505 and pump 525 can have lower power requirements and can be accommodated on a single circuit breaker. In some embodiments, the vacuum motor 505 and pump 525 can use a single power cord (not shown). In some embodiments, the system 100 can have an independent power source, such as, for example and not limitation, a battery pack or solar array.
FIG. 6 depicts a perspective view of an embodiment of a dam of a water collection and removal system embodiment in accordance with some embodiments of the present invention. Water infiltration into structures can be caused, at least in part, by cracks 605 , or breaks, in foundation walls 110 or floors 120 . The crack 605 can enable positive hydrostatic pressure behind the wall 110 or beneath the floor 120 to drive water into the structure 600 . Creating a watertight seal across and through the crack 605 can be difficult because the crack 605 can cause an uneven surface, or void, where the dam 305 meets the floor 120 or wall 110 . This can cause the water to follow the crack 605 under the dam.
To prevent leakage across and through the crack 605 it may be necessary to drill a hole 610 in the floor 120 and/or wall 110 in the vicinity of the crack. It is preferable that the crack 605 generally bisects the hole 610 , if possible. Caulk, adhesive, or another suitable sealer 615 can then be pumped into the hole 610 until the hole 610 is slightly overfilled. The sealer 615 can provide a pliable surface across which the dam 305 can form a watertight seal. This can prevent water from leaking under the dam 305 via the crack 605 . While illustrated using a crack in the floor 120 , this method can also be employed effectively on the wall 110 by drilling a horizontal hole (not shown).
FIG. 7 is a flow chart depicting a method of use for the water collection and removal system embodiment in accordance with some embodiments of the present invention. In some embodiments, the method can be implemented using the above-discussed embodiments.
In some embodiments, at 710 , it may be necessary determine if there are existing cracks in the floor or walls that must be repaired prior to installation of the dam. In some embodiments, at 712 , it may be necessary to fill any cracks in the floor with a sealant. Filling the cracks 712 can enable the dam to form a watertight seal over and through the cracks. In some embodiments, such as with a particularly deep or wide crack, it may be necessary to first drill a hole in the crack. The hole can then be filled with a suitable sealant such as for example and not limitation, latex or silicone caulk, hydraulic cement, or polyurethane. This can enable the dam to form a watertight seal over the crack.
Next, at 715 , one or more dams can be installed to create retention areas. The retention areas can be installed in the vicinity of the infiltration points for the water. In the case of a single leaking corner, for example, this can be as simple as placing a dam across the corner from wall to wall to create a triangular retention area. On the other hand, in a flood, it may be necessary to create a moat-like retention area all the way around the room. See, e.g., FIG. 2A .
After the retention area(s) have been established, at 720 , one or more water collection and removal systems can be placed proximate to the retention areas. In some applications, it may be necessary to adjust the height of the first conduit based on the height of the retention area. This can allow for variations in the floor, for example. In some embodiments, it may be necessary or desirable to adjust the height of the sensor. In some embodiments, the height of the sensor can be set based on the height of the first conduit.
Next, at 725 , the second conduit can be connected to the system to place the system. The second conduit can be in fluid communication with a suitable egress point for the water. In some configurations, an egress point can be an existing floor or tub drain. In other configurations, the second conduit can be run outside through a window, or other opening. In some installations, the second conduit can be run to, for example, an exterior storm drain.
At 730 , the system can be connected to one or more power sources. In other words, in some installations, the pump and vacuum motor of the system can be plugged into outlets on separate circuits. In some embodiments, however, this can be unnecessary, e.g., if the circuit breaker in the structure has sufficient load capacity. If sufficient capacity exists, the pump and the vacuum motor can be plugged into the same outlet. In some embodiments, the pump and vacuum motor can have a common power cord. In still other embodiments, the system can have an on-board power supply such as, for example and not limitation, a battery pack obviating this step.
Upon installation, the system 100 can be configured to be substantially self-sufficient provided power is not interrupted. It can be desirable from time to time to check the system 100 and remove, for example, any accumulated debris from the vicinity of the first conduit 140 and to check the operation of the various components, e.g., the sensors 155 , 160 . The system 100 can be advantageous in times of high demand, when installers are suffering backlogs, for instance, and the system 100 can provide a means for keeping a structure with ongoing water infiltration substantially dry. The system 100 can be quickly deployed until a more permanent waterproofing solution can be installed
It can be seen that embodiments of the present invention provide a system 100 and method 700 for providing a means for effectively removing water. In some embodiments, the present invention is a system 100 capable of containing and removing water from a structure. The water can then be removed to a drain inside the structure or a suitable location outside the structure. In some embodiments, the system 100 can comprise a dam 125 , a water collection system 145 , and a water removal system 165 . In some embodiments, the dam 125 can sequester and collect water in a water retention area 135 . This can facilitate water removal into the reservoir 130 of the system 100 . When the reservoir 130 is sufficiently full, the water removal system 165 can remove accumulated water from the structure 105 . The water can be removed via a drain, or other suitable means.
It can also be seen that embodiments of the invention provide a number of different systems 100 and methods 700 . These systems 100 and methods 700 can be used to remove water from a structure 105 until permanent repairs can be affected. The system 100 can be easily adjusted to conform to a variety of structures 105 and water infiltration scenarios. Installed, embodiments of the present invention provide a safe, convenient, temporary solution to this ubiquitous problem. The various embodiments of the invention described above provide methods of using the system 100 and method 700 when compared with prior approaches.
It will be appreciated by those skilled in the art, however, that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. For example, embodiments of the invention have been described with respect to a method 700 ; however, the method 700 could be performed using a different sequence of steps, or omitting certain steps, without deviating from the spirit of the invention. For example, if upon inspection 710 , no cracks are found in the floor 120 or walls 110 , it can be unnecessary to drill and fill cracks 712 prior to installation of the dam(s) 715 .
In addition, while the invention has been described in the context of system 100 for removing water from a structure 105 , the concepts described herein need not be limited to these illustrative embodiments. For example, embodiments of the present invention could be used in many situations in which a user wishes to remove undesirable water from a variety of structures, such as, for example, a boat, recreational vehicle, underpass, or parking garage.
The specific configurations, choice of materials, and the size and shape of various elements could be varied according to particular design specifications or constraints requiring a device, system, or method constructed according to the principles of the invention. Such changes are intended to be embraced within the scope of the invention. The presently disclosed embodiments, therefore, are considered in all respects to be illustrative and not restrictive. 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 of equivalents thereof are intended to be embraced therein.
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Systems for removing water from an area where water is not desired are discussed and provided. The system can include a dam, a water collection system, and a water removal system. The dam can create a waterproof seal so that the dam is configured to define a reservoir, or retention area, capable of holding water. The water collection system can remove substantially all of the water that collects in the retention area and deposit the water in a reservoir when the water collection system is triggered by a first sensor. The water removal system can move the water collected in the reservoir to an area of safe disposal through a hose or drain when triggered by a second sensor. Other aspects, features, and embodiments of the present invention are claimed and described.
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This application is a continuation of application Ser. No. 07/682,359 filed Apr. 9, 1991 now abandoned.
FIELD OF THE INVENTION
The present invention relates to a method for treating aphthous ulcers and other mucocutaneous disorders.
BACKGROUND OF THE INVENTION
Aphthous ulcers, often referred to as canker sores, are characterized by painful eruptions in the mucous membrane of the mouth. Of unknown etiology, they are covered by a grey exudate, and surrounded by a reddened area. They range in size from several millimeters to two centimeters in diameter. The ulcers are limited to oral mucous membranes not bound to periosteum, e.g. the inner portion of the lip or cheek. Aphthous ulcers may occur as solitary or multiple lesions, and heal spontaneously in one or two weeks. (Steadman's Medical Dictionary, 25th Ed., Williams & Wilkins)
Other mucocutaneous disorders can also result in the formation of oral ulcers that can be extremely painful.
Therapy for mouth ulcers generally involves use of topical anesthetics such as benzocaine in preparations made with a carrier designed to protect the ulcer from saliva and hold the anesthetic at the site. Zilactin is a topical medication composed of hydroxypropylcellulose, salicylic, lauric and tannic acids which has mucosal adherence properties. The mode of action of the product appears to be its effective film-forming capability that insulates the ulcer from the mouth environment. Because this characteristic requires effective formation of such a film, the product is difficult to apply in a manner sufficient to optimize its effect.
Still lacking is a method of treating aphthous ulcers and other mucocutaneous disorders which is easier to apply and which actually speeds the healing of the ulcers. These objectives are achieved by the present invention, which involves the use of oral pastes, troches and mouthwashes which contain as an active ingredient, amelexanox and its analogs.
As disclosed in U.S. Pat. No. 4,143,042, amlexanox is a compound of the formula 2-amino-7-(1-methylethyl)-5-oxo-5H[1]benzopyrano(2,3-b)pyridine-3-carboxylic acid. Amlexanox and its homologs and analogs are known to have anti-allergic activity, and are of value as prophylactic and curative drugs for the treatment of allergic asthma, allergic dermatitis, hay fever and other allergic diseases in mammals, including humans. In Chemical Marketing Reporter, Aug. 14, 1989, it was reported that tests were under way to test use of amlexanox on mouth ulcers. No results were provided.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a novel and effective method of treating aphthous ulcers and other mucocutaneous disorders.
Another object of the present invention is to provide a method of treating aphthous ulcers and the other mucocutaneous disorders in various dosage forms that are convenient to use.
Another object of the invention is to provide a method of treating aphthous ulcers and other mucocutaneous disorders in dosage forms that can be applied at a specific site in the oral cavity with a finger tip or which can be easily masticated for contact with the oral mucosa.
An additional objective of the invention is to provide a method of treating aphthous ulcers and other mucocutaneous disorders in formulations with various release rates for greater efficacy.
To achieve the foregoing objectives and in accordance with the purposes of the invention as embodied and broadly described herein, there is provided a method of treating aphthous ulcers and other mucocutaneous disorders comprising contacting the aphthous ulcer or other mucocutaneous disorder with a composition containing an effective amount of a compound of the formula: ##STR2## wherein R 1 is hydrogen, alkyl, phenyl, carboxyl, hydroxyl, alkoxy, carboxyalkyl (i.e. esters), cyano, acylamino, or amino group which may be unsubstituted or substituted by up to two alkyl groups; m is 0, 1 or 2 and R 2 is alkyl, alkenyl, alkoxy, halogen, nitro, hydroxy, carboxyl, butadienylene (--CH═CH--CH═CH--) which forms a benzene ring with any adjacent carbon atoms, cyano, carboxyalkyl, trifluoromethyl, or amino group which may be unsubstituted or substituted by at least one alkyl; and R 3 is carboxyl, cyano, arylalkoxycarbonyl, alkoxycarbonyl, or carboxamide which may be unsubstituted or substituted by at least one alkyl, and the salts thereof.
DETAILED DESCRIPTION OF THE INVENTION
Amlexanox and its homologs can be used to treat aphthous ulcers and other mucocutaneous disorders. Dosage forms suitable for delivering a drug to the oral mucosal membrane may include paste, solution, gel, quick-disintegrating tablet, mouthwash, ointment, cream, powder, adhesive patch, aerosolized spray, lozenge, troche, dentifrice and dental floss. Although all of these dosage forms are convenient to use, some of them, such as paste, lozenge, troche, solution and gel, may be considered even more advantageous due to the relative ease with which they can be applied at a specific site in the oral cavity with a finger tip, or the ease with which they can be easily masticated for contact with the oral mucosa.
An important physical characteristic for all dosage forms is the rate of release of the drug from the dosage form. It is known, for example, that tablets containing nitroglycerin are formulated to disintegrate quickly under the tongue for immediacy in drug availability to ameliorate anginal pain. This characteristic may not, however, be desirable for all drugs. In drugs which are intended for a topical mode of action, or for a drug which may possess a relatively low rate of absorption through the oral mucosa, it would be desirable to release the drug slowly from the dosage form. Such a slow release rate would minimize swallowing of the drug and would also lower or eliminate the occurrence of pharmacological or toxicological side effects. It is also known that generally a solubilized version of the drug is absorbed faster through the skin and mucous membrane than the solid version. In the case of amlexanox, it was decided to formulate both versions to provide both types of release rates.
Oral paste formulas and troches contain solid crystalline amlexanox. Mouthwash formulas contain the solubilized version of amlexanox.
Oral Paste
The major criteria of a paste for use in the oral cavity are as follows: (1) the paste should adhere to the mucous membrane until the desired amount of drug has been released; (2) the paste should not move from its site of application; (3) it should be composed of safe, edible excipient; (4) it should not alter the taste or should not leave an aftertaste in the mouth; (5) it should be viscous enough to facilitate the application via fingertip, and; (6) it should be homogeneous and non-gritty.
Paste formulas may contain the following categories of ingredients: (1) diluents (also known as fillers) such as dicalcium phosphate, lactose and starch; (2) adhesives that provide adhesion in the presence of saliva and moisture such as gelatin, pectin, acacia gum, xanthan gum and starch derivatives (3) viscosity builders such as microcrystalline wax, carboxymethylcellulose sodium (abbreviated as CMC-Na or CMC Sod or CMC), cross-linked carboxymethylcellulose sodium, petrolatum and polyethylene polymer; (4) plasticizers such as mineral oil and vegetable oils such as olive, safflower, peanut, sesame and sweet almond oil; (5) anionic or nonionic emulsifiers or wetting agents such as glyceryl monostearate, sodium stearate, polysorbate 60, polysorbate 80, Ceteth-20, Steareth-20 and Laureth-23; (6) flavoring agents such as fruit or vegetable flavors, vanilla and chocolate; (7) sweetening agents such as sucrose, saccharin sodium, cyclamate and aspartame; (8) antibacterial preservatives such as benzyl alcohol and sodium benzoate; (9) taste modifiers such as sodium ascorbate, citric acid and sodium tartrate, and; (10) coloring or opaquing agents such as edible colors, dyes and titanium dioxide.
Mouthwash
Amlexanox may be solubilized and formulated into a mouthwash to provide a limited amount of drug in a pleasant-tasting, flavored vehicle which may be used more than once during the day. A distinct advantage of a mouthwash resides in its ability to reach deeper crevices between teeth and the distant areas of the mouth which are inaccessible to the fingertips for a comfortable or convenient mode of application. It is not difficult for a patient to gargle with the medicated mouthwash to provide medication to the deeper areas of the throat.
The following ingredients may be included in a mouthwash formula: (1) diluents such as plain water or flavored water, (2) solvents such as glycerin, ethanol, propylene glycol and other polyols; (3) buffering agents such a sodium citrate and sodium phosphate; (4) organic acids such as citric, phosphoric or tartaric acid; (5) sweeteners such as sucrose, saccharine sodium, cyclamate or aspartame; (6) flavoring agents; (7) coloring agents; (8) preservatives such as sodium benzoate and benzyl alcohol; (9) inorganic acids such as hydrochloric or phosphoric to adjust the pH; (10) water soluble salts such as sodium chloride as taste modifier, and zinc chloride/citrate as astringent, and; (11) antibacterial agents such as cetylpyridinium chloride or benzalkonium chloride at appropriate concentration as allowed by the regulatory authorities.
Troches
Also known as lozenges or pastilles, troches are round discshaped solids containing the drug in a suitable flavored base. The base may be preferably glycerinated gelatin or a mixture of sugar and a mucilagenous gum such as acacia or tragacanth. The drug, i.e., amlexanox or analog may be dispersed at a concentration between 0.1% to 10.0% by weight in a mixture of powdered sugar and powdered acacia or tragacanth. The mucilagenous gum (acacia or tragacanth) may be incorporated in the formula at a concentration of 2% to 10% by weight. The preferred concentration of acacia or tragacanth is between 5% and 8% by weight. This concentration of gum gives sufficient adhesiveness to the mass. The mass is formed by slowly adding water to the mixture of powdered sugar, amlexanox and powdered gum. The water is added until a pliable mass is formed. The mass is rolled out on a clean glass plate and the troche pieces are cut out using a cutter. The mass may be otherwise rolled into a cylinder and divided into pieces of desirable weight. Each piece is then shaped and allowed to dry before packing. Alternate suitable mechanical means may be employed to produce such drug containing troches. The following examples serve to illustrate the method of the invention without restricting said process,
EXAMPLE 1
Table 1 sets forth several paste formulations that were found useful in practicing the method described herein.
TABLE 1__________________________________________________________________________ FORMULA FOR VEHICLE PASTE (A) (B) (C) (D) (E) (F) (G) (H) (I)__________________________________________________________________________Mineral Oil 27.3 26.3 38.3 36.3 46.0 28.8 28.8 47.5 32.2Gelatin 17.5 17.5 18.5 18.4 12.5 18.4 18.4 20.0 17.5Pectin 17.5 17.5 18.5 18.3 12.5 18.4 18.4 20.0 17.5Petrolatum 11.4 11.4 5.0 3.3Cross-linked Carboxymethylcellulose sodium 18.3 12.5 10.0Carboxymethylcellulose sodium (7HF) 8.7 8.7 9.2 9.2 9.2 8.7Carboxymethylcellulose sodium (7MF) 8.7 8.7 9.2 9.2 9.2 8.7Microcrystalline wax 6.7 3.4 12.8Glyceryl monostearate 6.4 6.4 6.7 6.7Polyethylene 4.3 3.6 4.0 2.5Xanthan gum 12.5Titanium dioxide 1.0 2.0 1.1Benzyl alcohol 2.5 2.5 2.6 2.6 1.5Flavor, Sweetner qs qs qs qs qs__________________________________________________________________________
EXAMPLE 2
The following ranges of excipients (percent weight/weight) were found useful in vehicle pastes.
______________________________________Excipient Percent w/w Range______________________________________Mineral Oil 27.0-47.5Gelatin 12.0-20.0Pectin 12.0-20.0Petrolatum 3.0-11.5Cross-linked CMC Sodium 10.0-20.0CMC Sodium (7HF) 8.0-10.0CMC Sodium (7MF) 8.0-10.0Microcrystalline wax 3.0-7.0Glyceryl monostearate 3.0-10.0Polyethylene 2.0-4.5Xanthan gum 1.0-15.0Titanium dioxide 0.1-3.0Benzyl alcohol 0.5-3.0Final Composition of PasteIngredient PERCENT WEIGHT/WEIGHTAMLEXANOX 10.0 7.5 5.0 2.5 0.1VEHICLE 90.0 92.5 95.0 97.5 99.9______________________________________
Method of Preparation of Oral Paste
Screen all the solids through a suitable sieve such as 60 or 70 mesh sieve and then mix the preweighed amounts in a suitable blender such as a V-Blender until adequately mixed. In a separate suitable vessel add weighed formula amounts of mineral oil, petrolatum, surfactant such as glyceryl monostearate, polysorbates and polyethylene. Heat this vessel with constant stirring until a homogeneous fluid is obtained. While slowly cooling with continuous stirring add the blended solids and keep stirring to obtain a homogeneous dispersion of solids in the oil phase. At 45°-50° C. add the preservatives and cool down to room temperature with continuous stirring. Pass the final semisolid product through an ointment roller mill to homogenize the product.
EXAMPLE 3
The formulas described below represent particularly preferred mouthwash formulations:
______________________________________Ingredient Percent weight/weight______________________________________Water 81.7 82.3 83.2Ethanol 12.8 12.8 12.8Glycerin 3.0 3.0 3.0Sodium citrate 0.2 -- --Citric acid 0.2 -- --Triethanolamine 1.0 0.7 0.7Amlexanox 1.0 1.0 1.0Flavoring agent 0.1 0.1 0.1Coloring agent q.s. q.s. q.s.Hydrochloric -- q.s. q.s.acid to pH to pH 7.5 7.5______________________________________
The above mentioned ingredients may be used in the percent (w/w, range described below to obtain a more suitable version:
______________________________________Ingredient Percent w/w range______________________________________Water 60.0-95.0Ethanol 8.0-15.0Glycerin 1.5-6.5Sodium citrate 0.1-0.9Citric acid 0.1-1.0Triethanolamine 0.1-1.5Amlexanox 0.1-1.5Flavoring agent 0.1-1.0Coloring agent 0.1-1.0Astringent Salt 0.1-1.5______________________________________
Method of Preparation Of Mouthwashes
To a suitable vessel add the formula amount of amlexanox and add designated amount of triethanolamine. Stir to mix well. To this mixture, add while stirring, ethanol, glycerin, water, buffering agents, flavors and colors. Stir well to mix.
EXAMPLE 4
The following amlexanox pastes formulations were tested and found useful in the treatment of aphthous ulcers:
______________________________________Formula No. 04-27a(A)AC-9 Homopolymer(polyethylene; Allied) 3.8%Kaydol Mineral Oil (viscosity 340-355) 38.3%Pectin, USP 17.4%Gelatin, NF 18.1%CMC-Na 7MF (Aqualon) 8.7%CMC-Na 7HF (Aqualon) 8.7%Amlexanox 5.0%Formula No.: 04-27a(C)AC-9 Homopolymer(polyethylene; Allied) 4.3%Kaydol Mineral Oil (viscosity 340-355) 38.5%Pectin, USP 17.4%Gelatin, NF 17.4%CMC-Na 7MF (Aqualon) 8.7%CMC-Na 7HF (Aqualon) 8.7%Amlexanox 5.0%______________________________________
Paste Manufacturing Procedure
1) Screen gelatin to a fine mesh (preferably 100 mesh sieve).
2) Mechanically grind pectin to a fine powder.
3) To a blender add pectin, gelatin, CMC 7HF and CMC 7MF
4) To a separate container add AC-9 homopolymer and mineral oil and heat to 90 C or until mixture is clear and homogeneous.
5) While hot, add step 3 to step 4 with stirring and cool to room temperature with constant stirring.
6) Mill the mixture from step 5 on a 3-roll mill until homogeneous This formulation appears to be physically stable after aging 2 weeks at 40° C.
EXAMPLE 5
Study Summary
Objective
The objective of this clinical study was to evaluate the tolerance and efficacy of 5% amlexanox adhesive paste when applied to patients with aphthous ulcers.
Study Plan
This 4-day clinical study utilized a double-blind, randomized, uneven parallel-group, multi-center design.
Thirty-five patients with aphthous ulcers who met all of the inclusion and none of the exclusion criteria were enrolled into this study. Patients were treated on the buccal mucosa, oral labial mucosa, floor of mouth or the distal half of the tongue.
Patients enrolled into the study were treated with either the 5% amlexanox adhesive paste or the vehicle adhesive paste. The study drug was applied to a maximum of 3 ulcers identified for treatment twice daily for 3 days. Tolerance and efficacy evaluations were made twice daily and again in the morning of the fourth day.
RESULTS
Demographic and Background Data
Data consisted of information from 35 patients who were treated with either the 5% amlexanox (aml.) adhesive paste or the vehicle.
______________________________________Demographics Total Patients No. Safety No. EfficacyStudy Drug Enrolled Analysis Analysis______________________________________5% aml. 21 21 18Vehicle 14 14 14Total 35 35 32______________________________________
Efficacy
The efficacy data was generated from an evaluation of the signs and symptoms of the patients with the aphthous ulcers. The evaluations included a measurement of ulcer size, the severity of erythma and pain, and an evaluation of overall improvement. The evaluations were made twice daily for three days and again on the morning of the fourth day. The following table summarizes the results from all study sites.
______________________________________Summary of Efficacy Evaluations______________________________________ Median Mean 5% 5%Evaluation aml. Vehicle aml. Vehicle p. value______________________________________% Reduction in 93% 57% 73% 61%Pain% Reduction in 88% 37.5% 69% 41%SizeErythema* -4 1-.5 -2.9 -1.4Improvement.sup. 3 0.5 2.4 0.9 <0.0001______________________________________*ERYTHEMA ADJUSTMENT SCALE-4 = No Erythema 0 = No Change from Day 1 AM-3 = Marked Decrease 1 = Slight Increase-2 = Moderate Decrease 2 = Moderate Increase-1 = Slight Decrease 3 = Marked IncreasePHYSICIAN'S IMPROVEMENT SCALEGrade Description of Ulcer4 = Aphthous ulcer cleared3 = Marked improvement (the ulcer is barely perceptible with minimal or no pain and marked decrease in size)2 = Moderate improvement (the ulcer is visible with moderate decrease in erythema and a moderate decrease in pain and moderate decrease in size)1 = Slight improvement (the ulcer is visible with a slight decrease in size, minimal decrease in erythema and a slight decrease in pain)0 = No change from the A.M. Day 1-1 = Aphthous ulcer worsened (greater erythema and/or pain or size)
Safety
The safety of the 5% amlexanox oral paste was assessed on the basis of the incidence, nature and severity of the adverse experiences reported during the study. During the conduct of this study no adverse experiences were reported.
Discontinuations
A total of 3 patients discontinued therapy with the 5% amlexanox oral paste. All three patients discontinued due to conflicts in scheduling.
Conclusion
Patients with aphthous ulcers who had been treated twice-a-day for three days with 5% amlexanox showed clinically significant improvement in all parameters measured over the vehicle paste. Statistical significance was seen in the measurements of ulcer size, reduction in erythema and overall improvement. No adverse reactions of any type were reported by either the patient or the investigator during the study.
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A method of treating aphthous ulcers and other mucocutaneous disorders is disclosed. The method comprises contacting the mucocutaneous disorder with a composition in the form of a paste, solution, gel, quick-disintegrating tablet, mouthwash, ointment, cream, powder, adhesive patch, aerosolized spray, lozenge, troche, dentifrice, or dental floss that contains an effective amount of an active compound of the formula: ##STR1## wherein R 1 is hydrogen, alkyl, phenyl, carboxyl, hydroxyl, alkoxy, carboxyalkyl (i.e. esters), cyano, acylamino, or amino group which may be unsubstituted or substituted by up to two alkyl groups; m is 0, 1 or 2 and R 2 is alkyl, alkenyl, alkoxy, halgoen, nitro, hydroxy, carboxyl, butadienylene (--CH═CH--CH═CH--) which forms a benzene ring with any adjacent carbon atoms, cyano, carboxyalkyl, trifluoromethyl, or amino group which may be unsubstituted or substituted by at least one alkyl; and R 3 is carboxyl, cyano, arylalkoxycarbonyl, alkoxycarbonyl, or carboxamide which may be unsubstituted or substituted by at least one alkyl, and the salts thereof.
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FIELD OF THE INVENTION
The present invention relates to impedance cardiographs which determine cardiac output by evaluating changes in impedance across the patient's chest cavity.
BACKGROUND OF THE INVENTION
Impedance cardiography is a non-invasive technique for determining cardiac performance in humans. When such equipment is employed, a high frequency electric signal is applied to the patient across outer electrodes positioned, for example, on the patient's head and lower thorax. Voltage differences between sensing inner electrodes positioned between the outer electrodes on the patient's neck and chest are measured and used to compute an impedance (Z). The impedance is based on the low magnitude, known electrical current passing between the outer electrodes.
In 1932, Atzler and Leyman reported that cardiac output of a human could be determined by such impedance methods in Uber ein neues Verfahren zur Darstellung der Herztatigkeit (Dielektrographie), Arbeitsphysologie, 5:636-680. In 1966, Kubichek reported the ability to correlate changes in base line impedance and the first derivative of impedance to stroke volume (SV) according to the following Equation (1) disclosed in U.S. Pat. No. 3,340,867 and in the publication: Development and Evaluation of an Impedance Cardiac Output System, Aerospace Medicine, 37: 1208-1212. ##EQU1## where: p1 ρ is the resistivity of blood; L is the spacing between the sensing electrodes;
Z 0 is an average or baseline impedance; and ##EQU2## is the magnitude of the peak negative value of the time derivative of the impedance Z for a period of time, typically a second.
Cardiac output may be deduced from stroke volume by multiplying the latter times the heart rate.
Although the Kubichek formula provides a value that correlated with cardiac output, the absolute accuracy of the method remained doubtful and, in particular, subjects with certain cardiovascular problems show values with great inaccuracies.
In 1982, Sramek proposed a modification of the Kubichek formula of equation (1) which resolved the base line impedance Z 0 2 into a dynamic and static component as reported in the publication: Cardiac Output by Electrical Impedance, Med. Elect., 2:274-290.The static term Z 0 s was described by the following equation: ##EQU3## where A is the area of the thorax being measured.
The dynamic component Z 0 d was simply the baseline or average of the impedance being measured:
Z.sub.0 d=Z.sub.0 ( 3)
Incorporating the static term and dynamic term into the Kubichek equation provides the following formula: ##EQU4##
The value of A may be estimated by approximating the chest as a cylinder in which case equation (4) becomes: ##EQU5## where C is circumference of the chest near the area of measurement. Alternatively, Sramek proposed that the term ##EQU6## be replaced with either ##EQU7## where H is the height of the patient because 1.7*H approximates L.
These approximations did not produce good results and so Sramek was ultimately led to produce a set of charts attempting to establish correlation between area and the three factors of gender, height and weight.
In 1986, Bernstein proposed a modified equation in which the separation of the electrodes and the height of the patient were considered, in the following form: ##EQU8##
All of the above methods suffer from lack of accuracy and indicate, in some subjects, falsely high or low values of stroke volume.
SUMMARY OF THE INVENTION
The present invention provides an improved method and apparatus for deducing stroke volume (and hence cardiac output) from impedance measurements. The invention provides an improved estimation of body volume and a processing of the derivative of the impedance signal that improves the reliability of the derived values of stroke volume and cardiac output.
Specifically, in an impedance cardiograph for use on a human patient having a height of H and a chest circumference C, a means for applying an electrical excitation signal to the patient is used in conjunction with electrodes positioned on the chest with a separation distance of L, the electrodes producing a first electrical impedance signal Z which varies with impedance changes in the patient. A user input device, such as a keyboard, is provided to enter data on the height, electrode separation distance and circumference to produce corresponding second and third electrical signals H, L and C indicating those values. An electrical circuit, which may be an electronic computer, receives the second and third electrical signal and provides an indication of the patient's cardiac stroke volume, SV, as a function of Z, A, L and left ventricular ejection interval L vet where A is deduced by the following approximation: ##EQU9## where K is a predetermined constant.
Thus, the impedance cardiograph may calculate SV according to the following formula: ##EQU10## which may be simplified to: ##EQU11## or by combining constants: ##EQU12##
Thus, it is one object of the invention to provide a simple, yet more accurate characterization of a critical term A used in the calculation of stroke volume from patient impedance. In the present invention, the area of the impedance measurement, which is difficult to measure, is accurately derived from the readily measured values of chest circumference and patient height.
The present invention has also recognized that variation in the derivative of impedance, one of the factors used in deducing stroke volume, is a significant source of inaccuracy in the computed stroke volume. Accordingly, whereas ##EQU13## may simply be the magnitude of the minimum derivative of impedance with time, it may also be compressed to reduce the amount that this maximum deviates from the norm. One method of weighting the maximum is according to the formula: ##EQU14## where: ##EQU15## is the magnitude of the minimum time derivative of ##EQU16## is the compressed value of ##EQU17## is a predetermined normal value and is an average value of ##EQU18## for a population.
Thus, it is yet another object of the invention to reduce the effect of a significant source of error in the calculation of stroke volume from impedance by implementation of a normal based weighting system.
The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration, a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made therefore to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the circuitry for an impedance cardiograph according to the present invention, showing a computer as used to analyze the impedance data to produce a value of stroke volume and cardiac output; and
FIG. 2 is a flow chart of the software employed by the computer of FIG. 1 in analyzing the impedance and ECG signals acquired from the patient.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a portable impedance cardiograph 10 is connected to a patient 12 by five patch electrodes 14(a)-(e). The first electrode 14(a) may be positioned on the patient's skin behind the right ear at the level of the ear canal. The second electrode 14(b) may be located at the left side of the neck on a flat surface approximately between the level of the chin and base of the hairline at least 5 cm below the level of electrode 14(a). The third electrode 14(c) may be located just above the base of the sternum on the anterior median lines. The fourth and fifth electrodes 14(d) and 14(e) may be located at least 5 cm below the electrode 14(c) on the patient's right and left sides respectively at the costal arch and the anterior axillary line.
Electrodes 14(a) and (d) are attached to an oscillator 18 which produces a constant current of approximately 1 milliamperes RMS through the patient 12. This electrical excitation establishes a series of equal potential surfaces through the patient 12 perpendicular to a line extending between the two outer electrodes 14(a) and 14(d).
Electrodes 14(b) and 14(c) may sense the equal potential lines generated by the current flowing between the outer electrodes 14(a) and 14(d). Because the current between the outer electrodes 14(a) and 14(d) is of constant amplitude, the amplitude of the voltage sensed between the inner electrodes 14(b) and 14(c) is proportional to the thoracic impedance of the patient 12. The inner electrodes 14(b) and 14(c) are connected to differential amplifier 20 producing a signal Z.
The amplifier 20 includes isolation circuitry that electrically isolates the inner electrodes 14(b) and 14(c) from the subsequent circuitry. Differential amplifier 20 also includes a precision half wave rectifier and low pass filter so as to provide a slowly varying DC signal whose value is proportional to the impedance being measured. The input impedance of the differential amplifier 20 is very high (e.g. 10 megohms) as compared to the impedance of the patient 12 between the inner electrodes 14(b) and 14(c). Thus, negligible current will flow through the inner electrodes 14(b) and 14(c) to amplifier 20.
The impedance signal Z is received by a multiplexer 32, such as are known in the art, to be periodically connected to an analog to digital converter 22 which samples the signal and provides a binary data word that may be read by microprocessor 24 via a bus 26.
A first, vertical ECG signal is measured across electrodes 14(b) and 14(c) lying generally along a generally vertical line. This ECG signal is received by differential amplifier 30 to produce an electrocardiograph signal E v according to techniques well known in the art.
A second, horizontal ECG signal is measured across electrodes 14(c) and 14(e) lying generally along a horizontal line. This ECG signal is received by differential amplifier 31 to produce an electrocardiograph signal E h . Both signals E v and E h are received by multiplexer 32 which periodically connects these signals to the analog to digital converter 22 to be sampled and converted to digital words for transmission on internal bus 26.
Differential amplifiers 30 and 31 receiving the ECG signal also include isolation circuitry and a low pass filter having a cut-off frequency such as to substantially remove the 50 kHz oscillator signal from oscillator 18. As will be described further below, the direct and quadrature ECG signals are combined to produce a single ECG signal largely independent of the electrical orientation of the patient's heart.
Also attached to bus 26 is computer memory 34 which may be composed of both random access memory ("RAM") and read only memory ("ROM") according to well known computer architectures. Memory 34 provides a means for storage of the binary representations of signals Z and E v and E h under the control of microprocessor 24, and also holds a stored program defining the operation of the microprocessor 24 for the calculation of cardiac output as will be described.
Also attached to bus 26 is a pushbutton switch 25 which may be used by the patient to mark the occurrence of some event, such as a cardiac episode, during the recording of data from the patient 12 as will be described.
The bus 26 also communicates with an infra-red transceiver 36, which permits the microprocessor to transmit and receive data to and from a similar transceiver 35 in a detachable base unit 37. The transceiver 35 is connected by a serial cable 38 to a desk-top computer 42 having a video monitor 43, a keyboard 44 and a disk drive 48 such as are known in the art. As such the impedance cardiograph 10 is portable and may be powered by internal batteries so as to be carried with the patient in the manner of a Holter monitor.
Generally, the impedance cardiograph receives signals from the patient 12, isolates, amplifies and filters those signals, and then translates the signals to digital values which may be read and stored by microprocessor 24 to be processed according to the stored program in memory 34. Results of the processing may be transmitted to the computer 42 to be displayed on the video monitor 43 or saved on disk 48.
The operation of the impedance cardiograph 10 according to the stored program is controlled by a human operator through keyboard 44. The operator prepares the patient 12 for the impedance measurements and may enter certain data to the keyboard 44 that characterizes the patient 12 and that is necessary for the analysis of the signals from the patients 12 as will be described. This analyses is done in partially in the microprocessor 24 so as to reduce the amount of data to be stored in memory 34, but, as will be understood in the art, the analyses of the data may be shared between the microprocessor 24 and the computer 42 as a matter of engineering choice.
Referring now to FIG. 2, at the first step in the analyses, indicated by process block 50, certain data related to the particular patient 12 or related to fundamental and essentially universal physiological parameters, may be entered by the operator.
The first of these parameters is ρ which is the resistivity of blood in ohms-cm. Generally, this value may be approximated as a constant for all patients, however, it may be modified by the operator in abnormal cases based on the measurement of hematacrit.
A second value, C, is the circumference of the patient's chest in cm taken at the site of inner electrode 14(c) around the patient's chest.
The value L is also input, being the distance between the inner electrodes 14(b) and 14(c) in cm. The height of the patient, H, in cm is also entered.
Once the necessary fixed parameters are entered at process block 50, two variable parameters: heart rate HR and ventricular ejection time L vet are entered per process block 52. For this purpose, the ECG signal E may be directly displayed on the video monitor 43 so that these quantities may be determined according to methods well known in the art. The ECG signal is calculated from the vector sum of the values of E v and E h most simply as follows: ##EQU19##
This vector summing reduces the need to precisely orient the ECG electrodes with respect to an electrical polarity of the heart and therefore in practice provides a superior ECG signal.
Generally, L vet is the time between the opening of the aortic valve and the closing of the aortic valve. The heart rate is simply the number of beats per second which is the inverse of the period between successive R waves. The heart rate may be averaged over a number of beats according to methods well known in the art. Both quantities may be determined by inspection by the operator or preferably may be determined automatically after sufficient ECG and Z data is acquired as indicated by process block 52. The value of L vet in the preferred embodiment is determined by analyzing the impedance signal Z to measure a period beginning when ##EQU20## is first less than zero and ending when the value of ##EQU21## reaches a local maximum above zero. The heart rate HR is measured by detecting and counting R waves in the ECG signal.
The acquisition of the ECG and Z signal per process block 54 continues. This acquisition is on a continuous basis and occurs concurrently with the subsequent calculations so that the cardiac output may be continuously stored in memory 34 or displayed in essentially a real-time manner.
The acquired impedance data is in the form of discreet samples taken approximately 300 times per second, each sample which may be represented by Z i where i is an index number of the particular sample. As each sample Z i is acquired, it is stored in consecutive addresses in memory 34 to indicate its relative position with respect to other samples and to indicate the time of the sample indirectly through the constant sampling rate.
Because the impedance cardiograph 10 is portable, there is a risk that artifacts may be introduced into the impedance measurement by electrode movement. This is because the measured impedance values are approximately two orders of magnitude lower than the electrode to skin resistance. Accordingly, the impedance data over a period of approximately one minute is "ensemble" averaged, per process block 56, to reduce its noise content. Ensemble averaging is a well known technique in which blocks of impedance data are averaged on a point-by-point basis with other blocks of impedance data so that the averaged points are from corresponding portions of the impedance waveform cycle. Thus, the shape of the impedance waveform is not destroyed in the averaging process. In order to perform such ensemble averaging, it is necessary to identify a common fiducial point to align the blocks of data. Selection of the fiducial point must be extremely precise, otherwise the characteristics of the impedance waveform will be "blurred" by a mis-registration of other blocks.
This fiducial point may be the peak of the R wave of the ECG signal. Normal techniques for determining the time of the R wave, such as may be used for the measurement of heart rate, however, are not suitably accurate for the purpose of ensemble averaging. Accordingly an extremely accurate identification process is used. First, as represented by process block 58, the ECG signal is monitored to isolate a standard R wave. Only portions of the received ECG signal having no detectable artifacts or noise are considered. This standard R wave is then correlated to the incoming ECG signal to identify the precise location of the R wave (by the value of highest correlation). This location is used at the point of common alignment for the impedance waveforms to be ensemble averaged. Periodically, a new standard R wave is obtained so that the standard remains current over time.
After pairs of data Z i and Z i +1 are acquired and averaged, a derivative value is ##EQU22## may be computed by a simple subtraction of adjacent samples of the ensemble average per process block 58, that is: ##EQU23##
Alternatively, in order to reduce the presence of 50 Hz or 60 Hz noise, this derivative computation can employ samples Z i+6 -Z i or Z i+5 , respectively.
It has been determined that variation in the magnitude of the minimum of this value, ##EQU24## is a significant source of error in the calculation of cardiac output. Accordingly, at process block 60, a compressed derivative, ##EQU25## is computed according to the following formula: ##EQU26## where: ##EQU27## is the magnitude of the minimum time derivative of Z as previously defined; ##EQU28## the compressed value of ##EQU29## is the predetermined normal maximum value and is an average value ##EQU30## for a population and is about 1.73 ohms per second.
Equation (8) has the effect of reducing the excursions of ##EQU31## Other nonlinear compression systems may also be used provided they have the effect of compressing ##EQU32## about the norm.
At succeeding process block 52, the value of Z 0 is also computed. Z 0 is the base transthoratic impedance and in this implementation, simply the average value of Z for one cardiac cycle. Because of the need to average a number of samples, when the sampling is first begun, no display is provided to the video terminal 43 until sufficient samples have been made to insure the accuracy of this value Z 0 .
At process block 64 a stroke volume may be calculated according to the following formula: ##EQU33##
It will be recognized that this is simply Equation (5) with the addition of a factor ρ and the addition of a factor ##EQU34## this latter factor approximating a slice of body volume in the area of the impedance measurement.
This calculation of stroke volume has shown significant improvements in accuracy and correlation coefficients in clinical studies.
Also at process block 64, cardiac output may be determined by multiplying the stroke volume times the heart rate:
CO=SV*HR (10)
As cardiac output is computed, it is displayed in graphical form on video monitor 43. Thus, the operator is provided with concurrent ECG data and cardiac output data on an essentially real-time basis per the display indicated by process block 66.
After each updating of the display of 43 is accomplished, the program acquire additional data until the measurement session is complete.
While this invention has been described with reference to particular embodiments and examples, other modifications and variations will occur to those skilled in the art in view of the above teachings. Accordingly, the present invention is not limited to the preferred embodiment described herein, but is instead defined in the following claims.
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An impedance cardiograph which determines cardiac output from a measurement of variations of chest impedance, provides an improved method of calculating the effect of patient volume on the measurement from measurable patient height and chest circumference, and provides a correction process that identifies as a source of error variations in the first derivative of impedance. This latter source of error is minimized by preprocessing the impedance derivative value with a compression function which reduces the range of values of the impedance derivative when that value differs significantly from a norm of the population.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an image synthesizing apparatus and method, for combining two images encoded according to the JPEG-2000 Standard, for example, and more particularly to an image synthesizing apparatus and method suitable for use in the cross fading.
This application claims the priority of the Japanese Patent Application No. 2003-120367 filed on Apr. 24, 2003, the entirety of which is incorporated by reference herein.
2. Description of the Related Art
Conventionally, the cross fading is well-known as an image processing technique for representing a transition from one image as a whole to another, for example (cf. Japanese Published Unexamined Patent Application Nos. 2000-78467 and -184278). The cross-fading technique is used in the computer graphics, special playback in a broadcast equipment, special playback in a camcorder, image processing in a game machine, etc.
Normally, the cross fading is implemented by linearly interpolating pixels included in two different images and taking spatially corresponding positions in the images, respectively, and combining the two images together.
Recently, more and more researches have been done of the techniques of dividing an image into a plurality of frequency bands by a so-called filter bank including a high-pass filter and low-pass filter in combination to encode each of the frequency bands. Of such techniques, the wavelet transform coding is considered as a new promising technique which will take the place of DCT (discrete cosine transform) because a high compression results in no considerable block distortion as in the DCT. For example, the JPEG-2000 Standard established as an international standard in January, 2001 has attained a greater improvement in efficiency of coding than the conventional JPEG by adopting a combination of the wavelet transform and a high-efficiency entropy coding (bit modeling and arithmetic coding, both in units of a bit plane).
Note here that to form an encoded code stream of a cross-faded image from an encoded code stream of each of two images with the use of the above-mentioned conventional technique, it is necessary to decode the encoded code streams according to the JPEG-2000 Standard, combine the two decoded images thus acquired by the linear interpolation to generate a cross-faded image, and encode the cross-faded image according to the JPEG-2000 Standard.
However, such a technique requires a memory for storing the two decoded images and also a memory for storing the cross-faded image. In addition, it needs both an image decoder and image encoder, which comply with the JPEG-2000 Standard.
OBJECT AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to overcome the above-mentioned drawbacks of the related art by providing an image synthesizing apparatus and method, capable of combining two encoded code streams easily and effectively with a reduced use of the memory space.
The above object can be attained by providing an image synthesizing apparatus that synthesizes an encoded code stream by filtering first and second input images, generating code blocks each having a predetermined size via division of a subband resulted from the filtering, generating, per code block, a bit plane including bits from a most significant bit to a least significant bit, generating a coding pass by bit modeling of each bit plane, making input of first and second encoded code streams generated by making arithmetic coding within the coding pass, and combining the first and second encoded code streams to generate the synthetic encoded code stream, the apparatus including, according to the present invention, first and second image decoding means each including a code stream analyzing means for analyzing the first and second encoded code streams, a code block extracting means for extracting code block information on the basis of the result of analysis from the code stream analyzing means, and an arithmetic decoding means for making arithmetic decoding of the code block information; a synthesizing means for multiplying a coefficient value for each of the code blocks supplied from the first and second image decoding means by first and second real-number values, respectively, and adding the results of multiplication together; and an arithmetic coding means for making arithmetic coding of the result of addition from the synthesizing means to generate the synthetic encoded code stream.
Also, the above object can be attained by providing an image synthesizing method in which an encoded code stream is synthesized by filtering first and second input images, generating code blocks each having a predetermined size via division of a sub band resulted from the filtering, generating, per code block, a bit plane including bits from a most significant bit to a least significant bit, generating a coding pass by bit modeling of each bit plane, making input of first and second encoded code streams generated by making arithmetic coding within the coding pass, and combining the first and second encoded code streams to generate the synthetic encoded code stream, the method including, according to the present invention, first and second image decoding steps each including the steps of analyzing the first and second encoded code streams, extracting code block information on the basis of the result of analysis from the code stream analyzing means; and making arithmetic decoding of the code block information; a synthesizing step of multiplying a coefficient value for each of the code blocks supplied from the first and second image decoding means by first and second real-number values, respectively, and adding the results of multiplication together; and an arithmetic coding step of making arithmetic coding of the result of addition from the synthesizing means to generate the synthetic encoded code stream.
In the above image synthesizing apparatus and method, two code streams encoded according to the MPEG-2000 Standard for example, are combined together to generate the synthetic encoded code stream, which synthesis being effected in a coefficient domain, not in any spatial domain. Thus, the present invention permits to provide the same result as that of the synthesis in a spatial domain only by utilizing a part of an image decoder and encoder, that comply with the MPEG-2000 Standard, and with a smaller sharing of the memory capacity than in the synthesis in the spatial domain.
These objects and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 explains the concept of a conventional cross-fading technique;
FIG. 2 is a schematic block diagram of a conventional image synthesizer in which the conventional cross-fading technique shown in FIG. 1 is adopted;
FIG. 3 explains subbands in wavelet transform down to a second level;
FIG. 4 explains the relation between code blocks and subbands;
FIG. 5 explains a bit plane, in which FIG. 5A shows a quantization coefficient consisting of 16 coefficients in total, FIG. 5B shows a bit plane of the absolute values of the coefficient, and FIG. 5C shows a bit plane of codes;
FIG. 6 explains a procedure of processing a coding pass in the code block;
FIG. 7 explains a procedure of scanning the coefficients in the code block;
FIG. 8 is a schematic block diagram of an image synthesizer as an embodiment of the present invention;
FIG. 9 shows an example of a cross-faded image when α=0.2;
FIG. 10 shows an example of a cross-faded image when α=0.5; and
FIG. 11 shows an example of a cross-faded image when α=0.8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in detail below concerning an embodiment thereof with reference to the accompanying drawings. Prior to starting the description of the present invention, however, there will be described a conventional technique of generating a cross-faded image by combining two images and a conventional image synthesizer in which the conventional technique is applied for synthesis of images encoded according to the MPEG-2000 Standard.
Conventionally, a cross-faded image G(x, y, t) is generated from an image F 1 (x, y, t) and image F 2 (x, y, t) via linear interpolation of samples existent in identical positions in different frames at the same time. The cross-faded image G(x, y, t) is represented as given by the following formula (1):
G ( x, y, t )=α( t )× F 1 ( x, y, t )+(1−α(t ))× F 2 ( x, y, t ) (1)
where x and y indicate horizontal and vertical coordinates of an image and t indicates the time.
For application of the conventional technique for synthesis of images encoded according to the MPEG-2000 Standard, there is used an image synthesizer, generally indicated with a reference 100 in FIG. 2 for example. As shown, the image synthesizer 100 is supplied with code streams D 100 and D 101 encoded according to the MPEG-2000 Standard, and makes cross fading of the code streams D 100 and D 101 to provide an encoded code stream D 115 , having thus undergone the cross fading.
In the image synthesizer 100 , an EBCOT (embedded coding with optimized truncation) decoder 101 decodes the encoded code stream D 100 to generate a quantization coefficient D 102 , and supplies it to a dequantizer 103 . This dequantizer 103 dequantizes the quantization coefficient D 102 to generate a wavelet transform coefficient D 104 , and supplies it to a wavelet inverse-transformer 105 . The wavelet inverse-transformer 105 makes wavelet inverse-transform of the wavelet transform coefficient D 104 to generate a decoded image D 106 , and supplies it to and a cross-fading unit 107 .
Similarly, an EBCTO decoder 102 decodes the encoded code stream D 101 to generate a quantization coefficient D 103 , and supplies it to a dequantizer 104 . The dequantizer 104 dequantizes the quantization coefficient D 103 to generate a wavelength transform coefficient D 105 , and supplies it to a wavelet inverse-transformer 106 . The wavelet inverse-transformer 106 makes wavelet inverse-transform of the wavelet transform coefficient D 105 to generate a decoded image D 107 , and supplies it to the cross-fading unit 107 .
The cross-fading unit 107 includes multipliers 108 and 109 and an adder 110 . Making a calculation as given by the formula (1), the cross-fading unit 107 generates a cross-faded image D 110 . The multiplier 108 multiplies the decoded image D 106 by a coefficient α(t), while the multiplier 109 multiplies the decoded image D 107 by a coefficient (1−α(t)). Then, the adder 110 is supplied with images D 108 and D 109 from the multipliers 108 and 109 , respectively, adds them together to provide a cross-faded image D 110 , and supplies the cross-faded image D 110 to a wavelet transformer 111 . It should be noted that the decoded images D 106 and D 107 and the cross-faded image D 110 correspond to F 1 (x, y, t), F 2 (x, y, t) and G(x, y, t), respectively, in the above formula (1).
With the above operations, the cross-faded image D 110 is generated from the input encoded code streams D 100 and D 101 . In a system downstream of the system down to the wavelet inverse-transformer 111 , the cross-faded image D 110 is encoded according to the MPEG-2000 Standard to generate an encoded code stream D 115 .
The wavelet transformer 111 is normally a filter bank including a low-pass filter and a high-pass filter. It should be noted that a digital filter has to be pre-buffered with a sufficient amount of input images for filtering since it normally shows an impulse response (filter factor) for a plurality of tap lengths. However, no digital filter is illustrated in FIG. 2 because its configuration is simple.
The wavelet transformer 111 is supplied with a minimum necessary amount of cross-faded images D 110 for filtering and filters it for wavelet transform to generate a wavelet transform coefficient D 111 .
In the above wavelet transformation, a low-frequency component is normally repeatedly transformed as shown in FIG. 3 because majority of the image energy is concentrated to the low-frequency component. It should be noted that the level number of the wavelet transform in FIG. 3 is 2 (two), and thus a total of seven subbands is generated. More specifically, the horizontal size X_SIZE and vertical size Y_SIZE are halved by a first filtering to provide four subbands LL 1 , LH 2 , HL 2 and HH 2 . The subband LL 1 is quartered by a second filtering to provide four subbands LL 0 , LH 1 , HL 1 and HH 1 . It should be noted that in FIG. 3 , “L” and “H” indicate a low-frequency band and high-frequency band, respectively, and numbers suffixed to “L” and “H”, respectively, indicate resolution levels, respectively. That is, “LH1”, for example, indicates a subband having a resolution level of 1 (one) in which a low-frequency band extends horizontally while a high-frequency band extends vertically.
The synthesizer 100 further includes a quantizer 112 that makes irreversible compression of the wavelet transform coefficient D 111 supplied from the wavelet transformer 111 . This quantizer 112 may adopt a scalar quantization to divide the wavelet transform coefficient D 111 by a quantization step size.
Also, the synthesizer 100 includes an EBCOT encoder 113 that makes an entropy coding, defined in the JPEG-2000 Standard and called “EBCOT”, of the quantization coefficient D 112 for each of the subbands generated by the quantizer 112 to generate an arithmetic code D 113 . The EBCOT encoder 113 encodes the quantization coefficient D 112 for each of the aforementioned code blocks. It should be noted that the EBCOT (embedded coding with optimized truncation) is described in detail in “ISO/IEC FDIS 15444-1, JPEG-2000 Part-1 FDIS, 18 Aug., 2000” and the like.
More particularly, the EBCOT encoder 113 first divides the quantization coefficient D 112 for each of the subbands generated by the quantizer 112 into code blocks that are units of coding defined in the JPEG-2000 Standard. Namely, code blocks each having a size of about 64×64 are generated in each of the subbands after thus divided as shown in FIG. 4 . It should be noted that the JPEG-2000 Standard defines that the size of a code block is expressed by a power of 2 both horizontally and vertically and that a size of 32×32 or 64×64 is normally used in many cases.
Then, the EBCOT encoder 113 makes, for each bit plane, coefficient bit modeling of the quantization coefficient for each code block as will be described below. The concept of this bit plane will be described below with reference to FIG. 5 . FIG. 5A shows an assumed quantization coefficient including a total of 16 coefficients (=4 vertical coefficients by 4 horizontal coefficients). The largest absolute-value one of these 16 quantization coefficients is 13 (thirteen) that is binary-notated as “1101”. Therefore, the bit planes defined by the coefficient absolute-values include four as shown in FIG. 5B . It should be noted that all elements in each bit plane take a number 0 (zero) or 1 (one). On the other hand, the only one of the quantization coefficients which has a negative sign is “−6”, while all the other quantization coefficients are 0 (zero) and positive-signed ones. Therefore, the bit plane of signs is as shown in FIG. 5C .
Each of the code blocks is encoded per bit plane independently in a direction from the most significant bit (MSB) to least significant bit (LSB). A quantization coefficient is expressed by a signed binary number of n bits, and bit 0 to bit (n-2) represent the bits, respectively, included between LSB and MSB. It should be noted that the remaining one bit is a sign. The code blocks are sequentially encoded starting with the MSB-side bit plane via three types of coding passes as shown below:
(a) Significant propagation pass (also called SP pass)
(b) Magnitude refinement pass (also called MR pass)
(c) Clean-up pass (also called CU pass)
The three types of coding passes are used in a sequence as shown in FIG. 6 . As shown in FIG. 6 , a bit plane (n−2) at the MSB side is first encoded via the CU pass. Next, bit planes are sequentially encoded toward the LSB side. The bit planes are encoded via the SP pass, MR pass and CU pass in this order.
Actually, however, it is written in a header in which bit plane counted from the MSB there will appear “1”, and all-zero bit planes will not be encoded. The three types of coding passes are repeatedly used in this order to encode the bit planes, and the encoding is ceased after an arbitrary bit plane is encoded via an arbitrary one of the coding passes. Thereby, a tradeoff can be made between the bit rate and image quality, namely, the bit rate can be controlled.
The coefficients are scanned as will be described below with reference to FIG. 7 . The code blocks are grouped at each height of four coefficients into a stripe. The stripe is as wide as the width of the code block. The “scanning sequence” means a sequence in which all coefficients in one code block are scanned. In a code block, the coefficients are scanned in a sequence from the upper to lower stripe. In each stripe, the coefficients are scanned in a sequence from the left to right row. In each of the rows, the coefficients are scanned in a sequence from the top to bottom. It should be noted that in each coding pass, all the coefficients in a code block are scanned in these sequences of scanning.
As above, the EBCOT encoder 113 decomposes the quantization coefficient in each code block into bit planes, each of the bit planes into three coding passes, and generates a quantization coefficient for each of the coding passes. Then, the EBCOT encoder 113 makes arithmetic coding of the quantization coefficient for each coding pass.
The image synthesizer 100 further includes a rate controller 114 that controls the bit rate to approximate a target bit rate or compression ratio while counting the amount of the arithmetic codes D 113 supplied from the EBCOT encoder 113 . More specifically, the rate controller 114 controls the bit rate by truncating at least a part of the coding pass for each code block.
The image synthesizer 100 also includes a code stream generator 115 that packetizes the rate-controlled arithmetic code D 114 supplied from the rate controller 114 according to the JPEG-2000 Standard, and adds a header to the packet to provide a final encoded code stream D 115 .
As above, in the image synthesizer 100 , the two encoded code streams encoded according to the MPEG-2000 Standard, are supplied for cross fading. When outputting the encoded code streams after cross fading, two images are combined in a spatial domain to generate a cross-faded image, then the cross-faded image is encoded to generate a cross-faded encoded code stream.
For the image synthesizer 100 configured as above, however, there should be used a memory to store the two decoded images and also a memory to store the cross-faded image. Also, the image synthesizer 100 needs an image decoder and image encoder, both complying with the JPEG-2000 Standard.
The image synthesizer according an embodiment of the present invention makes cross fading in the coefficient domain, not in the spatial domain, to overcome the above-mentioned drawbacks of the conventional image synthesizer. This will be explained herebelow.
Referring now to FIG. 8 , there is schematically illustrated in the form of a block diagram the image synthesizer as the embodiment of the present invention. As shown in FIG. 8 , the image synthesizer as the embodiment of the present invention is generally indicated with a reference 1 . As shown, it includes code stream analyzers 10 and 11 , code block extraction units 12 and 13 , EBCOT decoders 14 and 15 , cross-fading unit 16 , EBCOT encoder 20 , rate controller 21 , and a code stream generator 22 . The cross-fading unit 16 includes multipliers 17 and 18 and an adder 19 .
The code stream analyzer 10 is supplied with a code stream D 10 , encoded according to the JPEG-2000 Standard, and analyzes the encoded code stream D 10 with a technique defined in the MPEG-2000 Standard. The code block extraction unit 12 supplies encoded information D 14 for each code block to the EBCOT decoder 14 according to analysis information D 12 supplied from the code stream analyzer 10 . The EBCOT decoder 14 decodes the encoded information D 14 to generate a quantization coefficient D 16 for each code block, and supplies the quantization coefficient D 16 to the cross-fading unit 16 .
Similarly, the code stream analyzer 11 is supplied with a code stream D 11 , encoded according to the JPEG-2000 Standard, and analyzes the encoded code stream D 11 with a technique defined in the MPEG-2000 Standard. The code block extraction unit 13 supplies encoded information D 15 for each code block to the EBCOT decoder 15 according to analysis information D 13 supplied from the code stream analyzer 11 . The EBCOT decoder 15 decodes the encoded information D 15 to generate a quantization coefficient D 17 for each code block, and supplies the quantization coefficient D 17 to the cross-fading unit 16 .
The cross-fading unit 16 includes the multipliers 17 and 18 and adder 19 . Combining the quantization coefficients D 16 an dD 17 , the cross-fading unit 16 generates a cross-fading quantization coefficient D 20 . More specifically, on the assumption that the quantization coefficient D 16 is Q_cb1(x, y) and quantization coefficient D 17 is Q_cb2(x, y), the cross-fading unit 16 generates a cross-fading quantization coefficient using the following formula (2).
It should be noted that since Q_cb1(x, y) and Q_cb2(x, y) are assumed to be at the same time, no time t is necessary as a parameter as in the above formula (1):
G — Q ( x, y)=α(t)× Q — cb 1(x, y )+(1−α( t ))× Q — cb 2( x, y ) (2)
where x and y indicate horizontal and vertical positions, respectively, of the quantization coefficient domain.
That is, the multiplier 17 multiplies the quantization coefficient D 16 by a coefficient α(t), and multiplier 18 multiplies the quantization coefficient D 17 by a coefficient (1−α(t)). The adder 19 adds the quantization coefficients D 18 and D 19 supplied from the multipliers 17 and 18 to provide a cross-fading quantization coefficient D 20 , and supplies the cross-fading quantization coefficient D 20 to the EBCOT encoder 20 .
The EBCOT encoder 20 makes EBCOT entropy coding of the cross-fading quantization coefficient D 20 from the cross-fading unit 16 to generate an arithmetic code D 21 .
The rate controller 21 controls the bit rate to approximate a target bit rate or compression ratio while counting the amount of the arithmetic codes D 21 supplied from the EBCOT encoder 20 . More specifically, the rate controller 21 controls the bit rate by truncating at least a part of the coding pass for each code block. It should be noted that the arithmetic code D 21 may be supplied as it is to the code stream generator 22 while controlling the bit rate. In this case, the image synthesizer 1 does not need the rate controller 21 .
The code stream generator 22 packetizes the rate-controlled arithmetic code D 22 supplied from the rate controller 21 according to the JPEG-2000 Standard, and adds a header to the packet to provide a final encoded code stream D 23 .
The encoded code streams D 10 and D 11 are ones resulted from coding of an parrot image and a house-including landscape. FIGS. 9 to 11 show cross-faded images processed by the cross-fading unit 16 with α=0.2, α=0.5 and α=0.8, respectively. As seen in FIGS. 9 to 11 , the house-including landscape and parrot image appear smoothly faded. It should be noted that FIGS. 9 to 11 show images resulted from cross fading with three values of α: α=0.2, α=0.5 and α=0.8 but the smoothness of cross fading can be changed in degree by changing the ratio in time change among the values of α(t).
As having been described in the foregoing, the image synthesizer 1 as the embodiment of the present invention makes cross fading of input two code streams encoded according to the JPEG-2000 Standard to provide a cross-faded encoded code stream. The cross fading in the coefficient domain can provide the same result as that of a cross fading in the spatial domain, and uses only a part of the image decoder and encoder that comply with the JPEG-2000 Standard.
Also, the cross fading in the coefficient domain advantageously uses the memory capacity less than the cross fading in the spatial domain. In particular, since the image synthesizer 1 as the embodiment of the present invention makes cross fading for each code block, so it can make the cross fading with a rather smaller use of the memory capacity than that in the cross fading made for an entire image.
In the foregoing, the present invention has been described in detail concerning certain preferred embodiments thereof as examples with reference to the accompanying drawings. However, it should be understood by those ordinarily skilled in the art that the present invention is not limited to the embodiments but can be modified in various manners, constructed alternatively or embodied in various other forms without departing from the scope and spirit thereof as set forth and defined in the appended claims.
For example, in the aforementioned image synthesizer 1 , the image decoding means (code stream analyzer 10 , code block extraction unit 12 and EBCOT decoder 14 ) provided for decoding the encoded code stream D 10 down to the quantization coefficient D 16 , and the image decoding means (code stream analyzer 11 , code block extraction unit 13 and EBCOT decoder 15 ) provided for decoding the encoded code stream D 11 down to the quantization coefficient D 17 , may be separately provided or may be included in one image decoder. In the latter case, the image decoding can be parallelized using the technique called “pipeline processing” used in many hardware.
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In an image synthesizer ( 1 ), code stream analyzers ( 10, 11 ), code block extraction units ( 12, 13 ) and EBCOT decoders ( 14, 15 ) work together to decode encoded code streams (D 10 , D 11 ) encoded according to the MPEG-2000 Standard and generate quantization coefficients (D 16 , D 17 ) for each code block. In a cross-fading unit ( 16 ), multipliers ( 17, 18 ) multiply the quantization coefficients (D 16 , D 17 ) by coefficients (α(t), (1−α(t))) and an adder ( 19 ) adds together the results of multiplication to provide a cross-fading quantization coefficient (D 20 ). An EBCOT encoder ( 20 ), rate controller ( 21 ) and code stream generator ( 22 ) work together to encode the cross-fading quantization coefficient (D 20 ) to provide a final encoded code stream (D 23 ). Therefore, the image synthesizer ( 1 ) can combine two encoded code streams easily and effectively with a reduced use of a memory capacity.
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FIELD OF THE INVENTION
The present invention relates to a storage and dispensing container for a liquid product and at least one additional product which are separated during storage.
It is known that it may be necessary to keep separate during storage two compounds which must be dispensed and used simultaneously. This condition is imperative when the mixture or the solution of the two compounds is unstable in the long term as is the case, for instance, with certain medicinal or cosmetic preparations.
PRIOR ART
For this purpose, many embodiments of containers are already known which permit the separate storage of on the one hand a liquid product and, on the other hand, of a liquid, pulverulent or granular product and yet ensure the mixing or dissolution of these two products before they are dispensed.
In certain relatively simple devices, such as those described in French Pats. 1,350,383 and 1,559,586 and in the U.S. Pat. No. 3,156,369, a charge of a pulverulent or granular product is contained in a cartridge disposed in the neck of a bottle; this cartridge is closed at its lower portion but open at its upper portion which is surrounded by a collar bearing against the upper edge of the neck of the bottle; within this cartridge, there is engaged a tubular perforator with a chamfered lower edge which is next to the bottom of the cartridge. At its upper end, the perforator is integral with a push button which is protected by an external envelope surrounding at least a part of the bottle neck and which is held on this neck. This external envelope can be, as in the case of the two above mentioned French Patents, a metallic capsule crimped under one or more flanges of the neck and which must be removed to gain access to the push button, in order to depress the perforator axially inwardly of the bottle so that the perforator pierces the bottom of the cartridge whose charge thus drops into a liquid contained in the bottle. In certain cases, the perforator can only be depressed after removal of a shim having at least one frangible portion and disposed between the collar of the cartridge and a collar of the upper end of the perforator in order to prohibit, by virtue of its presence, any descent of the perforator. As described in the above mentioned United States Patent, the external envelope can also be a cap made of a plastic material which is screwed around a bottle neck and applies the cartridge collar in a leakproof manner against the upper edge of the neck via an internal shoulder, the upper portion of the cap having a central frangible disc which must be detached from the peripheral portion of the cap by the user's finger pressure in order to allow pressure on the button and the perforator. Because of the initial engagement of the perforator in the cartridge, the charge of the additional product contained in the cartridge cannot be kept in a leakproof compartment which can be very annoying when the additional product is physically or chemically sensitive to air, to water vapour or to the vapours of the liquid contained in the bottle. Moreover, in the opened cartridge the additional product can no longer be stored totally independently of the liquid in the bottom of tne container. Finally, the dispensing of the mixture or of the solution can only be effected through the cartridge after the perforator has been removed, or through the bottle neck after removal of the stoppering device constituted by the cartridge, the perforator and, in certain cases, any external envelope whose removal is necessary for gaining access to the perforator. In these cases, these operations necessitate specific interventions on the part of the user.
In other known embodiments, the two products are stored in a leakproof manner but the devices are relatively expensive to manufacture. U.S. Pat. Nos. 2,524,364, 2,524,365, 2,642,870, 2,653,609 and 2,659,370 describe many variants of the device comprising essentially a bottle containing a liquid and having its neck obturated by a stopper of rubber or a similar material which has at least one lower cut-out to accommodate a pellet of the additional product. The cut-out is closed on the inner side of the bottle either by a disc elastically secured or squeezed into position in the stopper, or by a lower diaphragm intended to be perforated. On the outer side of the bottle, the lower cut-out is closed by an upper diaphragm which is either extensible or intended to be perforated and which separates the lower cut-out from at least one upper cut-out of the stopper; in this upper cutout, there is engaged the lower end of an axial element whose upper end is integral with the central upper and deformable portion of a cap, also of rubber or a similar material; a lateral wall of the said cap at least partly surrounds the stopper and/or the bottle neck and is anchored by its lower portion, possibly in the form of an internal bead, either against or below a flange of the stopper which is itself tightened against or below a flange of the bottle neck or yet again fastened by a flange against a flange of the stopper by an integrity strip held under a flange of the bottle neck.
The axial element integral with the cap is either a tubular perforator which pierces the upper diaphragm and drives the disc towards the inside of the bottle and may also pierce the lower diaphragm when the upper portion of the cap is elastically driven towards the pellet which can thus fall into the bottle, or a push button which is possibly solid and may have for instance, a frustoconical shape with the small end lowermost to stretch the upper diaphragm and to drive the disc, pushing the pellet into the bottle. In view of the small diameter of the perforator, of the chamfered form of its lower end, and of the nature of the material constituting the diaphragm or diaphragms, in the embodiments provided with a perforator the holes in the diaphragm or diaphragms are generally self-obturating holes which close up again when the perforator has been elastically returned into its initial position after pressure on the upper portion of the cap has been relaxed.
As a result the mixture or the solution cannot be dispensed, even by turning the container upside down, and it is necessary to use either a hypodermic syringe which is lowered into the central duct of the perforator and into the diaphragm or diaphragms, or to remove the stoppering device comprising the stopper the cap and the perforator in order to allow the mixture to be poured out. This is all the more necessary in embodiments where the upper end of the tubular perforator does not open out to the outside of the upper portion of the cap, but instead opens at the level of a cover to be pierced for drawing off the contents of the bottle by a syringe. When the axial element is a push button, it is also necessary either to withdraw the stoppering device or to withdraw the cap and the perforator and then to pierce the stopper by means of a syringe. Whatever procedure is followed, specific manual operations by the user are necessary and the mixture is only allowed to pass via the perforator through the duct accommodating the perforator if it is withdrawn from the cap after being depressed or through the bottle neck.
In order to permit an easier dispensing of the mixture or solution by means of a device whose structure is simpler and whose manufacture is less expensive and wherein the two products are stored in a leakproof manner and independently of each other, the assignees of the applicant have already proposed a storage and dispensing container of this type in French Pat. No. 71-08902 wherein the additional product is contained in a covered pot, disposed inside the bottle neck and having one flange applied against the end edge of the neck by an internally threaded stopper cooperating with an external thread of the neck, the neck comprising in its central portion an opening for a tubular perforator which is capable of sliding translationally in relation to the stopper, over an adequate travel, for passing from a storage position opposite the cover of the pot to a second position where it perforates the cover and the bottom of the pot, the perforator being integral with a cap which is slidable on the stopper and which comprises a perforated dispenser fitting disposed as an extension of the perforator.
After the sliding of the perforator and a mixing of the product, promoted for instance by shaking, it suffices to upend the container to effect the desired dispensing by way of gravity through the fitting, or even to press and deform the pliable wall of the bottle to evacuate the mixture via the end fitting.
As all the components of such a container can be made of a moulded plastic material, it will be understood that its cost can be relatively low. However, in order to simplify the making of this device still further and to reduce its height to facilitate storage, the assignees of the applicant have proposed, in the first Certificate of Addition No. 72-02321 based on French Pat. No. 71-08902, a variant wherein the threaded button is dispensed with.
In that variant, the flange of the lateral wall of the covered part which bears on the end edge of the bottle neck, is crimped on that end, and the cap and the perforator integral therewith can slide, while being guided by at least one zone of the wall of the bott-e and the cap comprises at least one element capable of cooperating with a stop arranged on the lateral wall of the bottle so that preferably after removal of a detachable integrity strip disposed between the cap and the bottle, the cap can be rotated in relation to the bottle, abutment of a cap element on an element of the bottle (to keep the perforator removed from the part cover during storage) is eliminated and subsequently, the cap can be slid relative to the bottle to perforate the covered pot for mixing the two products.
The fact remains that in this embodiment, as in the preceding ones, the mixture is dispensed through the annular perforator. Moreover, taking into account the presence of the slender-shaped end fitting in the extension of the perforator and projecting on the top of the central portion of the cap, it is necessary to make provision in the upper portion of the cap for a large annular disc performing the function of the push element offering a sufficient bearing surface to manipulate the perforator without the user having to exert considerable force.
The object of the present invention is to provide a container of the above mentioned type wherein the two products can be stored separately in a leakproof manner and which has an economic manufacturing structure allowing the mixture to be dispensed without passing through the perforator and without it being necessary to remove the perforator, making it possible, moreover, to benefit from a perforator having a large bearing surface.
SUMMARY OF THE INVENTION
The present invention provides a new industrial product constituted by a storage and dispensing container for a liquid product and at least one other additional product, in liquid or powder form, the first mentioned liquid product being contained in a bottle whose neck is surmounted by a cap comprising a dispenser fitting, the said additional product being contained in a leakproof envelope kept poised by means of a peripheral flange on the end edge of the bottle neck, a perforator being located opposite the leakproof envelope during storage and being intended to slide in relation to the bottle over a travel sufficient to perforate two opposed portions of the leakproof envelope, characterised in that the cap fixed on the bottle comprises a central duct wherein the perforator is slidably mounted, and an eccentric duct forming the dispenser fitting. Thus, after the perforator has been depressed and the leakproof envelope perforated, said additional product is mixed with the first-mentioned liquid product in the bottle and the mixture resulting therefrom is dispensed not via the perforator but via the eccentric dispenser fitting, and there is thus enough room in the central portion of the cap for mounting a perforator with a large bearing surface. For this reason, the perforator is advantageously integral at its upper portion with a push button comprising a peripheral skirt surrounding the upper portion of the perforator, the push button sliding along the internal surface of the central duct of the cap. The bearing surface can thus be delimited on the push button whilst the perforator can retain a limited transverse cross section, which is favourable to a proper perforation of the leakproof envelope, not only by reason of the shape of the perforator cross-section but also because of the amplification of the perforation pressure in the ratio of the areas of the bearing surface and the surface of the transverse cross section of the perforator, in particular at its lower end.
In order to avoid any leakage of the mixture between the skirt of the push button and the internal surface of the central duct, when the container is upended or when the lateral wall of the bottle is pressed and deformed for dispensing the mixture via the eccentric duct, the skirt of the push button has, projecting on its external surface, at least one circular bead ensuring leakproof sliding of the skirt in the central duct.
With a view to facilitating the flow of the dispensed mixture towards the eccentric duct, whereas the perforation of the leakproof envelope to release the mixture from the bottle is effected in the central portion of the bottle neck, the lower portion of the skirt of the push button has at least one gap allowing the dispensed contents of the bottle to pass in a substantially radial direction towards the eccentric duct after the perforator has been depressed and the leakproof envelope has been perforated. For the same reason, the lower portion of the central duct has at least one gap allowing the contents of the bottle to pass in a substantially radial direction towards the eccentric duct.
In a preferred limited capacity variant of the embodiment, which is simple to make and allows a saving in the material constituting the cap, the two ducts of the cap are adjacent one another and share a common wall having at least one of the passage gaps of the lower portion of the central duct.
In order to obtain in the leakproof envelope perforations with a progressive opening and whose shape promotes the pouring of the whole of the additional product into the liquid product contained in the bottle, the perforator advantageously has a channel-shaped transverse cross-section except at its lower end which is formed by a V-shaped tip directed towards the bottom as an extension of the web of the channel.
In a simple embodiment allowing moreover separate storage of an additional product in good condition, the leakproof envelope is a thermoformed shell with a dome-shaped upper cover in its central portion and fixed in a leakproof manner via its peripheral edge to the peripheral edge of a substantially flat lower cover so that the additional product is contained in a chamber delimited between the central portions of the two covers, the thermoformed shell being disposed above the plane passing through the end edge of the bottle neck. This disposition of the thermoformed shell on the neck and not in the neck as is the case in all the embodiments of the prior art, in particular, simplifies the assembly of the container and makes it possible to utilise a larger internal volume of the bottle to accommodate the liquid product. In this case, in order to ensure leakproof storage of the liquid product in the bottle when the thermoformed shell is fitted on the neck, and before the cap is fixed, the lower cover of the thermoformed shell is heat-sealed at its peripheral edge to the end edge of the neck of the bottle. Preferably, the peripheral edge of the leakproof envelope is, moreover, applied against the end edge of the bottle neck by an internal radial shoulder of the cap.
In a simple embodiment, the lower portion of the cap has the shape of a tubular section which is fitted on the bottle neck and which has an outwardly extending recess to be elastically catch-engaged behind a laterally outwardly projecting peripheral bead around the bottle neck.
Finally, the position of the perforator in relation to the cap during storage is maintained thanks to a detachable integrity strip whose presence indicates that the container has not yet been used and which must be removed to allow the perforator to slide in relation to the cap.
BRIEF DESCRIPTION OF THE DRAWINGS
To render the invention more readily understood, one embodiment will now be described with reference to the attached drawings, by way of purely illustrative and non restrictive example. In the drawings:
FIG. 1 is an axial cross-section of a container according to the invention, comprising a central perforator sliding in a cap provided with an eccentric dispenser fitting, the container being in the storage position;
FIG. 2 is a combination, in the same plane, of two transverse cross-sectional views respectively along line b--b of the base of the push button of the perforator and along line c--c of the base of the central duct of the container of FIG. 1;
FIG. 3 is a view, along the direction of arrow III, of the perforator of the container of FIGS. 1 and 2;
FIG. 4 is a transverse cross-sectional view of the perforator along line IV--IV of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there will be seen a polyethylene bottle 1, with an upwardly dome-shaped bottom, and containing a liquid 2. Bottle 1 has a neck 3 having a laterally or radially outwardly projecting peripheral bead 4. Heat sealed against the upper end edge of neck 3, is the peripheral flange 6 of a thermoformed shell 5. This shell 5 is constituted by a bottom cover 7, substantially in the shape of a flat disc, and by a cap-shaped top cover 8 whose central portion is upwardly domed and whose peripheral flat edge is applied against the peripheral edge of the bottom cover 7. The two covers 7 and 8 thus delimit, between their central portions, a chamber 9 accommodating a pellet 10 of an additional product and, so as to store pellet 10 away from air and water vapor and the liquid 2, this chamber 9 is sealed in a leakproof manner by thermowelding or heat sealing the edges of the two covers 7 and 8 to each other, forming the flange 6 of shell 5. It is clear that manufacture of the shell 5 is advantageously effected on a separate assembly line, distinct from the production lines of the bottles 1 and the lines where the latter are filled with liquid 2, as well as from the production lines of the cap described below, and from the container assembly line.
A cap 11, also of polyethylene, is fixed on the bottle 1. The cap 11 has a lower portion shaped as a tubular section 12 whose transverse cross-sectional shape corresponds to that of the transverse cross-section of neck 3 and which is fitted on and around the neck 3 by being fitted thereon by elastic catch engagement of a recess 13 extending radially inwardly on the internal surface of section 12, under the external bead 4 of neck 3. The internal surface of the section 12 is joined to the internal surface of the rest of the cap 11 via an internal radial shoulder wherewith the peripheral flange 6 of shell 5 is held tightly against the upper end edge of neck 3 to improve the storage seal for the liquid 2 in the bottle 1 when cap 11 is in place. At its upper portion, the moulded cap 11 comprises a dispenser fitting constituted by an eccentric duct 13 and a central duct 14. The eccentric duct 13, in the shape of a long and narrow lateral tube, and the central duct 14 which is shorter but of a considerably larger internal diameter than the duct 13, are adjacent and have a common wall 15. The central duct 14, whose upper opening is contained in a circular cross-section cylindrical surface portion having a horizontal axis which, being transverse in relation to the plane of FIG. 1, and whose periphery progressively and regularly joins the periphery of the eccentric duct 13, has its open end situated a short distance above the peripheral flange 6 of the shell 5 and around the central domed portion of this shell 5 containing the pellet 10. As represented in FIG. 2, three gaps 16, each opening over an angular sector of 60° , are regularly distributed over the periphery and separated by wall portions 17 which also extend over an angular sector of 60°, are formed at the lower end of the central duct 14 and thus delimit three radial passages whereof one, situated at the lower end of common wall 15 of the two ducts 13 and 14, constitutes a radial passage between the central duct 14 and the eccentric duct 13. In the central duct 14 there is slidably mounted a push button 18, comprising a tubular skirt 19 and closed at its upper end by a horizontal actuating face 20 having a large surface. At its open lower end, as represented in FIG. 2, there are formed in the skirt 19 two gaps 21, each opening over an angular sector of 90° and separated by two wall sections 22 also each extending over an angular sector of 90°, one of the gaps 21 opening opposite the common wall 15 of the two adjacent ducts 13 and 14. The portion of the skirt 19 which is just above the gap 21 carries two radially outwardly projecting circular beads 23, axially interspaced from each other and ensuring a leakproof sliding fit for the skirt 19 of the push button 18 along the internal surface of the central duct 14. A perforator 24 moulded integrally with the push button 18 extends axially therewithin and is partially surrounded by the cap skirt 19. As shown in FIGS. 3 and 4, the perforator 24 has at its lower end a channel-shaped cross section whose web 25 and whose two vertical sides 26 are joined at their upper end to the lower surface of the push button disc 20, whilst the web 25 is extended at its lower end beyond the horizontal lower ends of sides 26 by a V shaped tip 27, constituting the perforator point of the perforator 24. As shown in FIG. 1, the point 27 and the lower ends of sides 26 are situated well below the lower end of the cap skirt 19 and the point 27 is slightly above the domed portion of the shell 5 in the storage configuration of the container. In this storage configuration the push button 18 and its perforator 24 are held in the position shown in FIG. 1 in relation to cap 11 and hence also in relation to the bottle 1. This is preferably ensured by a frangible integrity strip or tab (not shown) initially disposed between the cap skirt 19 and the internal duct 14, at the lowest height level of the duct 14, (on the right of FIG. 1), for instance, between the lower bead of the cap skirt 19 and the gap 21 on that side. In order to ensure the leakproof storage of the liquid 2 in the bottIe 1 as soon as possible when the container is assembled and to ensure a proper hold of the shell 5 in position on the neck 3, before and during the fixing of cap 11 on bottle 1, it is preferably for the shell 5 to be fixed to the neck 3 by heat sealing the peripheral flange 6 of the shell 5 on the end edge of the neck 3, thus suitably positioning the shell 5 just above the plane passing through this edge.
The device described above is used as follows: Starting from the storage configuration of FIG. 1, the user tears off the detachable integrity tab which holds the push button 18 in position in relation to the cap 11. Then he or she presses on the push button disc 20 to drive down the push button 18 and the perforator 24 in the central duct 14 towards the shell 5. First of all the point 27 of the perforator first comes into contact with the top cover 8 and perforates it, then it passes through the pellet 10 and subsequently perforates the lower cover 7, thanks to its V-shaped form. The holes thus formed in the covers 8 and 7 progressively open out, and then the passage of the lower ends 26 causes slits substantially perpendicular to the holes, to form substantially rectangular openings of a relatively large area in the covers 8 and 7, these large openings allowing the additional product 10 to drop into the liquid 2. When the push button 18 has been depressed as far as possible, the wall portions 22 of the lower end of the skirt 19 abut against a small internal flange 28 of the wall portions 17 at the base of the central duct 14. In this position, one of the gaps 21 of the skirt 19 is in register with the gap 16 in the base of the common wall 15. Since the shell 5 has been pierced the interior of the eccentric duct 13, which is already open at its upper end, communicates with the interior of bottle 1 by way of the gaps 16 and 21 and by way of the openings in the shell 5. When the bottle 1 is upended, or when it is squeezed and deformed, its contents 1 flow out to the eccentric duct 13 and can thus be dispensed towards the outside.
It is clear that all the container components may be made of a moulded plastic material so that its cost can be low, especially since the assembly of the various components is easy and, during its production, storage of the liquid product in the bottle and of the additional product contained in the leakproof shell 5 can be easily stored separately from one another.
It shall be duly understood that the embodiment described above is in no way restrictive, and can give rise to any desirable modification without thereby departing from the spirit and scope of the invention.
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A container comprises a bottle for a liquid product and having at the end of its neck a leakproof envelope enclosing an additional product to be stored separately from the liquid in the bottle. A cap on the neck includes a slidable push button carrying a perforator to open the envelope in a central region of the envelope to allow the additional product to mix with the liquid and then to be discharged through an eccentric duct in the cap rather than having to pass through the center of the cap where the perforator is positioned.
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CROSS-REFERENCE TO PRIOR APPLICATIONS
This is a continuation patent application which claims priority to U.S. patent application Ser. No. 11/504,404, filed Aug. 15, 2006.
BACKGROUND OF THE INVENTION
This invention relates generally to equipment used in producing fluid from a well and more particularly concerns tools to enhance the operation of downhole reciprocating pumps.
U.S. Pat. No. 6,068,052, issued to the present inventor on May 30, 2000, explains the common practice and problems of “tapping” and discloses a no tap tool for downhole reciprocating pumps. That tool eliminates the need for “tapping” in the operation of a downhole pump, reduces the unidirectional application of force to the plunger of a downhole pump and allows the plunger to take the path of least resistance to overcome a “stuck” condition.
The tool is connectable between the last sucker rod of the sucker rod string and the downhole pump. A cylinder with a closed end and an internal annular seat proximate an open end houses a piston which reciprocates slidably within the cylinder and is free to rotate within the cylinder. The tool components are concentric about the longitudinal axis of the tool, so the tool components are independently free to rotate about the tool axis, allowing the plunger of the pump to rotate to the path of least resistance to achieve its freedom, thereby further reducing the forces exerted on the system components.
The freedom of the tool components to independently rotate is one of the keys to the success of this “old” tool. However, because of this freedom of the tool components to independently rotate, use of the tool in the string renders the tool and any of the equipment downhole of the tool irretrievable without retrieval of all of the equipment downhole of the tool.
It is, therefore, an object of this invention to provide a no tap tool which affords the benefits of the “old” tool. To this end, it is also an object of this invention to provide a no tap tool which utilizes independently rotating components. But, it is a further object of this invention to provide a no tap tool which does not prevent retrieval of equipment downhole of the tool.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a diametric cross section of a preferred embodiment of the no-tap tool;
FIG. 2 is an elevation view of the upper portion of the piston of the tool of FIG. 1 ;
FIG. 3 is a cross-sectional view taken along the line 3 - 3 of FIG. 1 ;
FIG. 4 is a cross-sectional view taken along the line 4 - 4 of FIG. 1 ; and
FIG. 5 is a cross-sectional view taken along the line 5 - 5 of FIG. 1 .
While the invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
SUMMARY OF THE INVENTION
In accordance with the invention, a tool is provided for connection between the last sucker rod of a sucker rod string and a downhole pump. A circular cylinder has a closed upper end which is externally adapted for connection to the last sucker rod of the sucker rod string. A circular cylindrical piston slides reciprocally and rotates freely within the cylinder. The piston has a lower portion which extends through an open lower end of the cylinder and is adapted for connection to the pump. The closed upper end of the cylinder and the upper face of the piston have a cooperable tongue and groove which prevent relative rotational motion of the piston in the cylinder when the tongue is engaged in the groove. Preferably, the tongue and groove are of rectangular cross section, are diametric in relation to the cylinder and piston and the groove is sufficiently wider than the tongue to facilitate their engagement.
In a preferred embodiment, the cylinder is concentric about a vertical longitudinal axis and has an internally threaded upper portion, a smooth middle portion and a lower portion of inner diameter less than the inner diameter of the middle portion so as to form an annular seat at a junction of the cylinder middle and lower portions. The piston is a plunger which is concentric about the vertical longitudinal axis and has an externally threaded lower portion adapted to be coupled to the pump, a smooth middle portion and a smooth upper portion with a horizontal end face and an outer diameter greater than an outer diameter of the middle portion so as to form an annular stop at a junction of the plunger middle and upper portions. The plunger upper portion slides reciprocally and rotates within the cylinder middle portion and the stop and seat are cooperable to limit the lowermost travel of the plunger upper portion within the cylinder. A pin concentric about the vertical longitudinal axis has an externally threaded lower portion with a horizontal end face engaged in the internally threaded upper portion of the cylinder, a middle portion of outer diameter greater than an inner diameter of the plunger so as to position the pin end face at the top of the cylinder middle portion when the pin lower portion is fully threaded into the cylinder upper portion and an externally threaded upper portion adapted for engagement with the last sucker rod of the sucker rod string. The pin and plunger end faces are cooperable to limit the uppermost travel of the plunger upper portion within the cylinder with the plunger lower portion extending below the cylinder lower portion. The horizontal end face of the pin has a diametric groove therein and the plunger upper portion horizontal end face has a diametric tongue thereon. The tongue and groove are cooperable to disconnect the tool from the pump in response to rotation of the string to engage and turn the tongue and groove at the uppermost stroke of the plunger.
DETAILED DESCRIPTION
Turning to FIGS. 1 through 5 , the tool consists of a cylinder 30 , a piston or plunger 50 and a pin 70 , all concentrically aligned on a vertical longitudinal axis 27 .
In the preferred embodiment shown, the cylinder 30 has an internally threaded upper portion 31 , a smooth middle portion 33 and a lower portion 35 . The lower portion 35 has an inner diameter less than the inner diameter of the middle portion 33 so as to define an internal annular seat 37 at the junction of the middle and lower portions 33 and 35 of the cylinder 30 . At least one aperture 41 is provided through the upper side wall of the middle portion 33 of the cylinder 30 , preferably substantially immediately below the top of the middle portion 33 of the cylinder 30 . At least one aperture 43 is also provided through the lower side wall of the middle portion 33 of the cylinder 30 , preferably substantially immediately above the internal seat 37 . Preferably, four upper apertures 41 and four lower apertures 43 will be substantially equally spaced about the circumference of the cylinder 30 .
The piston or plunger 50 has a smooth upper portion 51 , a smooth middle portion 53 and an externally threaded lower portion 55 . The outer diameter of the middle portion 53 is less than the outer diameter of the upper portion 51 , thus providing a stop 57 which cooperates with the seat 37 of the cylinder 30 to limit the lowermost travel of the downstroke of the piston 50 within the cylinder 30 . The length of the middle portion 53 of the piston 50 is such that the upper portion 51 of the piston 50 can reciprocate from the top to the bottom of the middle portion 33 of the cylinder 30 with the lower threaded portion 55 of the piston 50 extending below the bottom of the cylinder 30 . Since the components of the cylinder 30 and the components of the piston 50 are all concentric, the piston 50 may be slidably reciprocated along the tool axis 27 and is also free to rotate within the cylinder 30 about the tool axis 27 . As shown, the middle portion 53 of the piston 50 is provided with tooling flats 61 .
As best seen in FIGS. 1 and 2 , a diametric tongue 63 extends upwardly from the upper face 59 of the piston 50 . The tongue 63 shown is, looking at FIG. 1 , rectangular in cross-section, but is most easily formed by use of a rotating cutter so that the upper face 59 of the piston 50 is, looking at FIG. 2 , arcuate. Other cross-sections and machining methods may be used, however, and the upper face 59 of the piston 50 may be in a horizontal plane. The upper face 65 of the tongue 63 is, preferably, in a horizontal plane, as is hereafter explained.
The pin 70 has an externally threaded lower portion 71 which engages within the internal threads of the upper portion 31 of the cylinder 30 . The middle portion 73 of the pin 70 has an outer diameter which is greater than the inner diameter of the upper portion 31 of the cylinder 30 so that, when the pin 70 is fully threaded into the cylinder 30 , the middle portion 73 of the pin engages the upper end of the cylinder 30 and sets the horizontal lower face 75 of the pin 70 at the junction of the upper and middle portions 31 and 33 of the cylinder 30 . The upper portion 77 of the pin 70 is externally threaded for engagement with a polish rod coupling at the lowermost end of the sucker rod string. The pin 70 closes the upper end of the cylinder 30 and the lower horizontal face 75 of the pin 70 is cooperable with the upper face 59 of the piston to limit the uppermost travel of the piston 50 within the cylinder 30 . As shown, the middle portion 73 of the pin 70 is provided with tooling flats 81 .
As best seen in FIGS. 1 and 5 , a diametric groove 83 extends upwardly into the lower horizontal face 75 of the threaded lower portion of the pin 70 . The groove 83 in the pin 70 is wider than the tongue 63 of the piston 50 . The difference should be sufficient to facilitate engagement of the tongue 63 in the groove 83 even if the tongue 63 is slightly flared or debris may have collected in the path of engagement.
In operation, the tool is mounted between the lowermost sucker rod and the pump. The stroke of the plunger in the pump is set so that the plunger does not strike the pump at the bottom of its stroke. However, during the reciprocation of the sucker rod string, as the cylinder 30 is reciprocated, the upper face 65 of the tongue 63 of the piston 50 strikes the lower face 75 of the pin 70 and the stop 57 of the piston 50 strikes the seat 37 in the cylinder 30 , resulting in cyclical upward and downward impact on the pump plunger without impacting the pump. At the same time, the piston 50 and therefore the plunger which is attached to it, are free to rotate about the tool longitudinal axis 27 , thus allowing the plunger to take the path of least resistance and resulting in minimal force being exerted on the other system components while the plunger is freed from a stuck condition.
Since the piston 50 is free to rotate in the cylinder 30 , it is possible but relatively uncommon that the piston tongue 63 will align with the groove 83 in the pin 70 during normal operation of the tool. Generally, the upper horizontal face 65 of the tongue 63 will strike the lower horizontal face 75 of the pin 70 . However, even if this rare event should occur, the minimal duration of any penetration of the tongue 63 into the groove 83 will have no substantial effect on the freedom of rotation during normal operation. The tool is presented as seen in FIG. 1 to illustrate the intentional alignment of the tongue 63 and groove 83 so that the tool can be disengaged from the downhole equipment for retrieval of the tool without the equipment. This is accomplished by an intentional rotation of the string and, therefore, the tool pin 70 at the top of the stroke. As the groove 83 rotates it comes into alignment with the tongue 63 and the upward inertia of the tongue 63 causes it to engage in the groove 83 and turn the tool. The opposite rotation of the string can be used as a tool is lowered to engage the tongue 63 and groove 83 and permit connection of the tool to downhole equipment.
While, in the preferred embodiment, the piston 50 extends through the open lower end of the cylinder 30 , the tool could be inverted and the piston 50 adapted for connection to the sucker rod string and the pin 70 adapted for connection to the pump.
Thus, it is apparent that there has been provided, in accordance with the invention, a no-tap tool that fully satisfies the objects, 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 and in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit of the appended claims.
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A tool which connects the last sucker rod of a sucker rod string to a downhole pump has a circularly cylindrical cylinder and piston so that the piston slides reciprocally and rotates freely within the cylinder. However, the closed upper end of the cylinder and the upper face of the piston have a cooperable tongue and groove which prevent relative rotational motion of the piston in the cylinder when the tongue is engaged in the groove so that the tool can be disconnected from the pump in response to rotation of the string at the uppermost stroke of the plunger to engage and turn the tongue and groove.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to new liquid-crystal compounds and to liquid crystal compositions containing the same, particularly smectic liquid crystal compositions.
The liquid-crystal compounds herein include those compounds which are useful as a component of liquid crystal compositions even though they do not exist in the form of liquid crystal.
(2) Description of the Related Art
Twisted nematic (TN) and dynamic scatter (DS) types, both employing nematic liquid crystal cells, are the modes of liquid-crystal display most extensively used at present. One disadvantage of conventional nematic liquid crystal cells is low response speeds (on the order of milliseconds at the highest), which limit the use of this type of liquid crystal cells.
It has recently been found that higher response speeds can be achieved by smectic liquid crystal cells and that some of optically active smectic compounds are ferroelectric. The ferroelectric liquid crystals are a group of compounds which are ferroelectric when they exist as chiral smectic C (hereinafter abbreviated as "SmC*") phase and are typified by 2-methylbutyl 4-(4-n-decyloxybenzylideneamino)cinnamate (hereinafter abbreviated as "DOBAMBC") of the following structural formula [J. Physique, 39, L-69 (1975)], ##STR2##
More recently N. A. Clark et al. [Appl. Phys. Lett., 36, 89 (1980)] found that very high response speeds on the order of microseconds can be achieved by thin-film DOBAMBC cells. Since then ferroelectric liquid crystals have been receiving attention not only as a material for display in liquid-crystal TV sets, but also as an element for optoelectronics devices (e.g., photo printer heads, optical Fourier transformation elements, and light valves).
DOBAMBC remains ferroelectric only within a relatively narrow temperature range, and is unsatisfactory in physical and chemical stability because it is a Schiff base. Hence there has been a great demand for new ferroelectric compounds which are stable both physically and chemically, remain ferroelectric over a wide temperature range, have large dielectric constant, and can be driven at a low voltage.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a stable smectic liquid crystal compound which possess a large spontaneous polarization about room temperature and a liquid crystal composition containing said liquid crystal compound.
Briefly, this object and other objects of the invention as hereinafter will become readily apparent can be attained by a liquid crystal of the formula (1): ##STR3## wherein R 1 represents C 1-18 alkyl group, R 2 represents straight or branched alkyl group or aralkyl group with or without optically active carbon, X represents a group selected from --OCOO--, --O--, --COO--, --OCO-- or single bond, Y represents a group selected from --COOCH 2 --, --OCO-- or --OCOO--, in which either X or Y is at least --OCOO-- group, m represents 0 or 1, Z represents a chlorine or bromine, a carbon atom marked with * represents optically active carbon atom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the graphical representation of the relationship between the temperatures and the dielectric constant values of embodiments of the liquid crystal compound of the present invention, (2R,3S)-2-chloro-3-methyl-pentanoic acid-4'-(4"-octyloxycarbonyloxyphenyl) phenyl ester.
FIGS. 2 and 3 show infrared spectra of the crystal compound of the present invention, (2R,3S)-2-chloro-3-methylpentanoic acid-4'-(4"-octyloxycarbonyloxyphenyl) phenyl ester and (2S,3S)-4-(4'-octylcarbonyloxyphenyl)phenyl-2-chloro-3-methylpentyloxycarboxylic acid ester.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention, smectic liquid crystal compounds having C 6-14 of R 1 represented by supra general formula (1) is defined especially as a compound which shows a smectic C phase or any smectic phase under appropriate conditions.
The compounds of this invention show ferroelectricity. In addition, these compounds may be combined with a substance which is not ferroelectric, thereby lowering the ferroelectric temperature range without affecting the ferroelectric characteristics.
The compounds of this invention that are optically active may also be added to nematic liquid-crystal compound for White-Tayler type color display, for display of cholesteric/nematic conversion type, and to prevent formation of reversed domain in TN type cells.
It is also possible to use the compounds of the invention, which are smectic liquid-crystal compounds, as memory-type display element for thermal and laser writing.
As mentioned supra, many ferroelectric liquid crystals are known, but a ferroelectric liquid crystal (2R,3S)-2-chloro-3-methylpentanoic acid-4'-(4"-octyloxycarbonyloxyphenyl)phenyl ester, which shows chemical stability, a large spontaneous polarization up to 236 nC/cm 2 and good enantiomerism, was not yet known.
One of the compound of formula (2) can be presented according to the following steps, (a) or (b): ##STR4## wherein R 1 represents C 1-18 alkyl group, R 2 represents straight or branched alkyl group or aralkyl group with or without optically active carbon, Z represents a chlorine or bromine, a carbon atom marked with * represents optically active carbon atom,
(a-1) reacting of alkoxycarbonic chloride with 4,4'-biphenol,
(a-2) dehydration of 4-alkyloxycarbonyloxyphenyl phenol and alkylcarboxylic acid halide in nonactive solvents such as carbontetra chloride by using a dehydrating agent such as dicyclohexylcarbodiimide, or
(b) reacting of halogen-alkylcarboxylic acid chloride and 4-alkyloxycarbonyloxyphenyl phenol in basic solvent such as pyridine.
Further one of the compound of formula (3) can be presented according to the following steps (c): ##STR5## wherein R 1 represents C 1-18 alkyl group, R 2 represents straight or branched alkyl group or aralkyl group with or without optically active carbon, Z represents a chlorine or bromine, a carbon atom marked with * represents optically active carbon atom.
(c-1) Alkoxycarboxylic acid chloride was reacted with 4,4'-hydroxybiphenylcarboxylic acid to obtain alkoxycarbonyloxyphenylbenzoic acid.
(c-2) Then the obtained compound was reacted with thionyl chloride to obtain acid chloride.
(c-3) Acid chloride reacted with alcoholic halide in pyridine solvent to obtain the compound of formula (3).
Optically active groups represented by Y(CH 2 ) m CH(Z)R 2 in the above-mentioned general formula (1) are useful especially for ferroelectronic liquid crystal composition. The optically active groups are easily derived from, for example, the following optically active alcohols or optically active carboxylic acids;
2-methylbutanol, 3-methylpentanol, 4-methylhexanol, 2-butanol, 2-pentanol, 2-hexanol, 2-heptanol, 3-hexanol, 2-octanol, 1-phenylethanol, p-(2-methylbutyl)phenol, linalool, narolidol, carbeol, cholesterol, 2-halo-2-phenylethanol, 2-phenyl-3-halo-1-propanol, 3-phenyl-2-halo-1-propanol, 1-phenyl-2-halo-1-propanol, 3-halo-2-methyl-1-propanol, 1,1,1-trihalo-2-propanol-2-halo-1-butanol, 3-halo-1-butanol, 2,3-dihalo-1-butanol, 2,4-dihalo-1-butanol, 3,4-dihalo-1-butanol, 1,1,1-trihalo-2-butanol, 4,4,4-trihalo-3-halo-1-butanol, 2,3,4-trihalo-1-butanol, 3,3,4,4,4-pentahalo-2-butanol, 2-halo-3-methyl-1-butanol, 2-halo-3,3-dimethyl-1-butanol, 2-halo-1-pentanol, 3-halo-1-pentanol, 4-halo-1-pentanol, 2,4-dihalo-1-pentanol, 2,5-dihalo-1-pentanol, 1,1,1-trihalo-2-pentanol, 1,1,1,2,2-pentahalo-3-pentanol, 2-halo-3-methyl-1-pentanol, 2-halo-4-methyl-1-pentanol, 2-halo-3-monohalomethyl-4-methyl-1-pentanol, 2-halo-1-hexanol, 3-halo-1-hexanol, 4-halo-1-hexanol, 5-halo-1-hexanol, 2,5-dihalo-1-hexanol, 2,6-dihalo-1-hexanol, 1,1,1-trihalo-2-hexanol, 2,5,6-trihalo-1-hexanol, 2-halo-1-heptanol, 1,1,1-trihalo-2-heptanol, 2-halo-1-octanol, 1,1,1-trihalo-2-octanol.
2-halo-2-phenylethanoic acid, 3-halo-2-methylpropanoic acid, 2-phenyl-3-halopropanoic acid, 3-phenyl-2-methylpropanoic acid, 2-phenyl-3-halopropanoic acid, 2-halobutanoic acid, 3-halobutanoic acid, 2,3-dihalobutanoic acid, 2,4-dihalobutanoic acid, 3,4-dihalobutanoic acid, 4,4,4-trihalo-3-halobutanoic acid, 2,3,4-trihalobutanoic acid, 2-halo-3-methylbutanoic acid, 2-halo-3,3-dimethylbutanoic acid, 2-halopentanoic acid, 3-halopentanoic acid, 4-halopentanoic acid, 2,4-dihalopentanoic acid, 2,5-dihalopentanoic acid, 2-halo-4-methylpentanoic acid, 2-halo-3-methylpentanoic acid, 2-halo-3-monohalomethyl-4-methylpentanoic acid, 2-halohexanoic acid, 3-halohexanoic acid, 4-halohexanoic acid, 5-halohexanoic acid, 2,5-dihalohexanoic acid, 2,6-dihalohexanoic acid, 2,5,6-trihalohexanoic acid, 2-haloheptanoic acid, 2-halooctanoic acid, 2-phenylpropanoic acid, 2-phenylbutanoic acid, 3-phenyl-2-methylpropanoic acid, 2-methylbutanoic acid, 2,3-dimethylbutanoic acid, 2,3,3-trimethylbutanoic acid, 2-methylpentanoic acid, 3-methylpentanoic acid, 2,3-dimethylpentanoic acid, 2,4-dimethylpentanoic acid, 2,3,3,4-tetramethylpentanoic acid, 2-methylhexanoic acid, 3-methylhexanoic acid, 4-methylhexanoic acid, 2,5-dimethylhexanoic acid, 2-methylheptanoic acid, 2-methyloctanoic acid, 2-trihalomethylpentanoic acid, 2-trihalomethylhexanoic acid, 2-trihalomethylheptanoic acid (wherein halo represents chlorine, bromine and iodine).
Some of the optically active alcohols just mentioned can be easily prepared by asymmetric reduction ketones with metal catalyst, microorganisms or enzyme. Some other optically active alcohols may be derived from optically active amino acids or oxy acids which are found in nature or obtainable by optical resolution. And some of the optically active carboxylic acid just mentioned can be prepared by oxidation of alcohol or de-amination of alcohol. Some other optically active carboxylic acids may be derived from optically active amino acids or optically active oxy acid which are found in nature or obtainable by optically resolution such as alanine, valine, leucine, isoleucine, phenylalanine, serine, threonine, allo-threonine, homoserine, allo-isoleucine, tert-leucine, 2-aminobutyric acid, norvaline, norleucine, ornitine, lysine, hydroxylysine, phenylglycine, trifluoalanine, aspartic acid, glutanic acid, lactic acid, mandelic acid, tropic acid, 3-hydroxybutyric acid, malic acid, tartaric acid and isopropylmalic acid.
Examples
The following Examples further illustrate this invention but are not intended to limit its scope.
The phase transition temperature values in the following description may be varied slightly in dependence on the method of measurements or the purity of the products.
Hereinafter following words are abbreviated as in (); crystal (C), chiral smectic C (SC*), chiral smectic I phase (SI), nondetected chiral smectic phase (SX), smectic A (SA), chiral smectic F (F*), chiral nematic (N*), isotropic phase (I) and carbon atom marked with * shows an asymmetric carbon atom.
EXAMPLE 1
Preparation and properties of (2R,3S)-2-chloro-3-methylpentanoic acid-4'-(4"-octyloxycarbonyloxyphenyl)phenyl ester (A) ##STR6##
Forty seven grams of 4,4'-biphenol were dissolved with 20 ml of pyridine. 25 ml of octyloxycarboxylic acid chloride were added in the solution with stirring, after 2 hours; the mixture was neutralized with hydrogen chloride. Then crude 4-(4'-octyloxycarbonyloxyphenyl)phenol was extracted with chloroform from the neutral solution. The crude compounds were purified by passing through silica-gel column.
One gram of 4-(4'-octyloxycarbonyloxyphenyl)phenol, 0.7 g of dicyclohexylcarbodiimide, 0.5 g of (2R,3S)-2-chloro-3-methylpentanoic acid and 4-pyrrolidinopyridine as catalyzer were all dissolved with 60 ml of carbon tetrachloride and allowed to stand for overnight. Then the crystals and solvent were removed, the residue were purified by passing through silica-gel column and then recrystallized with hexane to obtain 1 g of the compound (A).
IR spectrum of the compound (A) was shown in FIG. 2.
To measure the dielectric constant by bridge method, the compound (A) was set in a cell, which was formed between two nesa glasses as electrodes by using spacer of 25 μm thick of polyethyleneterephthalate film, and a voltage with 100 Hz of alternative current was applied between said electrodes. The result was shown in FIG. 1. It is obvious that the value of the dielectric constant of the compound (A) was much larger than that of DOBAMBC. The other hand, the electric constant of the compound (A) measured by Sawyer-Tower method, using said cell, applying a voltage 300 Hz between said electrodes was 236 nC/cm 2 . The value means the excellent spontaneous polarization and was one of the largest dielectric constant among the known smectic liquid crystals.
In the case of applying a voltage with square wave to the compound, electro-photo-effects such as clear contrast and high speed response corresponding to the square wave were observed through making a microscopic observation.
EXAMPLE 2
Preparation and properties of (S)-2-chloro-3-methylbutyl-4-(4'-nonyloxycarbonyloxy)-biphenylcarbonic acid ester (B) ##STR7##
Ten grams of 4(4'-hydroxy)-biphenylcarboxylic acid was dispersed in 120 ml of carbontetrachloride and 50 ml of pyridine. 17 ml of nonanic acid chloride was dropped into the mixture with reflux-stirring. After heating for three hours, reducing the solvents and then a small amount of water was added to decompose unreacted nonanic acid chloride. The residue was washed with methanol to obtain 11.5 g of 4-(4'-nonyloxycarbonyloxy)biphenylcarboxylic acid (C). 9.0 g of the compound (C) was dispersed in 200 ml of carbontetrachloride. Then 10 ml of thionylchloride was dropped into the solution with reflux-stirring and reacting for three hours. After reducing the solvent, 4-(4'-nonyloxycarbonyloxy)biphenylcarboxylic acid chloride (D) was obtained. 1.0 g of the compound (D) was dissolved with 60 ml of carbontetrachloride and 5 ml of pyridine. 0.4 g of (S)-2-chloro-3-methylbutanol was added to the solution with stirring and cooling and then allowed to stand overnight. After removing the crystals and solvents, the residue was purified by passing through silica-gel column, 0.7 g of the compound (B) was obtained after recrystallizing the product with hexane.
The compound (B) was smectic liquid crystal having SC* phase and SA phase. The phase transition temperature of (B) were shown in table I.
EXAMPLE 3
The compounds of the present invention prepared by the similar methods in example 1 and 2 and its phase transition points were shown in table 1.
EXAMPLE 4
Preparation and properties of (2S,3S)-4-(4'-octylcarbonyloxyphenyl)phenyl-2-chloro-3-methylpentyloxycarboxylic acid ester (E) ##STR8##
Forty seven grams of 4,4'-biphenol were dissolved with 20 ml of pyridine with stirring, then 25 ml of octylcarboxylic acid was added. After reacting for two hours, the solution was neutralized with hydrogen chloride. The crude product of 4-(4'-octylcarbonyloxyphenyl)phenol was extracted with chloroform from the solution. The crude product was purified by passing through silica-gel column.
1 g of 4-(4'-octylcarbonyloxyphenyl)phenol and 0.5 g of (2S,3S)-2-chloro-3-methylpentyloxycarboxylic acid were dissolved with mixture solvent, 60 ml of carbontetrachloride and 10 ml of pyridine and then the mixture was allowed to stand overnight. The crude product was purified by passing through silica-gel column, after reducing crystals and solvents, then product was recrystallized with ethanol to obtain 1.0 g of the compound (E).
IR spectrum of the compound (A) was shown in FIG. 3. The compound was smectic liquid crystal having SC* phase and its phase transition points were shown in table II.
To measure the dielectric constant by bridge method, the compound (E) was set in a cell described in example 1. The electro-photo-effects of the compound (E) concerning clear constant and high speed response corresponding to the square were observed through making a microscopic observation by applying a voltage with square wave.
EXAMPLE 5
Preparation and properties of other smectic liquid crystals
The other smectic liquid crystals were obtained by same procedure as example 4 with using phenol derivatives instead of 4-(4'-octylcarbonyloxyphenyl)-phenol. The phase transition points of smectic liquid crystals were shown in table II.
In the following table I and II, a black circle () shows each that the compound forms the phase corresponding to an abbreviated word described above and upper black circle and figures in a same column show the results measured under condition at raising temperature and the lower them show results measured under condition at decreasing temperature. The carbon atom marked with * represents optically active carbon which is S form and the carbon atom with ** means R form.
TABLE I__________________________________________________________________________ ##STR9## Phase transition point (°C.)n X C Sl* SC* l__________________________________________________________________________ R.sup.38 OCO ##STR10## • • 59 • 58 •8 OCO ##STR11## • • 14 • 14 • 24 • 24 • 41 • 41 •8 OCO ##STR12## • • 22 • 22 • 25 • 25 • 37 • 37 •8 OCO ##STR13## • • 20 • 12 • 22 • 22 • 34 • 34 •8 OCO ##STR14## • • 62 • 70 • 70 • 80 • 80 •9 OCO ##STR15## • • 50 • 50 • 55 • 55 • 58 • 58 •9 OCO ##STR16## • • 25 • 25 • 27 • 27 • 43 • 43 •9 OCO ##STR17## • • 15 • 15 • 25 • 25 • 39 • 39 • R.sup.29 OCO ##STR18## • • 0 • 21 • 22 • 35 • 35 •9 COOCH.sub.2 ##STR19## • • 33 • 60 • 36 •__________________________________________________________________________
TABLE II__________________________________________________________________________ ##STR20## Phase transition point [°C.]n X R.sub.4 C SX Sl* SC* l__________________________________________________________________________6 COO ##STR21## • • 42 • 53 • 49 •8 COO ##STR22## • • 30 • 46 • 46 • 53 • 53 •9 COO ##STR23## • • 44 • 54 • 54 • 56 • 56 •8 O ##STR24## • • 43 • 43 • 50 • 50 •8 OCOO ##STR25## • • 64 • 52 •12 OCOO ##STR26## • • 66 • 47 •5 OCO ##STR27## oil condition8 OCO ##STR28## • • 48 • 44__________________________________________________________________________ •
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A liquid crystal compound represented by the following general formula (1), which possess a large spontaneous polarization about room temperature and a liquid crystal composition containing a liquid crystal compound represented by the following general formula (1) ##STR1## wherein R 1 represents C 6-14 alkyl group, R 2 represents straight or branched alkyl group with or without optically active carbon, X represents a group selected from --OCOO--, --O--, --COO--, --OCO-- or single bond, Y represents a group selected from --COOCH 2 --, --OCO-- or --OCOO--, in which either X or Y is at least --OCOO-- group, m represents 0 or 1, Z represents a chlorine or bromine, a carbon atom marked with * represents optically active carbon atom.
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BACKGROUND OF THE INVENTION
The invention relates to a device for quench propagation for a superconducting magnet. More particularly, the invention relates to a device for quench propagation for a superconducting magnet having at least one pair of superconducting coils, where in the event a first coil, which up to that point was superconducting, s becomes normal-conducting (quenches) where the quenching event occurs as a consequence of interference, the device causes the second coil of this pair to be converted from the superconducting operating state to the normal-conducting state with heating arrangements thermally connected to the coils.
In larger-sized superconducting magnets considerable quantities of energy are to be stored, which are, for example, in the MJ (mega-joule) range. In particular such magnets are strongly endangered in the event of an unintentional transition from the superconducting operating state to a normal-conducting state, even if this transition--also referred to as a "quench"--occurs initially only in one part of the magnet. Due to their low heat capacity, the superconducting coil conductors of the magnet, following a quench of one of the conductors, reach, very rapidly, high temperatures due to the resistance increase caused by the quench. Simultaneously, the specific resistance of the conductor also increases very quickly, which further increases the rate of heating. A consequence is excess voltages, which stress the insulation and, in the event of a flashover spark discharge, can lead to damage or destruction of the magnet.
Larger-sized superconducting magnets are frequently constructed as a combination of several superconducting coils, such as partial coils or partial windings. In order to protect these coils against damage or destruction through overheating, as through electrical flashovers, special protective measures are frequently provided. These measures may include, in particular, use of certain configurations for voltage limitation such as by bridging individual coils with protective resistors, as disclosed in German Patent Application No. DE-OS 23 01 152, semiconductor diodes, as disclosed in German Patent Application DE-OS 16 14 964, or with voltage limiters, as disclosed in German Patent Application No. DE-OS 17 64 369. In such a configuration however, in the event of a quench of one single coil, the currents of the coils of the magnet, generally connected in series, can assume widely differing patterns over time: the current of the quenched coil decreases in the process, while the current may increase in the neighbouring coils. In such a case, it is desirable to trigger cause a quench in additional or all coils of the magnet in order to de-excite the entire magnet or in order to uniformly distribute the magnetic energy converted into heat over the discrete coils. It may also be desired to favorably influence the current and field distribution during a coil quench. This is particularly important if the magnet includes a system of coils structured symmetrically in pairs. In the case of a coil pair the normally symmetric current distribution and, hence, also the field distribution, become asymmetric. The same is true of the interaction of the coils with their environment, in particular with induced eddy currents in a cryostat surrounding the coils or with ferromagnetic parts surrounding the coils such as, for example, iron screening. Under those conditions, considerable magnetic forces can occur stressing the cryogenic suspension of the coils.
Therefore, the intent is, in the event of a quench of one coil of one such a coil pair, to also trigger, as rapidly as possible, normal conductivity in the coil being symmetrical to it in order to permit the current distribution in the entire magnet and, consequently, also the force effects on the surrounding to become symmetrical. The net force on the coil pairs and on the cryostat components can in this way be reduced.
Measures for accelerating the propagation of normally conducting regions in a magnet comprising several coils are known. For example, the article "Some Basic Problems in Superconducting Magnet Design" in IEEE Transactions on Magnetics, Vol. MAG-17, No. 5, Sept. 1981, pages 1815-1822 discloses that a quench propagation can be increased through use of electrical heating elements on the coils, which are activated by a particular quench detector and fed by an external current supply.
For reasons of reliability, however, many times a "passive" quench propagation is desirable for a large superconducting magnet. A passive device is distinguished from an active device in that it exercises its voltage, temperature and force limiting functions without the use of and without the actuation of active elements such as, for example quench detectors, switches, and externally fed heating elements.
A passive quench propagation device is described, for example, in a paper entitled "Quenches in Large Superconducting Magnets" from the Proc. 6th Int. Conf. on Magnet Technology (MT-6), Bratislava (CSSR), Aug. 28-Sept. 2, 1977, pages 654 to 662. According to this device a superconducting magnet is to be wound on a coil former, which is a good electrical conductor such zs as highest grade aluminum, or on a secondary short circuit winding. In the event of a quench, the coil former or secondary short circuit winding takes over a part of the energy, functioning as transformer, and simultaneously heats the still superconducting parts of the magnet. In such a device, however, large losses of helium coolant occur in the process of informal excitation and de-excitation due to induced currents. If the rate of change is too high, then even the danger of triggering a quench unintentionally exists.
Another quench propagation device is disclosed in EP-B-0 115797. This quench spreading device works passively. This device, which is provided for a superconducting magnet with several discrete coils or partial coils, contains special heating arrangements in the form of films of normal-conducting material, which are connected in good heat-conducting contact with an associated coil. The operating voltages required in the event of a quench for these heating elements are tapped from a network of quench protecting resistors. In this case, however, the quench propagation from the quenched coil to the remaining coils takes place relatively slowly so that for a correspondingly long transition of time in the magnet correspondingly non-uniform conditions of current distribution and, hence, force effects can occur.
Corresponding magnets are applied, for example in the field of medical technology, as static ground field magnets in installations for nuclear spin tomography as disclosed in EP-B-0 011 335 or EP-A-0 056 691. Such ground field magnets contain in general several, for example four or six, annular superconducting single coils, which are arranged symmetrically in pairs with respect to a center plane. These superconducting single coils are expediently bridged with quench protective resistors or diodes. In that case, however, in the event of a quench, due to the non-symmetry of the single coil currents in the coils lying on both sides of the center plane, axial forces between these coils, cryogenic shields and possibly a present iron shielding can occur. These forces are, in a magnetic coil system for nuclear spin tomography, by far greatest at the front face single coils, since these coils in general have the greatest number of windings.
SUMMARY OF THE INVENTION
The device of the present invention improves the passive quench propagation device whereby the danger of unintentional triggering is decreased in that rapid magnet de-excitation is made possible.
The problems described above are solved by an apparatus according to the present invention which includes a discrete conductor of normal-conducting material having a predetermined specific electrical esistance and in which the auxiliary windings assigned to the coils of the coil pair are short circuited with each other so that the direction of current flow in one auxiliary winding is opposite to the direction of current flow in the second auxiliary winding.
One of the advantages arising from this design of the quench propagation device is that the second coil of a coil pair assigned to a quenching coil is converted relatively rapidly to the normal-conducting state without the necessity of special external (active) components. In the event of a quench of one coil of a coil pair voltages are induced in its auxiliary winding, due to magnetically closed coupling of the auxiliary windings with their assigned coils. The auxiliary winding which is a counterpart of the auxiliary winding associated with the quenched coil functions as a heater driving a heating current on the second coil of the coil pair and triggers a quench there as well. In this connection it is of particular advantage that the structure of the two auxiliary windings assigned to a coil pair is quasisymmetric; i.e. the roles of induction and heat development are reversed depending on the origin of the initial quench occurrence. During operational activation and de-activation, due to the antisymmetric wiring of the two auxiliary windings, voltage and heat output are practically zero. That is, even s rapid operational change cannot trigger a quench, and the losses of cryogenic coolant caused by the auxiliary windings are correspondingly minimal.
BRIEF DESCRIPTION OF THE DRAWINGS
For further elucidation of the invention, reference is made to the drawings, in which:
FIG. 1 illustrates a quench propagation device according to the present invention;
FIG. 2 illustrates a specific design possibility for such a device.
DETAILED DESCRIPTION
The quench propagation of the present invention can advantageously be provided for all superconducting magnets, which have at least one pair of superconducting single coils.
The embodiment shown schematically in FIG. 1 in view is based on two superconducting coils in the region of the front sides of a corresponding magnet 2. These coils, largely identical at least with respect to construction, are designated 3 and 4 and are arranged symmetrically with respect to an imaginary center plane M of the magnet. For example, the coils 3 and 4 are located on a tubular carrier 5 around an axis A, the intersection of which with the imaginary center plane M is drawn in a dotted line. These coils 3 and 4, forming a coil pair P, are in addition, according to the invention, equipped with a device for propagation of a quench, which occurs in one of the two coils (for example in coil 3) as rapidly as possible onto the other coil (coil 4) of coil pair P and so effect a more symmetrical current drop in the two coils. Under those conditions, eddy current forces, discrete net forces, largely balance, with the cryogenic supports required for the coils correspondingly being relieved of load.
The device according to the invention for quench propagation has one single-layer auxiliary winding 6 or 7 of at least one discrete, tape or wire-shaped insulated conductor L. However, they can also be constructed of several conductors. The conductor L consists of normal-conducting material with a predetermined specific electrical resistance. Several windings "W" of the conductor L are arranged as the auxiliary windings 6, 7 assigned to the coils 3 and 4 respectively in each case in such a way that good thermal contact to the particular coil is ensured. Of course, instead or in addition, windings w of the auxiliary windings can also be located on the underside or on at least one of the narrow-sided front surfaces of their assigned coils The two auxiliary windings 6 and 7 are so connected with each other, i.e. short-circuited, that the direction of current flow indicated by the arrows 11 in the intermediate coil 6 is opposite to the current flow direction illustrated through arrows in the auxiliary winding 7. The required two axial connection conductors between the two auxiliary windings 6 and 7 are designated in the FIG. 1 by 13 and 14. No electrical connection exists from the auxiliary windings 6 and 7 to the rest of magnet 2.
Following a coil quench, assumed to occur for example, in coil 3, a voltage is induced in the auxiliary winding 6 magnetically closely coupled to quenched coil 3. The counterpart auxiliary winding 7 acts as heater and drives a heating current on the second coil 4 and, consequently, triggers a quench there as well.
The structure of the device according to the invention for propagation of quench is hence quasi-symmetrical; i.e. the roles of induction windings (for example auxiliary winding 6) and heater winding (auxiliary winding 7) are reversed depending on the origin of the quench occurrence. In the course of operational excitation and de-excitation of the magnet, by contrast, voltage and heat output are minimal due to the antisymmetrioal connection of the two auxiliarY windings 6 and 7.
A rapid quench trigger demands good electrical conductivity of the auxiliary windings. On the other hand, the temperatures related electrical resistance of the auxiliary winding on the quenched coil, which now heats up, should not increase too rapidly because this weakens the induced current. Advisably a material is selected for conductor L, having a specific electrical resistance ρ, at 4.2° K., which lies between 10 -9 and 10 -11 Ω.m. So that further a thermally coupled winding can still operate in the range of the temperature-dependent residual resistance, a value of the residual resistance ratio ρ (at 300° K.)/ρ (at 4.2° K.) of between approximately 50 to 500 should not be exceeded With single-layer auxiliary windings of tape or wire-shaped copper or aluminum directly on the particular coils, the listed demands can readily be met. It is advisable to provide as the stabilization material of the superconductors, the material of which the superconducting coils are built. Additionally, for conductor L of the auxiliary winding, a wire diameter should be chosen, which is similar to that of the superconductor of the assigned coil. In this way, good heat contact and simple winding technique can be ensured. To this end, the auxiliary windings must be wound tightly onto the particular coils, since otherwise the Lorentz force on the heating side can lift the conductor off the coil and lessen the thermal contact. The number of windings has practically no influence on the effect; that is, a few closely wound centimeters suffice For reasons of sufficient heat diffusion it is advantageous if the auxiliary windings are produced of windings closely wound one next to the other, with an axial minimum width "b" of the windings being 2 cm.
For electrical insulation between the auxiliary windings and their assigned coils, in general, a normal wire insulation is sufficient, which possibly is additionally reinforced by a thin insulating film. On the other hand, the auxiliarY windings must be thermally sufficiently insulated against the cryogenic medium helium in order to prevent the heat of the auxiliary windings from being too rapidly eliminated in the event of a quench. To that end, the auxiliary windings can be thermally insulated against the cryogenic medium, for example with layers of wax or synthetic resin a few mm thick.
For a rough estimate of the effect of a quench propagation device according to the invention it may be assumed that the magnetic flux penetrating the coils and their particular assigned auxiliary winding and, consequently, the induced voltage U i winding are approximately of the same order of magnitude. In a fully quenched coil U i is approximately also identical to the resistive voltage drop U r /winding, if all current flows in the normally conducting stabilization material of the superconductor of the coil. The current densities j h in the auxiliary windings are then proportional to U i and ρ -1 . If copper is chosen as material for the auxiliary windings 6 and 7 with ρ (4.2° K.) being approximately 1 to 2×10 -10 Ω.m, then approximately one half the current density j h of that in the conductor of the assigned superconducting coil 3 or 4 can be achieved. The quench propagation from the heating auxiliary winding in the topmost coil layer takes place approximately in that time which in a coil, of current density j h is required for a quench of a one layer by a quench zone Which progresses with the propagation velpcotu V r . According to the article "Protection of the pulsed superconducting Dipole ALEC", Proc. 6th Int. Cryogenic Engng. Conf. - ICEC 6, Grenoble, 11-14 May, 1976, pages 492 to 496 (FIG. 2) V r is a few cm/sec; i.e. the trigger time for a quench is accordingly a few 1/10 seconds. This is short enough compared to the time to build the maximum force, a few seconds, in order to effectively reduce the load on the cryogenic coil supports.
In the embodiment illustrated in FIG. 1 the assumption was made that the magnet 2 has only two coils 3 and 4 arranged symmetrically to each other, to which a quench propagation device according to the invention is to be assigned.
It is understood that the magnet can contain additional pairs of superconducting coils with a quench propagation device being provided for each additional pair or also only for a few of the pairs. Beyond that, it is also possible to combine several coils considered to be partial coils or partial windings of a magnet, so that they form a pair of coil sets arranged symmetrically to each other. The thus created pair of coil sets can then be equipped with a quench propagation device according to the invention with one auxiliary winding to be assigned to one coil set. In this embodiment, coils 3 and 4 shown in FIG. 1 are not both just one single coil; rather, coils 3 and 4 can be combined from several discrete coils to form one coil set. If a superconducting magnet has more than one pair of individual coils, which are symmetrical to each other, and if one of these coil pairs in the event of a quench of one of its two coils calls forth significantly greater asymmetric forces than the at least one additional coil pair, it becomes possible in this case to assign solely to the coils of the coil pair with the greater force effect a quench propagation device according to FIG. 1. The remaining less critical coils can then be quenched with planar ohmic heat elements, which are placed in the series circuit of the auxiliary windings of the quench spreading device.
A corresponding embodiment for a magnet with two pairs of superconducting single coils forms the basis of the embodiment shown schematically in FIG. 2. An oblique view, as for FIG. 1, was chosen. parts that are identical in the Figures are provided with identical reference numbers. FIG. 2 differs from FIG. 1 in that the magnet labeled 20, has between its frontal face coils 3 and 4 forming an outer coil pair P, an additional inner coil pair P, with coils 21 and 22, which, for example have a lower ampere winding number than their adjacent superconducting coils 3 respectively 4. The quench propagation device provided for this magnet 20 contains again the two auxiliary windings 6 and 7 around the assigned superconducting coils 3 respectively 4. These two auxiliary windings 6, 7 are connected with each other through axially extending connection conductors 13 and 14', with the predetermined directions of current flow being ensured. At the coils 21 and 22 of the inner coil pair P' ohmic heat elements 24 and 25, are arranged with good heat-conducting contact and are series-connected in at least one of the two connection conductors, for example, in the connection conductor 14'. The electrical series resistance of both heat elements together should advantageously be 1 to 10 times the series resistance of both auxiliary windings 6 and 7. In case of a quench of one of the two coils (3 or 4) of the outer coil pair P, then in the series circuit a heating current is called forth by the quenching coil, which can heat up the ohmic planar heating elements 24 and 25 so that the two coils 21 and 22 of the inner coil pair P' assigned to those heating elements also quench.
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A quench propagation device for a superconducting magnet having at least one pair of superconducting coils operates so that in the event of a transition to normal-conductance (quench) of a first coil of the coil pair, which up to that point was superconducting, the second coil of this pair is also converted from the superconducting operating state to the normal-conducting state using heating arrangements thermally connected to the coils. This device is constructed so that in the event of a quench rapid magnet de-excitation and uniform current distribution and, consequently force relationships, are achieved. The heating arrangements include two auxiliary windings magnetically closely coupled with their particular assigned coils of the coil pair. The auxiliary winding material is a discrete normal-conducting conductor having a predetermined specific electrical resistance. The two auxiliary windings are short-circuited with each other so that the direction of current flow in one auxiliary winding is opposite to the direction of current flow in the second auxiliary winding.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is:
a divisional of U.S. application Ser. No. 11/750,622, filed May 18, 2007, now U.S. Pat. No. 7,479,608 (which application claimed the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application 60/801,989 filed May 19, 2006, 60/810,272, filed Jun. 2, 2006, 60/858,112, filed Nov. 9, 2006, and 60/902,534, filed Feb. 21, 2007); a divisional of U.S. application Ser. No. 12/270,518, filed Nov. 13, 2008, now U.S. Pat. No. 7,714,239; a divisional of U.S. application Ser. No. 12/728,471, filed Mar. 22, 2010, now U.S. Pat. No. 8,269,121; and a divisional of U.S. application Ser. No. 13/571,159, filed Aug. 9, 2012,
the entire disclosures of which are all hereby incorporated herein by reference in their entireties.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
n/a
FIELD OF THE INVENTION
The present invention lies in the field of switches, in particular, a force switch. The device can be used along with any tool in which a particular longitudinal force needs to be overcome prior to reaching a given detected force.
BACKGROUND OF THE INVENTION
In various applications, a compressible material is compressed between two surfaces for modification of the material in some way after being compressed. The material can be compressed too little, too much, or in an acceptable range of compression. It would be beneficial to provide an electrical switch that can indicate when the acceptable minimum compression force has been exceeded. It would further benefit if the switch actuates over a small gap and is longitudinally in-line with the device in which the switch is incorporated. It would also be beneficial if the minimum force setting of the switch could be pre-set to given force values.
BRIEF SUMMARY OF THE INVENTION
The invention overcomes the above-noted and other deficiencies of the prior art by providing an electronic switch that actuates over a small gap (on the order of 25 to 200 micrometers), is longitudinally in-line with the device in which the switch is incorporated, and switches dependent upon a longitudinally expanding external force that can be pre-set over a given floor force value.
A characteristic of the force switch described herein is that the longitudinal forces that the force switch can withstand are significantly higher than that existed in the past. With a force switch having approximately a 6 mm diameter, for example, an approximately 5 to 8 pound longitudinally pulling force changes the switch state while, at the same time, being able to withstand almost 300 pounds of longitudinal pulling or compressive force. This is an almost twenty-fold difference.
There are many uses for the force switch in various different technology areas.
In a first exemplary area of technology, the force switch can be used to measure compressive forces imparted upon tissue by medical devices. In many medical procedures, tissue is compressed between two surfaces before a medical device is caused to make a change in the compressed tissue. If the tissue is compressed too little, then the change sought to be effected might not be sufficient. If the tissue is, on the other hand, compressed too much, the change sought to be effected might actually destroy the area of interest. When compressing such tissue, there are measurable force ranges that fall between these two extremes. Knowing the “safe” force range can allow the user to select a pre-tensioning of the force switch to change its state (i.e., indicate to the user the pre-tensioned force has been exceeded) within the “safe” range of that tissue.
The force switch described herein can be constructed in a customized way to have the state-changing pre-tension match the “safe” range of the tissue to be operated upon.
One type of medical device that is used to change a state of tissue is a medical stapling device. Ethicon Endo-Surgery, Inc. (a Johnson & Johnson company) manufactures and sells such stapling devices. Circular stapling devices manufactured by Ethicon are referred to under the trade names PROXIMATE® PPH, CDH, and ILS. Linear staplers manufactured by Ethicon under the trade names CONTOUR and PROXIMATE also can use the force switch. In each of these exemplary staplers, tissue is compressed between a staple cartridge and an anvil and, when the staples are ejected, the compressed tissue is also cut. In this specific example, the tissue can be compressed too little (where blood color is still present in the tissue, too much (where tissue is crushed), or just right (where the tissue is blanched). Staples delivered have a given length and the cartridge and anvil need to be at a given distance so that the staples close upon firing. Therefore, these staplers have devices indicating the relative distance between the two planes and whether or not this distance is within the staple length firing range. However, these staplers do not have any kind of active compression indicator that would also optimize the force acting upon the tissue that is to be stapled. The force switch described herein provides such a feature. Some exemplary procedures in which these staplers could use the force switch include colon dissection and gastric bypass surgeries.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a method of creating a switch to be disposed along a longitudinal axis of a device, comprising providing a hollow body defining an interior cavity; disposing a switching element movably within the interior cavity, the switching element having a longitudinal switching axis disposed parallel to the longitudinal axis of the device and defining a switch-making position at a first longitudinal position along the switching axis and a switch-breaking position at a second longitudinal position along the switching axis, the second longitudinal position being different from the first longitudinal position, and a biasing element; coupling an electrically-conductive contact to the switching element to define a switch-making state when the switching element is in the switch-making position and a switch-braking state when the switching element is in the switch-braking position; and imparting a variable longitudinal bias to the switching element with the biasing element to place the switching element in one of the switch-making position and the switch-braking position until an external force imparted to the switching element along the switching axis exceeds the longitudinal bias thereby causing the switching element to move to the other one of the switch-making position and the switch-braking position.
In accordance with another feature of the invention, the switching element is a piston.
In accordance with a further feature of the invention, the electrically-conductive contact is physically coupled to the switching element and is moveable along the switching axis between the switch-making position and the switch-breaking position.
In accordance with an added feature of the invention, the method further comprises defining a second interior cavity by a stop element in which the switching element is movably disposed, the stop element being at least partly disposed in the interior cavity of the hollow body.
In accordance with an additional feature of the invention, the switching element further comprises a bias device.
In accordance with yet another feature of the invention, the biasing element is disposed about at least a portion of the switching element between the stop element and the bias contact.
In accordance with yet a further feature of the invention, a magnitude of the longitudinal bias is dependent upon a longitudinal position of the stop element within the interior cavity of the hollow body.
In accordance with yet an added feature of the invention, the switching axis is disposed coincident with the device axis.
In accordance with yet an additional feature of the invention, the biasing element imparts the longitudinal bias to place the switching element in the switch-breaking position to create a normally open switch configuration.
In accordance with again another feature of the invention, the biasing element imparts the longitudinal bias to place the switching element in the switch-making position to create a normally closed switch configuration.
In accordance with again a further feature of the invention, a distance between the first longitudinal position and the switch-breaking position is between approximately 25 μm and approximately 750 μm.
In accordance with again an added feature of the invention, a distance between the first longitudinal position and the switch-breaking position is between approximately 75 μm and approximately 200 μm.
In accordance with again an additional feature of the invention, a range of force sufficient to cause the switching element to move between the switch-making state to the switch-breaking state is between approximately 3 ounces and approximately 20 pounds.
In accordance with still another feature of the invention, a range of force sufficient to cause the switching element to move between the switch-making state to the switch-breaking state is between approximately 5 pounds and approximately 8 pounds.
In accordance with still a further feature of the invention, the method further comprises electrically insulating the electrically-conductive contact from the hollow body and the switching element.
In accordance with still an added feature of the invention, the method further comprises forming a switch sub-assembly having the electrically-conductive contact, a switch housing longitudinally fixed and electrically conductively connected to the hollow body and at least partially surrounding the electrically-conductive contact, a switch insulator electrically insulating the electrically-conductive contact from the switch housing, and a piston contact movably disposed in the switch housing and longitudinally fixedly and electrically conductively connected to the piston.
In accordance with still an additional feature of the invention, the switching element has a first exterior, the bias contact has a second exterior having a larger diameter than the first exterior, the interior cavity of the hollow body has a first interior substantially equal in diameter to the second exterior, the second interior cavity has a second interior substantially equal in diameter to the first exterior, the bias contact has a third exterior substantially equal in diameter to the first interior, and the electrically-conductive contact has a fourth exterior smaller in diameter than the first interior.
In accordance with still an additional feature of the invention, the method further comprises electrically connecting an electric indication circuit to the switching element and the electrically-conductive contact, the electric indication circuit having an indicator operable to transmit state-change information to signal a user that a state change of the switching element has occurred.
In accordance with yet an additional feature of the invention, the biasing element is a compression spring compressed between the bias contact and the stop element around the switching element to bias the switching element in a direction away from the stop element.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a force switch, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of embodiments the present invention will be apparent from the following detailed description of the preferred embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view from a side of an exemplary embodiment of a force switch according to the invention.
FIG. 2 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 3 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 4 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 5 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 6 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through approximately a longitudinal axis of the switch;
FIG. 7 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a far half of the switch;
FIG. 8 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 6 with the switch in an un-actuated position;
FIG. 9 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 6 with the switch in an actuated position;
FIG. 10 is a perspective view from a side of another exemplary embodiment of a force switch according to the invention.
FIG. 11 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a near half of the switch;
FIG. 12 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a near half of the switch;
FIG. 13 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through approximately a longitudinal axis of the switch;
FIG. 14 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a far half of the switch;
FIG. 15 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a far half of the switch;
FIG. 16 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 13 with the switch in an un-actuated position; and
FIG. 17 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 13 with the switch in an actuated position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Referring now to the figures of the drawings in detail and first, particularly to FIGS. 1 to 9 thereof, there is shown a first exemplary embodiment of a force switch 1 . FIGS. 10 to 17 illustrate a second exemplary embodiment of the force switch 1 . As will be described in more detail below, the first exemplary embodiment represents a “normally open” switch configuration and the second exemplary embodiment represents a “normally closed” switch configuration. Where features of the switch 1 are similar in the two embodiments, for ease of understanding, similar reference numerals will be used.
The force switch 1 can be incorporated into a device where force along the longitudinal axis of the device needs to be measured and an action needs to be taken when that force exceeds a given predetermined value. This force switch 1 can be used, for example, in a medical device, but is not limited to the exemplary embodiment of a medical device. As will be described in further detail below, the force switch 1 can be used with a circular surgical stapling device such as is disclosed in U.S. Pat. No. 5,104,025 to Main
FIGS. 1 to 9 represent different portions of the force switch 1 . FIG. 6 provides an example view through the longitudinal axis 2 of the force switch 1 that allows one to see all parts of the switch 1 . A contact piston 10 provides a central part around which other parts of the switch 1 may be explained. A nose piece or tip 20 is fastened to the distal end 12 of the contact piston 10 . The distal end 12 and an internal bore 22 of the tip 20 are illustrated with straight lines in FIGS. 4 to 9 , however, in a first exemplary embodiment, the distal end 12 can be provided with external male threads and the bore 22 can be provided with internal female threads. Alternatively, the tip 20 can be press-fit, glued, welded, or otherwise connected to the distal end 12 of the contact piston 10 . In the configuration shown in FIGS. 4 to 9 , a proximal portion 24 of the internal bore 22 has a non-threaded flat portion for receiving therein the distal-most end of the piston 10 such that, when completely threaded into the bore 22 , the proximal portion 24 acts as a stop for further threading of the distal end 12 therein.
At the proximal end of the piston 10 , a widening 14 is provided on the outside surface of the piston 10 and an internal bore 16 is formed in the interior thereof.
A hollow body tube 30 is disposed around at least a portion of the contact piston 10 . One exemplary embodiment of the interior of the tube 30 includes a relatively narrower proximal bore 32 and a relatively wider distal bore 34 (although the opposite configuration is also possible). The bores 32 , 34 surround a proximal portion of the piston 10 that includes a central shaft 18 thereof and the widening 14 . The exterior shape of the widening 14 and the interior shape of the proximal bore 32 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the proximal bore 32 is substantially equal to the outer diameter of the widening 14 . As used herein, substantially equal means that there is only a sufficient clearance between the two parts to allow one to slide within the other. Thus, if a given first material requires a particular first spacing between the outer surface of the piston 10 and the inner surface of the body tube 30 to permit the piston 10 to move therein, then that first spacing exists between the two parts 10 , 30 , whereas, if a given second material requires a smaller (or larger) spacing between the outer surface of the piston 10 and the inner surface of the body tube 30 to permit the piston 10 to move therein, then that that second spacing exists between the two parts 10 , 30 .
There are two parts between the piston 10 and the body tube 30 , an adjustable end cap 40 and a bias device 50 . The exterior shape of the end cap 40 and the interior shape of the distal bore 34 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the distal bore 34 is substantially equal to the outer diameter of the end cap 40 . Thus, when the end cap 40 is inserted into the distal bore 34 , the cap 40 substantially closes an interior space defined by the interior surfaces of the distal and proximal bores 34 , 32 , the exterior surface of the central shaft 18 , the distal transverse surface of the widening 14 , and the proximal end surface of the cap 40 . The bias device 50 is disposed inside this interior space. The bias device 50 and the cap 40 act together with the widening 14 to bias the piston 10 in a given direction, in this case, in the proximal direction. Force of the bias device 50 can be dependent upon the position of the cap 40 . For example, if the cap 40 is closer to the widening 14 , the bias device 50 can exert a first biasing force and if the cap 40 is further from the widening 14 , the bias device 50 can exert a second biasing force. Depending upon the bias device 50 used, the first force can be greater than the second, or vice-versa. It is beneficial, but not required, if the cap 40 is adjustable between various locations along the body tube 30 . In such a configuration, the bias device 50 can be adjusted to a user-desired pre-bias.
One embodiment of the cap 40 and bias device 50 is shown in FIGS. 2 to 9 . The following description, however, will be directed to the view of FIG. 8 . In this embodiment, the distal bore 34 has a larger diameter than the proximal bore 32 . The end cap 40 has exterior threads 42 that mate with non-illustrated internal female threads of the distal bore 34 . In such a configuration, the cap 40 can be rotated into the distal bore 34 along any longitudinal point within the distal bore 34 . With the proximal bore 32 having a smaller diameter than the distal bore 34 , the distal endpoint 36 of proximal bore 32 forms a stop for insertion of the cap 40 . The cap 40 is formed with an interior bore 44 having a shape substantially equal to the outer shape of the central shaft 18 of the piston 10 . Thus, while the cap 40 can be screwed into the distal bore 34 such that longitudinal forces will not press the cap 40 out from the distal bore 34 , the central shaft 18 of the piston 10 can move longitudinally freely within the bore 44 and with respect to the cap 40 .
The bias device 50 is embodied, in this example, as a compression spring 50 . As such, when the spring 50 is placed around the central shaft 18 of the piston 10 up to the distal transverse surface of the widening 14 , and when the threaded cap 40 is also placed around the central shaft 18 and screwed at least partially within the distal bore 34 , the spring 50 can be compressed between two extremes defined by the longitudinal connection distance that the cap 40 can traverse between being securely but barely inside the distal bore 34 and fully inserted therein up to the stop 36 .
Because the piston 10 moves, it can form one contact of an electrical switch for signaling a state of the piston 10 . Another contact needs to be provided that is electrically insulated from the piston 10 . Thus, the piston 10 needs to be associated with a switch sub-assembly so that the electrical switch is in a first state when the piston 10 is in a first longitudinal position and in a second state when the piston 10 is in a second longitudinal position (the first and second states being off/on or on/off). This switch sub-assembly is formed at a proximal end of the piston 10 and the body tube 30 and, in the following text, is shown in two exemplary embodiments. The first embodiment, the “normally open” switch has been mentioned as being related to FIGS. 1 to 9 . The second embodiment relates to FIGS. 10 to 17 and is a “normally closed” switch.
The normally open switch sub-assembly is explained with regard to FIGS. 8 to 9 . A switch bushing 60 has a distally projecting stub 62 that is inserted into the proximal end of the body tube 30 . This stub 62 can be connected to the body tube 30 in any number of ways (e.g., by bonding, welding, adhesive, press-fit, screw threads). The proximal end of the switch bushing 60 is attached to a mounting body 70 . In one embodiment, each of the piston 10 , the tip 20 , the body tube 30 , the cap 40 , the switch bushing 60 , and the mounting body 70 are electrically conductive and provide a first electrical contact of the force switch 1 . However, the tip 20 and cap 40 need not be conductive. To form a second electrical contact that, when put into electrical connection with the first contact, completes an electrical circuit (or interrupts an electrical circuit as shown in FIGS. 10 to 17 ), an insulating body needs to be disposed between the second contact and the first contact needs to be operatively moved into (or out of) contact with the second contact.
Various switch embodiments disclosed herein include parts that are electrically conductive and actually form part of the electronic circuit. The switch according to the present invention, however, is not limited to embodiments where parts of the switch form the circuit. An alternative configuration can take advantage only of the mechanical switch-breaking aspects of the invention to have the movement of the piston actuate a separate electrical switch adjacent the switch, e.g., the piston. Such an external switch can be embodied as what is referred to in the art as a tact switch because such a switch is very small. Various microswitches can be used as well if there is sufficient room for such larger switches.
In the exemplary embodiment of FIGS. 1 to 9 , the second electrical contact is formed by a contact ring 80 and the insulating body is formed by an insulating stub 90 . The part that connects the ring 80 and the insulating stub 90 to the piston 10 is a T-shaped connecting bar 100 . Each of the ring 80 , the stub 90 , and the bar 100 are nested in their shape so that they can fit in an easy assembly into the switch bushing and the body tube 30 . The insulating stub separates the contact ring 80 from the connecting bar 100 , which is in electrically conductive contact with the piston 10 and the switch bushing 60 .
More specifically, the internal bore 16 is shaped to receive a distal boss 102 of the connecting bar 100 . The connection between the distal boss 102 and the internal bore 16 can be like any of the embodiments of the connection between the piston 10 and the tip 10 . If the boss 102 has an external male thread, for example, then the internal bore 16 has a corresponding female internal thread. Such an exemplary configuration makes attachment of the connecting bar 100 and the piston 10 easy with regard to manufacturing costs and time.
The contact ring 80 has an internal bore 82 having a shape dimensioned to correspond substantially to the outer shape of a distal contact portion 92 of the insulating stub 90 . This external outer shape of the distal contact portion 92 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the contact ring 80 corresponds thereto so that the contact ring 80 can be inserted thereon and fixed (whether by press-fit, adhesive, bonding, welding, or any other connection process) thereto so that control of contact between the ring 80 and any other portion of the first contact can be made with high precision.
After the contact ring 80 is connected to the insulator stub 90 , the combined assembly can be connected to the connecting rod 100 . The external shape of an intermediate portion of the rod 100 is made to correspond to an internal shape of a bore 94 extending through the insulator stub 90 . Again, the outer shape of the intermediate portion of the rod 100 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the insulator stub 90 corresponds thereto so that the insulator stub 90 can be inserted thereon and fixed (whether by press-fit, adhesive, bonding, welding, or any other connection process) thereto so that control of contact between the ring 80 , mounted to the stub 90 , and any other portion of the first contact can be made with high precision.
With such a connection, the connecting rod 100 electrically contacts the piston 10 (and, thereby, the tip 20 , the body tube 30 , the cap 40 , the switch bushing 60 , and the mounting body 70 ). The outer shape/diameter of the contact ring 80 is dimensioned to be smaller than the inner shape/diameter of the switch bushing 60 and insertion of the contact ring 80 inside the switch bushing 60 creates a transverse gap 110 therebetween. Thus, the contact ring 80 is electrically isolated from the switch bushing 60 on the outer side thereof by the transverse gap 110 and is electrically isolated (insulated) from the connecting rod 100 on the inner side thereof by being in direct contact with the outside surface of the insulator stub 90 .
To make an electric circuit including the contact ring 80 and any electrically conducting part of the first contact ( 10 , 20 , 30 , 40 , 60 , 70 ), an electrical connection must be made at the contact ring 80 . One exemplary embodiment for such a connection is illustrated in FIGS. 5 to 9 . Specifically, the connecting bar 100 is formed with the proximal longitudinal bore 103 extending from the proximal transverse exterior surface 104 up to and including at least a part of the intermediate portion the connecting rod 100 that is located at a longitudinal position where the contact ring 80 is disposed. A further transverse bore 106 is formed to connect the longitudinal bore 103 with an interior surface of the contact ring 80 . In such a configuration, an insulated wire 206 can be threaded through the longitudinal 103 and transverse 104 bores and fastened (e.g., by welding) to the interior surface of the contact ring 80 . For ease of such a connection, the contact ring 80 can be formed with a depression (or a series of depressions) on the inside surface for receiving the electrical portion of the wire while the insulating portion of the wire remains in contact with the entirety of the longitudinal 103 and transverse 104 bores of the connecting rod 100 .
Such an electrical connection is, for example diagrammatically shown in FIG. 7 , where circuitry 200 is disposed between the contact ring 80 and the mounting body 70 . This exemplary circuitry includes a power source 202 and a contact indicator 204 (i.e., an LED) that lights the LED when the electrical circuit is completed. If the mounting body 70 and the insulated wire 206 are each connected to the circuitry 200 (as shown in FIG. 7 ), then, when electrical contact occurs between the contact ring 80 and any part of the first contact ( 10 , 20 , 30 , 40 , 60 , 70 ), the LED 204 will illuminate.
With the above exemplary configuration set forth, the functioning of the switch 1 between the first and second states can be described with regard to a comparison between FIGS. 8 and 9 . The piston 10 is longitudinally fixed to the tip 20 and to the connecting rod 100 . Further, the insulator stub 90 and the contact ring 80 are longitudinally fixed to the exterior of the connecting rod 100 . The piston 10 is slidably disposed inside the bore 44 of the cap 40 at the distal end and is slidably disposed inside the proximal bore 32 of the tube body 30 . Thus, the entire piston sub-assembly ( 10 , 20 , 80 , 90 , 100 ) can move in a longitudinal direction because a longitudinal gap 112 exists between the distal transverse surface of the contact ring 80 and a proximal end surface 64 of the stub 62 of the switch bushing 60 . It is this gap 112 that forms the space over which the force switch 1 can function.
The bias device (e.g., compression spring) 50 disposed between the adjustable cap 40 and the distal transverse surface of the widening 14 imparts a proximally directed force against the piston 10 when the cap 40 is adjusted to compress the spring 50 . This force, referred to herein as a pre-tension, keeps the contact ring 80 at a distance from the electrically conductive stub 62 of the switch bushing 60 —which is defined as the longitudinal gap 112 . Without any external force imparted on the force switch 1 , the pre-tension will always keep the contact ring 80 at this position and electrical contact between the first contact and the contact ring 80 will not occur. A distally directed external force F imparted upon the tip 20 could alter this situation. See FIG. 9 . If the force F is not as great as the pre-tension force imparted by the spring 50 , then the spring will not compress any further than it has already been compressed by the adjustable cap 40 . However, if the force F is greater than the pre-tension force imparted by the spring 50 , then the spring will compress and the tip 20 along with the remainder of the piston sub-assembly—the piston 10 , the connecting rod 100 , the insulating stub 90 , and the contact ring 80 —will move in a distal longitudinal direction. The distal longitudinal direction is limited by the proximal end surface 64 of the stub 62 of the switch bushing 60 because contact between the end surface 64 and the distal side of the contact ring 80 completely prevents further movement of the tip 20 . This configuration, therefore, provides an electrical switch that has an adjustable longitudinal pre-tension force that must be overcome before the switch 1 can actuate and complete the electrical circuit that is “open” until the contact ring 80 touches the switch bushing 60 . FIG. 9 shows the piston sub-assembly ( 10 , 20 , 80 , 90 , 100 ) in the actuated distal position and FIG. 8 shows the piston sub-assembly in the un-actuated proximal position
One exemplary process for assembly of the force switch 1 of FIGS. 1 to 9 , has the spring 50 inserted over the central shaft 16 of the piston 10 . The cap 40 is also screwed into the proximal bore 34 of the body tube 30 . The piston-spring sub-assembly is, then inserted through the interior bore 44 of the cap 40 and the tip 20 is fastened (e.g., screwed) onto the distal end 12 of the piston 10 . This forms a piston sub-assembly.
The insulating stub 90 is attached to the intermediate portion of the connecting bar 100 by being placed, first, over the distal boss 102 and, second, over the intermediate portion. Similarly, the contact ring 80 is attached to the insulating stub 90 by being placed thereover. The ring 80 is longitudinally connected to the insulating stub 90 and the stub 90 is longitudinally connected to the intermediate portion of the connecting bar 100 . The insulated wire 206 is passed through the bore of the mounting body 70 and through both the longitudinal 103 and transverse 106 bores of the connecting rod 100 and electrically connected to the interior surface of the contact ring 80 without electrically connecting the wire 206 to any portion of the mounting body 70 or the connecting bar 100 . This connection forms a switch sub-assembly that is ready to be connected to the piston sub-assembly.
Either or both of the distal boss 102 of the connecting bar 100 or the stub 62 of the switch bushing 60 can have threads for connecting the boss 102 to the piston 10 and/or the stub 62 to the body tube 30 . As such, the entire switch sub-assembly can be connected (both physically and electrically) to the piston sub-assembly. With these two sub-assemblies connected together, only the mounting body 70 needs to be connected to the proximal end of the switch bushing 60 . Such a connection can take any form, for example, the connection can be a weld or a mated set of screw threads.
FIGS. 10 to 17 illustrate a second exemplary embodiment of the force switch 1 having a “normally closed” switch configuration.
FIGS. 10 to 17 illustrate different portions of the force switch 1 . FIG. 14 provides an example view approximately through the longitudinal axis 2 of the force switch 1 that allows visualization of all parts of the switch 1 . The contact piston 10 provides a central part around which other parts of the switch 1 may be explained. The tip 20 is fastened to the distal end 12 of the contact piston 10 . The distal end 12 and the internal bore 22 of the tip 20 are illustrated with straight lines in FIGS. 13 to 15 and 17 , however, in the exemplary embodiment, the distal end 12 can be provided with external male threads and the bore 22 can be provided with internal female threads. Alternatively, the tip 20 can be press-fit, glued, welded, or otherwise connected to the distal end 12 of the contact piston 10 . In the configuration shown in FIGS. 13 to 15 and 17 , the proximal portion 24 of the internal bore 22 has the non-threaded flat portion for receiving therein the distal-most end of the piston 10 such that, when completely threaded into the bore 22 , the proximal portion 24 acts as a stop for further threading of the distal end 12 therein.
The piston 10 has a proximal end at which the widening 14 is provided to extend radially the outside surface of the piston 10 . The internal bore 16 is formed in the interior of the piston 10 at the proximal end.
As shown in the enlarged view of FIG. 16 , a hollow body tube 120 is disposed around at least a portion of the contact piston 10 . As compared to the first embodiment of the body tube 30 , the interior of this tube 120 has a constant diameter bore 122 . The bore 122 has a shape substantially equal to an exterior shape of the widening 14 and surrounds the central shaft 18 of the piston 10 . Accordingly, in a circular configuration, the interior diameter of the bore 122 is substantially equal to the outer diameter of the widening 14 .
There are two parts of the force switch 1 disposed between the piston 10 and the body tube 120 : a spring stop puck 130 and a bias device 50 . The exterior shape of the spring stop puck 130 and the interior shape of the bore 122 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the bore 122 is substantially equal to the outer diameter of the spring stop puck 130 so that the spring stop puck 130 slides within the bore 122 substantially without play but also without substantial friction. This spring stop puck 130 differs from the end cap 40 in that it floats entirely separate within the body tube 120 . More specifically, as the tip 20 is threaded onto the distal end 12 of the piston 10 , the proximal transverse surface pushes against but is not fixed to the distal transverse surface of the puck 130 . In such a configuration, it would, at first glance, seem to indicate that the compression spring 50 could only be set to one given compression value because the puck 130 has a fixed longitudinal length. This would be correct except a set of pucks 130 are provided, each having different longitudinal lengths. Therefore, the pre-tensioning of the spring 50 is adjusted by selecting one of the set of pucks 130 . Also, it is not necessary to thread the tip 20 entirely onto the distal end 12 of the piston 10 as shown in FIG. 13 , for example. Thus, if the tip 20 is not entirely threaded on the piston 10 , user-desired pre-tensioning of the bias device 50 occurs by providing a specifically sized puck 130 and threading the tip 20 onto the piston 10 at a predefined distance. Alternatively, the puck 130 can solely determine the pre-tension if the tip 20 is entirely threaded onto to the piston 10 . One embodiment of the stop puck 130 and bias device 50 is shown in FIGS. 10 to 17 . The following description, however, is directed to the view of FIG. 13 . The stop puck 130 is formed with an internal bore 132 having a shape substantially equal to the outer shape of the piston 10 so that the piston 10 can traverse through the puck 130 without hindrance.
When the spring stop puck 130 is within the bore 122 , the stop puck 130 substantially closes an interior space defined by the interior surfaces of the bore 122 , the exterior surface of the central shaft 18 , the distal transverse surface of the widening 14 , and the proximal transverse surface of the puck 130 . The bias device 50 is disposed inside this interior space. The bias device 50 and the stop puck 130 act together with the widening 14 to bias the piston 10 in a given direction, in this case, in the proximal direction. Force of the bias device 50 is dependent upon the longitudinal length of the stop puck 130 .
The bias device 50 is embodied, in this example, as a compression spring 50 . As such, when the spring 50 is placed around the central shaft 18 of the piston 10 up to the distal transverse surface of the widening 14 , and when the stop puck 130 is also around the central shaft 18 and the tip 20 is attached to the piston 10 , the spring 50 is compressed or pre-tensioned therebetween.
Because the piston 10 moves, it can form one contact of an electrical switch for signaling a state of the force switch 1 . Another contact needs to be provided that is electrically insulated from the piston 10 . Thus, the piston 10 needs to be associated with a switch sub-assembly so that the electrical force switch 1 is in a first state when the piston 10 is in a first longitudinal position and in a second state when the piston 10 is in a second longitudinal position (the first and second states being off/on or on/off). This switch sub-assembly is formed at a proximal end of the piston 10 and the body tube 120 and, in the following text, applies to the second exemplary “normally closed” embodiment.
The switch bushing 60 has a distally projecting stub 62 that is inserted into the proximal end of the body tube 120 . This stub 62 can be connected to the body tube 120 in any number of ways (e.g., by bonding, welding, adhesive, press-fit, screw threads). The proximal end of the switch bushing 60 is attached to a mounting body 70 . In one embodiment, each of the piston 10 , the tip 20 , the body tube 120 , the stop puck 130 , the switch bushing 60 , and the mounting body 70 are electrically conductive and provide a first electrical contact of the force switch 1 . However, the tip 20 and stop puck 130 need not be electrically conductive. To form a second electrical contact that, when put into electrical connection with the first contact, interrupts an electrical circuit as shown in FIGS. 10 to 17 , an insulating body needs to be disposed between the second contact and the first contact needs to be operatively moved out of contact with the second contact.
In the exemplary embodiment of FIGS. 10 to 17 , the second electrical contact is formed by a contact pin 140 and the insulating body is formed by an insulating bushing 150 . The part that connects the insulating bushing 150 and the contact pin 140 to the piston 10 is a T-shaped, electrically conductive, contact screw 160 . The insulating bushing 150 and the contact pin 140 are nested in their shape so that they can fit in an easy assembly into the switch bushing 60 and the mounting body 70 . The insulating bushing 150 physically and electrically separates the contact pin 140 from the mounting body 70 and the switch bushing 60 , which is in electrically conductive contact with at least the piston 10 and the switch bushing 60 .
More specifically, the internal bore 16 is shaped to receive a distal boss 162 of the contact screw 160 . The connection between the distal boss 162 and the internal bore 16 can be like any of the embodiments of the connection between the piston 10 and the tip 10 . If the boss 162 has an external male thread, for example, then the internal bore 16 has a corresponding female internal thread. Such an exemplary configuration makes attachment of the contact screw 160 and the piston 10 easy with regard to manufacturing costs and time. A transverse end surface 164 of the contact screw 160 also provides a stop for indicating complete insertion of the distal boss 162 inside the internal bore 16 of the piston 10 .
The insulating bushing 150 has an internal bore 152 having a shape dimensioned to correspond substantially to the outer shape of a proximal contact portion 142 of the contact pin 140 . This external outer shape of the proximal contact portion 142 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore 152 of the insulating bushing 150 corresponds thereto so that the insulating bushing 150 can be inserted thereon and fixed thereto (whether by press-fit, adhesive, bonding, welding, or any other connection process) so that control of contact between the contact pin 140 and any other portion of the first contact can be made with high precision.
After the insulating bushing 150 is connected to the contact pin 140 , the combined insulating sub-assembly can be connected to the mounting body 70 . The external shape of a proximal portion of the insulating bushing 150 is made to correspond to an internal shape of an internal bore 72 extending through the mounting body 70 . Again, the outer shape of the proximal portion of the insulating bushing 150 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the mounting body 70 corresponds thereto so that the insulating bushing 150 can be inserted thereon and fixed thereto (whether by press-fit, adhesive, bonding, welding, or any other connection process) so that control of contact between the contact pin 140 (mounted in the insulating bushing 150 and the mounting body 70 ) and any other portion of the first contact can be made with high precision.
With such a connection, the contact screw 160 electrically contacts the piston 10 (and, thereby, the body tube 120 , the switch bushing 60 , and the mounting body 70 , and possibly even the tip 20 and the stop puck 130 if desired). The outer shape/diameter of a distal transverse widening 144 of the contact pin 140 is dimensioned to be smaller than the inner shape/diameter of the switch bushing 60 and insertion of the contact pin 140 inside the switch bushing 60 creates a transverse gap 110 therebetween. Thus, the transverse gap 110 electrically isolates the distal widening 144 of the contact pin 140 from the inside of the switch bushing 60 , and the proximal contact portion 142 of the contact pin 140 is electrically isolated (insulated) from the mounting body 70 and the switch bushing 60 on the outer side thereof by being in direct contact with the interior bore 152 of the insulating bushing 150 .
To make an electric circuit between the contact pin 140 and any electrically conducting part of the first contact (e.g., 10 , 20 , 60 , 70 , 120 , 130 ), an electrical connection must be made at the contact pin 140 . One exemplary embodiment for such a connection is illustrated in FIGS. 11 to 17 . Specifically, the contact screw 160 is formed with a proximal transverse widening 166 extending radially from the intermediate portion thereof and defines a proximal transverse surface 168 . The bias device 50 biases the piston 10 and, thereby, the contact screw 160 in a proximal direction to electrically conductively contact the distal transverse surface 148 of the contact pin 140 to the proximal transverse surface 168 of the contact screw 160 . Because such contact needs to only be made between these two surfaces to complete an electrical circuit of the switch sub-assembly, the outer shape/diameter of the proximal widening 166 of the contact screw 160 can be any size or shape that slides within the interior bore 66 of the switch bearing 60 .
The other electrical contact of the contact pin 140 resides on the proximal side of the contact pin 140 . In one exemplary embodiment, a longitudinal bore 146 is formed from the proximal transverse surface of the contact pin 140 inward and receives therein an insulated wire 206 . The conductor of this wire 206 can be fastened (e.g., by welding) to the interior surface of the longitudinal bore 146 . Such an electrical connection is, for example diagrammatically shown in FIG. 7 . In such an exemplary configuration, the power source 202 supplies power to the contact indicator 204 (LED) and lights the LED when the electrical circuit is completed, which will always be the case in this normally closed configuration of the force switch 1 . Conversely, when electrical contact between the first contact and the contact pin 140 is removed, the LED 104 will turn off. Of course, the indicator need not be visual (e.g., the LED 104 ). It can also be audible (e.g., speaker with sound) or tactile (e.g., vibration), or any combination thereof.
It is also possible to provide circuitry 300 between the contact pin 140 and the mounting body 70 that lights the LED 204 only when the electrical circuit is opened (i.e., not completed). Any logic circuitry can be used to control the LED 204 based upon the two states of the force switch 1 shown in FIGS. 10 to 17 . For example, the logic 300 including a NOR gate and an AND gate can be connected to the force switch 1 circuit as shown in FIG. 13 . In such a configuration, when the switch 1 is in its normally closed state, the LED is off and when contact is broken, as shown in FIG. 17 , the LED will illuminate.
With the above exemplary configuration set forth, the functioning of the switch 1 between the first and second states can be described with regard to a comparison between FIGS. 16 and 17 .
As set forth above, the contact pin 140 is longitudinally secured within the insulating bushing 150 and the insulating bushing 150 is longitudinally secured within at least one of the switch bearing 60 and the mounting body 70 . The body tube 120 is longitudinally secured to the distal end of the switch bearing 60 . The stop puck 130 is disposed, freely longitudinally, between the spring 50 and the tip 20 . The piston 10 is longitudinally fixed to the tip 20 and to the contact screw 160 and this piston sub-assembly slides within the body 120 biased in the proximal direction by the spring 50 . Accordingly, the entire piston sub-assembly ( 10 , 20 , 130 , 160 ) can move in a distal longitudinal direction to compress the spring 50 inside the body tube 120 and this compression distance forms a space 134 (see FIG. 17 ) over which the force switch 1 functions as a switch.
The bias device (e.g., compression spring) 50 disposed between the puck 130 and the distal transverse surface of the widening 14 imparts a proximally directed force against the piston 10 when the puck 130 compresses the spring 50 . This force, referred to herein as a pre-tension, keeps the contact screw 160 against the electrically conductive distal transverse surface of the contact pin 140 . Without any external force imparted on the force switch 1 , the pre-tension will always keep the contact pin 140 at this position and electrical contact between the first contact and the contact pin 140 will remain. A distally directed external force F imparted upon the tip 20 could alter this situation. See FIG. 17 . If the force F is not as great as the pre-tension force imparted by the spring 50 , then the spring 50 will not compress any further than it has already been compressed by the puck 130 . However, if the force F is greater than the pre-tension force imparted to the piston 10 by the spring 50 , then the spring 50 will compress further and the tip 20 , along with the remainder of the piston sub-assembly ( 10 , 130 , 160 ) will move in a distal longitudinal direction. The distal longitudinal direction is limited by the greatest compression distance of the spring 50 , which, in most applications of the force switch 1 , will not occur. This configuration, therefore, provides an electrical switch that has an adjustable longitudinal pre-tension force that must be overcome before the switch 1 can actuate and complete the electrical circuit that is “closed” until the contact screw 160 no longer touches the contact pin 140 . The switching distance of the force switch 1 of FIGS. 10 to 17 is defined by the longitudinal gap 112 existing between the proximal transverse surface of the stub 62 and the distal transverse surface of the widening 166 . FIGS. 17 and 19 show the piston sub-assembly ( 10 , 130 , 160 ) in the actuated distal position and FIG. 16 shows the piston sub-assembly in the un-actuated proximal position.
One exemplary process for assembly of the force switch 1 of FIGS. 10 to 17 , the distal end of the switch bushing 60 having the projecting stub 62 is fastened longitudinally to the proximal end of the body tube 120 . The piston 10 inserted inside the body tube 120 and the spring 50 inserted over the central shaft 16 of the piston 10 inside the body tube 120 . The puck 130 is placed over the distal end 12 of the piston 10 and the tip 20 is fully or partially screwed onto the exterior threads of the distal end 12 of the piston 10 . At this point, if the tip is fully screwed onto the piston 10 , the piston 10 will impart the pre-tension force onto the stub 62 of the switch bushing. To avoid this force, the tip 20 can be only partially screwed onto the distal end 12 of the piston 10 . The contact screw 160 is, then, screwed into the internal bore 16 of the piston 10 at the proximal end thereof to capture the stub 62 between the widening 14 of the piston 10 and the widening 166 of the contact screw 160 . This forms a piston-spring sub-assembly.
The mounting body 70 is longitudinally fixedly connected to the contact pin 140 with the insulating bushing 150 therebetween. Because of the nested shapes of these parts, the order of the connection is limited only by the costs and time for manufacturing the connections. Alternatively, the insulating bushing 150 and the contact pin 140 can be placed inside the distal end of the mounting body 70 , but, in such a case, these two parts could move longitudinally if the distal end of the force switch 1 is tilted downward. This forms a contact pin sub-assembly.
The piston-spring and contact pin sub-assemblies are connected together by fastening, longitudinally, the mounting body 70 to the switch bushing 60 . If the tip 20 is fully screwed onto the piston 10 , then the fastening will have to overcome the pre-bias force of the spring 50 . If, however, the tip 20 is minimally screwed onto the piston 10 such that no pre-bias exists in the spring 50 , then, after all longitudinal fastening has occurred, the tip 20 can be fully screwed onto the distal end 12 of the piston 10 to place the spring 50 in the pre-tensioned state. The conductor of the insulated wire 206 is attached in the longitudinal bore 146 of the contact pin 140 to complete the circuit 300 .
In each case of the normally open and normally closed configurations, the longitudinal gap 112 has a length of between approximately 25 μm (0.001″) and approximately 750 μm (0.030″), or in a shorter range between approximately 75 μm (0.003″) and approximately 200 μm (0.008″).
The conductive parts of the force switch 1 can be of stainless steel, copper, nickel-plated copper, nickel-plated brass, for example. Where the conductor of the insulated wire 206 needs to be soldered, each of these materials will be sufficient.
The range of force that the force switch 1 applicable for switching between the two states can be between approximately 3 ounces to approximately 20 pounds, or a shorter range of approximately 5 pounds to approximately 8 pounds.
With regard to the mechanics of selecting the spring 50 , the desired pre-tension force is selected to be within or at the mid-range of the range of a given spring 50 . In other words, the change in state of the force switch will occur not close to a maximum of the spectrum of the spring 50 pre-tension but, instead, somewhere in the middle of the spectrum.
The circuitry described above only provides a binary output—whether or not the force on the external object that is transmitted through the force switch 1 is greater or less than the pre-tensioning. If the force switch is provided with a strain gauge, also referred to as a load cell, then a continuous force output can be displayed to the user in which, for example, a row of LEDs gradually light up dependent upon the amount of force or an LCD or LED numerical field increments numerical values corresponding to the amount of force imparted through the force switch 1 .
The force switch 1 above will now be described with respect to use in an intraluminal anastomotic circular stapler as depicted, for example, in U.S. Pat. No. 5,104,025 to Main et al. (“Main”), and assigned to Ethicon Endo-Surgery, Inc. This reference is hereby incorporated herein in its entirety. As can be seen most clearly in the exploded view of FIG. 7 in Main, a trocar shaft 22 has a distal indentation 21, some recesses 28 for aligning the trocar shaft 22 to serrations 29 in the anvil and, thereby, align the staples with the anvils 34. A trocar tip 26 is capable of puncturing through tissue when pressure is applied thereto. FIGS. 3 to 6 in Main show how the circular stapler 10 functions to join two pieces of tissue together. As the anvil 30 is moved closer to the head 20, tissue is compressed therebetween, as particularly shown in FIGS. 5 and 6. If this tissue is overcompressed, this surgical stapling procedure might not succeed. The interposed tissue can be subject to a range of acceptable compressing force during surgery. This range is known and is dependent upon the tissue being stapled. The stapler shown in Main cannot indicate to the user any level of compressive force being imparted upon the tissue prior to stapling. However, if the force switch 1 described herein is substituted for the trocar shaft 22, then the stapler 10 will be capable of showing the user when the compressive force (acting along the longitudinal axis 2 of the force switch 1 ) has exceeded the pre-tension of the switch 1 . This pre-tension can be selected by the user to have a value within the range of acceptable tissue compressive force.
FIGS. 1 and 10 of the present application show a tip 20 having a pointed distal end that can function within at least the CDH surgical stapler manufactured and sold by Ethicon Endo-Surgery, Inc. The proximal end of the trocar shaft 22 in Main requires a male threaded screw for attachment to the head 20. Other circular staplers require an opposing tang embodiment that is shown in FIGS. 1 and 10 of the present application. Thus, the mounting body 70 can be in the form illustrated in FIGS. 1 to 17 or in the form shown in FIG. 7 in Main. The tip 20 and mounting body 70 can be customized to fit into any kind of similar surgical device.
The foregoing description and accompanying drawings illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
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A method of creating a switch to be disposed along a longitudinal axis of a device, comprising providing a hollow body defining an interior cavity, disposing a switching element movably within the interior cavity, the switching element defining a switch-making position and a switch-breaking position and having a biasing element, coupling an electrically-conductive contact to the switching element to define a switch-making state when the switching element is in the switch-making position and a switch-braking state when the switching element is in the switch-braking position, and imparting a variable longitudinal bias to the switching element with the biasing element to place the switching element in one of the switch-making position and the switch-braking position until an external force imparted to the switching element along the switching axis exceeds the longitudinal bias thereby causing the switching element to move to the other one of the switch-making position and the switch-braking position.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent application is a divisional patent application of U.S. Ser. No. 12/842,021 filed on Jul. 22, 2010, which claims priority to U.S. Provisional Application Ser. No. 61/271,559, filed Jul. 22, 2009 and U.S. Provisional Application Ser. No. 61/276,215, filed Sep. 9, 2009, the contents of which are incorporated by reference herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with U.S. Government support under Contract No. IIP-0912711 awarded by the National Science Fund (NSF). The government has certain rights in this invention.
TECHNICAL FIELD OF THE INVENTION
[0003] The present invention relates to devices and methods designed to apply forces to the exterior surface of a heart to promote cardiac assist, support and diastolic recoil of a diseased or damaged heart with diastolic dysfunction, systolic dysfunction, or a combination of diastolic and systolic dysfunction.
BACKGROUND OF THE INVENTION
[0004] Congestive heart failure (CHF) is a major public health issue in the developed and developing world. In the U.S., CHF affects more than 5.7 million people with 550,000 new cases diagnosed each year. Approximately 20% of hospitalizations are due to acute CHF, incurring a health-care system cost of $37.2 billion (AHA statistics, 2009). Heart failure has two main forms: systolic dysfunction and diastolic dysfunction. Some people with heart failure have both types of dysfunction. In systolic dysfunction, the heart contracts less forcefully and cannot pump out as much of the blood that is returned to it as it normally does. As a result, more blood remains in the lower chambers of the heart (ventricles). In diastolic dysfunction, the heart is stiff and does not relax normally after contracting, which impairs its ability to fill with blood. The heart contracts normally, but is unable to pump a normal proportion of blood out of the ventricles because filling was sub-optimal. Often, both forms of heart failure (systolic and diastolic) occur together. Although systolic heart failure is more commonly mentioned, there is growing recognition that congestive heart failure (CHF) caused by a predominant abnormality in diastolic function (i.e., diastolic heart failure) is both common and causes significant morbidity and mortality. Diastolic heart failure can occur alone or in combination with systolic heart failure. In patients with isolated diastolic heart failure, the only abnormality in the pressure-volume relationship occurs during diastole, when there are increased diastolic pressures with normal diastolic volumes. When diastolic pressure is markedly elevated, patients are symptomatic at rest or with minimal exertion (NYHA class III to IV). With treatment, diastolic volume and pressure can be reduced, and the patient becomes less symptomatic (NYHA class II), but the diastolic pressure-volume relationship remains abnormal.
[0005] In patients with systolic heart failure, there are abnormalities in the pressure-volume relationship during systole, which includes decreased ejection fraction (EF), stroke volume, and stroke work. In addition, there are changes in the diastolic portion of the pressure-volume relationship. These changes result in increased diastolic pressures in symptomatic patients, which indicate the presence of combined systolic and diastolic heart failure. Whereas the diastolic pressure-volume relationship may reflect a more compliant chamber, increased diastolic pressure and abnormal relaxation reflect the presence of abnormal diastolic function. Thus, all patients with systolic heart failure and elevated diastolic pressures likely have combined systolic and diastolic heart failure.
[0006] Another form of combined systolic and diastolic heart failure is also possible. Patients may have only a modest decrease in EF and a modest increase in end-diastolic volume but a marked increase in end-diastolic pressure and a diastolic pressure-volume relationship that reflects decreased chamber compliance. Therefore, all patients with symptomatic heart failure potentially have abnormalities in diastolic function; those with a normal EF have isolated diastolic heart failure, and those with a decreased EF have combined systolic and diastolic heart failure.
[0007] Heart failure typically begins after an “index event” produces an initial decline in pumping capacity of the heart. Following this initial decline in pumping capacity of the heart, a variety of compensatory mechanisms are activated, including the adrenergic nervous system, the renin angiotensin system and the cytokine system. In the short term these systems are able to restore cardiovascular function to a normal homeostatic range with the result that the patient remains asymptomatic. However, with time the sustained activation of these systems can lead to secondary end-organ damage within the ventricle, with worsening left ventricle (LV) remodeling and subsequent cardiac decompensation. As a result of resultant worsening LV remodeling and cardiac decompensation, patients undergo the transition from asymptomatic to symptomatic heart failure (Heart Failure Reviews, 10, 95-100, 2005).
[0008] In systolic heart failure, the LV undergoes a transformation from a prolate ellipse to a more spherical shape resulting in an increase in meridional wall stress of the LV, which in turn creates a number of de novo mechanical burdens for the failing heart. This LV remodeling dramatically alters the mechanical environment, which in turn influences growth and remodeling processes. A positive feedback loop emerges leading to acute dysfunctional cardiac pumping, pathologic neurohormonal activation, and the inability of the remodeled LV to respond appropriately to compensatory mechanisms.
[0009] Progressive LV dilation and subsequent remodeling is one of the mechanisms that lead to LV wall stress and myocardial stretch. Increased LV wall stress may lead to sustained expression of stretch-activated genes (angiotensin II, endothelin and tumor necrosis factor) and/or stretch activation of hypertrophic signaling pathways as stretch triggers myocyte responses both by inducing the release of humoral factors that are important in the initiation and maintenance of hypertrophy, as well as via the direct activation of signaling pathways as well.
[0010] LV dilation and increased LV sphericity are also sensitive indicators of poor long-term outcome. Thus, cardiac wall stress (which can be defined as the “force per unit of cross-sectional area”) of the ventricular wall is directly related to the difference in pressure between the ventricles and ventricular radius, and inversely related to ventricular wall thickness. So with LV remodeling, an increase in ventricular volumes and a subsequent increase in ventricular radius, a larger force is required from each individual myocyte to produce enough pressure in the ventricles. Wall tension is seen as a function of both internal pressure and vessel radius. Also, with ventricular remodeling, cardiac mass can increase, with a corresponding increase in ventricular wall thickness. Any such increase in wall thickness would result from remodeling at the cellular/extracellular matrix level by several processes including myocyte hypertrophy, cell slippage, and interstitial growth. However, such increases in wall thickness do not adequately compensate for the increase in wall stress resulting from cardiac chamber dilation with an increasing metabolic stress. Thus, ventricular remodeling is maladaptive, despite any incremental increase in ventricular wall thickness. Laplace's equation provides a framework for defining means of mitigating ventricular remodeling. Ventricular wall stress can be reduced by (1) decreasing transmural pressure; (2) reducing cardiac chamber radius; and/or (3) promoting greater ventricular wall thickness. A diastolic support device can have a significant impact on effective transmural pressure which can lead to a decrease in the diastolic wall stress and modulate the end-diastolic volume.
[0011] Of the 5.7 million people in the US and 25 million people worldwide who suffer from heart failure, between 30-55% of these patients suffer from diastolic heart failure (DHF) and are without effective treatment. The term diastolic heart failure (DHF) generally refers to the clinical syndrome of heart failure associated with a preserved left ventricular EF, in the absence of major valvular disease. Forty percent of incident CHF cases and 50-60% of prevalent CHF cases occur in the setting of preserved systolic function. Mortality rate among patients with DHF is considered lower than in systolic heart failure. Some challenge this notion, showing that the natural history of patients with DHF may not be different from that of patients with systolic heart failure. The morbidity and rate of hospitalization are similar to those of patients with systolic heart failure. Due to its higher prevalence in the elderly population, the incidence of DHF is expected to rise with the increased aging of the western world population. The fundamental problem in diastolic heart failure is the inability of the left ventricle to accommodate blood volume during diastole at normal filling pressures.
[0012] Two basic types of diastolic abnormalities may be present, impaired ventricular relaxation, which primarily affects early diastole, and increased myocardial stiffness, which primarily affects late diastole. The rate and extent of the active relaxation may influence LV suction during the early filling phase. Both abnormalities lead to elevation of diastolic pressures. In DHF patients, a relatively small increase in central blood volume or an increase in venous tone, arterial stiffness, or both, can cause a substantial increase in left atrial and pulmonary venous pressures and may result in exercise intolerance and acute pulmonary edema. The mechanisms underlying abnormalities in diastolic function can be divided into factors intrinsic to the myocardium itself and factors that are extrinsic to the myocardium. Myocardial factors can additionally be divided into cellular and extracellular. Cellular factors include impaired calcium homeostasis leading to abnormalities in both active relaxation and passive stiffness, changes in sarcomeric proteins isotypes, such as titin, which acts as a viscoelastic spring that gains potential energy during systole and provides a recoiling force to restore the myocardium to its resting length during diastole. Since relaxation is an energy consuming process, any abnormalities in cellular energy supply and utilization can lead to impaired relaxation. Extracellular factors include changes in structures and quantity of the extracellular matrix, i.e. fibrosis, that lead to increased myocardial stiffness. There is limited data on neurohumoral markers in DHF patients other than natriuretic peptides (NPs). This probably reflects the fact that DHF has only recently been recognized as an important clinical problem. The present work is towards development of a novel diastolic recoil device to manage patients with diastolic heart failure.
[0013] For treating systolic heart failure there are several classes of solutions, e.g., pharmaceuticals, stem cells, electrical devices, mechanical devices, and surgical reconstruction. Each of these are designed for some limited target action (i.e., beta-blockade, ACE inhibition, electrical pacing, cardiac assist, etc.); consequently, heart failure remains a cause of tremendous morbidity and healthcare burden. Conventional approaches fail to address the possibility that mechanical stimuli are important parameters for guiding growth and remodeling, processes that may ultimately facilitate the recovery of mechanical organs. The mechanical heart assist devices Class IIIA and IIIB are classified into active devices that provide pumping energy, and passive devices that modulate the shape of the heart. The active devices are subdivided into blood pumps, counter pulsation assist devices (aortic balloon pumps), and direct cardiac compression devices (DCCDs). The passive, “support” devices directly interact with the heart to change shape or limit growth.
[0014] Diastolic heart failure therapies presently include mostly pharmaceutical products and there are few, if any, devices available. There are presently no approved devices for treatment of the DHF symptoms. However, two preclinical stage recoil device concepts, LEVRAM and Imcardia have a potential role in the treatment of DHF patients. These and other devices are seen in U.S. Patent Application Publication No. 2008/0071134, In Vivo Device for Assisting and Improving Diastolic Ventricular Function; U.S. Patent Publication No. 2006/0276683, In-Vivo Method and Device for Improving Diastolic Function of the Left Ventricle; and U.S. Patent Application Publication No. 2006/0241334, In Vivo Device for Improving Diastolic Ventricular Function.
[0015] Cardiac strain patterns appear to be a major controller of cardiac stem cell differentiation into functional cardiomyocytes. The exact normal or physiologic strain pattern of the heart is not currently known. Tests to determine the normal strain pattern in the heart of eight healthy sheep using bi-plane x-ray data of radio-opaque markers produced eight distinctly different patterns. It appears that cardiac contraction is similar to gait; there are gross similarities amongst individuals (e.g., toe off and hip twist), but the details can be distinctly different (e.g., angle of leg at toe off, amount and timing of the hip twist). In fact, people can often be recognized from their gait. While it is difficult to describe a normal gait, it is quite easy to classify abnormal gaits. Likewise, normal cardiac strain pattern is difficult to define and prescribe, yet it is quite easy to identify abnormal cardiac strain patterns such as dyskinesis and hypokinesis.
[0016] It is well established that mechanical stimuli (e.g., stress or strain) are important epigenetic factors in cardiovascular development, adaptation, and disease. In the vasculature, for example, it appears that perturbed loading conditions heighten the turnover of cells (proliferation and apoptosis) and matrix (synthesis and degradation) in altered configurations, thus resulting in altered geometries, properties, and biologic function. Just as similar mechanisms appear to be operative in hypertension, aneurysms, and micro-gravity induced changes, it is likely that they are operative in cardiac disease.
[0017] Dyskinesis or aberrant motion of the myocardium during contraction is likely important in all diseases of the heart that involve remodeling of the myocardium. Clearly, borderzone myocardium is viable yet overloaded to the extent that it is dyskinetic, i.e., lengthens when it should shorten. It is likely that overloading leads to aberrant remodeling because offloading leads to: normalization of genes that regulate calcium handling, tumor necrosis factor and cytoskeleton proteins; regression of fibrosis and cellular hypertrophy, and improved in-vitro contractile function. Too much offloading is suspected to result in heart atrophy, whereby gradual weaning from a device should be sought along with combination therapy such as with clenbuterol.
[0018] At the cellular level, myofibrillar organization, sarcomere alignment and cell migration are all known to be mediated by mechanical factors. Mechanical factors are also known to play an important role in the behavior of stem cells, suggesting that understanding and control of the mechanical environment may be critical to the realization of the potential for stem cell therapies.
[0019] Cellular and subcellular investigations have established that altered hemodynamic loading leads to growth and remodeling of myocytes and extra-cellular matrix and myocytes are very sensitive to perturbations in strain and respond with altered gene expression. Abnormal cardiac kinematics is often considered as a symptom of heart failure when in actuality it may be a primary cause of the aberrant growth and remodeling. Other CHF mechanisms or co-contributors are, among others, loss of myocyte shortening capability, calcium dysregulation and unspecified myocyte apoptosis.
[0020] Regenerative therapies incorporating stem cells have demonstrated potential but have yet to be fully developed. Benefits observed in stem cell studies have been controversial, e.g., there is a general lack of evidence that implanted stem cells are actually integrating with the native tissue as functional cardiomyocytes. Stem cells are typically transplanted into the diseased myocardium where fiber alignment is highly disorganized and disrupted by fibrotic tissue. In the dyskinetic myocardium, the mechanical and environmental cues required to guide alignment and migration of transplanted cells are severely compromised. The device described herein, provides the means to restore motion that may be critical to establishing the appropriate physiologic mechanical environment required to optimize stem cell transplant therapies.
[0021] The various mechanical assist therapies (i.e., drugs, biventricular pacing, blood contacting assist devices, surgical manipulations, or passive stents and constraints etc.) typically off-load the heart and thus only modulate the strain pattern indirectly (e.g., through greater ejection fraction). Only direct cardiac compression devices (DCCDs) can directly induce a particular strain pattern. However, most prior DCCDs have been developed for enhancing ejection fraction or for ease of implantation rather than for strain modulation. Most induce aberrant strain patterns during contraction.
[0022] What follows is a discussion of the disadvantages of the prior art. FIGS. 1A-1D shows the normal, null, and inverted curvature in apex-to-base, radial plane (long axis) of the heart. FIG. 1A illustrates a normal or positive curve with the inside of the curve toward the chamber, where the top references the base and the bottom references the apex. FIG. 1B illustrates a null curvature. FIG. 1C illustrates an inverted or negative curvature where the inside of the curve is away from the chamber. FIG. 1D is an illustration that shows the curvature inversion of the Anstadt cup as illustrated in FIG. 9 of the Anstadt patent (U.S. Pat. No. 5,119,804). DCCDs have been characterized as most promising with good hemodynamics and ease of implantation. A number of DCCDs are being developed. The Anstadt cup is shown in FIG. 1D . The CardioSupport System by Cardio Technologies Inc. is similar to the Anstadt cup. The attachment is via vacuum on the apical end and the assist is via inflation of a membrane that lies between a rigid shell and the epicardial surfaces of the right ventricle (RV) and left ventricle (LV). The devices of Parravicini and the AbioBooster by Abiomed Inc. are sewn to the interventricular sulci, and elastic sacks between the shell and the epicardial surface are inflated during systole. The DCC Patch by Heart Assist Tech Pty Ltd. is similar to the AbioBooster. It has been described as “ . . . two patches shaped to suit the profile of the heart . . . inflated and deflated in synchrony with the heart . . . ” The heart booster is composed of longitudinal tubes that have elliptical cross-sections with the major axis of the ellipse in the hoop direction.
[0023] To understand how all of these DCCDs induce aberrant strain patterns, it is important to note that contraction strain depends on both the end-diastolic configuration (reference configuration) and the end-systolic configuration (current configuration). The strain field is a function of the gradient (with respect to reference position) of the mapping of material points from the reference configuration to the current configuration. Thus, the fact that prior DCCDs fit the diastolic configuration is inconsequential to achieving an appropriate contraction strain pattern because their end-systolic configurations are grossly aberrant. Although strains induced by such motions as torsion may not perturb the heart geometry; if the overall geometry is abnormal, then the strain must be abnormal. Unphysiological geometries are illustrated in FIGS. 1A-1D .
[0024] Generally, the curvature is inversely proportional to the radius-of-curvature and that curvature changes sign when the origin of the radius-of-curvature changes sides. As should be evident from FIG. 1D , curvature inversion can greatly increase EF. However, the curvature of the ventricles in a normal heart does not invert during systole, thus rendering such motions grossly abnormal. A healthy heart, moreover, will resist having its curvature inverted and heart function needs to decline by 30% before the effect of “non-uniform direct cardiac compression” becomes noticeable. In short, the heart resists assist when a DCCD induces aberrant strains. DCCD devices described above induce motions that are grossly abnormal. The Vineberg device inverts curvature in long axis planes and short axis planes. The Anstadt cup and Cardio-Support System invert curvature in long axis planes yet preserve curvature in the short axis planes. The AbioBooster, DCC Patch, Hewson device, and Parravicini devices pull on the interventricular sulci and push on the freewall such that the curvature will increase at the sulci and decrease on the freewalls. The Heart Booster inverts curvature in short axis planes, yet preserves curvature in the long axis planes. Because they were not designed to eliminate aberrant motions, it should not be surprising that these existing DCCDs described above induce aberrant strain patterns.
[0025] Additionally, none of the existing DCCDs described above are implanted in a minimally invasive fashion, and such an implantation method is highly desirable, clinically useful, and commercially advantageous. Given that strain is a primary stimulus of myocardial growth and remodeling, there is a need for a DCCD that eliminates dyskinetic or hypokinetic motions in the heart.
[0026] This device, described in U.S. patent application Ser. No. 10/870,619, filed Jun. 17, 2004 (the '619 application), which is incorporated by reference herein, is the first implantable device to proactively modulate the strain pattern during contraction. The class of devices claimed in the '619 application are those that apply direct cardiac compression in a manner such that the end-diastolic and end-systolic configurations are physiologic with normal cardiac curvature, i.e. the class of direct cardiac compression device that achieve cardiac rekinesis therapy. The device disclosed in the '619 application must be attached to the valve plane of the heart. An attachment developed in benchtop trials consists of suture runs along the right and left free walls together with stents that go from the device shell to the center of the valve plane via the transverse pericardial sinus (anterior stent) and oblique pericardial sinus (posterior stent). In addition to keeping the heart in the device, the stents eliminate the need to suture near the coronary arteries in the interventricular sulci. The highly elastic membrane on the epicardial surface is sealed tightly with the rigid shell to contain the pneumatic driving fluid (e.g., air). A typical membrane requires about 1 kPa (10 cm H20) of vacuum to unimpede heart filling. This is similar to that of the native heart which typically requires about 9 cm H20 of transmural pressure to fill (e.g., 6 cmH20 of venous pressure minus a negative 3 cm H20 of intrathoracic pressure). The pressure waveforms (with compression for systole and tension for diastole) were generated by a Superpump System made by Vivitro Systems Inc. for cardiovascular research. The sync out signal was amplified, made bipolar, and used to pace the heart via right atriam (RA) leads.
[0027] One method of overcoming some negative effects of a hard-shelled DCCD (e.g., the need for a large thoracotomy) is to use a soft-shelled device. Soft-shelled devices include DCCDs with primary components that are constructed out of highly deformable materials. Such DCCDs can be collapsed and possibly implanted through a small incision this is likely to be sub-xiphoid (e.g., inferior to the xiphoid process) or a left thoracotomy. The Abiobooster and Heart Booster are currently existing soft-shelled devices. However, as described above, both of these devices induce an aberrant strain pattern in the heart. Additionally, implantation methods for these devices still require sewing the devices to the heart or pericardium.
[0028] The above mentioned direct cardiac compression devices are active devices or assist devices that have a power source and method of delivering the power to increase cardiac output. Other devices that contact the outer surface of the heart are cardiac support devices and diastolic recoil devices. Cardiac support devices are useful for limiting the heart size, but they constrict the heart and thus impede filling (at best, they do not impede filling until some limit point where size of the heart is limited). Dynamically adjustable support devices are further useful because the limit point can be controlled to additionally decrease the size of an enlarged heart. Diastolic recoil devices are useful for increasing the recoil or filling of the heart, but they do not necessarily limit the heart size.
[0029] What is desired is a mechanical oriented device and therapy designed to optimize the mechanical environment for heart growth and remodeling that are restorative and potentially rehabilitative in nature.
SUMMARY OF THE INVENTION
[0030] The present invention is a mechanical oriented therapy designed to optimize the mechanical environment for heart growth and remodeling that are restorative and potentially rehabilitative in nature. More specifically, the present invention is an extra-cardiac, biphasic and dynamic support and diastolic recoil device with intrinsic pneumatic attachment to the exterior surface of the heart, with a mechanism to enable heart motions such as twisting and contracting, and/or a combination of the recoil device with adjustable passive support and/or active assist so to treat both systolic and diastolic causes of heart failure. The device action of the present invention is biphasic with a “filling impediment” phase and with a “filling enhancement” phase. The “filling impediment” phase reduces heart size and alleviates the problems associated with cardiac dilatation. The “filling enhancement” phase assists the heart fill during diastole and alleviates the problems associated with diastolic dysfunction. The present invention further comprises a diastolic recoil mechanism device that is biphasic about a “limit point” with “filling enhancement” for cardiac volumes below the limit point and “filling impediment” for cardiac volumes above the limit point. In a further embodiment, the limit point of the present invention can be dynamically adjustable post implantation.
[0031] The present invention is a mechanical oriented therapy designed to optimize the mechanical environment for heart growth and remodeling that are restorative and potentially rehabilitative in nature. The present invention is a recoil device with intrinsic pneumatic attachment to the exterior surface of the heart, with a mechanism to enable heart twisting motion, and/or a combination of the recoil device with adjustable passive support and/or active assist so to treat both systolic and diastolic causes of heart failure. Some embodiments of the present invention produce a normal cardiac strain pattern while other embodiments eliminate or reduce abnormal strain patterns. By eliminating aberrant strain patterns with the present invention, abnormal growth and remodeling is retarded and becomes restorative. Further, by eliminating hypokinesis, for example, the device may reduce apoptosis, enhance myocyte development from native stem cells, and lead to ventricular recovery.
[0032] The present invention provides a direct cardiac contact device adapted to be implanted in a patient suffering from congestive heart failure and related cardiac pathologies, said cardiac device having means for providing ventricular assist, ventricular support and diastolic recoil, or for providing ventricular support and diastolic recoil only.
[0033] The device includes a means for determining a phase transition point (target end diastolic volume (TEDV)) that may be adjustable or provide a means for dynamic adjustable support in some embodiments. For cardiac volumes below TEDV, the device enhances filling in a filling enhancement phase and for cardiac volumes above TEDV the device impedes filling in a filling impediment phase.
[0034] The device provides an adjustable passive support component that continually applies support to the epicardial surface of the heart, thereby promoting reverse remodeling. In addition the method may include the step of adjusting the support wherein, as the diseased heart begins to respond to the support by becoming smaller, the TEDV can be adjusted to provide the same amount of support as the initial treatment intervention.
[0035] The present invention may also include a diastolic recoil enhancement having elastic memory component which is utilized when cardiac pressures are lower than TEDV by creating a negative pressure that promotes ventricle filling and when cardiac pressure exceeds TEDV, the device acts to constrain filling and cardiac volume. The diastolic recoil device is adapted to remain deployed about the heart via intrinsic pneumatic attachment without suturing or any direct attachment method.
[0036] The device may include one or more elastic energy storing elements that is a frame or mesh made of shape memory alloys or polymers. The device may also include components designed to provide adjustable passive support, active assist, or a combination of active assist and adjustable passive support to a damaged or diseased heart. The diastolic recoil device also includes imparting a twisting motion to a heart as it is contracted and then untwists as it recoils. The present invention also includes a diastolic recoil device for assisting a diseased or damaged heart by providing direct cardiac contact that compresses the heart during contraction without inverting or significantly perturbing the curvatures of the heart.
[0037] The present invention includes a method of using a direct cardiac contact ventricular assist, ventricular support and diastolic recoil by determining a phase transitioning point (target end diastolic volume (TEDV)); and operating in a biphasic mode about an adjustable phase transition point (TEDV). The method may also include enhancing filling in a filling enhancement phase when cardiac volumes are below TEDV and or and impeding filling (i.e., “filling impediment” phase) when cardiac volumes above TEDV.
[0038] The present invention includes a direct cardiac contact diastolic recoil device to improve diastolic recoil of a heart and reduce postoperative pericardial adhesion. The device includes a first biocompatible film for adhesion to the epicardial surface of the heart; a second biocompatible film for adhesion to the chest cavity, one or more fluid filled bladders that separate the first biocompatible film and the second biocompatible film to prevent adhesion between the epicardial surface of the heart and the chest wall; and one or more structural elements in contact with the first biocompatible film, the second biocompatible film or both to store elastic energy during heart contraction and release energy during heart filling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] A more complete understanding of the present invention may be obtained by reference to the following Detailed Description, when taken in conjunction with the accompanying Drawings, wherein:
[0040] FIGS. 1A-1D are diagrams showing the normal, null and inverted curvature in apex-to-base, radial plane of the heart;
[0041] FIGS. 2A-2B are schematic diagrams of the cross-section, top down view, of a device according to one embodiment of the present invention without a heart inside, wherein FIG. 2A is in the deflated state and FIG. 2B is in the pressurized state;
[0042] FIGS. 3A-3B are schematic diagrams of the long-section of a device according to one embodiment of the present invention without a heart inside, wherein FIG. 3A is in the deflated state and FIG. 3B is in the pressurized state;
[0043] FIGS. 4A-4B are schematic diagrams of the cross-section of a device according to one embodiment of the present invention with a heart inside, wherein FIG. 4A is in the deflated state and FIG. 4B is in the pressurized state;
[0044] FIGS. 5A-5B are schematic diagrams of the long-section of a device according to an embodiment of the present invention with a heart inside, wherein FIG. 5A is in the deflated state and FIG. 5B is in the pressurized state;
[0045] FIGS. 6A-6B are schematic diagrams of one embodiment of the present invention configured to reduce right ventricle input by reducing right ventricle filling;
[0046] FIG. 7 is an illustration of one embodiment of the present invention wherein a nitinol scaffold is incorporated to mediate the end-diastolic configuration;
[0047] FIG. 8 is an illustration of one embodiment of the present invention wherein a nitinol scaffold is incorporated to mediate the end-diastolic configuration;
[0048] FIG. 9 is a cross-section illustration of one embodiment of the present invention depicting its support, assist, and recoil components;
[0049] FIG. 10 is a plot which illustrates the biphasic character of the present invention; and
[0050] FIG. 11 is a plot which illustrates the ability of the present invention to adjust the target end-diastolic volume (TEDV) or transition point when the device of the present invention is adjusted.
DETAILED DESCRIPTION OF THE INVENTION
[0051] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0052] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
[0053] As used herein, the “cardiac rekinesis therapy” is the restoration of physiological or beneficial motion to the heart, or in other words, to eliminate aberrant or pathophysiological motions or strains, as opposed to circulatory assist therapies.
[0054] As used herein, a “biomedical material” is a material which is physiologically inert to avoid rejection or other negative inflammatory response.
[0055] The present invention will now be described more fully with reference to the accompanying drawings, in which preferred embodiments of the present invention are shown. The present invention may, however, be embodied in many different forms and should not be constructed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art.
[0056] The present invention comprises a contoured diastolic recoil device that enhances diastolic recoil of a damaged or diseased heart. The diastolic recoil device does not need to be sutured or directly attached to the heart. Rather, the diastolic recoil device intrinsically attaches to the heart via pneumatic locking. In operation, there is no free air in the chest between the device and heart so if the heart becomes smaller (due to ejection of blood), the device is pulled inward. Likewise, when the device pushes outward, it applies a suction-like traction to the heart. If free air were present in the chest, which it normally is not, the suction-like traction would draw air between the device and heart. However, with no free air, the suction traction is applied directly to the heart surface. This pneumatic locking, or intrinsic pneumatic attachment, is illustrated by analogy: it is very difficult to pull a water balloon out of a cup when they are placed inside of a bag in which the air has been evacuated (i.e., like a closed chest). After air in the mediastinum is removed, the heart and device are pneumatically locked in a co-axial configuration.
[0057] The diastolic recoil device of the present invention uses the intrinsic pneumatic attachment and its elastic properties to enhance the diastolic recoil of the heart. At the end of systole and the beginning of diastole the diastolic recoil device of the present invention acts like a loaded spring, applying negative pressure to the exterior epicardial surface of the heart, helping the ventricles of the heart to fill.
[0058] The present invention is a significant innovation in the cardiac device industry, as it can address both systolic and diastolic heart failure with a single device design. The present invention can be used with patients having either systolic or diastolic heart failure but also those with combined systolic and diastolic failure. Conventional passive devices for treating systolic heart failure are designed to provide mechanical constraint and support of an enlarged myocardium; but, unlike the present invention are not adjustable following implant. Further, such conventional devices lack the ability to sustain reduction of the left ventricular dimensions. Moreover, the conventional devices are designed to fibrose to the heart surface to stabilize the device-heart interaction. The present invention can be adjusted post implant. The ability to adjust the device of the present invention following implant provides a proactive means to constrain and gradually reduce hypertrophy in the diseased heart. Accordingly, the present invention, with its diastolic recoil design, also addresses the problem of diastolic heart failure. The present invention provides a means for stimulating cardiac remodeling events under conditions that are restorative toward full cardiac rehabilitation.
[0059] The present invention comprises a minimally-invasive device that is deployed into the pericardial space surrounding the heart for modulating the mechanics of a failing heart. The adjustable passive support and diastolic recoil technology achieves ventricular size reduction and also enhanced ventricular filling in both systolic and diastolic heart failure patients.
[0060] Though different devices exist today with specific indications for medium/long term support, the minimally invasive implantable device of the present invention is the first device which provides an adjustable passive support and diastolic recoil technology integrated in a same device design.
[0061] The adjustability of the device enables cardiologists to proactively intervene in heart failure whereby specific mechanical conditions can be generated and employed to direct growth and remodeling events that are restorative and/or rehabilitative in nature. In particular, the present invention can directly shift the end-diastolic pressure volume relationship (EDPVR) to the left, i.e., toward lower volumes and reduced LV size.
[0062] The present invention minimizes invasiveness, infection, and coagulation. Heart replacement is highly invasive and induces great trauma on the patient and complications from anti-rejection medication. Current, blood-contacting assist technologies are greater risk for blood trauma, clotting activation, and sepsis. Blood-contacting assist technologies cannot be started and stopped because of clot formation. The present invention can be used in combination therapies which combine mechanical, electrical, pharmaceutical, and/or stem cell therapies.
[0063] The present invention enables an integrated research approach for correcting both systolic and diastolic heart failure in patients with either one of the ventricular dysfunctions or combined systolic and diastolic dysfunction.
[0064] The present invention comprises a contoured diastolic recoil device that reduces dyskinesis and hypokinesis. The device of the present invention includes a selectively inflatable end-systolic heart shaped bladder with one or more contoured supports configured to surround at least a portion of the heart to provide curvatures similar to the proper shape of the heart when pressurized and one or more fluid connections in communication with the selectively inflatable end-systolic heart shape bladder for pressurization and depressurization.
[0065] The one or more contoured supports form one or more inflatable compartments having an expanded curvature are optimized to fit generally the proper end-systolic shape of the heart. The selectively inflatable end-systolic heart shaped bladder comprises an inner membrane that is at least partially folded when depressurized and at least partially unfolds when pressurized.
[0066] The one or more contoured supports may include one or more dividers individually of similar or different materials, one or more wires individually of similar or different materials or a combination thereof to form a shape generally appropriate to the proper end-systolic shape of the heart. The selectively inflatable end-systolic heart shaped bladder includes a material that is substantially biocompatible, fluid-impermeable and substantially elastic. For example, at least a portion of the device may be made from elastomeric polyurethane, latex, polyetherurethane, polycarbonateurethane, silicone, polysiloxaneurethane, hydrogenated polystyrene-butadiene copolymer, ethylene-propylene and dicyclopentadiene terpolymer, hydrogenated poly (styrene-butadiene) copolymer, poly (tetramethylene-etherglycol) urethanes, poly (hexamethylenecarbonate-ethylenecarbonate glycol) urethanes and combinations thereof.
[0067] The selectively inflatable end-systolic heart shaped bladder is generally collapsible when depressurized and is reinforced to resist radially outward expansion during pressurization. The device of the present invention may take many configurations depending on the particular treatment. For example, the selectively inflatable end-systolic heart shaped bladder may include 12 inflatable tapered compartments formed by the one or more contoured supports to provide an expanded curvature similar to the proper end-systolic shape of the heart; however, other embodiments may have 1 or more inflatable tapered compartments. Furthermore, the distribution of the inflatable tapered compartments may vary from the design of 4 chambers on the RV side and 8 chambers that are mostly on the LV but also overlapping the interventricular sulci. For example, the device may have 1 to 12 or more chambers on the RV side and 1 to 24 or more chambers that are mostly on the LV and overlapping the interventricular sulci.
[0068] The inflatable tapered compartments are connected to a fluid pressure source through an inlet port and an outlet port. The device is inflated with a positive pressure during systole and deflated via suction during diastole. Other configurations and multiple connections are also possible depending on the particular application and configuration.
[0069] The present invention further comprises a contoured diastolic recoil device that applies forces to the exterior, epicardial boundary of the heart to restrict inflow and modulate right flow versus left flow through the heart. The device includes a selectively inflatable end-diastolic contoured bladder having one or more contoured supports configured to releasably engage the heart. The one or more contoured supports protrude inward towards the right ventricle to decrease the end-diastolic volume of the right ventricle during diastole. The device also has an inlet connection and outlet connection in communication with the selectively inflatable end-diastolic contoured bladder to pressurize and depressurize the selectively inflatable end-diastolic contoured bladder. Residual pressure is applied about the right ventricle to not fully deflate during diastole. Generally, the inlet line is in communication with the inlet connection to operatively expand the selectively inflatable end-diastolic contoured bladder and an outlet line is in communication with the outlet connection to operatively withdraw fluid from the selectively inflatable end-diastolic contoured bladder. This allows connection to conventional devices to apply and remove pressure or custom devices specifically for the present invention.
[0070] Once access to the heart of the patient is provided, the present invention, being a selectively inflatable end-systolic heart shaped bladder can be positioned about at least a portion of the periphery of the heart. The selectively inflatable end-systolic heart shaped bladder is then connected to a fluid source to inflate the selectively inflatable end-systolic heart shaped bladder with a positive pressure during systole and deflate the selectively inflatable end-systolic heart shaped bladder during diastole. Alternatively, the selectively inflatable end-systolic heart shaped bladder is connected to the fluid source before positioning and subsequently activating to inflate and deflate the selectively inflatable end-systolic heart shaped bladder.
[0071] The present invention further comprises a contoured diastolic recoil device that reduces dyskinesis and hypokinesis having an end-systolic heart contoured bladder with one or more contoured supports configured to surround at least a portion of the heart to provide curvatures that are similar to the proper end-systolic shape of the heart.
[0072] The present invention further comprises a method for promoting a physiological mechanical environment conducive to cardiac stem cell proliferation and differentiation into functional cardiomyocytes. The method includes providing access to a heart of a patient and positioning a selectively inflatable end-diastolic heart shape bladder about at least a portion of the periphery of the heart. The selectively inflatable end-diastolic heart shape bladder is connected to a fluid source to the selectively inflatable end-diastolic heart shape bladder to inflate with a positive pressure during systole and deflate the selectively inflatable bladder during diastole. The residual pressure is applied about the right ventricle to not fully deflate during diastole.
[0073] The present invention further comprises a selectively inflatable end-diastolic heart shape bladder that includes a pressurizable chamber formed by an inner membrane and an outer membrane and one or more contoured supports positioned within the pressurizable chamber to provide curvatures that are similar to the proper end-diastolic shape of the heart when the pressurizable chamber is pressurized. The one or more end-diastolic contoured supports form one or more inflatable compartments having an expanded curvature optimized to fit the heart geometry similar to the proper end-diastolic shape of the heart.
[0074] The diastolic recoil device that applies forces to the exterior, epicardial boundary of the heart optimized to fit an end-systolic shaped heart geometry is provided by the present invention. The diastolic recoil device includes a selectively inflatable bladder having one or more end-systolic contoured supports configured to surround at least a portion of the periphery of the heart and provide curvatures similar to the proper end-systolic shape of the heart when the pressurizable chamber is pressurized and one or more fluid connections in communication with the selectively inflatable bladder to pressurize and depressurize the selectively inflatable bladder.
[0075] The present invention further comprises a diastolic recoil device that may separately modulate the end-systolic and end-diastolic configurations of the heart. Of the selectively inflatable compartments or bladders, some may be specifically designed to only inflate during systole while others are designed to remain inflated during systole and diastole. By inflating during diastole, the diastolic recoil device can regulate the end-diastolic volume and shape of the heart and by selectively inflating during systole the diastolic recoil device can regulate the end-systolic volume and shape of the heart.
[0076] The present invention further comprises a diastolic recoil device that promotes a contraction strain pattern on a diseased or damaged heart that reduces dyskinetic or hypokinetic motions. The device includes a selectively inflatable end-systolic heart shaped bladder with one or more contoured supports configured to surround at least a portion of the heart to provide curvatures that are similar to the proper shape of the heart when pressurized. The device also includes one or more fluid connections in communication with the selectively inflatable end-systolic heart shaped bladder for pressurization and depressurization.
[0077] The present invention further comprises a method of assisting a diseased or damaged heart including providing a diastolic recoil device that compresses the heart during contraction without inverting or significantly perturbing the curvatures of the heart by positioning a selectively inflatable end-systolic heart shape bladder about at least a portion of periphery of the heart once access is made to the heart of the patient. The next step is the activating of a fluid source to the selectively inflatable end-systolic heart shape bladder to inflate with a positive pressure during systole and deflate the selectively inflatable bladder during diastole.
[0078] The present invention further comprises a diastolic recoil device that applies forces to the exterior, epicardial boundary of the heart optimized to fit an end-systolic shaped heart geometry. The device includes two or more contoured compartments, an inlet connection and an outlet connection. The two or more contoured compartments are configured to surround at least a portion of the heart and are individually contoured to provide curvatures that are similar to the proper end-systolic shape of the heart when pressurized. The inlet connection is in communication with the two or more inflatable contoured compartments and an outlet connection in communication with the two or more inflatable contoured compartments.
[0079] The present invention further comprises a dyskinesis and hypokinesis reduction system including a contoured heart assist device and a pressurization apparatus. The contoured heart assist device includes a selectively inflatable end-systolic heart shaped bladder with one or more contoured supports configured to surround at least a portion of the heart to provide curvatures similar to the proper shape of the heart when pressurized and one or more fluid connections in communication with the selectively inflatable end-systolic heart shape bladder for pressurization and depressurization. The pressurization apparatus in communication with the one or more fluid connections of the contoured heart assist device includes a pressurization mechanism and a depressurization mechanism. The pressurization apparatus can apply pressure to the contoured heart assist device and remove pressure from the contoured heart assist device. The pressurization apparatus is controllable to allow for different cycling rates between pressurized and depressurized states.
[0080] The present invention further comprises a diastolic recoil device, particularly a soft-shelled direct cardiac compression device, and methods of implanting it. In particular it is directed to a soft-shelled direct cardiac compression device that proactively modulates the strain pattern in the heart during contraction so as to reduce apoptosis in the myocardium and/or induce a beneficial growth and remodeling of the myocardium and/or a beneficial mechanical environment conducive to cardiac stem cell regeneration. In particular, the device of the present invention does not invert or grossly perturb the curvature of the heart during contraction.
[0081] In certain embodiments of the present invention, the strain pattern is a physiological strain pattern, near physiologic strain pattern or a strain pattern that is not aberrant. A physiological strain pattern, for the purposes of the present invention, is one which does not invert or grossly alter the heart's curvature during systole. The present invention also maintains a normal curvature or strain pattern during diastole, or relaxation of the heart.
[0082] Certain embodiments of the present invention, when implanted in a patient, for example to eliminate dyskinesis in the borderzone, preserves myocardium and minimizes infarct expansion and promotes cardiac stem cell proliferation and differentiation into functional cardiomyocytes.
[0083] In most cases, the device of the present invention may be inserted through a small incision. Devices of the present invention may also be attached to the atrial appendages via clamps that may also be used to synchronize the device to the electrocardiogram (ECG) or to pace the heart relative to the device activation.
[0084] Certain embodiments of the present invention can be used in conjunction with cardiac stem cell therapies. Stem cells used for cardiac regeneration therapy include but are not limited to stem cells derived from embryonic stem cells, somatic stem cells taken from bone marrow, progenitor cells from cardiac tissue, autologous skeletal myoblasts from muscle tissue, hematopoietic stem cells, mesenchymal stem cells, and endothelial precursor cells. The present invention can also be used in combination naturally occurring cardiac stem cells. Transplanted stem cells may be injected directly into cardiac tissue including, infarcted regions, cardiac scar tissue, borderzones, or healthy cardiac tissue. Transplanted stem cells may also be injected systemically feeding regions of cardiac tissue and may migrate to regions of the damaged or diseased heart and engraft to regions of the damaged or diseased heart. Transplanted stem cells may also provide diffusible products to regions of the damaged or diseased heart.
[0085] In operation, the present invention applies forces to the exterior, epicardial surface of the heart to promote a physiological mechanical environment in order to mechanically stimulate stem cells to differentiate into functional cardiomyocytes and engraft to a diseased heart. The following description is of various embodiments of a diastolic recoil device designed to apply such forces.
[0086] The present invention comprises a diastolic recoil device that applies forces to the exterior, epicardial boundary of the heart such that transplanted stem cells are subjected to strain patterns typically associated with normal cardiac mechanics. The diastolic recoil device can manipulate the mechanical environment about the heart such that stem cells are stimulated to grow, repopulate and differentiate into functional cardiomyocytes via mechanical factors. The diastolic recoil device can promote a contraction strain pattern on a diseased or damaged heart that reduces dyskinetic and/or hypokinetic motions by providing direct cardiac compression to a diseased or damaged heart that compresses the heart during contraction without inverting or significantly perturbing the curvatures of the heart.
[0087] To model the treatment paradigm for embodiments of the present invention and grossly estimate what driving pressures are needed, one may use Laplace's law for a spherical vessel which gives an average wall stress (“σ”) based on average radius (“R”), thickness (“H”) and transmural pressure difference (P in −P out ) where P in is the pressure in the ventricle and P out is the pressure outside the ventricle. In particular,
[0000] σ=( P in −P out ) H/ 2 R
[0088] Because blood is nearly incompressible, flow is dominated by pressure gradients (or less accurately by pressure differences). Without loss in generality, one may define blood pressure as its difference from atmospheric pressure. Because of rarification and densification, flows in compressible fluids are mediated by both pressure gradients and absolute pressure. Often P out is judiciously chosen as zero, yet for the present calculations, it is an important parameter because selected devices of the present invention are modulating P out by applying pressure to the epicardial surface of the heart. The focus of certain embodiments of the present invention thus is to increase P out to obtain a lower σ and thus greater motion or ejection. For a large, thin, and hypokinetic heart, one may need to make σ at least as low as a normal heart.
[0089] Let P in be a typical mean systolic pressure (e.g., 7.5 kPa or approximately 100 mmHg). A typical thickness-to-radius ratio at end-diastole for a normal adult sheep is 1 to 2.5; whereas for overloaded, remodeled myocardium (as in the apical aneurysm model of Guccione et al., 2001) the thickness-to-radius ratio is about 1 to 4.
[0090] Using the equation above, to normalize σ with the same P in , a P out of 2.8 kPa is needed. This is similar to the maximum driving pressure (approximately 3 kPa) used in in vitro tests described further in Example 2. For ventricular recovery, external pressures are likely needed that are about the same order as or slightly higher than pulmonary artery pressure. Hence, right ventricle (“RV”) ejection fraction is expected to be nearly 100%. External pressure is transferred through the incompressible RV myocardium and incompressible blood in the RV chamber, while RV outflow is accelerated. It has been demonstrated that uniform pressure applied to the entire epicardial surface will assist the heart at all levels of contractility.
[0091] Certain embodiments of the present invention can decrease RV input to compensate for the expected increase in RV output. Absent this capability, it is likely that the RV and healthy regions of the LV would atrophy due to excessive off-loading. However, certain embodiments of the present invention are ideal for weaning or gradually decreasing Pout, and the use of clenbuterol which has been shown to be useful in achieving ventricular recovery by preventing atrophy.
[0092] One embodiment of the present invention is a soft-shelled DCCD that has inflatable, longitudinally oriented chambers that when deflated are collapsible, allowing for minimally invasive implantation. In addition, the deflated chambers are shaped and adjoined to form a structure that allows typical diastolic configurations. When pressurized the chambers push on the exterior of the heart in such a way as to induce a systolic configuration with normal curvatures.
[0093] FIGS. 2A and 2B illustrate a horizontal cross section of one embodiment of the device 1 of the present invention in the deflated state, as seen in FIG. 2A and the inflated state in FIG. 2B . The device 1 includes 12 chambers 2 - 13 arranged with 4 chambers on the RV side and 8 chambers that are mostly on the LV but also overlapping the interventricular sulci. The chambers 2 - 13 are constructed from polyethylene film in one embodiment; however, other materials may be used. The side of the chambers 2 - 13 , that are on the outer boundary, form a shape that is similar to the end diastolic shape of the heart. The interior surface 14 has folds and crenulations such that when inflated the chambers 2 - 13 mostly expand inward.
[0094] FIGS. 3A and 3B illustrate a vertical cross section of one embodiment of the device 1 of the present invention in the deflated state as seen in FIG. 3A and the inflated state in FIG. 3B . Device 1 includes chambers 5 and 12 in the inflated and deflated states using access port 19 . The interior surface 14 of the chambers 2 - 13 that are on the outer boundary form a shape that is similar to the end diastolic shape of the heart. The interior surface 14 has folds and crenulations such that when inflated the chambers 2 - 13 mostly expand inward to contact the epicardium 16 of the heart 15 .
[0095] FIGS. 4A and 4B illustrate a horizontal cross section of one embodiment of the device 1 of the present invention fitted to the heart 15 . FIG. 4A is in the deflated state and FIG. 4B is in the inflated state. The device 1 includes 12 chambers 2 - 13 arranged with 4 chambers on the RV side and 8 chambers that are mostly on the LV but also overlapping the interventricular sulci. The chambers 2 - 13 include interior surface 14 that contacts the epicardium 16 of the heart 15 . The side of the chambers 2 - 13 that are on the outer boundary form a shape that is similar to the end diastolic shape of the heart. The interior surface 14 has folds and crenulations such that when inflated the chambers 2 - 13 mostly expand inward. The shape of the interior regions of the heart 17 and 18 can be compared in the inflated state as seen in FIG. 4B and the deflated state in FIG. 4A .
[0096] FIGS. 5A and 5B illustrate a vertical cross section of one embodiment of the device 1 fitted to the heart 15 in the deflated state as seen in FIG. 5A and the inflated state as seen in FIG. 5B . Device 1 includes chambers 5 and 12 in the inflated and deflated states using access port 19 . The interior surface 14 of the chambers 2 - 13 that are on the outer boundary form a shape that is similar to the end diastolic shape of the heart. The interior surface 14 has folds and crenulations such that when inflated the chambers 2 - 13 mostly expand inward to contact the epicardium 16 of the heart 15 . The shape of the interior regions 17 and 18 can be compared in the inflated state as seen in FIG. 5B and the deflated state as seen in FIG. 5A .
[0097] The fully pressurized shape without the heart inside is helpful for illustrating one embodiment of the present invention, yet the shape will be significantly different when the device surrounds a heart which contains blood under pressure as seen in FIGS. 2B and 4B . With a heart inside, the pressure in the lumen of the device is higher than the pressure in the inflatable chambers. Because the chambers cannot fully expand, the inner film of the chambers is not taut. Rather than being supported by tension in the film, e.g., FIG. 2B , pressure on the lumen side of the longitudinal chambers is supported by contact forces on the epicardial surface, e.g., FIG. 4B . Without tension on the inner film, the attachment points are not drawn inward, e.g., FIG. 2B . Instead, the shape of the outer sides of the chambers becomes circular to support the pressure within the chambers, e.g., FIG. 4B . Note how the inner membrane is crenulated and thus not under tension. Consequently, the pressure in the device chambers applies direct pressure to the heart surface. In a similar manner, a blood pressure cuff applies direct pressure to the surface of a patient's arm.
[0098] Because the inflatable chambers taper as they go from base to apex in a manner that resembles natural cardiac curvature as seen in FIG. 3B , the apex of the heart will have a physiological curvature. Moreover, because the device is rigid when pressurized, the curved shape of the apical end will act to prevent the heart from being expelled from the device. Basically, for the heart to leave the device the apical shape would have to pucker or a vacuum would need to form in the apical end of the device, both of which are unlikely.
[0099] FIGS. 3 and 5 show the access port 19 on the apex (i.e., the hole in the bottom of the device) which is useful for implantation and for removing fluid that could accumulate between the heart and device. Additionally, a biocompatible lubricant, anti-clotting, anti-fibrosis, pharmaceuticals, or antibiotic agent may be injected into the space between the heart and device. So that the device may be removed easily after weaning, the device may be covered with a film that retards fibrous adhesions such as Surgiwrap®.
[0100] As noted above, because the RV operates at a lower pressure and has a thin wall, certain diastolic recoil devices of the present invention will enhance RV ejection more than LV ejection. As observed in the implantation of a prototype, driving pressures that are equal to or greater than pulmonary artery pressure may occur, resulting in a 100% RV ejection fraction is expected. Pulmonary congestion may result if RV output is continuously increased relative to LV output. Autoregulatory mechanisms may mitigate this enhancement of RV ejection over LV ejection. If not, separation of RV and LV chambers in the diastolic recoil device may be useful. In particular, it may be possible to impede RV filling with residual pressurization of the 4 RV chambers during diastole. By controlling input to the RV the ratio of RV output to LV output can be modulated.
[0101] FIG. 6 illustrates how RV input (i.e., filling) can be modulated by the application of residual RV epicardial pressure (RRVEP). During diastole, the myocardium is relaxed and the heart shape is easy to perturb. This is particularly true of the RV freewall because it is very thin. Hence, residual gas in the four chambers abutting the RV freewall will likely prevent the RV from filling while leaving the LV unperturbed. It is, in essence, easier to differentially modulate filling than to modulate ejection.
[0102] FIGS. 6A and 6B illustrate a horizontal cross section of one embodiment of the device 1 of the present invention fitted to the heart 15 . FIG. 6A is in the deflated state and FIG. 6B is in the inflated state. The device 1 includes 12 chambers 2 - 13 arranged with 4 chambers on the RV side and 8 chambers that are mostly on the LV but also overlapping the interventricular sulci. The chambers 2 - 13 include interior surface 14 that contacts the epicardium 16 of the heart 15 . The side of the chambers 2 - 13 that are on the outer boundary form a shape that is similar to the end diastolic shape of the heart. The interior surface 14 has folds and crenulations such that when inflated the chambers 2 - 13 mostly expand inward. The shape of the interior regions 17 and 18 can be compared in the inflated state as seen in FIG. 6B and the deflated state as seen in FIG. 6A .
[0103] The present invention overcomes the disadvantage of the potential RV freewall atrophying as a result of the RV volume being chronically decreased and native RV stroke work being decreased. Advantageously, the present invention proactively modulates the strain pattern, which is ideal for weaning the heart from a device because assist can be graded. Conventional DCCDs only assist when the heart is weak enough to be grossly deformed.
[0104] At end-systole of the cardiac cycle, the present invention has a shape with curvatures that are similar to the proper end-systolic shape of the heart. The present invention is active in the sense that energy is consumed to accomplish the shape change during systole and energy is liberated to accomplish the shape change during diastole. The energy source is from a pneumatic pressure source. During systole (i.e., shape change from end-diastole to end-systole) the device is inflated with a positive pressure. During diastole (i.e., shape change from end-systole to end-diastole) the device of the present invention is deflated via suction. If enabled for RV flow restriction, the device of the present invention is not fully deflated during diastole because some residual pressure is applied to chambers that abut the right ventricle.
[0105] The present invention is soft or collapsible when deflated. In addition the present invention minimizes the risks of thrombosis and infection as there is no contact with the blood. Many of the devices in the art when pressurized or the end-systolic shape of prior devices is grossly abnormal and this is evidenced by the various schemes used to attach the DCCD to the heart (e.g., sewing to ventricle, basal drawstring, apical suction cup, etc.).
[0106] There is no need to attach the present invention to the heart because the heart is naturally drawn into the pressurized or activated device. Specifically, for the heart to leave the device (i.e., be extruded from the diastolic recoil device), the device curvature would need to invert, yet the device rigidity (when pressurized) resists curvature inversion. This is very useful because implantation time and complications due to attachment are minimized when this feature is present—i.e., when the activated shape of the device cavity (i.e., the inner wall of the diastolic recoil device which touches the epicardial or outer boundary of the heart) is nearly end-systolic shape. It can eliminate dyskinesis (defined as abnormal cardiac motions). Current evidence indicates that differentiation of cardiac stem cells into functional cardiomyocytes is influenced by mechanical stimuli such as the motion during cardiac contraction whereby the elimination of dyskinesis is of paramount importance. The device provides some of the pumping power demanded of the heart to energize or pressurize the circulatory system. Abnormal hearts often need to be “off-loaded” or be assisted with satisfying the circulatory demands of the body.
[0107] FIG. 7 is an illustration of one embodiment of the present invention wherein a nitinol scaffold is incorporated to mediate the end-diastolic configuration. FIG. 8 is an illustration of one embodiment of the present invention wherein a nitinol scaffold is incorporated to mediate the end-diastolic configuration.
[0108] The present invention comprises a biphasic and dynamic support device as illustrated in FIG. 9 . The present invention is biphasic about an adjustable “phase transition point” also known as a target end-diastolic volume (TEDV). FIG. 10 is a PV plot illustrating the relationship that for cardiac volumes below TEDV, the device of the present invention enhances filling (i.e., “filling enhancement” phase), and for cardiac volumes above TEDV the device of the present invention impedes filling (i.e., “filling impediment” phase). The filling impediment of the biphasic component of the device of the present invention can be used to adjust passive support throughout the entire treatment cycle. The adjustable passive support component will continually apply support to the epicardial surface of the heart, thereby promoting reverse remodeling. As the diseased heart begins to respond to the support by becoming smaller, the TEDV can be adjusted to provide the same amount of support as the initial treatment intervention as seen in FIG. 11 . The filling enhancement of the biphasic component of the present invention acts to enhance diastolic recoil. The device of the present invention has an elastic memory component that is utilized when cardiac pressures are lower than TEDV by creating a negative pressure that promotes ventricle filling. Diastolic recoil enhancement is critical for effective treatment. FIG. 10 thus demonstrates the biphasic assist component of the device of the present invention. When cardiac pressures are below the transition point, i.e., the TEDV, the device of the present invention enhances filling and increases cardiac volume, but when cardiac pressure exceed the transition point, the device of the present invention constrains filling and cardiac volume. The present invention is soft or collapsible when deflated.
[0109] Unlike conventional devices that have specific indications for support, the biphasic and dynamic support device of the present invention has a dual component of active assist and adjustable passive support. The adjustable passive support of the present invention reduces the size of an enlarged heart over a period of 6-8 months. While passive support is helpful long term, it can cause an increase in venous pressure acutely. With the dynamic support component of the present invention, this complication can be mitigated. The dynamic support component of the present invention applies active cardiac assist that restores normal cardiac motion. The dynamic support component of the present invention is configured such that when the active assist is utilized, it applies pressure to the epicardial surface of the heart, thus promoting physiological motion and increasing stroke work as needed to maintain cardiac output. The present invention can regulate the amount of dynamic assist depending on the needs of the individual and provide a means for managing cardiogenic shock.
[0110] The biphasic and dynamic support device of the present invention further comprises multiple layers of a biocompatible film with fluid filled bladders between the film layers. This structure prevents and/or reduces postoperative pericardial adhesions between the epicardial surface of the heart and the chest wall. The inner layer of the anti-pericardial adhesion device forms adhesions to the epicardial surface of the heart while the outer layer of the device forms adhesions to the chest cavity. The fluid filled bladder between the two layers acts as a barrier preventing adhesions between the epicardial surface of the heart and the chest wall. This permits easier access to the heart in case subsequent surgeries are required and also allows the heart to move freely inside the chest cavity during normal cardiac function.
[0111] The present invention provides (1) adjustable passive cardiac support and constraint by controlling the TEDV so as to facilitate the gradual reduction in size of hypertrophied diseased hearts and enhance diastolic recoil and improve pumping efficiency; and (2) active synchronous cardiac assist to maintain optimum cardiac performance, i.e., stroke volume, cardiac output, ejection fraction, stroke work, etc. and kinematics conducive to restorative remodeling processes. The present invention further creates a fluid filled barrier between the heart and chest wall to prevent pericardial adhesions and improve cardiac motion. Because the present invention does not come in contact with blood, the risks of thrombosis and infection is minimized.
[0112] Unlike conventional devices that, when pressurized, have an end-systolic shape that is grossly abnormal as evidenced by the various schemes used to attach the DCCD to the heart (e.g., sewing to ventricle, basal drawstring, apical suction cup, etc.), there is no need to attach the present invention to the heart because the heart is naturally drawn into the pressurized or activated device. Specifically, for the heart to leave the device (i.e., be extruded from the diastolic recoil device), the curvature of the device of the present invention would have to invert.
[0113] This does not occur due to the rigidity of the device that, when pressurized, resists curvature inversion. This is advantageous as implantation time and complications due to attachment are minimized when the activated shape of the device cavity (i.e., the inner wall of the diastolic recoil device which touches the epicardial or outer boundary of the heart) is in nearly end-systolic shape. Hence, this can eliminate dyskinesis, defined as abnormal cardiac motions.
[0114] Current research indicates that differentiation of cardiac stem cells into functional cardiomyocytes is influenced by mechanical stimuli such as the motion during cardiac contraction whereby the elimination of dyskinesis is of paramount importance. An advantage of the present invention is that it provides some of the pumping power demanded of the heart to energize or pressurize the circulatory system. Abnormal hearts often need to be “off-loaded” or be assisted with satisfying the circulatory demands of the body.
[0115] Another advantage of the device of the present invention is that it offers a failsafe mechanism. In particular, the device does not hinder cardiac performance when the device is deflated or deactivated. In the various embodiments described herein, the device can be completely deflated (defaulted to vacuum) to make the device soft and collapsible.
[0116] Generally when a material is implanted in the body, the body recognizes the presence of the foreign material and triggers an immune defense system to eject and destroy the foreign material. This results in edema, inflammation of the surrounding tissue and biodegradation of the implanted material. As a result, the present invention is at least partially comprised of biomedical implantable material. Examples of suitable, biocompatible, biostable, implantable materials used to fabricate the present invention include, but are not limited to, polyetherurethane, polycarbonateurethane, silicone, polysiloxaneurethane, hydrogenated polystyrene-butadiene copolymer, ethylene-propylene and dicyclopentadiene terpolymer, and/or hydrogenated poly (styrene-butadiene) copolymer, poly (tetramethylene-ether glycol) urethanes, poly (hexamethylenecarbonate-ethylenecarbonate glycol) urethanes and combinations thereof. In addition, the present invention may be reinforced with filaments made of a biocompatible, biostable, implantable polyamide, polyimide, polyester, polypropylene, and/or polyurethane.
[0117] The material used in the construction of the present invention minimizes the incidence of infection associated with medical device implantation such as entercoccus, pseudomonas auerignosa, staphylococcus and staphylococcus epidermis infections. Embodiments of the present invention include bioactive layers or coatings to prevent or reduce infections. For example, bioactive agents may be implanted, coated or disseminated on the present invention and include antimicrobials, antibiotics, antimitotics, antiproliferatives, antisecretory agents, non-steroidal anti-inflammatory drugs, immunosuppressive agents, antipolymerases, antiviral agents, antibody targeted therapy agents, prodrugs, free radical scavengers, antioxidants, biologic agents or combinations thereof. Antimicrobial agents include but are not limited to benzalkoniumchloride, chlorhexidine dihydrochloride, dodecarbonium chloride and silver sufadiazine. Generally, the amount of antimicrobial agent required depends upon the agent; however, concentrations range from 0.0001% to 5.0%.
[0118] In addition, certain embodiments of the present invention may have leads, electrodes or electrical connections incorporated into the device. When present, they may be made from noble metals (e.g., gold, platinum, rhodium and their alloys) or stainless steel. In addition, ordinary pacemaker leads and defibrillation leads can be incorporated into the present invention to provide cardiac pacing or defibrillation.
[0119] The one or more contoured supports form one or more inflatable compartments having an expanded curvature optimized to fit generally the proper end-systolic shape of the heart. The selectively inflatable end-systolic heart shaped bladder comprises an inner membrane that is at least partially folded when depressurized and at least partially unfolds when pressurized.
[0120] The selectively inflatable end-systolic heart shaped bladder is generally collapsible when depressurized and is reinforced to resist radially outward expansion during pressurization. The device of the present invention may take many configurations depending on the particular treatment. For example, the selectively inflatable end-systolic heart shaped bladder may include 12 inflatable tapered compartments formed by the one or more contoured supports to provide an expanded curvature similar to the proper end-systolic shape of the heart; however, other embodiments may have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 or more inflatable tapered compartments. Furthermore, the distribution of the inflatable tapered compartments may vary from the design of 4 chambers on the RV side and 8 chambers that are mostly on the LV but also overlapping the interventricular sulci. For example, the device may have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or more chambers on the RV side and 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 or more chambers that are mostly on the LV and overlapping the interventricular sulci. That chambers distribution determination for a particular application and treatment is within the scope of the skilled artisan.
[0121] The present invention also provides a direct cardiac compression device that promotes a contraction strain pattern on a diseased or damaged heart that reduces dyskinetic or hypokinetic motions. The device includes a selectively inflatable end-systolic heart shaped bladder with one or more contoured supports configured to surround at least a portion of the heart to provide curvatures that are similar to the proper shape of the heart when pressurized. The device also includes one or more fluid connections in communication with the selectively inflatable end-systolic heart shaped bladder for pressurization and depressurization.
[0122] It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method, kit, reagent, or composition of the invention, and vice versa. Furthermore, compositions of the invention can be used to achieve methods of the invention.
[0123] It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
[0124] All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
[0125] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
[0126] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
[0127] The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.
[0128] All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
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The present invention provides a biphasic and dynamic direct cardiac contact device adapted to be implanted in a patient suffering from congestive heart failure and related cardiac pathologies, said cardiac device having means for providing ventricular assist, ventricular support and diastolic recoil, or for providing ventricular support and diastolic recoil only.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an image-shake correction apparatus, and particularly to an image-shake correction apparatus that implements image-shake correction in a lens unit used for a virtual system or the like.
[0003] 2. Description of the Related Art
[0004] In recent television broadcasting, a technique has frequently been used in which an actually captured video image captured by a television camera and an electronic video image (CG video image) created by a computer, or the like, are synthesized. As a technique for synthesizing video images, the chroma-key synthesis method is generally known. In the chroma-key synthesis method, a photographic subject that is to be a foreground image of a synthesized video image is captured by a television camera or the like, with, for example, a blue cloth (blue background) as a background. From the resultant video signal, a key signal (an outline signal that indicates the outline of the foreground image) for distinguishing a foreground-image area from a blue-background area is created. Meanwhile, a background image that is to be a background of the synthesized video image is created, for example, by a computer or the like. By cutting based on the key signal the foreground-image area out of the background image and replacing the foreground-image area by the foreground image, the synthesized video image in which the foreground image and the background image are synthesized is created (refer to Japanese Patent Application Laid-Open No. 10-42307 and the like).
[0005] In addition, a video image synthesis system (a virtual system), referred to as a virtual studio, has been frequently used in which not only video images are simply synthesized through the chroma-key synthesis method, but also a photographic subject captured actually by a television camera is displayed as if the photographic subject were present in a virtual space (virtual studio) created as an electronic video image.
[0006] In a virtual system, a desired virtual space is created by a computer or the like and a virtual camera is arranged within the virtual space. Accordingly, image capturing in the virtual space is implemented virtually by the virtual camera, whereby an electronic video image of the virtual space is created. The capturing conditions for the virtual camera is changed in accordance with the change in the capturing conditions, such as focusing operation, zooming operation, and pan/tilt operation, for a television camera (real camera) that actually captures video images; therefore, a synthesized video image is created that is displayed as if a photographic subject for the actually captured video image were present in the virtual space. In addition, in some cases, the synthesis is implemented in such a way that an actually captured video image is used as a background and an electronic video image is used as a foreground image, or actually captured video images are synthesized.
[0007] Additionally, in recent years, an image-shake correction apparatus that corrects an image shake has been used in many cases, due to enhancement of the zoom magnification ratio of a lens unit. An image-shake correction apparatus that is integrally incorporated in a lens unit and an image-shake correction apparatus that is an adapter used, as an auxiliary device, attached to a lens unit are known. For example, an image-shake correction apparatus is known in which, in an image-capturing optical system, a correction lens for correcting an image shake is movably arranged in a direction perpendicular to the optical axis, and when a camera (image-capturing optical system of the camera) is vibrated, the correction lens is driven by a motor in such a way as to cancel the image shake caused by the vibration, thereby correcting the image shake (e.g., refer to Japanese Patent Application Laid-Open Nos. 2001-142103 and 2003-107554 and the like). In addition, image-shake correction methods other than the method in which a correction lens is used that moves in a direction perpendicular to the optical axis. In each image-shake correction method, an image displacement device is provided that displaces optically or electronically the formation position of an image formed by an optical system, in the horizontal or vertical direction within the image formation plane; and image-shake correction is implemented by controlling the amount of image displacement through the image displacement device so as to cancel an image shake.
SUMMARY OF THE INVENTION
[0008] Meanwhile, in some cases, when the foregoing image-shake correction apparatus is used in the real camera for a virtual system, respective motions in an actually captured video image and an electronic video image do not coincide with each other. For example, while the camera is vibrated, an electronic video image is created that is displayed as if the virtual camera were also vibrated in conjunction with the movement of the real camera. In contrast, because, in the real camera, the image shake is corrected by the image-shake correction apparatus, the effect of the vibration on the real camera is reduced. Thus, synthesized video images demonstrate a state in which only the portion created through the electronic video image is vibrated, whereby an unnatural synthesized image is displayed.
[0009] The present invention has been made in view of the foregoing circumstances and provides an image-shake correction apparatus in which, in order to prevent the occurrence of defects due to image-shake correction, information on the image-shake correction can be supplied to an external apparatus that obtains capturing conditions of a camera and implements predetermined processing.
[0010] For that purpose, an image-shake correction apparatus according to a first aspect of the present invention is characterized by including an image displacement device that displaces on an image forming plane an image formed by an image-capturing optical system, an image-shake correction device that displaces an image by use of the image displacement device in such a way as to cancel an image shake due to a vibration exerted on the image-capturing optical system, and an output device that outputs to a predetermined external apparatus information on image displacement by the image displacement device.
[0011] According to the present invention, the external apparatus can find out the state of image-shake correction, whereby the external apparatus can implement processing in consideration of the image-shake correction.
[0012] The image-forming apparatus according to a second aspect of the present invention is characterized in that, in the first aspect, the output device includes a connector for connecting the image-shake correction apparatus with the external apparatus, by use of a cable.
[0013] The second aspect of the present invention enables the image-shake correction apparatus to be connected through the connector with the external apparatus, by use of a cable.
[0014] An image-shake correction apparatus according to a third aspect of the present invention is characterized in that, in the first or the second aspect, the output device outputs the information to the external apparatus, by use of an analogue signal.
[0015] According to the third aspect of the present invention, the information on image displacement by the image displacement device is outputted (transmitted), by use of the analogue signal; therefore, compared with a case where the information is outputted by use of a digital signal, the circuit is simplified.
[0016] An image-shake correction apparatus according to a fourth aspect of the present invention is characterized in that, in the first or the second aspect, the output device outputs the information to the external apparatus, by use of a digital signal.
[0017] According to the fourth aspect of the present invention, the information on image displacement by the image displacement device is outputted (transmitted), as serial communication, by use of the digital signal; therefore, in the case where the external apparatus that receives the signal requests transmission by use of a digital signal, conversion, by an A/D converter, of an analogue signal into a digital signal is not required.
[0018] An image-shake correction apparatus according to a fifth aspect of the present invention is characterized in that, in the first, the second, the third, or the fourth aspect, the output device outputs a value corresponding to an amount of image displacement by the image displacement device.
[0019] The fifth aspect shows one mode of information on image displacement by the image displacement device.
[0020] An image-shake correction apparatus according to a sixth aspect of the present invention is characterized in that, in one of the first to the fifth aspect, the output device outputs the information to an image creation apparatus, as the external apparatus, that creates another video image to be synthesized with a video image obtained by capturing an image formed by the image-capturing optical system.
[0021] The sixth aspect shows an example of the external apparatus; in the case where, in a video-image synthesis apparatus used in a virtual system, one of video images to be synthesized is created, in addition to an video image from a camera in which the present invention is used, the video images to be synthesized can be created in consideration also of the effect of image-shake correction. Accordingly, a defect can be cancelled in which a synthesized video image demonstrates a partial image shake.
[0022] An image-shake correction apparatus according to a seventh aspect of the present invention is characterized in that, in one of the first to the sixth aspect, the image-shake correction apparatus is integrated in a lens unit including the image-capturing optical system or mounted, as an auxiliary device, outside the lens unit.
[0023] The seventh aspect shows that the present invention is effective for both cases where the image-shake correction apparatus is integrated in the lens unit and the image-shake correction apparatus is mounted, as an auxiliary device, outside the lens unit.
[0024] An image-shake correction apparatus according to a eighth aspect of the present invention is characterized in that, in one of the first to the seventh aspect, the image displacement device displaces an image, by displacing a correction lens that, in the image-capturing optical system, is arranged movably in directions perpendicular to the optical axis.
[0025] The eighth aspect shows a mode in which the image-shake correction is optically implemented and a correction lens is used that moves in directions perpendicular to the optical axis so as to displace an image.
[0026] An image-shake correction apparatus according to a ninth aspect of the present invention is characterized in that, in the eighth aspect, the output device outputs, as information on image displacement by the image displacement device, a value based on a detected position obtained by a detection device that detects the position of the correction lens or a predetermined target position in the case where the correction lens is moved to the target position.
[0027] The ninth aspect shows that, in the case where a value indicating the position of the correction lens or the displacement amount of an image that is displaced corresponding to the position of the correction lens is outputted as information on image displacement by the image displacement device, both cases are possible where a value based on the position, of the correction lens, actually detected by the detection device is outputted and a value based on the target position for control of the correction lens is outputted.
[0028] An image-shake correction apparatus according to a tenth aspect of the present invention is characterized in that, in the ninth aspect, the output device outputs a value indicating the detected position or the target position of the correction lens.
[0029] The tenth aspect shows a mode in which, as a value indicating the position of the correction lens, a value indicating the actually detected position of the correction lens or a value indicating the target position for control of the correction lens is outputted.
[0030] According to the present invention, in order to prevent the occurrence of defects due to image-shake correction, information on the image-shake correction can be supplied to an external apparatus that obtains capturing conditions of a camera and implements predetermined processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a block diagram schematically illustrating the configuration of a virtual system utilizing a lens unit in which an image-shake correction apparatus according to the present invention is integrated;
[0032] FIG. 2 is a block diagram illustrating only the configuration, in the virtual system in FIG. 1 , that relates to image-shake correction; and
[0033] FIG. 3 is a block diagram illustrating another embodiment of only the configuration, in the virtual system in FIG. 1 , that relates to image-shake correction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The best mode for embodying an image-shake correction apparatus according to the present invention will be explained in detail below, with reference to the accompanying drawings.
[0035] FIG. 1 is a block diagram schematically illustrating the configuration of a virtual system utilizing a lens unit in which an image-shake correction apparatus according to the present invention is integrated. In FIG. 1 , the virtual system is configured mainly of a television camera 10 including a camera head 11 and a lens unit 12 , a camera platform 14 that supports the television camera 10 , and a computer 16 for the virtual system (referred to as a system computer 16 , hereinafter). The camera head 11 is a lens-interchangeable camera used for broadcasting or professional video recording; by mounting on the mount of the camera head 11 the camera cone described later, of an image-capturing optical system (image capturing lens) the camera head 11 can be used for image capturing, as a television camera. The camera head 11 is equipped with an imaging device (such as a CCD) that photoelectrically converts an image formed through the image-capturing optical system of the lens unit 12 , a signal processing circuit, which applies predetermined processing to a signal obtained from the imaging device and outputs the processed signal as a predetermined-type video signal, and the like. The video signal, for the captured video image, created through the circuits is outputted from a predetermined output terminal.
[0036] The lens unit 12 is provided with the image-capturing optical system (image-capturing lens) that forms the image of a photographic subject and a control system that drives and controls the image-capturing optical system; the image-capturing optical system is configured of various optical components, i.e., provided with a group of movable focus lenses for adjusting the focus, a group of movable zoom lenses for adjusting the zoom-magnification ratio (focal length), a diaphragm for adjusting the brightness, a group of master lenses for forming an image finally, a movable correction lens for image-shake correction, and the like. The control system is configured of respective motors that drive movable constituent elements, of the image-capturing optical system, such as a focus lens, a zoom lens, a diaphragm, a correction lens, and the like, a position sensor that detects respective states (positions) of the movable constituent elements, a control circuit that drives and controls the motors to control the respective positions and speeds of the movable constituent elements to be in predetermined states, and the like. Through the control by the control system, the focus lens and the zoom lens each move back and forth along the optical axis, and the correction lens moves in a direction perpendicular to the optical axis.
[0037] In addition, to the lens unit 12 , a controller, unillustrated in FIG. 1 , is connected that instructs the control circuit the position of the focus lens (focus position) and the position of the zoom lens (zoom position), through the user's operation of a focus demand or a zoom demand and the like. However, in some lens units, the focus lens and the zoom lens are manually driven; that lens units do not require any motor or controller that drives the focus lens and the zoom lens.
[0038] The camera platform 14 supports the television camera 10 and is provided with a pan/tilt mechanism that implements pan/tilt operation of the television camera 10 manually or automatically; the camera platform 14 is provided with a position sensor that detects the pivoting angle (pan position), of the television camera 10 supported by the camera platform 14 , on a panning plane (on the horizontal plane) and a position sensor that detects the pivoting angle (tilt position), of the television camera 10 , on a tilting plane (on the vertical plane).
[0039] In the system computer (computer for the virtual system) 16 , various kinds of processing items and control items are implemented mainly through computing processing by a CPU; however, FIG. 1 illustrates a schematic configuration in the case where contents of processing implemented by the CPU in the system computer 16 are divided into processing blocks. As can be seen from FIG. 1 , the system computer 16 is configured mainly of a chroma-key-signal generation section 18 , an electronic-video-image generation section 20 , and a video-image synthesis section 22 . The outline of video-image synthesis processing in the system computer 16 configured of the foregoing constituent sections will be explained; in the system computer 16 , through the chroma-key synthesis technique, a synthesized video image is created that is a synthesis of an actually captured video image, of a photographic subject, captured by a television camera 10 (referred to as a real camera 10 , hereinafter), with a blue background and an electronic video image, of a virtual space (virtual studio), captured by a virtual camera.
[0040] The image capturing, of an actually captured video image, by the real camera is the work of capturing a real photographic subject (a foreground photographic subject for the foreground image of a synthesis image) to be arranged (synthesized) surrounded by the virtual space; by making the portion, of the synthesis image, excluding the foreground photographic subject to be arranged surrounded by the virtual space a blue background, the image capturing is implemented. Additionally, in this situation, by implementing the zooming operating or the focusing operation of the real camera 10 , the foreground photographic subject is captured with a desired capturing condition. The chroma-key-signal generation section 18 of the system computer 16 receives from the real camera 10 the video signal for the actually captured video image captured as described above.
[0041] The chroma-key-signal generation section 18 creates, based on the video signal for the actually captured video image received from the real camera 10 , a key signal (an outline signal that indicates the outline of the foreground image) for distinguishing the image (the foreground image) area for the foreground photographic subject from the blue-background area and a video signal for the foreground image, and then outputs the key signal and the video signal to the video-image synthesis section 22 .
[0042] Meanwhile, the electronic-video-image generation section 20 creates, based on creation data preliminarily stored to build a virtual space, an electronic video image, for the virtual space, that is captured by a virtual camera arranged in the virtual space. To the electronic-video-image generation section 20 , data on a focus-lens position (focus position), a zoom-lens position (zoom position), and a correction-lens position is provided from the lens unit 12 of the real camera 10 , and data on a pan position and a tilt position is provided from the camera platform 14 . The data items are sequentially received by the electronic-video-image generation section 20 , as capturing data items for recognizing the capturing condition for the real camera 10 . Based on the capturing data items, the electronic-video-image generation section 20 makes the capturing condition for the virtual camera that captures the virtual space coincide with the capturing condition for the real camera 10 . Accordingly, an electronic video image is created that is displayed as if the virtual space were being captured by the real camera 10 . The electronic video image created in the electronic-video-image generation section 20 is outputted to the video-image synthesis section 22 .
[0043] Any transmission method may be employed for transmitting the capturing data items from the lens unit 12 and the camera platform 14 to the system computer 16 ; as is the case with analogue transmission by use of an analogue signal, or digital transmission such as serial transmission, arbitrary method can be used. Additionally, in some cases, relay devices that make the signal modes coincide with each other are arranged between the system computer 16 and the lens unit 12 and between the system computer 16 and the camera platform 14 .
[0044] Based on the key signal supplied to the chroma-key-signal generation section 18 , the video-image synthesis section 22 cuts the image in an area into which the foreground image is synthesized (inserted) out of the electronic video image supplied from the electronic-video-image generation section 20 . Thereafter, the foreground image supplied from the chroma-key-signal generation section 18 is inserted into the area from which the image has been cut out. As a result, the foreground image in the actually captured video image and the virtual-space image in the electronic video image are synthesized, and the signal for the synthesized image is outputted from the video-image synthesis section 22 .
[0045] The video signal outputted from the video-image synthesis section 22 is transmitted to a broadcasting apparatus or an editing apparatus other than the system computer 16 .
[0046] In addition, with regard to synthesis of the actually captured video image obtained from the real camera 10 and the electronic video image, the foregoing method is not the sole one, but other methods may be utilized.
[0047] Next, the configuration and processing, in the virtual system, related to image-shake correction will be explained. FIG. 2 is a block diagram illustrating only the configuration, in the foregoing virtual system, that relates to image-shake correction. As illustrated in FIG. 2 , in the image-capturing optical system of the lens unit 12 , a correction lens 30 for image-shake correction is arranged, for example, after the other constituent elements of the optical system. The correction lens 30 is adapted to be supported movably in directions (vertically and horizontally) perpendicular to the optical axis of the image-capturing optical system and driven by a motor 32 , in the directions. In addition, in FIG. 2 , two motors that drive the correction lens 30 in the up-and-down directions and in the left-and-right directions, respectively, are illustrated with the single motor 32 .
[0048] Meanwhile, as a shake detection sensor that detects a vertical and horizontal vibration of the image-capturing optical system, a gyroscopic sensor 36 that detects the vertical and horizontal angular velocity is provided in the control system of the lens unit 12 . In addition, in FIG. 2 , two gyroscopic sensors that detect angular velocities in the up-and-down directions and in the left-and-right directions, respectively, are illustrated with the single gyroscopic sensor 36 .
[0049] Additionally, the control system of the lens unit 12 is equipped with a CPU 34 that integrally controls the entire lens unit 12 ; the CPU 34 obtains an angular velocity signal outputted from the gyroscopic sensor 36 and computes, based on the obtained angular velocity signal, the positions, of the correction lens 30 , that are appropriate for canceling an image shake caused by vibration, i.e., the displacement amounts from a reference position, in the up-and-down directions and in the left-and-right directions, respectively. In addition, by applying integral processing to the angular velocity signal from the gyroscopic sensor 36 , an angular signal can be obtained; however, detailed explanation will be omitted. The angular signal indicates the magnitude of displacement, of an image (the magnitude of an image shake), due to a vibration; based on the relationship between the angular signal and the amount of image displacement for the displacement of the correction lens 30 , the position, of the correction lens 30 , that is appropriate for canceling the image shake caused by a vibration is obtained.
[0050] Additionally, depending on the focal length of the image-capturing optical system, i.e., the position of the zoom lens (zoom position), the image-shake magnitude for the same vibration magnitude changes, whereby the position, of the correction lens 30 , that is appropriate for canceling the image shake also changes. Therefore, from a position sensor 38 installed in the zoom lens, the CPU 34 obtains through an A/D converter 39 information on the zoom position and computes the position, of the correction lens 30 , for canceling the image shake.
[0051] The CPU 34 displaces by use of the motor 32 the correction lens 30 in such a way that the position (target position), of the correction lens 30 , indicated by the vertical and horizontal coordinates and the respective present position (detected position), of the correction lens 30 , obtained from the position sensor 30 coincide with each other. As a result, the image shake is prevented. In addition, two position sensors that detect positions in the up-and-down directions and in the left-and-right directions, respectively, are illustrated with the single position sensor 38 . The position sensor 38 outputs an analogue signal for the voltage corresponding to the present position of the correction lens 30 ; the signal is converted by an A/D converter to a digital signal and then inputted to the CPU 34 . Additionally, an image-shake correction apparatus is known in which it is determined whether the angular velocity signal obtained from the gyroscopic sensor 36 indicates an image shake, due to a vibration, to be corrected or an image shake due to the pan/tilt operation intentionally implemented by an operator, and when it is determined that the shake has been caused by the pan/tilt operation, the image-shake correction is stopped. Regardless of whether or not the foregoing processing is implemented, the present invention can be applied to the image-shake correction apparatus.
[0052] As described above, as the capturing data that indicates the capturing condition of the television camera (real camera) 10 , data that indicates the position of the correction lens 30 is supplied from the lens unit 12 to the electronic-video-image generation section 20 of the system computer 16 . A signal-output connector 44 is provided in the lens unit 12 ; to the signal-output connector 44 , the output terminal of the position sensor 40 that detects the present position of the correction lens 30 is connected through a driver 42 . Accordingly, a position signal, as an analogue signal, that indicates the vertical and horizontal coordinates of the detected position (present position), of the correction lens 30 , detected by the position sensor 40 can be outputted from the connector 44 to a desired external apparatus.
[0053] To the signal-output connector 44 , a predetermined signal-input connector 60 of the system computer 16 is connected through an AD box 50 , by use of a cable. Accordingly, the position signal outputted from the signal-output connector 44 of the lens unit 12 is converted by the AD box 50 into a digital signal and then transmitted to the signal-input connector 60 of the system computer 16 . Thereafter, the electronic-video-image generation section 20 of the system computer 16 obtains the position data for the correction lens 30 , by use of the position signal received through the signal-input connector 60 .
[0054] On the other hand, as described above, in addition to the position data for the correction lens 30 , the electronic-video-image generation section 20 obtains the data items, as the capturing data items indicating the capturing conditions of the real camera 10 , such as the focus position, the zoom position, the pan position, and the tilt position; thus, based on the capturing conditions, the electronic-video-image generation section 20 makes the capturing conditions of the virtual camera that captures the virtual space coincide with the capturing conditions of the real camera 10 .
[0055] In this situation, a case will be explained in which, regardless of the position of the correction lens 30 , the capturing conditions of the virtual camera are set. When the real camera 10 is vibrated, the pan and tilt positions of the real camera 10 are displaced. The virtual camera is also displaced. Accordingly, the electronic video image captured by the virtual camera also demonstrates an image shake corresponding to the pan-position displacement and the tilt-position displacement. In contrast, the image-shake correction makes the image captured by the real camera 10 insusceptible to a vibration; therefore, in the case where the foreground image created from an actually captured video image and the background image created from an electronic video image are synthesized, only the background image demonstrates an image shake, whereby the synthesized image is rendered awkward.
[0056] Thus, by obtaining as the capturing data the position data for the correction lens 30 in the real camera 10 , the electronic-video-image generation section 20 sets the capturing conditions of the virtual camera, in consideration of the image-shake correction in the real camera 10 . In other words, by, as is the case with the real camera 10 , implementing the image-shake correction in the virtual camera, the image shake cancelled through the image-shake correction in the real camera 10 is cancelled also in the virtual camera. As a result, the awkward phenomenon is cancelled that, in a synthesized image in which the foreground image created from an actually captured video image and the background image created from an electronic video image are synthesized, only the background image vibrates.
[0057] In the configuration illustrated in FIG. 2 , an analogue signal for the voltage corresponding to the position of the correction lens 30 is outputted from the lens unit 12 , through the signal-output connector 44 ; however other configurations may be conceivable. FIG. 3 is a block diagram in the case where the position data for the correction lens 30 is transmitted through serial transmission to the system computer 16 . The same or similar constituent elements as those in FIG. 2 are designated by the same reference numerals, and explanations for them will be omitted. In a configuration illustrated in FIG. 3 , the CPU 34 reads from the position sensor 40 the present position of the correction lens 30 and outputs a value indicating the present position to a serial-communication interface circuit 70 , by use of a digital signal. The serial-communication interface circuit 70 is connected to a serial-communication connector 72 provided in the lens unit 12 ; to the serial-communication connector 72 , a serial-communication connector 74 of the system computer 16 is connected by use of a cable. Accordingly, signal transmission/reception through serial communication is enabled between a serial-communication interface circuit 76 of the system computer 16 and the serial-communication interface circuit 70 of the lens unit 12 . Through serial transmission, the serial-communication interface circuit 70 of the lens unit 12 can transmit to the system computer 16 the position data, for the correction lens 30 , supplied from the CPU 34 ; the electronic-video-image generation section 20 obtains the position data, through the serial-communication interface circuit 76 .
[0058] In the foregoing embodiment, information on the present position (detected position), of the correction lens 30 , detected by the position sensor 40 is outputted from the lens unit 12 to the system computer 16 ; however, instead of the present position of the correction lens 30 , the target position, as the position of the correction lens 30 that corrects an image shake, computed by the CPU 34 may be outputted to the system computer 16 . Moreover, as long as information other than a value indicating the present position or the target position of the correction lens 30 is a value based on the present position or the target position of the correction lens 30 , such as a value indicating the amount of displacement of an image that has been displaced through the displacement of the correction lens 30 to the present position, or a value indicating the amount of displacement, on the image-forming plane, of the image that is displaced through the displacement of the correction lens 30 to the target position, outputting the information to the system computer 16 enables the system computer 16 to implement the same processing as that in the foregoing embodiment. In addition, the amount of displacement, of the correction lens 30 , from the reference position is in proportion to the amount of image displacement; therefore, the amount of image displacement versus the position of the correction lens 30 can readily be computed by the CPU 34 in the lens unit 12 .
[0059] Additionally, in the foregoing embodiment, an aspect has been explained in which an image shake is corrected by the correction lens 30 arranged movably in directions perpendicular to the optical axis; however, the present invention can be applied also to a case where image-shake correction is implemented in accordance with another method. In other words, the present invention enables an image shake due to a vibration to be cancelled by an image displacement device that optically or electronically displaces the position, on the image-forming plane, of an image that is formed by an image-capturing optical system; therefore, regardless of the type of the image displacement device, the present invention can be applied. In this situation, by outputting to the system computer 16 information on the displacement, of the image, by the image displacement device, e.g., the image-displacement amount or a value corresponding thereto, the system computer 16 can implement the same processing as that in the foregoing embodiment.
[0060] Moreover, in the foregoing embodiment, a case has been explained in which the image-shake correction apparatus is integrated in the lens unit 12 ; however, the present invention can be applied even to a case where the image-shake correction apparatus is separated from the lens unit and mounted, as an auxiliary device, outside the lens unit (or integrated in the camera head). In the case where the image-shake correction apparatus is separated from the lens unit, the connector for connecting the image-shake correction apparatus with the system computer 16 may be provided in the image-shake correction apparatus.
[0061] Still moreover, in the foregoing embodiment, a case has been explained in which an image-shake correction apparatus according to the present invention is used as an image-shake correction apparatus of the lens unit in a virtual system; however, even when the image-shake correction apparatus is used for other applications, the present invention is effective in the case where a predetermined external apparatus requests information on the image displacement by the image displacement device.
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The present invention provides an image-shake correction apparatus comprising: an image displacement device that displaces on an image forming plane an image formed by an image-capturing optical system; an image-shake correction device that displaces an image by use of the image displacement device in such a way as to cancel an image shake due to a vibration exerted on the image-capturing optical system; and an output device that outputs to a predetermined external apparatus information on image displacement by the image displacement device, in order to prevent the occurrence of defects due to image-shake correction, information on the image-shake correction can be supplied to an external apparatus that obtains capturing conditions of a camera and implements predetermined processing.
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REFERENCE TO RELATED APPLICATIONS
This Application is a Continuation-in-Part of patent application Ser. No. 12/438,381, filed 23 Sep. 2009, currently pending.
FIELD OF THE INVENTION
The present invention relates to a method for providing weaving material, and particularly to a method for producing thread using nonwoven.
BACKGROUND OF THE INVENTION
The textile industry is an industry of manufacturing textile goods using a variety of textile raw materials. The main fabrication processes include fiber production, spinning, textile manufacturing, dyeing and printing, finishing, and the final read-to-wear business. The textile industry is an important civil industry of a country. The applications of textile goods include the ready-to-wear business, the upholstery, and the industrial products. The ready-to-wear business includes garments for men, women, and children. The upholstery includes furniture, domestic goods, and domestic decorative cloth, etc. The industrial products include conveyers in factories, filtering cloth, and outdoor tent appliances. In addition, textile goods can be applied to shoemaking and interior decoration of transportations (automobiles or airplanes). Their applications are extremely extensive. Among them, the read-to-wear industry occupies the most significant proportion.
In general, weaving can be classified into knitting and tatting:
1. Knitting: A weaving method that uses a single thread of yarn or a set of threads of yarn to move unidirectionally, and classified into manual knitting and machine knitting.
(a) Manual knitting is performed using two knitting needles alternately. Loops are distributed uniformly on the knitting needle. A row of loops is formed with width the same as that of the textile. When knitting is performed, the row of loops will connect with next row of loops. In this way, a textile is knitted. (b) Machine knitting uses a knitting needle in each of the loops. When knitting, all knitting needles are operating simultaneously and forming a row of loops.
2. Tatting: Knitting a thread of warp yarn and a thread of well yarn perpendicularly. The warp yarn is the vertical yarn; the well yarn is the horizontal yarn. In fact, when the primitives first interwove branches of a tree and grass to form a mat or a basket, the history of weaving was started.
In addition, there exists a textile formed without the spinning process. Firstly, a fiberweb structure is formed by arranging short fibers or long filaments at fixed orientation or randomly. Then, a mechanical, thermal bonding, or chemical method is adopted to fix the fiberweb structure. To put it in a nutshell, the textile is not formed by interweaving or knitting threads of yarn, but is formed by bonding fibers together through a physical means directly. Thereby, it is not possible to find any end of a thread in the textile. Nonwoven breakthroughs traditional weaving principles with the advantages of short manufacturing process, fast production speed, high throughput, low cost, wide applications, and having varied material sources. The main applications include:
1. Medical hygienic cloth: surgery gowns, protection clothing, sterilized cloth, facemasks, diapers, and feminine sanitary napkins, etc.; 2. Domestic decorative cloth: wallpaper, tablecloths, bed sheets, and coverlets, etc.; 3. Backing: lining, bonding lining, flocculus, shaping cotton, and various base cloth for synthetic leather, etc.; 4. Industrial cloth: filtering materials, insulation materials, packing bags for cement, earthwork cloth, and covering cloth, etc.; 5. Agricultural cloth: agriculture mulch, cloth for raising seedlings, irrigation cloth, and thermal insulating curtains, etc.; 6. Others: space cotton, heat and sound insulating materials, oil absorption felts, cigarette filters, and tea bags, etc.
Nonwoven can be classified into:
1. Spunlace nonwoven: Jet high-pressure minute water to a single or multiple layered fiberweb to entangle the fibers. Thereby, the fiberweb can be reinforced and t its strength is increased. 2. Heat-bonded nonwoven: Add fiber-shaped or powdery heat-melt binding and reinforcing materials to a fiberweb. Then the fiberweb is heated and cooled to form reinforced cloth. 3. Airlaid pulp nonwoven: The airlaid pulp nonwoven is also called airlaid paper or drylaid nonwoven. Wood pulp fibers are loosened up into single fibers. Next, air is applied to agglomerate the fibers onto a web curtain. The fiberweb is then reinforced to form cloth. 4. Wetlaid nonwoven: Fiber raw materials placed in water are loosened up into single fibers and mixed with various fiber raw materials to give fiber suspensions. The suspensions are delivered to the webbing mechanism. The fibers are laid into web under wet conditions and then reinforced to form cloth. 5. Spunbonded nonwoven: Polymers are extruded and lengthened to form continuous long threads, which are laid into a fiberweb. The fiber web is then processed to form nonwoven through self-bonding, heat-bonding, chemical bonding, or mechanical reinforcement methods. 6. Meltblown nonwoven: Polymers are melt and extruded to form fibers. The fibers are cooled and blown into a fiberweb. Then the fiberweb is reinforced to form cloth. 7. Needle-punched nonwoven: This is one kind of drylaid nonwoven. The punching effect of needles is used to reinforce a loose fiberweb. 8. Stitch-bonded nonwoven: This is one kind of drylaid nonwoven. Use warp and weft loop structures to reinforce the fiberweb, yarn layer, non-fabric materials (such as plastic flakes, plastic foils, metal foils, etc.) or their combinations and form nonwoven.
Accordingly, before weaving process, taking polymer material as an example, the preparation process is very complicated including synthesis, reeling, and spinning. During reeling and spinning, mechanical strength of fibers is extremely important because fibers are reeled and pulled by machines. If the mechanical strength of fibers is not enough, difficulties will result. The present invention provides a method using nonwoven as the yarn, eliminating the need of considering mechanical characteristics of fibers while the nonwoven includes different materials.
SUMMARY
An objective of the present invention is to provide a method for producing thread using nonwoven, which can provide nonwoven yarns for applying into a weave procedure without the need of considering physical characteristics, such as strength and stress, of fibers.
In order to achieve the objectives and effects described above, the present invention provides a method for producing thread using nonwoven, which discloses that nonwoven including different materials is slit first, and obtaining a plurality of nonwoven threads, and then the nonwoven threads are used for a twisting process to get a plurality of nonwoven yarns. In the twisting process, the nonwoven yarns with different materials have good mechanical characteristics and can be added for producing textiles with various functionalities while each of the nonwoven threads are manufactured from the nonwoven with different materials.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a manufacturing flowchart according to a preferred embodiment of the present invention;
FIG. 2 shows a weaving flowchart according to a preferred embodiment of the present invention; and
FIG. 3 shows a manufacturing flowchart according to another preferred embodiment of the present invention.
DETAILED DESCRIPTION
In order to make the structure and characteristics as well as the effectiveness of the present invention to be further understood and recognized, the detailed description of the present invention is provided as follows along with preferred embodiments and accompanying figures.
The present invention uses nonwoven as the yarn, and weaves with itself or yarn of other materials to produce cloth.
FIG. 1 shows a manufacturing flowchart according to a preferred embodiment of the present invention. As shown in the figure, the present invention uses nonwoven having different materials to produce the yarns, and comprises steps of: step S 10 , taking nonwoven, the nonwoven is made of different materials, such as Polyester, Polypropylene, Polyethene, polyvinyl ester, polyolefin; step S 12 , performing slitting process on the nonwoven and obtaining a plurality of nonwoven threads. Due to the nonwoven made of different materials, the nonwoven yarns get good mechanical characteristics, such as textile strength and stress; the step S 14 , twisting the nonwoven threads to obtain a plurality of nonwoven yarns. Otherwise, the steps further comprises steps S 16 and S 18 , wherein the step S 16 , performing a weaving procedure on the plurality of nonwoven yarns for producing cloth, wherein the weaving procedure is performed by tatting, knitting, plain weaving, or mesh weaving. The step S 18 , performing a appearance working process on the cloth produced by the nonwoven yarns, where the cloth is dyed or printed with at least one pattern or at least one stamp, such as dyeing or printing the flower pattern, gear pattern, block stamp, or cloud stamp on the cloth during the appearance working process. The dyed cloth gets different color effect due to the nonwoven yarns made from the nonwoven made by different materials with different rendering properties. Otherwise, the cloth is also able to be coated with a water-resistant material during the appearance working process, for adding the water-resistant property on the cloth.
Further, due to the nonwoven made of different materials, the shapes of the patterns or the stamps would be contoured obviously. For example, the appearance effect of the cloth is determined by the different depth of the stamp on the cloth. On the other hand, the solid impression of the cloth would be enhanced by the different depth of the stamp caused by the different materials arranged cross each other.
Because nonwoven has the physical characteristics of softness, using it as the yarn can increase usability of cloth. In addition, by taking advantage of the softness characteristics of nonwoven along with various weaving schemes, different appearances and applications can be provided.
The nonwoven described above is the fabrics manufactured by bonding, needle punching, water mangling, heat melting, spunbonding, and meltblowing using different materials as the raw material. The nonwoven described in the present invention is not the technological characteristic of the present invention. Thereby, cloth manufactured by wetlaid, drylaid, or polymer extrusion can be used as well.
Furthermore, the weaving methods according to the present invention include tatting, knitting, plain weaving, or mesh weaving. Taking tatting as an example and referring to FIG. 2 , the weaving method comprises the following steps. Step S 20 , warping: organize the yarn and install it on the beam. Step S 21 , sizing: the strength of yarn is not sufficient. Hence the yarn has to immerse into the thick amylum liquid. Step S 22 , leasing and healding: divide the threads in the beam into odd and even threads, and install them in the heald frame. Step S 23 : reeding: installing the heald frame to the weaving machine. Step S 24 , weaving: when the warp yarn is carried up or down depending on odd or even numbering, the weft yarn is carried by a shuttle back and forth to weave the two sets of yarns. Step S 25 , examination: Examine if flaws exist in the woven cloth. Mending is performed if required. Step S 26 , finishing: deliver the finished textile or perform further dyeing and finishing.
FIG. 3 shows a manufacturing flowchart according to another preferred embodiment of the present invention. As shown in the figure, the manufacturing process according to another preferred embodiment of the present invention comprises steps of: step S 30 , taking nonwoven, the nonwoven is also made of different materials; step S 32 , performing slitting process on the nonwoven and obtaining a plurality of nonwoven yarns; step S 34 , performing a twisting procedure on the plurality of nonwoven threads to obtain a plurality of nonwoven yarns. The steps further comprises steps S 36 and S 38 , wherein step S 36 , performing a weaving procedure on the plurality of nonwoven yarns and a thread of yarn for producing cloth, the weaving procedure is performed by tatting, knitting, plain weaving, or mesh weaving. The step S 38 , performing a appearance working process on the cloth produced by the nonwoven yarns, wherein the cloth is dyed or printed with at least one pattern or at least one stamp, such as the flower pattern, gear pattern, block stamp, or cloud stamp during the appearance working process.
Because yarn with different materials, which includes polymer, metal, or nonmetal materials, can be woven with the nonwoven yarns according to the present invention, textiles with various functionalities can produced. Besides, tatting or knitting or plain weaving or mesh weaving can be applied during weaving. Furthermore, the light shielding characteristic of the cloth is further made from the plain weaving or mesh weaving.
Accordingly, the present invention conforms to the legal requirements owing to its novelty, non-obviousness, and utility. However, the foregoing description is only a preferred embodiment of the present invention, not used to limit the scope and range of the present invention. Those equivalent changes or modifications made according to the shape, structure, feature, or spirit described in the claims of the present invention are included in the appended claims of the present invention.
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The present invention provides a method for producing thread using nonwoven, which discloses that nonwoven having different materials is slit first to get a plurality of nonwoven threads and then the nonwoven threads are used for performing a twisting process to get a plurality of nonwoven yarns. In the twisting process, each of the nonwoven threads has different materials, so that the nonwoven yarns have good mechanical characteristic and can be added for producing textiles with various functionalities.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electrical connector, and more particularly to an electrical connector for a sheet-like connection member such as a flexible printed circuit or cable (FPC), a flexible flat cable (FFC) and so forth. All of these cables and circuit hereafter will be generally referred to as “FPC” for simplification.
[0003] 2. Description of Related Art
[0004] A conventional FPC connector generally includes an insulative housing formed with an FPC inserting portion, a plurality of terminals loaded in parallel relationship with a predetermined pitch in the insulative housing and each including at least a contact beam for electrically contacting the FPC and a pivot beam integrally extending from the contact beam, and a pivoting actuator for establishing electrical contact between the conductors of the FPC and contact beams of the terminals. Typical connectors of this type can be seen in U.S. Pat. No. 6,837,740 and Japanese Patent Laid-Open No. 11-250147.
[0005] However, as the terminal including at least two beams (the contact beam and the pivot beam) is a one-piece structure, it is required the housing to provide a substantially like cavity for correspondingly receiving the terminal. Forming of such kinds of terminal receiving cavities would diminish the structural strength of the FPC connector. On the other hand, as the contact beam extends down from the pivot beam and then is bent to be parallel to the pivot beam, there is a long way from the contact point (which is adapted to electrically contact the FPC) of the contact beam to the solder pat. Thus the transmission path of electrical signals in the terminal is long and the impedance of the terminal is large, which would largely reduce the transmission efficiency of the FPC connector.
[0006] Therefore, a new FPC connector is desired to overcome the disadvantages of the prior arts.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide an FPC connector which has a reliable structural strength.
[0008] Another object of the present invention is to provide an FPC connector in which the impedance of terminals is reduced.
[0009] In order to achieve above-mentioned objects, an FPC connector for connecting an FPC in accordance with a preferred embodiment of the present invention includes a housing defining a longitudinal direction and a cavity having a front opening for receiving the FPC; terminals arranged in the housing along the longitudinal direction and each having a contact portion protruding into the cavity; pivot beams loaded in the housing and separately set from the terminals; and an actuator pivotally engaging with the pivot beams and rotatable between an open position and a closed position.
[0010] Other objects, advantages and novel features of the present invention will become more apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an assembled perspective view of an FPC connector in accordance with a first embodiment of the present invention;
[0012] FIG. 2 is another assembled perspective view of the FPC connector shown in FIG. 1 , taken from another aspect;
[0013] FIG. 3 is a third assembled perspective view of the FPC connector shown in FIG. 1 , taken from a third aspect;
[0014] FIG. 4 is a perspective view of the FPC connector shown in FIG. 1 wherein an actuator has been removed;
[0015] FIG. 5 is a plan view of FIG. 4 ;
[0016] FIG. 6 is a cross-sectional view of FIG. 1 taken along line 5 - 5 ;
[0017] FIG. 7 is a cross-sectional view of FIG. 1 taken along line 6 - 6 ;
[0018] FIG. 8 is an assembled perspective view of an FPC connector in accordance with a second embodiment of the present invention;
[0019] FIG. 9 is a cross-sectional view of FIG. 8 taken along line 9 - 9 ; and
[0020] FIG. 10 is a cross-sectional view of FIG. 8 taken along line 10 - 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] Reference will now be made to the drawing figures to describe the preferred embodiment of the present invention in detail.
[0022] Referring to FIGS. 1 and 3 , an FPC connector 100 for connecting an FPC (not shown) to a board or the like in accordance with a first embodiment of the present invention comprises an insulative housing 1 , a plurality of terminals 2 , pivot beams 3 , and an actuator 4 .
[0023] Referring to FIGS. 2, 4 , and 5 , the insulative housing 1 is of an elongated form and defines a longitudinal direction A, and is provided with an FPC receiving cavity 11 having both a top opening (not labeled) and a front opening (not labeled). The terminals 2 are arranged in two rows along the longitudinal direction A in the insulative housing 1 , and the terminals 2 in each row are arranged in a side-by-side fashion, wherein the first row of terminals 2 are inserted from the rear side of the insulative housing 1 while the second row of terminals 2 are inserted from the front side of the insulative housing 1 . Referring to FIGS. 4, 6 and 7 , the first and second rows of terminals 2 are arranged in a head-to-head relationship and terminals 2 in the first row and terminals 2 in the second row are alternatively arranged along the longitudinal direction A. Such an arrangement fashion of the terminals 2 makes the insulative housing 1 be able to accommodate as many terminals 2 as possible while there is still a enough space between each two adjacent terminals 2 and thereby will optimize the whole structure of the FPC connector 100 .
[0024] As best shown in FIGS. 6 and 7 , each of the terminals 2 has a fixing arm 21 fixed in the insulative housing 1 , a contact arm 22 running parallel to the fixing arm 21 , and a solder foot 23 extending down from a joint of the fixing arm 21 and the contact arm 22 , wherein the fixing arm 21 is formed with a retaining pawl 211 clasping the insulative housing 1 for preventing the terminal 2 from being withdrawn, and the contact arm 22 is formed with a contact portion 221 protruding to the FPC receiving cavity 11 .
[0025] Referring to FIGS. 3-6 , now the pivot beams 3 will be explained in detail. The pivot beams 3 are also arranged in a row at the upper side of the first row of terminals 2 , and along the longitudinal direction A, each pivot beam 3 is located between some of two adjacent terminals 2 in the first row. The pivot beam 3 has a retaining tail 31 hooking at the insulative housing 1 for diverting or dispersing the force that the pivot beam 3 puts on the insulative housing 1 , thereby making the pivot beam 3 firmly retained in the insulative housing 1 . The retaining tail would be a right-angled hook as illustrated in FIG. 6 and would also be other forms, such as a curve hook. The pivot beam 3 further defines a pivot concave 32 at a lower edge of the tip end thereof for pivotally engaging with the actuator 4 . By separating the pivot beam 3 from the terminal 2 and making it individual a one, the pivot beams 3 and the terminals 2 can be respectively assembled into the insulative housing 1 , and as the row of the pivot beams 3 and the first row of terminals 2 are separate and the space therebetween is filled with plastic of the insulative housing 1 , thus in certain extend enhancing the structural strength of the insulative housing 1 . Otherwise, the arrangement fashion that the pivot beams 3 are respectively located between some of two adjacent terminals 2 in the first row along the longitudinal direction A, as stated above, makes the pivot beams 3 and the terminals 2 in the first row be alternatively arranged along the longitudinal direction A, thereby further enhancing the structural strength of the insulative housing 1 .
[0026] Referring to FIGS. 1, 3 and 6 , the actuator 4 is form into a plate form so as to open or close the top opening of the FPC receiving cavity 11 , and comprises a plate portion 41 and a pivot edge 42 on one side of the plate portion 41 adjacent to the pivot beams 3 . In order to engage with the pivot concave 32 provided in the pivot beam 3 , a shaft portion 425 (shown in FIG. 6 ) is provided on the pivot edge 42 of the actuator 4 at a position corresponding to the position of pivot concave 32 . The shaft portion 425 is formed by providing a groove 423 corresponding to the pivot beam 3 on the pivot edge 42 of the actuator 4 . Between adjacent shaft portions 425 are pushing projecting portions 424 located between adjacent pivot beams 3 . The pushing projecting portions 424 extend from the lower surface of the actuator 4 , as best shown in FIG. 7 . The pivot edge 42 further has a pair of support bosses 421 at longitudinal ends thereof which are respectively supported on support recesses 14 at the insulative housing 1 so as to prevent the actuator 4 from downward movement to maintain engagement between the shaft portion 425 and the pivot concave 32 . As best shown in FIG. 6 , all the shaft portions 425 and the support bosses 421 have a common axis for pivotal rotation. By engaging the shaft portions 425 of the actuator 4 with the pivot concaves 32 of the pivot beams 3 , the actuator 4 is pivotable between an open position where the actuator 4 is raised so as to allow the FPC to be inserted into the FPC receiving cavity 11 with Zero-Insertion-Force and a closed position where the actuator 4 is oriented substantially parallel to the insulative housing 1 so as to push the FPC to electrically contact the contact portions 221 .
[0027] The plate portion 41 is provided with lock cutouts 411 at longitudinal end portions thereof, and corresponding to these lock cutouts 411 , the insulative housing 1 is formed with lock blocks 12 at longitudinal end portions thereof. When the actuator 4 is rotated to the closed position substantially parallel to the insulative housing 1 to close the top opening of the FPC receiving cavity 11 , the lock cutouts 411 will engage with the lock blocks 12 for maintaining the actuator 4 in that closed position.
[0028] Turning to FIGS. 8-10 , description will be made as an FPC connector according to the second embodiment of the present invention. Similar parts are designated by like reference numbers.
[0029] In the second embodiment, the terminals 2 ′ are arranged in two rows in the insulative housing 1 ′ wherein the terminals 2 ′ in different row are alternatively arranged along the longitudinal direction of the insulative housing 1 , and the pivot beams 3 ′ are disposed at the upper side of the first row of terminals 2 ′, as well as the first embodiment. The difference between the first and second embodiments is that the pivot beams 3 ′ in the second embodiment are disposed in the positions corresponding to the terminals 2 ′ in the first row as illustrated in FIGS. 8-10 , rather than that the pivot beams 3 are disposed between some of two adjacent terminals 2 in the first row, as disclosed in the first embodiment. That is to say, each of the pivot beams 3 ′ in the second embodiment is exactly positioned at the upside of one of the terminals 2 ′ in the first row. As the shape and arrangement of other parts is substantially the same as that of the first embodiment, it would be not repeated here.
[0030] However, the disclosure is illustrative only, changes may be made in detail, especially in matter of shape, size, and arrangement of parts within the principles of the invention.
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An electrical connector ( 100 ) adapted to be detachably fitted with a sheet-like member includes a housing ( 1 ) defining a longitudinal direction (A) and a cavity ( 11 ) having a front opening for receiving the sheet-like member; terminals ( 2 ) arranged in the housing along the longitudinal direction and each having a contact portion ( 221 ) protruding into the cavity; pivot beams ( 3 ) loaded in the housing and separately set from the terminals; and an actuator ( 4 ) pivotally engaging with the pivot beams and rotatable between an open position and a closed position.
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RELATED APPLICATIONS
This application is a continuation, of application Ser. No. 415,423, filed Sept. 7, 1982, which is a continuation-in-part of my copending application Ser. No. 307,300, filed on Sept. 30, 1981, and entitled "ORGANOCLAY WASTE DISPOSAL METHOD", both now abandoned. The entire disclosure of this parent application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for treating waste fluids containing organic contaminants to solidify the waste fluid to facilitate disposal; and more particularly relates to the forming of a substantially non-flowable matrix from an aqueous waste fluid containing organic contaminants.
2. Prior Art
One of the major problems facing cities, chemical manufacturers, and industries using various chemicals is waste disposal. This problem can generally be divided into three major categories: solidification of fluid waste, disposal of waste by land burial, and remedial action around existing disposal sites which are now leaking.
The use of finely divided or porous solid materials to solidify fluid wastes and spills is well known. Generally, the purpose of solidification is to aid in the disposal of fluid wastes or spills. Among the materials which have been used for solidification are cement, kiln dust, fly ash, soil, and sawdust. These materials have numerous disadvantages. The volume of solidified waste is usually four to five times the volume of the original waste. Additionally, these dusts and the like generally have no specific affinity for one component of the waste relative to another and, even after solidification, liquid components may leach from the waste. Liquid wastes containing five percent (5%) or more of organic contaminants also disrupt the cementatious reactions that help stabilize cement and kiln dust waste products.
These current techniques of waste solidification generally physically trap the organic waste in a solid matrix. When the solid matrix is breached, the organic waste is released unabated to the ground water. Another problem that plagues this method of waste disposal is that during the solidification process, the liquid phase and the solidification medium have a tendency to separate. This renders the method ineffective at stabilizing the waste. One method that has been reported for overcoming this problem is to mix small portions of bentonite with portland cement; this eliminates the aqueous phase separation problem. The bentonite, however, does not adsorb the organic waste. This technology still suffers from the inadequacy of not binding the organic waste other than by physically trapping it.
Prior art of which applicant is aware which relates to solidification of fluid waste are as follows:
British Pat. No. 1,280,373 to Davies et al describes the separation of an oil from an emulsion. Several methods are enumerated for forming the emulsion into two layers for evaporation of the aqueous layer. One of these methods utilizes a mixture of surface-active clay and a polyelectrolyte. First the surface-active clay and then a polyelectrolyte is added to the emulsion. Bentonite is described as a particularly suitable clay. Polyamides are described as particularly suitable polyelectrolytes.
U.S. Pat. No. 3,274,784 to Shock et al, describes a method for the disposal of radioactive waste. This is accomplished by forming a solidifiable composition containing the radioactive waste in the form of a solution or slurry in water and mixing with clay minerals, lime and caustic present in proportions to provide a solid mass on standing. The radioactive wastes contain fissionable products such as strontium, cesium, ruthenium, etc. The preferred clay is calcium montmorillonite. Bentonite was found to require temperatures too high for solidification to take place. Natural clays may also be used.
U.S. Pat. No. 3,948,770 to Goodrich et al describes the use of an anionic polyelectrolyte and a sodium or a calcium montmorillonite clay to effectively separate water oil droplets in sea water.
U.S. Pat. No. 4,033,764 to Colegate et al describes scavenging metal ions from solution by means of a complexing agent comprised of an inorganic substrate, such as a clay mineral, with covalent organic molecules, such as onium compounds, chemically bonded to the substrate.
U.S. Pat. No. 4,149,968 to Kupiec, describes the use of bentonite clays and portland cement in aqueous solutions containing polluting materials, e.g. metallic ions, to form a solid mass.
Japanese No. 015979 to Koyo Kasei KK, describes the detoxification of PCB-containing waste water by mixing the waste water with diatomaceous earth, bentonite or other clay which has been made lipophilic, and then mixing with cement, water, and aggregate. In the method, less than 20% PCB waste liquor, sludges, etc., are mixed with the diatomaceous earth, bentonite, or clay minerals of inorganic fine particles previously made lipophilic by surface treatment. The PCB's are allowed to be adsorbed on the mineral, and then the resulting materials are mixed with cement, water, and aggregate. Diffusing or leaching appears to be reduced. Activated carbon or silica gel may also be used in place of the clay.
Organoclays are well-known in the art, see for example the following U.S. patents:
U.S. Pat. No. 2,531,427 to Hauser;
U.S. Pat. No. 2,966,506 to Jordan;
U.S. Pat. No. 3,422,185 to Kuritzkef;
U.S. Pat. No. 3,974,125 to Oswald;
U.S. Pat. No. 4,081,496 to Finlayson; and
U.S. Pat. No. 4,105,578 to Finlayson et al
None of these aforementioned references teach or suggest the use of these organoclays to immobilize organic contaminants to facilitate their disposal.
SUMMARY AND OBJECTS OF THE INVENTION
A method is provided for treating polar or aqueous fluid compositions containing an amount of an organic contaminant to immobilize the contaminant by forming a nonflowable matrix containing the contaminant. The non-flowable matrix can be easily disposed of. The method comprises adding a sufficient amount of an organoclay to the fluid composition to absorb substantially all of the organic contaminant. A sufficient amount of solid adsorbent is added to the composition to absorb or react with substantially all of the polar fluid or water to form a substantially non-flowable matrix. Typically, such polar or aqueous compositions are in emulsion form with the organic contaminant and the addition of the organoclay breaks the emulsion, permitting removal of a portion of the water or polar fluid from the composition to thereby reduce the volume to be disposed of. The method of this invention immobilizes the organic contaminant, in such a manner that it is non-leachable from the matrix.
It is thus an object of this invention to provide a method for treating fluid wastes, e.g. ponds, streams, etc., to immobilize the organic contaminants contained therein to faciliate disposal.
It is a further object of this invention to provide a method for treating both aqueous and polar fluid waste containing such organic contaminants to facilitate disposal.
It is a further object of this invention to provide a method for immobilizing organic contaminants contained in a fluid waste, so that they do not leach out into the environment, which method substantially reduces the volume of the waste to facilitate disposal.
It is a further object of this invention to provide a method for treating fluid waste containing organic contaminants emulsified therein, to "break" the emulsion to permit removal of of water to reduce the volume and to immobilize the organic contaminants.
It is a yet further object of this invention to immobilize organic contaminants contained in a fluid waste so that the volatility of the organic contaminant is substantially reduced.
It is a still further object of this invention, to provide a method for treating fluid waste containing organic contaminants, to substantially reduce the volume of the waste so that it may be more economically transported to a waste site and disposed of.
It is yet a further object of this invention, to provide a method for treating fluid waste to form a substantially nonflowable matrix.
It is a further object of this invention, to provide a method for treating fluid waste to immobilize the organic contaminants contained therein, using materials which have a specific affinity for the organic contaminant, and consequently, preferentially absorb the contaminants to prevent leaching and volatilization.
It is a yet further object of this invention, to provide a substantially non-flowable matrix containing organic contaminants which can be easily disposed of.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a graph showing the relationship of the logarithm of the distribution co-efficient of certain organic contaminants with the logarithm of their solubilities in water.
FIG. 2 is a graph illustrating organic emissions from a simulated land farm disposal of petroleum sludge.
FIG. 3 is a graphical representation of the sequential leaching of a solidified waste containing 1% hexachlorocyclopentadiene and 1% ethyl parathion (Example 9).
FIG. 4 is a gas chromatagraphic (GC) analysis of the leached original waste and the leached solidified product of this invention (Example 10).
DETAILED DESCRIPTION OF THE INVENTION
Organoclays are well known in the art as exemplified by the aforementioned patents to Hauser, Jordan, Kuritzkey, Oswald et al, Finlayson, and Finlayson et al, the entire disclosures of which are incorporated herein by reference. In this invention, the term "organoclay" refers to various clay types, e.g. smectites, that have organo ammonium ions substituted for cations between the clay layers. The term "organo ammonium ion substituted" refers to a substituted ammonium ion in which one or more hydrogen atoms are replaced by an organic group.
The organoclays are essentially solid compounds that have an inorganic and organic phase.
The preferred clay substrates for use in this invention are the smectite-type clays, particularly the smectite-type clays which have a cation exchange capacity of at least 75 millequivalents per 100 grams of clay. Useful clays for such purposes include the naturally occuring Wyoming variety of swelling bentonite and similar clays, and hectorite, which is a swelling magnesium-lithium silicate clay. The clays, are preferably converted to the sodium form if they are not already in this form. This can be effected, by a cation exchange reaction with a soluble sodium compound. These methods are well-known in the art. Smectite-type clays prepared synthetically can also be utilized, such as montomorillonite, bentonite, beidelite, hectorite, saponite, and stevensite.
The organoclays useful in this invention include those set forth in U.S. Pat. No. 2,531,427 to Hauser. These organoclays are modified clays which exhibit in organic liquids, some of those characteristics which untreated clays exhibit in water. For example, they will swell in many organic liquids and will form stable gells and colloidal dispersions.
Generally, the quaternary ammonium salt substituted onto the clay has organic groups attached to the clay which will range from aliphatic hydrocarbon of from 1 to 24 carbons to aromatic organic molecules, such as benzyl groups that could have a host of groups substituted on the benzyl ring. The number of benzyl versus straight chain hydrocarbons substituted on the ammonium ion can vary from 3 to 0 (i.e. dimethyl dioctododecyl 0:2, methyl benzyl dioctododecyl 1:2, dibenzyl dioctobenzyl 1:1, tribenzyl octadecyl 3:1, methyl dibenzyl octodecyl 2:1). The amount of alkyl ammonium salt substituted on the clay can vary between 0.5% to 50%.
In particular, the preferred organoclay used in this invention comprises one or more of the following quaternary ammonium cation modified montmorillonite clays: ##STR1## wherein R 1 is an alkyl group having at least 10 carbon atoms and up to, for example, 24 carbon atoms, and preferably having a chain length of from 12 to 18 carbon atoms; R 2 is hydrogen, benzyl or an alkyl group of at least 10 carbon atoms and up to, for example, 24 carbon atoms, and preferably from 12 to 18 carbon atoms; and R 3 and R 4 are each hydrogen or lower alkyl groups, viz., they contain carbon chains of from 1 to 4 atoms, and preferably are methyl groups.
Other organoclays utilizable in the invention include benzyl organoclays such as dimethyl benzyl (hydrogenated tallow) ammonium bentonite; methyl benzyl di(hydrogenated tallow) ammonium bentonite; and more generally quaternary ammonium cation modified montmorillonite clays represented by the formula: ##STR2## wherein R 1 is CH 3 or C 6 H 5 CH 2 ; R 2 is C 6 H 5 CH 2 ; and R 5 and R 4 are alkyl groups containing long chain alkyl radicals having 14 to 22 carbon atoms, and most preferably wherein 20 to 35% of said long chain alkyl radicals contain 16 carbon atoms and 60% to 75% of said long chain alkyl radicals contain 18 carbon atoms.
The montmorillonite clays which may be so modified are the principal constituents of bentonite rock, and have the chemical compositions and characteristics described, for example, in Berry and Mason, "Mineralogy", 1959, pp. 508-509. Modified montmorillonite clays of this type in (i.e. organoclays) are commercially available from Southern Clay Products, Inc., Gonzales, Tex. under such trade designations as CLAYTONE 34 and 40, and are available from NL Industries, Inc., New York, N.Y. under such trade designations as BENTONE 27, 34, and 38. The preferred organoclays utilized in this invention, are the higher dialkyl dimethyl ammonium organoclays such as dimethyl di(hydrogenated tallow) ammonium bentonite; the benzyl ammonium organoclays, such as dimethyl benzyl (hydrogenated tallow) ammonium bentonite; and ethylhydroxy ammonium organoclays such as methylbis (2-hydroxyethyl) octodecyl ammonium bentonite.
The fluid waste, which may be an aqueous waste or a waste fluid whose carrier fluid is a polar composition, e.g. aliphatic alcohol, etc. contains an amount of organic contaminant. Typical organic contaminants are the chlorinated organic compounds; e.g. DDT, BDD, DDE, 2, 4-dichloro-phenol, tetrachloroethylene, and other organics such as benzene, toluene, methylene chloride, chloroform, 1, 2 dichloroethane 1, 1, 1- trichloroethane, trichloroethylene, tetrachloro ethylene, 2-nitrophenol, pentachlorophenol, dimethy phthalate, Lindane, Arochlor-1254, ethyl benzene, HCP, parathion, dichlorobenzene, hexachlorocyclopentadiene, ethylparathion, 2, 4-dinitrotoluene, naphtalene, pyrene, etc.
In the method of this invention, a sufficient amount of the organoclay is added to the aqueous or polar fluid composition to adsorb substantially all of the organic contaminants on the organoclay. Preferably, the amount of organoclay is at least about one percent (1%) by weight of the amount of organic contaminant and most preferably at least about five percent (5%) by weight of the organic contaminant. If too little organoclay is used, there will be insufficient solidification. The upper limit of organoclay is primarily dictated by cost. For general guidance, however, about ten percent (10%) by weight of the amount of the organic contaminant is a preferred upper limit.
The organoclay is mixed thoroughly with the fluid waste. The temperature at which the organoclay is mixed with the waste is not critical, with room temperature being preferred for obvious cost considerations.
The organoclay, upon mixing in the fluid waste, swells as the organic contaminant molecules are sorbed into and onto the organoclay. All current solidification technology only physically traps the organic contaminant molecules in voids in a solid matrix. The use of the organoclay helps to overcome this problem and tends to prevent separation of the organic contaminants during the solidification process. The organoclay additionally fixes the organic contaminant compounds through absorption involving partitioning of the organic molecules of the contaminant into the organoclay. This invention retains the advantages of retarding phase separation exhibited by the use of untreated bentonite and adds the extra advantage of fixing the organic contaminant in a physical chemical way rather than merely occluding it. This results in a solid phase that is far less leachable than with other known techniques.
The organic molecules of the contaminant preferably partition into the organic phase of the organoclay versus the aqueous phase or polar fluid phase. The magnitude of organic partitioning of a given organic molecule into the organoclay over, for example, the aqueous phase, can be predicted qualitatively by the solubility of the organic molecule in the aqueous phase. That is to say, an organic molecule that is very insoluble in an aqueous phase will partition very strongly into the organoclay relative to a more soluble organic molecule. This partitioning phenomenom also follows chromatagraphic theory which allows precise predictions of how organic molecules will migrate through a bed of organoclay. FIG. 1 shows the linear relationship of distribution co-efficients for several key organic species with three forms of organoclay. The distribution coefficients equals the amount of organic adsorbed in the clay divided by the amount left in solution times the volume of the solution divided by the mass of the clay. The aqueous solution contains the organics listed in FIG. 1. Generally, the amount in solution depends on solubility.
Broadly, the next step in the method of treating the waste fluid or liquor is adding a sufficient amount of solid adsorbent to adsorb or react with substantially all of the water therein to form a substantially non-flowable matrix. Solid adsorbants that may be utilized in this invention are portland cement, kiln dust, fly ash, clay, soil or attapulgite or mixtures thereof, e.g. attapulgite and cement. The appropriate ratio of solid adsorbent to be added to the organoclay waste mixture can vary from about zero (0) (when the organoclay alone is sufficient to solidify the waste stream) up to fifty percent (50%) by weight of the organic contaminant, although up to about one-hundred percent (100%) by weight of the organic contaminant may be added. The preferred lower range is about ten percent (10%) solid adsorbent. The addition of the solid adsorbant solidifys the mixture into a substantially non-flowable matrix containing an amount of water and an amount of organic contaminant molecules partitioned and bound within the organic phase of the organoclay portion of the solid matrix.
In a preferred embodiment of this invention, after the step of adding the organoclay, a portion of the water or polar fluid is removed, for example, by decanting or otherwise separating the fluid from the composition. Such procedure substantially reduces the volume of the solidified matrix. The organoclay when added to the fluid waste composition tends to break organic contaminant water emulsions. The organoclays are very effective at breaking emulsions at extremely low dose rates of organoclay. The breaking of the emulsion is particularly useful if the waste is to be solidified, for less mass must be solidified when water is removed, and this therefore provides for decreased cost in transportation and disposal. The water can also be recovered for further use. Additionally, this water removal or decanting step provides for the waste being incinerated at considerable savings since the BTU value of the waste has increased substantially by the exclusion of water. Still further, the organics left in the waste mass can be recovered for reuse and the organoclay regenerated.
Another aspect of this invention is providing a substantially non-flowable matrix comprising an amount of water or polar fluid, an amount of organic contaminant in the water or polar fluid, a sufficient amount of organoclay to absorb substantially all of the contaminants, and a sufficient amount of solid adsorbant to adsorb or react with substantailly all of the water or polar fluid to thereby form the substantially non-flowable matrix.
The method of this invention provides for several advantages which include substantially reducing the volume and mass of a finally solidified product compared to known prior art methods of solidifying waste. This yields substantial savings in mixing, transportation and disposal site costs. Additionally, the organic contaminant/water emulsions can be broken by the use of the organoclays, thus yielding further volume reduction and allowing water to be returned to the plant for further use. Removal of water also makes incineration more feasible since the solid matrix has a high BTU value. Still further, volatile emissions originating from the waste mass are substantially reduced by the method of this invention. This is important for the health and safety of workers and of residents who live near the disposal site. And finally, the leach rates of the waste are substantially reduced, thus lowering the environmental liability associated with disposal.
EXAMPLE 1
In order to demonstrate the efficacy of the organoclay used in this invention, several batch sorption experiments were performed with two forms of higher dialkyl dimethyl organoclay and compared to untreated montmorillonite sorption. These were conducted with 100:1 solution to solid ratio. The following Tables 1, 2 and 3 are a summary of these studies showing results from batch equilibration sorption studies of a montmorillonite, which has not been rendered into an organoclay, CLAYTONE® 34, and CLAYTONE® 40 respectively. CLAYTONE® 34 and CLAYTONE® 40 are organoclays, each being a dimethyl di(hydrogenated tallow) ammonium bentonite product, available from Southern Clay Products, Inc. of Gonzales, Tex.
It can be seen that extremely efficient removal occurs for all of the listed organics with the organoclays. The analyses for the majority of compounds in Tables 1, 2 and 3 were conducted by standard gas chromatographic techniques. The data for benzene, toluene and methylene chloride in these Tables are less accurate because the measurements were conducted by determining only the total organic carbon concentration.
TABLE 1__________________________________________________________________________ 24 Hours Batch Equili- 48 Hours Batch Inlet Con- Concen- brations Concentration Equilibration Concentration centrations tration Amount Blank Amount BlankOrganic Spiking Level in Blank Recovered (ppb) % Recovered (ppb) %Species (ppb) (ug/1) (ppb) (ug/1) (ppb) (ug/) (ug/1) Sorbed (ppb) (ug/1) (ug/1) Sorbed__________________________________________________________________________Aroclor 1254 3.65 0 4.95 0 0 13 0 0p,p'-DDT 0.88 0 0.82 0 7 0.96 0 0o,p'-DDT 1.77 0 2.11 0 0 2.16 0 0p,p'DDD 0.75 0 0175 0 0 0.88 0 0o,p'DDD 0.43 0 0.46 0 0 0.36 0 16p,p'-DDE 0.56 0 0.68 0 0 0.86 0 0o,p'-DDE 0.17 0 0.20 0 0 0.15 0 122,4-Dichlorophenol 18,000 0 11,000 0 39 11,000 0 39Tetrachloroethylene 318 0.20 278 2.10 13 331 0.70 0Benzene 1.35 × 10.sup.5 0 1.35 × 10.sup.5 0 0Toluene 5.4 × 10.sup.4 0 4.54 × 10.sup.4 8 16Methylene Chloride 5.12 × 10.sup.5 0 4.40 × 10.sup.5 0 14__________________________________________________________________________
TABLE 2__________________________________________________________________________ 24 Hours Batch Equili- 48 Hours Batch Inlet Con- Concen- brations Concentration Equilibration Concentration centrations tration Amount Blank Amount BlankOrganic Spiking Level in Blank Recovered (ppb) % Recovered (ppb) %Species (ppb) (ug/1) (ppb) (ug/1) (ppb) (ug/) (ug/1) Sorbed (ppb) (ug/1) (ug/1) Sorbed__________________________________________________________________________Aroclor 1254 3.65 0 0 0 100 0 0 100p,p'-DDT 0.88 0 0 0 100 0 0 100o,p'-DDT 1.77 0 0 0 100 0 0 100p,p'DDD 0.75 0 0 0 100 0 0 100o,p'DDD 0.43 0 0 0 100 0 0 100p,p'-DDE 0.56 0 0 0 100 0 0 100o,p'-DDE 0.17 0 0 0 100 0 0 1002,4-Dichlorophenol 18,000 0 200 0 99 200 0 99Tetrachloroethylene 318 0.20 25 0.3 92 24 0.2 92Benzene 13.5 × 10.sup.5 0 5400 0 96Toluene 5.4 × 10.sup.4 0 2160 0 96Methylene Chloride 5.12 × 10.sup.5 0 1.08 × 10.sup.5 0 79__________________________________________________________________________
TABLE 3__________________________________________________________________________ 24 Hours Batch Equili- 48 Hours Batch Inlet Con- Concen- brations Concentration Equilibration Concentration centrations tration Amount Blank Amount BlankOrganic Spiking Level in Blank Recovered (ppb) % Recovered (ppb) %Species (ppb) (ug/1) (ppb) (ug/1) (ppb) (ug/) (ug/1) Sorbed (ppb) (ug/1) (ug/1) Sorbed__________________________________________________________________________Aroclor 1254 3.65 0 0 0 100 0 0 100p,p'-DDT 0.88 0 0 0 100 0 0 100o,p'-DDT 1.77 0 0 0 100 0 0 100p,p'DDD 0.75 0 0 0 100 0 0 100o,p'DDD 0.43 0 0 0 100 0 0 100p,p'-DDE 0.56 0 0 0 100 0 0 100o,p'-DDE 0.17 0 0 0 100 0 0 1002,4-Dichlorophenol 18,000 0 200 0 99 200 0 99Tetrachloroethylene 318 0.20 27 0.3 92 25 0.30 92Benzene 1.35 × 10.sup.5 0 3420 0 76Toluene 5.4 × 10.sup.4 0 1620 0 97Methylene Chloride 5.12 × 10.sup.5 0 1.13 × 10.sup.5 0 78__________________________________________________________________________
EXAMPLE 2
The following Table 4 provides an initial comparison of literature values of sorption capacities of activated charcoal for several organic compounds and sorption capacities from experimental data for the dimethyl ditallow form of the organoclay for these organic compounds. The data for charcoal was taken from EPA Report 600/8-80-23 and for the organoclay from data based on a single experimental value per compound.
TABLE 4______________________________________Sorption Capacities (mg/g)Organic Compound Charcoal Organo-Clay______________________________________Benzene 0.1 18Toluene 25.0 6Methylene Chloride 1.2 49______________________________________
EXAMPLE 3
The superiority of the organoclay for sorption of organics was further investigated. The sorption of three forms of organoclay at various loading rates for 12 priority organics in water were compared with activated charcoal in laboratory experiments and these results are shown in the following Table 5.
TABLE 5__________________________________________________________________________PERCENTAGES OF SORPTION Dimethyl Benzyl Di(hydrogenated Tallow) Methylbis (2-hydroxy-Concentration (Hydrogenated Tallow) Dimethyl Ammonium ethyl) Octodecylof Organic Clay Type Ammonium Bentonite Bentonite Ammonium Bentonite Carbon ug/1 (ppb) Clay Dose (mg/L): 130 660 1300 130 660 1300 130 660 1300 130__________________________________________________________________________1,000 Chloroform 64 49 56 47 55 43 42 49 51 271,000 1,2 Dichloroethane 46 36 50 48 49 42 34 29 36 401,000 1,1,1 Trichlorethane 60 55 54 40 49 40 36 43 45 301,000 Trichloroethylene 27 24 25 12 43 9 5 13 22 861,000 Tetrachlorethylene 85 46 74 47 51 74 11 39 60 92 700 2 Nitrophenols 84 87 99 96 ND 27 92 87 97 94 49 84 91 95 97 96 85 750 Pentachlorophenol ND ND ND ND ND ND ND 94 92 ND 94 400 Dimethyphthalate 85 ND ND 92 94 ND ND 70 ND ND 92 400 Lindane 99.7 93 ND ND 99.9 85 ND 98 ND 99.9 ND ND -- 100 Arochlor 1254 40 29 90 88 95 94 88 77 98 90 98 95 81 74 84 65 92 89 99.7 15 Ethyl Benzene 29 16 22 13 24 71 8 16 -- --__________________________________________________________________________ ND = Not Detected
EXAMPLE 4
Experiments were conducted on solidifying industrial Class I toxic wastes. The organoclay utilized was a dimethyl di(hydrogenated tallow) ammonium bentonite. It was found that about ten percent (10%) organoclay by weight of the solidified matrix is sufficient to solidify the waste. The solidified waste had drastically reduced volatile organics emanating from it. This is reflected in organic sniffer results in Table 6.
These solids can be handled easily with conventional equipment such as trucks and front-end loaders. It was also determined that leaching of the solidified waste reduces the amount of organics that leach into the aqueous phase from 200 ppm to 20 ppm.
TABLE 6______________________________________ Sniffer, ppm in Gas Phase______________________________________20% waste, 2% organoclay 1878% kiln dust20% waste, 5% organoclay 375% kiln dust20% waste, 10% organoclay 070% kiln dust20% waste, 80% kiln dust 9020% waste, 2% organoclay 078% fly ash20% waste, 5% organoclay 075% fly ash20% waste, 10% organoclay 070% fly ash20% waste, 80% fly ash 90______________________________________
EXAMPLE 5
Volatile organics emanating from landfarm disposal of petroleum sludge can be reduced by application of organoclay. FIG. 2, A and B, illustrate, respectively, initial emissions from an untreated landfarm waste in soil and landfarm waste which was treated in soil with a thin layer of organoclay sprinkled onto the waste burdened surface. The magnitude of the emissions resulted from physically disturbing the landfarmed waste by disking or tilling, a normal commercial practice. FIG. 2, C and D, illustrate, respectively, the volatile organic concentration resulting from tilling the organoclay treated surface 24 and 72 hours after treatment. It can be seen that after the first disking, the emissions were reduced essentially to background levels. For up to ten days after the initial waste implacement, this same low level quantity of emissions occured even when the landfarm was disked repeatedly. Applications of organoclay also tended to solidify the waste-burdened surface producing a mechanically superior surface. Vehicles could travel over the organoclay treated area sooner after the waste was applied. Currently, industrial landfarm operations are delayed about three days between waste applications to ensure that there is a stable surface for heavy equipment. It is not uncommon for landfarm vehicles to become stuck in areas where the wastes are not percolating into the soil rapidly enough to accommodate a mechanically stable surface. Application of organoclay to these surfaces alleviated this situation.
EXAMPLE 6
The solidification of organic waste with organoclays also has the advantage of reducing the final disposal volume of the solidified waste. Table 8 contains examples of two wastes solidified in a conventional way versus solidification with the method of this invention using an organoclay.
TABLE 7______________________________________ Volume of Conventional Volume of Organoclay Solidification (yd.sup.3) Solidification (yd.sup.3)______________________________________1 square yard 4 1.4of class 1toxic waste1 square yard 4.97 1.1of class 2toxic waste______________________________________
EXAMPLE 7
In one series of tests a specific waste containing about forty percent (40%) water by weight was solidified according to established practice and by the method of this invention, with and without decanting. The organoclay utilized was a dimethyl di(hydrogenated tallow) ammonium bentonite. Details are set out in Table 8.
It can be seen from Table 8 that the major advantages of this invention are achieved.
TABLE 8__________________________________________________________________________SOLIDIFICATION OF AN API (AMERICAN PETROLEUMINSTITUTE) SEPARATOR SLUDGE WITH CONVENTIONALFLY ASH TREATMENT AND THE METHOD OF THIS INVENTION Method of the Invention Without With Conventional.sup.4 Decanting Decanting__________________________________________________________________________Volume of Waste (cc) 1,000 1,000 1,000Weight of Waste (g) 890 890 890Weight of Fly Ash (g) 3,846Weight of Organo-Clay (g) -- 22 22Weight of Attapulgite (g) -- 423 180Weight After Solidification (g) 4,736 1,335 1,092Volume After Solidification (cc) 4,850 1,550 800Sniffer Test (ppm in gas phase).sup.1 90 <1 <1TOC.sup.3 in Leachate (ppm).sup.2 50 20 --__________________________________________________________________________ .sup.1 Samples were placed in capped bottles and allowed to stand for 24 hours. The head space in the bottles was then measured with a TLV sniffer that was standardized against methane. .sup.2 The waste was leached in a pHadjusted neutral water solution for 2 hours with a ratio of 10:1 for water to waste. .sup.3 TOC Total Organic Content. .sup.4 Fly ash only.
EXAMPLE 8
The waste of Example 7 was approximately forty percent (40%) water. A waste with low percentage water and high viscosity was solidified. The results are shown in Table 9. In this case, the volume also was substantially reduced. This can result in substantial savings in mixing, transporation, and disposal site cost.
TABLE 9______________________________________SOLIDIFICATION OF A VISCOUS WASTE THATCONTAINS LESS THAN 10% WATER Method of Conventional Invention.sup.1______________________________________Waste Volume (cc) 1,000 1,000Weight of Waste (g) 930 930Weight of Fly Ash (g) 2,150 --Weight of Organoclay (g) -- 23Weight of Attapulgite (g) -- 288Weight After Solidification (g) 3,080 1,241Volume After Solidification (cc) 3,300 1,300______________________________________ .sup.1 No decanting. The clay utilized was a dimethyl di(hydrogenated tallow) ammonium bentonite.
EXAMPLE 9
In order to illustrate more quantitatively the change in leach rate achievable by employing the invention, a third waste containing 8% dichlorobenzene, 1% hexachlorocyclopentadiene, and 1% ethyl parathion was solidified and leached. The solidifications were conducted employing 0.5, 1, 2, 4, 8, and 15 grams of the organoclay and 5 milliliters of waste. The leachings were conducted for 24 hours. The results for the first batch leaching results are given in Table 10. It can be seen that substantial lowering of leach rate was obtained. A second batch leaching was performed on the same waste and the results of that leaching can be seen in Table 11. The leach rate was reduced even further in this second sequential leach. The results of these two leachings are presented graphically in FIG. 3.
TABLE 10______________________________________LEACHING RESULTS FOR SOLIDIFIED WASTECONTAINING 1% HEXACHLOROPENTADIENE AND1% ETHYL PARATHIONMass of pH 11Sorbent pH 3 pH 7 Para-(g) HCP Parathion HCP Parathion HCP thion______________________________________15 0% 0% 0% 4.1% 0% 17.1%8 0% 3.8% 0% 3.9% 0% 20%4 0% 4.2% 0% 9.5% 0% 21.4%2 0% 6.9% 0% 3.4% 0% 24.3%1. 0% 24.5% 0.82% 37.1%.5 0% 12.9% 3.4% 38.1% 4.9% 81.4%______________________________________ *100% is defined as the amount that leaches from conventional solidification with fly ash.
TABLE 11______________________________________PERCENT OF ORGANICS LEACHED IN SECOND BATCHEQUILIBRATION FOR WASTE CONTAINING 1%HEXACHLOROPENTADIENE, 1% ETHYL PARATHION,AND 8% DICHLOROBENZENEMass of Sorbent HCP Parathion 1,2-Dichlorobenzene(g) (%) (%) (%)______________________________________15 0 0 08 0 0 04 0 2 02 0 161 0 0 250.5 16 13.5 16______________________________________ *100% is defined as the amount that will leach from the waste if solidified with fly ash.
EXAMPLE 10
An example of the effect on leaching of organoclays on highly toxic waste can be seen in solidification of a waste obtained from Rocky Mountain Arsenal in Denver, Colo. The problems associated with these wastes have been widely-known and publicized in the Rocky Mountain area. This waste contained large amounts of industrial by-products and pesticides. This waste was solidified employing 5% by weight of a dimethyl di(hydrogenated tallow) ammonium bentonite organoclay, 30% attapulgite, and 80% cement. The waste was then subjected to the standard EPA extraction procedure. The extract was then analyzed for residues of the host of organics present in the original waste. Gas chromatographic analyses of the leached original waste and the leached solidified product are given in FIG. 4. It is clear that the method of this invention greatly reduces the leaching of the organics from this waste.
EXAMPLE 11
Table 13 shows examples of the effectiveness of the organoclays in breaking organic-water emulsions.
TABLE 12______________________________________ORGANOCLAY APPLIED TO BREAKINGOF ORGANIC WATER EMULSIONS Organoclay.sup.1 Percent of Dose (% of WaterType of Emulsion Composition Composition) Recovered______________________________________Texaco API Sepa- 60% organic 2.5% 98%rator Sludge 40% waterAmoco API Sepa- 80% organic 2.5% 95%rator Sludge 20% waterBFI Hazardous Waste 1/3 solids 2.5% 98% 1/3 organic 1/3 waterAlcoa Rolling Mill 10% solids 7% 90%Emulsion 40% organic 50% water______________________________________ .sup.1 Organoclay utilized was a dimethyl di(hydrogenated tallow) ammoniu bentonite.
Although the invention has been described in conjunction with the foregoing specific embodiments, many alternatives, variations and modifications are intended to fall within the spirit and scope of the appended claims.
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A method is provided for treating polar or aqueous fluid compositions containing an amount of an organic contaminant to immobilize the contaminant by forming a nonflowable matrix containing the contaminant. The non-flowable matrix can be easily disposed of. The method comprises adding a sufficient amount of organoclay to the fluid composition to absorb substantially all of the organic contaminant. A sufficient amount of solid adsorbent is added to the composition to absorb or react with substantially all of the polar fluid or water to form a substantially non-flowable matrix. Typically, such polar fluids or aqueous compositions are in emulsion form with the organic contaminant, and the addition of the organoclay breaks the emulsion, permitting removal of a portion of the water or polar fluid from the composition to thereby reduce the volume to be disposed of. The method of this invention immobilizes the organic contaminant, in such a manner that it is non-leachable from the matrix.
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This application claims the priority and benefit of U.S. Provisional Patent App. Ser. No. 60/973,798 filed Sep. 20, 2007.
FIELD OF THE INVENTION
The present invention relates generally to chiropractic health care and to devices that are used in the area of chiropractic treatment. More specifically, the present invention relates to an improved posture correction tool in the form of a novel table that is used by chiropractic practitioners to treat mechanical disorders of the spine and musculoskeletal system.
BACKGROUND OF THE INVENTION
Chiropractic health care is well known. Chiropractic health care focuses on disorders of the musculoskeletal system and its related nervous system, and the effects that such disorders have on a patient's general health and well-being. Doctors of Chiropractic, alternatively referred to as “chiropractors” or “chiropractic physicians,” practice a drug-free, hands-on approach to health care that includes patient examination, diagnosis and treatment. The most common treatment and therapeutic procedure performed by chiropractors on patients is known as “spinal manipulation” or “chiropractic adjustment.” Chiropractic manipulation or adjustment is a manual procedure whereby the chiropractor uses his or her hands to manipulate the joints of the body, particularly the spine, in order to reduce pain and restore or enhance joint function. Manipulation is generally a painless procedure that works by restoring normal joint function and position, and is a safe and effective treatment. To be therapeutic, the manipulation is directed in a very specific path relative to the joint to be treated. During the treatment, the joint is moderately distracted while a high velocity (i.e. very fast) low amplitude (i.e. relatively shallow) thrust is applied through the joint space to restore normal position and function to that joint.
Chiropractic tables, also known as “adjusting tables,” are also well known. When combined with the knowledge, skill and experience of the chiropractor, such tables are successfully used in therapeutic chiropractic manipulation as a means of restoring and enhancing the well-being of the patient. Using such adjusting tables during the performance of therapeutic manipulation, chiropractors are able to successfully manage the biomechanical relationship of the patient's spinal segments in relationship to each other as part of the overall central nervous system, the peripheral nervous system, the protective meningeal barriers and all of the other tissues that are connected to the spinal column. The chiropractic table provides the support means for properly positioning the patient prior to application of the manipulative joint thrust, thus allowing the chiropractor to effectively produce the intended result.
In the experience of this inventor, chiropractic tables of the prior art lack certain functionalities that could assist the chiropractor in the application of his or her treatment of the patient. For example, while such tables may include drop sections for assisting the chiropractor during application of the above-mentioned manipulative joint thrust, which is also known as a “drop adjustment,” they are very limited in their use.
Accordingly, it is an object of the present invention to provide an improved posture correction tool in the form of a chiropractic adjusting table that has certain new, useful and non-obvious features including:
1. Flying drops (thoracic and lumbar) in the thoracic and lumbar sections. “Flying drops” are defined as the thoracic and lumbar sections of the table of the present invention which are able to be raised and angled and cocked and dropped in any position. These “flying drops” allow the chiropractor to set up a patient in a specific posture and perform a drop adjustment without adding any incorrect postures. In other words, conventional drops find chiropractors unable to perform a drop without adding an incorrect posture to the patient's spine. In the past, attempts were made to compensate for the lack of “flying drops” by using foam wedges. These wedges, however, rarely allowed for an exacting postural set-up prior to a drop being administered. Therefore, chiropractors were often frustrated with the lack of postural correction results because they were often adding improper postures.
2. Pelvic elevation “flying drop” in the pelvic section. The pelvic section of the table can be raised, cocked, and dropped at any height. Here again, this “flying drop” allows the chiropractor to set up a patient in a specific posture and perform a drop adjustment without adding any incorrect postures. Conventional drops find chiropractors unable to perform a drop without adding an incorrect posture to the patient's spine and attempts were made to compensate for the lack of “flying drops” by using foam wedges. These wedges, however, rarely allowed for an exacting postural set-up prior to a drop being administered. As a result, chiropractors were often frustrated with the lack of postural correction results because they were often adding improper postures.
3. The cervical instrument adjusting fulcrum is a unique feature elevates and rotates in order to provide exact positioning for critical cervical instrument adjusting.
4. A head piece that lowers up to three inches (3″) below table horizontal while remaining fully functional in forty-five degree (45°) flexion and extension drop. The unique feature provides chiropractors the ability to have the table compensate for anterior or lateral head translation without adding unwanted postures when performing cervical drop work. Additionally, whether the head piece is raised or lowered, it maintains full functionality in forty-five degree (45°) flexion and extension drops.
5. The use of polyurethane pads, for the first time, provide a predictable rebound during the patient adjustment. In addition, is the polyurethane pad allows, for the first time, for a “pre-stress” to be used just prior to following through with the drop in an adjustment. The polyurethane pads have also allowed flexibility of a futuristic design that includes beveled edges and more of a human form outline for easier on- and off-patient access, as well as easier approach to the table by the chiropractor. Up to this point, chiropractic tables had traditionally been covered with a foam product that was limited in all that was described above.
6. This table was also designed for ease of mobility. It has lift rods at the head and foot of the table. It has wheels that are easily inserted or removed. Aside from portable chiropractic tables, the heavier permanent tables have not been designed with mobility in mind.
7. The table of the present invention was engineered with safety in mind. The majority of conventional “pinch points” have been eliminated.
SUMMARY OF THE INVENTION
The table the present invention has obtained these objects. It was designed to perform certain functions that no other table in the prior art performs. These unique functions require the chiropractic practitioner to essentially “re-learn” how to use the new posture correction tool table of the present invention. For example, the table of the present invention uses polyurethane pads that have been designed with densities to maximize the “pre-stress” that is needed for optimal mechano-reception and thus maximal neurological correction. The table of the present invention also comprises a unique head piece, a unique cervical instrument adjusting fulcrum, unique thoracic and lumbar pieces, and a unique pelvis piece.
The head piece in the table of the present invention is raised and lowered electrically. While the table remains horizontal, the head piece can be lowered a distance below the thoracic piece or can be raised a distance above it as well. The head piece thus allows for flexion and extension of the patient's head. The head piece can be moved up to an unprecedented height of about 8 inches and be fully usable as a “cock and drop” piece from any vertical position while also extending up to about forty-five degree (45°) in both flexion and extension at any given vertical position of the head piece. The head piece used in the table of the present invention can also be favored, or biased, to drop cephalad or caudad. The head piece includes a tension setting having a tension knob that covers the full spectrum of tension in just two and one-quarter turns. On the lowest tension setting, the weight of the individual table pads, themselves, is enough to cause that section to drop. At its highest tension setting, the relevant table pad requires a high amount of force to get the section to drop. It does not require much rotation of the sensitive tension knob to create a great change in tension setting.
The cervical instrument adjusting fulcrum in the table of the present invention is a feature that elevates and rotates in order to provide exact positioning for critical cervical instrument adjusting.
The thoracic and lumbar pieces in the table of the present invention include thoracic and lumbar drops that are mounted on a single plate and can be raised to fifty-five degrees)(55°) above horizontal. The thoracic drop is a “flying drop,” which means that the thoracic piece can be cocked and dropped at an angle. The table of the present invention can be equipped with a standard lumbar handle-cocking device, the lumbar piece also being a flying drop mechanism. The table may alternatively be equipped with an optional lumbar foot pedal cocking device wherein the flying drop is replaced with a lumbar drop that only functions in the horizontal position.
The pelvic piece in the table of the present invention is equipped with a standard pelvic-hinged drop which is either cocked with the standard handle-cocking device or optional foot pedal-cocking device. If the table is equipped with the optional pelvic elevation, it will come with a foot pedal-cocking device only and is a flying drop which can be cocked and dropped in any position. The manually operated optional pelvic elevation piece elevates approximately eight inches (8″) above horizontal.
Finally, the table of the present invention utilizes polyurethane pads that will not lose the integrity of their density as compared to upholstered foam pads. The densities of the pads have been designed to maximize the “pre-stress” needed for optimal mechano-reception and thus maximal neurological correction. Therefore, the practitioner needs to apply a force to the spine to take up slack in the polyurethane while following through to complete a drop.
The foregoing and other features of the table of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front, left side and top perspective view of a table constructed in accordance with the present invention.
FIG. 2 is an exploded front, left side and top perspective view of the table illustrated in FIG. 1 .
FIG. 3 is a top plan view of the table illustrated in FIG. 1 .
FIG. 4 is a left side elevational view of the table illustrated in FIG. 1 .
FIG. 5 is an enlarged partial left side elevational view of the head piece portion of the table illustrated in FIG. 4 and showing the head piece portion in its lowest position.
FIG. 6 is a partially sectioned top plan view of the forward-most portion of the bottom frame taken along line 6 - 6 of FIG. 5 .
FIG. 7 is the same view illustrated in FIG. 5 but showing the head piece portion in its highest position.
FIG. 8 is a view similar to those illustrated in FIGS. 5 and 7 but showing the head piece portion in an upwardly angled position.
FIG. 8A is an enlarged cross-sectioned view of a portion of the head piece support structure shown in FIG. 8 .
FIG. 9 is a bottom, left side and rear view of the handle-cocking assembly that is used in the head piece portion of the table of the present invention.
FIG. 10A is a partially sectioned left side elevational view of the head piece portion and showing the head piece drop pin in its “post-drop” position.
FIG. 10B is a partially sectioned rear elevational view of the handle-cocking assembly that is illustrated in FIG. 9 and showing the head piece drop pin in the position that it is in as shown in FIG. 10A .
FIG. 11A is a partially sectioned left side elevational view of the head piece portion and showing the head piece drop pin in its “pre-drop” or “cocked” position.
FIG. 11B is a partially sectioned rear elevational view of the handle-cocking assembly that is illustrated in FIG. 9 and showing the head piece drop pin in the position that it is in as shown in FIG. 11A .
FIG. 12 is a further enlarged left side elevational view of the cervical pad assembly in the table of the present invention and showing the cervical pad in its lowest vertical position relative to the table.
FIG. 13 is a view similar to that illustrated in FIG. 12 and showing the cervical pad in its highest vertical position relative to the table.
FIG. 14 is a bottom, left side and rear view of the handle-cocking assembly that is used in the lumbar and thoracic portion of the table of the present invention.
FIG. 15 is a partial left side elevational view of the lumbar and thoracic portion of the table illustrated in FIG. 4 and showing the lumbar and thoracic portion in its fully “down” position.
FIG. 16 is a view similar to that illustrated in FIG. 15 and showing the lumbar and thoracic portion in a “raised” position.
FIG. 17 is a further enlarged left side elevational view of the lumbar and thoracic portion of the table illustrated in FIGS. 15 and 16 and showing, in phantom view, the respective drop pin assemblies used with that portion.
FIG. 18 is an enlarged front, left side and bottom perspective view of the foot pedal-cocking assembly used in the pelvic portion of the table illustrated in FIG. 4 .
FIG. 19 is a partial left side elevational view of the pelvic portion of the table illustrated in FIG. 4 and showing the pelvic portion in its fully “down” position.
FIG. 20 is a view similar to that illustrated in FIG. 19 and showing the pelvic portion in a “raised” position.
FIG. 21 is a further enlarged view similar to that illustrated in FIG. 20 and showing relative movement of the foot pedal-cocking assembly and of the pelvic column.
FIG. 22 is a greatly enlarged cross-sectioned and left side elevational view of the drop pin assembly in the pelvic portion of the table.
FIG. 23 is a rear elevational view of the foot pedal-cocking assembly illustrated in FIG. 18 and showing the foot pedals in the “up” position.
FIG. 24 is a view similar to that illustrated in FIG. 23 and showing the foot pedals in the “down” position.
FIG. 25 is a partial left side elevational view of the leg and foot portions of the table illustrated in FIG. 4 and showing the leg and foot portions in their fully “down” position.
FIG. 26 is a view similar to that illustrated in FIG. 25 and showing the leg and foot portions in an “up” or raised position.
DETAILED DESCRIPTION
Referring now to the drawings in detail, wherein like numbered elements refer to like elements throughout, FIGS. 1 through 4 illustrate a representative structure, generally identified 10 , which is a preferred embodiment of a posture correction tool table that is constructed in accordance with the present invention. Generally speaking, the table 10 comprises a plurality of pads that are mounted onto a superstructure. It is this plurality of pads that support the patient during chiropractic treatment. More specifically, and moving from that forward-most point of the table 10 where the patient's head (not shown) would rest, it will be seen that the pads comprise a head pad 40 , a cervical pad 50 , a composite thoracic pad 60 , a lumbar pad 70 , a pelvic pad 80 , a leg pad 90 , and a foot pad 100 . Additionally, two semi-circular shaped arm pads 45 are located and mounted to either side of the head pad 40 . This allows the patient, who is supported in the prone position by the table 10 , to rest his or her arms on the arm pads 45 during chiropractic treatment.
As shown in FIG. 2 , the table 10 comprises a supporting super-structure generally comprising a bottom frame 20 and a top frame 30 . The bottom frame 20 comprises a plurality of longitudinally-extending bottom frame members 21 and a plurality of integrally-attached, transversely-extending bottom frame members 22 . The transversely-extending bottom frame members 22 each include castor/support subassemblies 23 . The castor/support subassemblies 23 provide for ease of mobility of the table 10 as may be desired or required. The top frame 30 comprises a plurality of vertically-disposed top frame members 31 and plurality of integrally-attached, longitudinally-extending top frame members 32 . A rail 33 is disposed forwardly of the top frame 30 , the purpose of which will be apparent later in this detailed description. The last part of the supporting super-structure of the table 10 of the present invention is the head pad frame 44 .
The head pad 40 is a structure comprised of opposing outer pad portions 40 a defining a central groove 40 b . See FIG. 3 . The head pad 40 is secured to a head pad plate 41 which is in turn attached to a top drop plate 43 by means of a plurality of cervical drop links 42 . Again, see FIG. 2 . A plurality of dome-shaped bumpers 48 are attached to the top drop plate 43 for cushioning. See also FIG. 7 . The top drop plate 43 is attached to a portion of the head pad frame 44 . Attached to the top drop plate 43 is the head and cervical drop sub-assembly 140 . Refer again to FIG. 2 . The head pad 40 is raised and lowered electrically. While the table 10 remains horizontal, the head pad 40 in the preferred embodiment and its related structures can be lowered three inches (3″) below the thoracic pad 60 or raised eight inches (8″) above the thoracic pad 60 . See FIGS. 5 and 7 , for example. This range of movement is accomplished by means of a carriage 34 that is attached to the head pad frame 44 and which is slidably and vertically movable along the rail 33 . This is accomplished by actuation of the ball drive 35 and ball screw 36 .
Referring now to FIGS. 9 , 10 A, 10 B, 11 A and 11 B, it will be seen that the head and cervical drop subassembly 140 comprises a drop pin 141 , a lever bottom stop 142 , a tension tube 143 and a tension knob 144 . To manually “cock” the head pad 40 and its related structure, the practitioner pulls upwardly on one end 146 of the cocking bar or lever 145 . It is to be understood that the table 10 of the present invention can be configured such that the head pad 40 can be favored to drop cephalad (towards the forward portion of the table 10 ) or caudad (towards the rearward portion of the table 10 ), depending upon the treatment that is desired or required.
As is illustrated in much greater detail in FIGS. 10A and 11A , it will be seen that the tension tube 143 houses a tensioning spring 147 that biases a release member 148 against the drop pin 141 . Specifically, the drop pin 141 comprises a cylindrically-shaped and dome-topped upper portion 151 and a circumferential and outwardly tapered bottom portion 152 , the bottom portion 152 terminating in a circumferential ridge 153 and capture groove 154 . As the practitioner raises the end 146 of the cocking bar or lever 145 , as shown in FIG. 11A , the drop pin 141 is elevated by means of a plate that engages a collar portion 155 of the drop pin 141 . In this motion, the upper portion 151 of the drop pin 141 urges the head pad plate 41 upwardly to the pre-drop position shown. In this position, the release member 148 housed within the tension tube 143 is “captured” within the groove 154 of the drop pin 141 . This position is maintained until a downward force is exerted on the head pad 40 thereby urging the drop pin 141 downwardly and causing the release member 148 to be pushed into the tension tube 143 and out of the groove 154 of the drop pin 141 .
At this point, it should be mentioned that the tension knob 144 covers the full spectrum of tension in just two and a quarter turns. On the lowest tension setting, the weight of the head pad 40 and its plate 41 is enough to cause the head pad 40 to drop. At its highest tension setting, the head pad 40 requires a high amount of force to get the section to drop. It does not require much rotation of the sensitive tension knob 144 to create a great change in tension setting. This functionality is also present in other portions of the table 10 , 12 will be apparent later in this detailed description, like tension knobs being bilateral, however.
Referring now to FIG. 8 , for example, it will be seen that the head pad 40 can also be moved upwardly or downwardly to allow for flexion and extension of the head pad 40 relative to the horizontal. In the table 10 of the present invention, the head pad 40 can be moved upwardly and downwardly relative to the horizontal and can also be positioned angularly to an unprecedented forty-five degrees (45°) in both flexion and extension. This movement is accomplished by use of the release lever 49 disposed to one side of a hydraulic tube or cylinder 46 , which use extends or retracts the rod 47 within the tube 46 . See FIG. 8A . More specifically, when the lever 49 is depressed upwardly, it releases the rod 47 of the gas cylinder 46 to quietly and smoothly raise, lower or angle and lock the head pad 40 . This functionality is present in other portions of the table 10 as well, as will be apparent later in this detailed description.
The table 10 of the present invention also comprises a cervical instrument adjusting fulcrum in the form of a cervical pad 50 , the cervical pad 50 being supported by and rotatably mounted about a vertically-adjustable structure 52 . See FIGS. 12 and 13 . The cervical instrument adjusting fulcrum that is utilized in the table 10 of the present invention is unique. To the knowledge of this inventor, no other table of past or current manufacture includes this structure. Use of this structure allows the chiropractor the ability to create the exact patient posture that is necessary in order to utilize impulse adjusting instruments to correct postural positioning of the patient. One such instrument is disclosed and claimed in U.S. Pat. No. 7,144,417 issued to Colloca et al. During usage of such an instrument with the adjusting fulcrum and cervical pad 50 , the patient is positioned on his or her side with the patient's neck being properly positioned for instrumental stimulation. Prior to this innovation, chiropractors would resort to supporting the patient's neck with pillows, wedges or some combination of both. Use of the adjustable cervical pad 50 is novel and unprecedented.
Referring again to FIGS. 1 through 4 , it will be seen that the thoracic pad 60 is comprised of opposing outer pad portions 60 a and a central pad portion 60 b . The next adjacent pad is the lumbar pad 70 . See also FIG. 15 . Referring specifically to FIGS. 1 , 16 and 17 , it will be seen that the thoracic pad 60 is attached to a thoracic pad plate 61 and that the lumbar pad 70 is attached to a lumbar pad plate 71 . The thoracic pad plate 61 and the lumbar pad plate 71 are each attached to a single “common” thoracic-lumbar support plate 62 . The common thoracic-lumbar support plate 62 is hingedly attached to a portion of the top frame 30 by means of a primary hinge 65 . A secondary hinge 63 is also provided to allow the thoracic pad plate 61 and the lumbar pad plate 71 to each rotate upwardly from the common thoracic-lumbar support plate 62 at the secondary hinge 63 . See FIG. 17 .
As shown in FIG. 16 , the common thoracic-lumbar support is plate 62 is rotatable about the primary hinge 65 . Elevation of the common thoracic-lumbar support plate 62 is accomplished by actuation of the hydraulic tube 66 via the bilateral lever 67 . The functionality of this hydraulic tube 66 is essentially identical to that of the hydraulic tube 46 that is used with the head pad 40 and its related structure. The hydraulic tube 67 that is attached to the common thoracic-lumbar support plate 62 allows the plate 62 to be raised up to fifty-five degrees)(55°) above the horizontal. A plurality of bumpers 68 are disposed between the common thoracic-lumbar plate 62 and the top frame 30 to cushion the return of the plate 62 to the horizontal.
Referring again to FIG. 1 , it will be seen that the common thoracic-lumbar plate 62 has a plurality of apertures 64 defined in it. The purpose of the apertures 64 is to allow for access to the thoracic pad plate 61 and to the lumbar pad plate 71 from below. Situated below each of these plates 61 , 71 is a thoracic drop subassembly 160 and a lumbar drop subassembly 170 , respectively.
Referring again to FIG. 17 , it will be seen that the thoracic drop subassembly 160 comprises a drop pin 161 , a lever bottom stop 162 , a tension tube 163 , a pair of bilateral tension knobs 144 (see FIG. 14 ) and a miter gear assembly 169 . To manually “cock” the thoracic pad 60 and its related structure, the practitioner pulls upwardly on one end 166 of the bilateral cocking bar or lever 165 . See also FIG. 14 . It will also be seen that the tension tube 163 houses a tensioning spring 167 that biases a release member 168 against that drop pin 161 . The drop pin 161 comprises a cylindrically-shaped and dome-topped upper portion 181 and a circumferential and outwardly tapered bottom portion 182 , the bottom portion 182 terminating in a circumferential ridge 183 and capture groove 184 . As the practitioner raises the end 166 of the bilateral cocking bar or lever 165 , the drop pin 161 is elevated by means of a plate that engages a collar portion 185 of the drop pin 161 . In this motion, the upper portion 181 of the drop pin 161 urges the thoracic pad plate 61 upwardly to the pre-drop position shown in phantom view in FIG. 17 . In this position, the release member 168 housed within the tension tube 163 is captured within the groove 184 of the drop pin 161 .
As is also shown in FIG. 17 , the table 10 of the present invention further comprises a lumbar drop sub-assembly 170 . The lumbar drop sub-assembly 170 comprises a drop pin 171 , a lever bottom stop 172 , a tension tube 173 , a pair of bilateral tension knobs 174 (see FIG. 14 ) and a miter gear assembly 179 . To manually “cock” the lumbar pad 70 and its related structure, the practitioner pulls upwardly on one end 176 of the cocking bar or lever 175 . It will also be seen that the tension tube 173 houses a tensioning spring 177 that biases a release member 178 against the drop pin 171 . This drop pin 171 again comprises a cylindrically-shaped and dome-topped upper portion 191 and a circumferential and outwardly tapered bottom portion 192 , the bottom portion 192 terminating in a circumferential ridge 193 and capture groove 194 . As the practitioner raises the end 176 of the cocking bar or lever 175 , the drop pin 171 is elevated by means of a plate that engages a collar portion 195 of the drop pin 171 . In this motion, the upper portion 191 of the drop pin 171 urges the lumbar pad plate 71 upwardly to the pre-drop position shown in phantom view in FIG. 17 . In this position, the release member 178 housed within the tension tube 173 is captured within the groove 194 of the drop pin 171 .
It should again be mentioned here that the tension knobs 164 , 174 illustrated in FIG. 14 cover the full spectrum of tension in just two and a quarter turns. On the lowest tension setting, the weight of the respective pads 60 , 70 and their plates 61 , 71 is enough to cause the pads 60 , 70 to drop. At their highest tension setting, the pads 60 , 70 require a high amount of force to effect a drop. It does not require much rotation of the sensitive tension knobs 164 , 174 to create a great change in tension setting.
The table 10 of the present invention further comprises a pelvic pad 80 . See FIGS. 3 , 4 and 19 through 21 in this regard. As shown, the pelvic pad 80 is supported by and attached to a pelvic pad plate 81 . The pelvic pad plate 81 is attached to a drop bracket 82 . Disposed vertically below the drop bracket 82 is a pelvic column outer-housing 83 and a pelvic column inner-housing 84 . The inner-housing 84 is slideably moveable within the outer-housing 83 . Disposed within the outer and inner-housings 83 , 84 is a hydraulic tube 86 that is actuated by a lever 87 . A plurality of bumpers 88 are mounted to the top frame 30 to provide cushioning for the pelvic pad plate 81 when the pelvic pad plate 81 is dropped or lowered to its bottom-most position.
Referring now to FIGS. 20 through 22 in particular, it will be seen that a pelvic drop sub-assembly 110 is also provided. The pelvic drop sub-assembly 110 comprises a drop pin 111 , a bottom stop 112 , a tension tube 113 , a pair of bilateral tension knobs 114 and a miter gear assembly 119 . As shown, the tension tube 113 houses a tensioning spring 117 that biases a release member 118 against the drop pin 111 . The drop pin 111 comprises a cylindrically-shaped upper portion 121 and a circumferential and outwardly tapered bottom portion 122 , the bottom portion 122 terminating in a circumferential ridge 123 and capture groove 124 . In the preferred embodiment, the cocking bar or lever (as was used with the other pad elements previously discussed) is replaced by a foot lever sub-assembly 130 . See FIGS. 18 , 23 and 24 . The foot lever sub-assembly 130 is attached to a link 133 which allows the drop pin 111 to be “cocked” by the practitioner pushing down on one of two spring-loaded bilateral foot pedals 131 . Depression of the foot pedal 131 rotates a linkage 132 that elevates a plate 133 that engages a collar portion 125 of the drop pin 111 . In this motion, the upper portion 121 of the drop pin 111 urges the pelvic pad plate 81 upwardly to the pre-drop position shown in FIG. 21 . In this position, the release member 118 housed within the tension tube 113 is captured within the groove 124 of the drop pin 111 . The drop pin 111 is further attached to a bottom-most shaft 129 by means of a pelvic drop link 89 . The bottom-most shaft 129 is also attached to the lowest portion of the hydraulic tube 86 of the pelvic drop portion of the table 10 . This results in coordinated movement between the drop pin 111 and the pelvic pad 80 .
Finally, disposed at the rearward-most end of the table 10 of the present invention are the leg pad 90 and the foot pad 100 . See FIGS. 3 , 4 , 25 and 26 in particular. As shown, the leg pad 90 is supported by and attached to a leg pad plate 91 . The leg pad plate 91 is attached to the top frame 30 by means of a hinge 92 . The hinge 92 allows the leg pad plate 91 and leg pad 90 to rotate about the top frame 30 . The leg pad plate 91 is variably positionable relative to the horizontal by means of a hydraulic tube 93 and actuation lever 94 of the type previously described. The foot pad 100 is attached to a supported by a foot pad bracket 101 . The foot pad bracket 101 is secured to a longitudinally-extending slide 102 , the slide being longitudinally moveable along a slide receiver 103 . This movement is shown in phantom view in FIGS. 25 and 26 .
In view of the foregoing, it will be apparent that there has been provided an improved posture correction tool in the form of a chiropractic adjusting table that has certain new, useful and non-obvious features including “flying drops” in the thoracic and lumber sections; pelvic elevation “flying drop” in the pelvic section; a cervical instrument adjusting fulcrum; a uniquely-movable head piece; polyurethane pads; and which is easy to move and eliminates conventional “pinch points” for enhanced safety.
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The claimed invention provides an improved posture correction tool in the form of a table to be used by chiropractic practitioners to treat mechanical disorders of the spine and musculoskeletal system. The improved posture correction tool provides a plurality of pads to support the various major areas of the body and has built in drop capability and adjustment capability for the pelvic pad, the lumbar pad, the thoracic pad and the head and cervical area. The claimed invention also has a novel cervical support.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to novel baths for generating microstructures which are required in numerous fields of application of the microsystem technique and in microstructuring.
[0002] Moreover such baths enable microstructuring of such layers or layer systems the application of which previously has been unusual in the foregoing fields of art. The application of the present invention is of particular advantage in structuring layer systems, the selective etching of which is critical when conventional etching means are used due to their similar chemical behavior, and has been feasible only by employing additional and expensive means such as etching barriers or the like.
[0003] Etching processes and developing processes previously used in microstructuring according to the state of art are generally based on poisonous chemicals and such being harmful to health, as for example strong acids, lyes, and oxidants, or require extremely expensive processes, such as reactive ion etching and plasma etching, respectively, (refer to S. Büttgenbach, Mikromechanik, B. G. Teubner, Stuttgart, 1994 ).
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide novel baths for producing microstructures which offer a less expensive and, above all, a solution for their disposal which is more friendly to environment than the known methods for manufacture of microstructures.
BRIEF DESCRIPTION OF THE INVENTION
[0005] The object is realized by the characteristic features of the first claim. Advantageous further embodiments are covered by the succeeding claims.
[0006] The invention is based on the discovery that in the field of microstructuring the masking layers which permit structurizing and previously were employed to this end, such as photoresist layers may, by their very presence, locally affect the properties of biopolymer films. The very essence of the invention consists in the intentional selection and in the application of biogenic catalysts, in particular of enzymes for microstructuring of thin layers and, in a particularly advantageous way, of thin layer systems, respectively. When there is in the frame of the invention reference to the term baths, then the same are understood as etching baths according to conventional and known technical solutions as well as solutions which are destined for the formation of a structurized and masked layer.
[0007] Biopolymers which previously have not been utilized in the field of microstructuring are generally enzymatically degradable, just as a great number of organic and inorganic layers and metals. Moreover, there are numerous enzymes disposable which under changed conditions can carry out reactions, which are adverse to their original function. Thus lipases, for example, in organic solutions react as acetylases.
[0008] Enzymes, under suitable conditions, are highly specific biogenic catalysts, which in addition to their proper function can be inhibited by specific inhibitors or competitors. Enzymatic reactions generally take place at ambient temperature and in mild buffer solutions which can be disposed of friendly to environment. Enzymes themselves according to their nature are readily degradable biologically. Very often enzymes are active in narrow temperature ranges. Hence, enzymes may be controlled also thermally as to their activities. It is generally feasible to thermally deactivate common enzymes in a range of from 40 to 120° C., wherein, in most cases, a heating above 60° C. will be sufficient. Thus the requirements are fulfilled to employ solutions as “etching baths” for microstructuring to which at least one additive from enzymes and biogenic catalysts, respectively, are given.
[0009] The invention will be explained in more detail in referring to five embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0010] In a first embodiment a double layer system from biopolymers, which previously were not used in microsystem techniques and which are coated with a masking layer, for example, of a photoresist, will be structurized. Gelatin will be employed for the double layer system, without limiting the invention thereto. To this end the fact that very often different enzymes may act in similar buffers with high efficiency and selectivity is utilized. A first gelatin layer of about 200 nm thickness is deposited on a substrate, for example, a cleaned silicon wafer and is cross-linked by the addition of glutaraldehyde. A second gelatin layer is deposited thereupon, to which short oligonucleotides (for example, 8 mer) are added and cross-linked with glutaraldehyde. The added oligonucleotides have a sequence which has a specific junction for a restriction enzyme (for example, 5′-GAATTC-3′ for EcoRI). A restriction enzyme of groupII generally acts in buffers which contain metal ions (for example, Mg 2+ ) in millimolar concentrations. It is feasible to degrade the lower and first gelatin layer by a protease (for example, protease K). Very often proteases are inhibited in their function by metal ions, for this reason protease buffers very often include EDTA, EGTA and other chelating agents, the task of which is to eliminate metal contaminations contained in solutions.
[0011] The first and the second gelatin layer will be degraded subsequently in one step. This is achieved by using a buffer solution consisting of 10 mM NaCl, 5 mM MgCl 2 , and 1% glycerol, the second and upper layer being selectively degraded by using a restriction enzyme in those portions which are uncovered by the masking layer. When the degradation is completed, what can be monitored by microscope, the buffer used is added a chelating agent (for example, 10 mM EDTA), which in this manner selectively degrades the first and lower.
[0012] Alternatively, it is feasible to add the chelating agent to the upper and second gelatin-oligonucleotide layer already while the latter is manufactured. Said chelating agent will be set free with progressing degradation of the oligonucleotides and in this way the inactivation of the buffer by the metal ions contained in the former is eliminated. The protease will then be capable to degrade the lower and first layer as well as the restriction enzyme. The allosteric regulation of the foregoing enzymes by way of metal ions is counteractive, permitting a successive application. There are also proteases which are only able to function by use of metals, which would permit a simultaneous application (for example, the family of zinc proteases, such as carpoxypeptidase A). Furthermore and according to the present state of biotechnological research, it is feasible without any problems to produce metal resistant or metal sensitive mutations of the enzymes. In a second embodiment the application of a bath according to the invention for producing a selfsupporting membrane will be disclosed. A thin biopolymeric layer of about 200 nm thickness is applied to a cleaned silicon wafer by spin-coating. In the present example, said layer is formed by 10% gelatin dissolved in water to which 5% glutaric dialdehyde is added. Said layer is not water-soluble and is resistant to conventional photoresist coating developers. In the present example a subsequent coating is carried out under use of a photoreversal resist as commonly on sale. Said photoresist layer is treated according to the instructions, masked according to a desired subsequent structure, exposed, and structurized. The entire sandwich assembly consisting of the silicon wafer, the cross-linked gelatin layer, and the structurized photoresist layer is inserted into an enzymic bath. Provided that gelatin is utilized for the biopolymer layer the enzymic bath preferably consists of a protease K-buffer substantially constituted of 10% SDS, 10 mM NaCl, 10 mM EDTA and 10 mM Tris-HCl, to which 10 mg/ml protease K is added. The pH-value of said bath is set to 8.5. When such an enzymic bath is employed a gelatin layer of about 200 nm thickness is entirely degraded at ambient temperature within about 8 h. The result of the “etching” process is a selfsupporting photoresist membrane.
[0013] In a third embodiment the action of a bath according to the invention will be described which provides a degradation stop (in analogy to known etching stop layers).
[0014] When a selected layer has to be protected against external influences and at the same time there has to be the possibility to definitely set free said layer, for example, to produce thin membranes what, in turn, will be described by example of gelatin, then this is feasible without any problems, provided that the gelatin layer which later forms the membrane is doped by metals or specific inhibitors for degradation of the used enzyme. Such inhibitors are generally artificial analogues of the transition states of the substrate which has to be enzymatically decomposed and have bonds which are not decomposable by the enzyme; for example, ether bonds by proteases which decompose peptide bonds. A thin layer prepared in this manner will be provided with a second thin layer of agarose having a thickness of about 1 μm. After applying a respective masking layer to the second thin layer the latter is provided with a desired recess by employing a bath consisting of 0.1 g/ml agarase, 5 mM EDTA, 10 mM NaCl, and 10 mM Na 2 HPO 4 . When the degradation has progressed to the prepared first thin layer, the agarase is inhibited to progress with degrading by the inhibitors provided in the first layer. In a fourth embodiment the application of a bath according to the invention to structurize a double layer system formed of gelatin and agarose is realized in that, in the present case, two enzymes are added to the bath consisting of 5 mM NaCl, 5 mM Na 2 HPO 4 , 0.1 g/ml agarase, and 1 mg/ml thermoresistant proteinase, recovered from a thermophilic organism (for example, thermos thermophilous). The agarase is characterized by being active at ambient temperature, at which the thermoresistant proteinase does not exhibit any detectable activity. In this first step of degradation, only the desired structure of the upper layer consisting of agarose is removed. Then the temperature of the bath is increased to 72° C. and thus the proteinase is activated, whereas the agarase does not show any detectable activity any longer. Only the degradation of the lower gelatin layer of the double layer system is carried out.
[0015] In a fifth embodiment the structurizing of a thin layer system constituted of iron-gelatin-lipid by virtue of at least one bath according to the invention will be disclosed. A solution is used to which a siderophor such as aerobactin or enterobactin is added by about 10 mg/ml. In the unmasked portions the iron layer of about 100 nm thickness is degraded after about 1 h at a temperature of 20° C. In the buffer solution according to the second embodiment including a proteinase, it is feasible to remove the gelatin layer under the mask which has been predetermined by the generated Fe-structure through which the lipid layer is set free. Said lipid layer can be structurized by way of an aqueous solution consisting of 1% glycerol and 1 mg/ml lipase which is suited for degrading the lipid layer.
[0016] The invention is not limited to the baths as disclosed in the foregoing embodiments. The selection of a special relevant biogenic catalyst, in particular an enzyme, with respect to an actual case of a thin layer to be structurized can be carried out without any further inventional activity and under use of biotechnological skill.
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The present invention relates to novel baths for generating microstructures which are required in numerous fields of application of the microsystem technique and in microstructuring. It is an object of the invention to provide novel baths for generating microstructures which offer a less expensive and, above all, a solution for their disposal which is more friendly to environment than the previous methods for manufacture of microstructures. The object is realized in that the respective baths are added at least one biogenic catalyst (in particular, an enzyme) which acts upon a preselectable thin layer.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] None.
BACKGROUND
[0002] The present disclosure relates generally to the field of window construction. Some window designs include a frame that houses the glazing of the window and a glazing bead that couples to the frame to enclose the glazing and provide decorative features. When the window is installed in a building, the outer glazing bead faces the exterior of the building. Water or other fluids or debris may collect in interior spaces of the frame between the frame, glazing, and glazing bead. It would be advantageous to provide drainage for a window frame with inconspicuous outlets.
SUMMARY
[0003] One embodiment of the invention relates to an apparatus for a window frame. The apparatus includes a window frame having a lower frame portion; a window glazing supported by the lower frame portion; a glazing bead; and at least two connectors operatively connecting the glazing bead to the lower frame. The connectors are spaced apart defining a fluid pathway allowing fluid to escape from the lower frame.
[0004] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
[0006] FIG. 1 is an isometric section view of a window, according to an exemplary embodiment.
[0007] FIG. 2 is an exploded view of the glazing bead for the window of FIG. 1 .
[0008] FIG. 3 is a section view of the window of FIG. 1 , taken generally along line 3 - 3 in FIG. 1 .
[0009] FIG. 4 is an isometric section view of the window of FIG. 1 with a portion of the glazing bead removed.
[0010] FIG. 5 is a detailed isometric view of the window of FIG. 2 , taken generally along line 5 - 5 in FIG. 4 .
[0011] FIG. 6 is a left side view of the window of FIG. 1 .
DETAILED DESCRIPTION
[0012] Referring to FIG. 1 , a window 10 includes a frame 11 surrounding at least one pane of glazing or glass 18 . Window 10 will be described herein as a generally rectangular frame including a lower frame portion 12 and a side frame portion 14 that is angled relative to lower frame portion 12 . Window 10 may further include a second side frame portion and an upper frame portion, not shown in FIG. 1 . According to a preferred embodiment, window 10 is a rectangular body with a horizontal lower frame portion 12 , a horizontal upper frame portion, and two vertical side frame portions 14 .
[0013] Lower frame portion 12 and side frame portion 14 may be made of wood, a vinyl material, a composite material, a plastic material, an aluminum material, a steel material, an combination thereof, or any other material suitable for a window. As shown in FIG. 1 , according to one embodiment, the components of frame are formed with an extrusion process from a suitable material such as a metal (e.g., aluminum, etc.) or a polymer (e.g., vinyl, etc.).
[0014] According to various exemplary embodiments, glazing 18 may include a single pane of glass, double panes of glass, triple panes of glass or any other number of panes. Any space between multiple panes of glass 18 may be filled with air, argon, krypton, a vacuum, or any other substance. Glazing 18 may be made of any type of glass material (e.g., soda lime glass, alkali silicate glass, etc.) of any thickness and may include any features of past, present, or future design (e.g., a low-E coating, lamination, tinting, impact resistance, shatter resistance, etc.) Glazing 18 may also be formed of any other type of window material such as plastic.
[0015] A glazing bead 20 is coupled to frame 11 around the periphery of glazing 18 . Glazing bead 20 is configured to secure glazing 18 in frame 11 and may also be designed as a decorative trim element to provide a pleasing appearance. Glazing bead 20 may be formed from a material used to form frame 11 such as wood, a vinyl material, a composite material, a plastic material, an aluminum material, a steel material, a combination thereof, or any other suitable material.
[0016] According to an exemplary embodiment, glazing bead 20 may include a flexible lip 21 to create a better seal against the surface of glazing 18 . Flexible lip 21 may be formed of the same material as the main body of glazing bead 20 and be flexible because of a reduced thickness or may be a different material that is coextruded, applied as a coating, or otherwise coupled to the main body of glazing bead 20 .
[0017] Glazing bead 20 may comprise several individual elements or may be a single, continuous element that is shaped (e.g., by bending) to extend about the periphery of glazing 18 . Referring to the exploded view in FIG. 2 , according to one exemplary embodiment, glazing bead 20 includes a lower glazing bead 22 and a side glazing bead 24 . Similar to frame 11 , glazing bead 20 further includes a second side glazing bead and an upper glazing bead not shown.
[0018] Referring still to FIGS. 1-3 , glazing bead 20 includes a front surface 26 (e.g., first surface, vertical surface, etc.) and a beveled surface 28 (e.g., second surface, angled surface, etc.). According to an exemplary embodiment, lower glazing bead 22 and side glazing bead 24 are coupled together to form a faux-butt joint 30 . Faux-butt joint 30 appears to an observer to be a butt joint (e.g., a joint with the components meeting at a face normal to the front face), however, referring to FIG. 3 , lower glazing bead 22 includes an angled cut 32 that is configured to mate with beveled surface 28 of side glazing bead 24 . Coupling lower glazing bead 22 and side glazing bead 24 along the angled mating surface between angled cut 32 and beveled surface 28 facilitates forming a better seal by increasing the area of contact between lower glazing bead 22 and side glazing bead 24 .
[0019] Referring now to FIG. 4 , connectors 40 are provided to couple glazing bead 20 to frame 11 . Connectors 40 are generally flat, elongated members that are received in a slot 15 in frame 11 and a slot 25 in glazing bead 20 . In one embodiment connectors 40 are continuous along the upper frame portion and side frame portions 14 . The continuous connectors 40 secured to the upper frame portion and side frame portions connect the glazing bead 20 and connect on the upper frame portion and side frame portions provide a water shed or seal to prevent leaks. However, in one embodiment multiple connectors 40 may be used along the bottom of lower frame portion 12 . The length, number, and spacing of connectors 40 may be varied based on the requirements of frame (e.g., the force needed to retain glazing 18 , etc.). The spacing between connectors 40 along the lower frame portion 12 on the exterior provides the route through which fluid may exit. Connectors 40 are also provided to couple an interior covering 92 to an interior surface of the frame. Note that connectors 40 on the lower frame portion 12 on the interior side of the frame that connect covering 92 need provide spacing. A continuous connector 40 may be used on the interior lower frame portion 12 to connect covering 92 . Interior covering 92 may be formed of wood, wood composite, plastic, fiberglass, vinyl or other decorative covering material.
[0020] Referring to FIG. 5 , a portion of window 10 is illustrated in greater detail, according to an exemplary embodiment. Connector 40 is configured for mating with frame 11 and glazing bead 20 with one or more barbs 42 . Either end of connector 40 includes multiple flexible barbs 42 (e.g., flaps, protrusions, fins, etc.) to aid in mating with frame 11 and glazing bead 20 . Barbs 42 may extend from either or both faces of connector 40 . As shown, barbs 42 are angled away from the distal edges of connector 40 relative to the main body of connector 40 .
[0021] Slots 15 and 25 are sized such that barbs 42 are compressed and otherwise deformed when connector 40 is inserted into slot 15 and/or slot 25 . The distortion of barbs 42 when connector 40 is inserted into slots 15 and 25 is resisted by an outward biasing force. The outward force provided by barbs 42 retains connector 40 in slots 15 and 25 and therefore couples glazing bead 20 to frame 11 and to secure glazing 18 in frame 11 . The retaining force of barbs 42 is sufficient to overcome opposing forces such as the weight of glazing bead 20 , wind, rain, etc. However, the retain force provided by barbs 42 can be overcome by a sufficient outward force, allowing glazing bead 20 to be removed for maintenance or replacement.
[0022] While barbs 42 are shown as being generally planar members of a single size and relative orientation, many variations are possible while still providing sufficient force for coupling frame 11 and glazing bead 20 . For example, instead of a continuous body extending the length of connector 40 , barb 42 may comprise several discrete elements. Barbs 42 may be oriented at a different angle or may have a different cross-sectional shape (e.g., triangular, rounded, etc.). Barbs 42 may vary in size on either side of connector to mate with slots of different sizes in frame 11 and glazing bead 20 . Further, barbs 42 may vary in size between the top and bottom faces of connector 40 .
[0023] The main body of connector 40 and barbs 42 may be made of different materials and integrally formed with a suitable process such as coextrusion. According to various exemplary embodiments, barbs 42 may be made of flexible polyvinyl chloride (PVC), thermoplastic elastomer (TPE), flexible urethane, a rubber based material, or a similar flexible extruded material. According to various exemplary embodiments, connector 40 may be made of PVC, polypropylene, acrylonitrile butadiene styrene (ABS), or any other rigid extrudable material.
[0024] Referring now to FIG. 6 , an end view window 10 is shown according to an exemplary embodiment, showing the structure below glazing 18 . Lower frame portion 12 may be a substantially hollow body (e.g., formed as an extruded aluminum or vinyl body, etc.) defined at least partially by an top face 60 , a first wall 62 , a first shelf 64 , a second wall 66 , a second shelf 68 , and a third wall 70 . Lower frame portion may further include an interior wall 72 extending along the inside face of glazing 18 . Wall 72 provides a physical stop that helps to secure and locate glazing 18 in frame 11 .
[0025] Glazing 18 is generally supported above top face 60 of lower frame portion 12 with support structures or spacers. Below the lower edge of glazing 18 is formed an open volume 50 (e.g., space, chamber, cavity, etc.), which is substantially enclosed by lower frame portion 12 and glazing bead 20 . Volume 50 is generally defined by glazing 18 , glazing bead 20 and top face 60 and wall 72 of lower frame portion 12 .
[0026] While the seal formed around glazing 18 by glazing bead 20 prevents the majority of water from passing through, moisture may still enter volume 50 . For example, moist air may enter volume 50 , allowing water to condense in volume 50 . A glazing compound 56 is placed between glazing bead 20 and glazing 18 to secure glazing bead 20 to glazing 18 . Glazing compound may include other materials and/or tape known in the art including but not limited to silicon compound, one hundred percent silicon, or a hot melt material. Wall 72 prevents water from flowing out of volume 50 into the interior space of the building or enclosure including window 10 . Glazing compound 56 is also located between wall 72 and glazing 18 . Glazing compound 56 assists in keeping water from entering the interior of the structure as well as from entering the interior of frame regions 50 and 86 .
[0027] To allow water, other fluids, or debris to exit volume 50 , flow paths 54 are formed by the components of window 10 . Flow paths 54 are formed by the arrangement of lower frame portion 12 , glazing bead 20 , and connectors 40 and does not require any additional openings (e.g., channels, holes, slots, etc.) to be formed in components. The weep or exit of flow paths 54 is provided inconspicuously between the lower edge 84 of glazing bead 20 and lower frame portion 12 .
[0028] According to an exemplary embodiment, flow path 54 is formed between glazing bead 20 and lower frame portion 12 . Connectors 40 couple glazing bead 20 to lower frame portion 12 such that glazing bead 20 creates a seal against glazing 18 while maintaining a separation 52 from first wall 62 of lower frame portion 12 . Referring to FIG. 4 , instead of a single component extending the entire length of lower frame portion 12 , connectors 40 are provided as multiple, separate components separated by gaps 56 . Flow path 54 extends between glazing bead 20 and lower frame portion 12 through gaps 56 between connectors 40 .
[0029] A second volume 80 is formed between lower frame portion 12 and glazing bead 20 below first volume 50 . Volume 80 is generally defined by first wall 62 and first shelf 64 of lower frame portion 12 and glazing bead 20 . After flowing out of volume 50 , fluids and debris enter volume 80 . Glazing bead 20 is coupled to lower frame portion 12 by connectors 40 such that a gap 82 is formed between the lower edge 84 of glazing bead 20 and first shelf 66 of lower frame portion 12 . Gap 82 is the only portion of flow path 54 that is visible when window 10 is assembled and installed.
[0030] Flow path 54 directs fluids and debris out of the interior of window 10 without entering lower frame portion 12 . Fluids and debris are allowed to escape volume 80 through gap 62 , flow down second wall 66 of lower frame portion 12 , over second shelf 68 , down a third wall 70 , and escape into the exterior environment. Top face 60 , first shelf 64 , and second shelf 68 of lower frame portion 12 may be pitched or angled to facilitate the flow of fluids and debris to the exterior space.
[0031] Volumes 50 and 80 and flow paths 54 direct any fluids or debris that may collect in the interior of window 10 to the exterior space, reducing the likelihood of damage to window 10 caused by the fluids or debris (e.g., by expansion of freezing water, etc.). The formation of flow paths 54 by the arrangement of components is advantageous because openings formed in components can be obstructed by debris, reducing the ability of fluids to escape volume 50 . Further, openings formed in components of window 10 to create flow paths may require additional manufacturing steps (e.g., machining, stamping, etc.), increasing manufacturing time and cost of window 10 .
[0032] A third volume 86 is located below first volume 50 and second volume 80 and is sealed such that no water is permitted to enter into volume 86 . Third volume 86 is formed by top face 60 , first wall 62 , first shelf 64 , a second wall 66 , a second shelf 68 , a third wall 70 , a bottom wall 88 and a fourth wall 90 .
[0033] For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally defined as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.
[0034] While window 10 is described as rectangular body, in other exemplary embodiments, window 10 and glazing 18 may differently shaped and still include construction that provides an inconspicuous weep. For example, window 10 may be square, another polygonal shape (e.g., hexagonal, octagonal, etc) or rounded. Regardless of the overall shape of window 10 , the lower portion of frame 11 and glazing bead 20 may be arranged such flow paths are formed to allow fluids and debris to flow out of the lower portion of window 10 .
[0035] The arrangement and construction of the frame members and glazing bead for window 10 provides an inconspicuous weep that can be adapted to many other styles of windows. While window 10 is shown in the FIGURES as a picture window frame, in other embodiments, window 10 may be of another construction, such as a casement window, a double hung window, or a bay window.
[0036] The present disclosure has been described with reference to exemplary embodiments, however, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted a single particular element may also encompass a plurality of such particular elements.
[0037] It is also important to note that the construction and arrangement of the elements of the system as shown in the exemplary embodiments is illustrative only. Although only a certain number of embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited.
[0038] Further, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the assemblies may be reversed or otherwise varied, the length or width of the structures and/or members or connectors or other elements of the system may be varied, the nature or number of adjustment or attachment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the spirit of the present subject matter.
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One embodiment of the invention relates to an apparatus for a window frame. The apparatus includes a window frame having a lower frame portion; a window glazing supported by the lower frame portion; a glazing bead; and at least two connectors operatively connecting the glazing bead to the lower frame. The connectors are spaced apart defining a fluid pathway allowing fluid to escape from the lower frame.
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[0001] The following specification particularly describes the nature of this invention and the manner in which it is to be performed:
TECHNICAL FIELD OF INVENTION
[0002] The present invention provides electronically conducting carbon and carbon based composites and nanocomposites by pyrolysis of dead leaves and other similar natural waste material in in argon gas flow at 1000° C. Particularly, present invention relates to synthesis of valuable functional carbon materials and their nanocomposites from different waste materials such as plant dead leaves and their use in several valuable applications.
BACKGROUND OF THE INVENTION
[0003] Waste management has always been a big problem in big cities. Fortunately through several environmental initiatives, communities have begun to separate dry and wet waste matter. The dry waste primarily comprises of natural dead leaves and similar waste as well as plastics. Dead leaves type of waste (including rice husk and other dry agricultural side products) is in fact available in plenty in woods as well as agricultural farms in villages. Most of this type of waste is a rich source of carbon but may contain other elements in different proportions depending on the source of the waste. Usually the waste from natural sources is just burnt producing ash and hazardous gaseous pollution products. There have been some initiatives to employ the ash but in most situations the use is in the form of passive fillers. If the natural waste and some of the man-made waste is harnessed to synthesize functional forms of carbon, one would get a high value-added product for diverse carbon based applications that have been growing rapidly in the past decade including super-capacitors, batteries, super-adsorbents for gases and toxins etc.
[0004] Carbon is the most naturally occurring abundant material present on earth exhibiting variety of molecular and structural forms such as graphite, diamond, nanotubes, graphene, fullerene, nano-diamonds, amorphous carbon, porous carbon etc. which have tremendous applications in various fields. Due to their high surface area, high mechanical strength, electrical, thermal and optical properties these forms have applications in super capacitor, battery, catalysis and other fields. Carbon has also been used in the form of nanocomposites with metals, metal oxides, nitrides, carbides, semiconductors etc.
[0005] Researchers have tried several synthetic techniques to get high quality carbon such as carbonization of organic/polymeric precursors, autoclave synthesis from small halogenated aromatic molecules, chemical vapour deposition, excimer laser ablation of graphitic targets, sputtering/plasma methods, arc discharge methods, chemical methods (autoclave) etc. Apart from these techniques scientists have now started utilizing organic waste material such as food, agricultural wastes, and insects for the synthesis of carbon in grapheme.
[0006] The use of plant leaves for removal of water soluble dyes such as methylene blue, brilliant green, congo red and methylene blue is reported in the literature, such as K. G. Bhattacharyya in Indian journal of chem Tech. 12, 2005, 285-295 discloses utilization of a biosorbent based on Azadirachta indica (Neem) leaves for removal of water-soluble dyes. Article titled “Removal of Direct Red Dye Using Neem Leaf Litter” by Sivamani S et al. in Helix Vol. 1(2):129-133 (2012) reported the adsorption of Congo red (CR) onto carbon prepared from Neem leaf litter.
[0007] Further Neha Gupta in Journal of the Taiwan Institute of Chemical Engineers 43, (4), July 2012, 604-613 discloses, batch adsorption using ashoka ( Saraca asoca ) leaf powder (ALP), as an adsorbent for the removal of cationic dyes such as methylene blue, malachite green, rhodamine B and brilliant green from aqueous solution. Dharmendra Singh et al in Inventi Rapid: Water & Environment Vol. 2011, 3 discloses removal of color from aqueous solution by using low cost adsorbent Azadirechta indica Leaves”.
[0008] The pyrolysis of neem ( Azadirachta indica ) and kikar ( Acacia arabica ) leaves at 400° C. in electric furnace for the preparation of carbon for fluoride removal is reported in J. Environ Biol. 2008 March;29(2):227-32 by Kumar S, et al.
[0009] Moreover Bhardwaj S. in Carbon Letters. 8 (4) (2007) 285-291 discloses the synthesis of carbon materials by pyrolysis of Soap-nut seeds ( Sapindus mukorossi ), Jack Fruit seeds ( Artocarpus heterophyllus ), Date-seeds ( Phoenix dactylifera ), Neem seeds ( Azadirachta Indica ), Tea leaves ( Ehretia microphylla ), Bamboo stem ( Bambusa bambus ) and Coconut fiber ( Cocos nucifera ), without using any catalyst. Amongst the various precursors, carbon fibers obtained from Soap-nut seeds ( Sapindus mukorossi ) and Bamboo stem ( Bambusa bambus ), even after 100th cycles, showed the highest capacity of 130.29 mAh/g and 92.74 mAh/g respectively.
[0010] Further Bhardwaj et al. (Asian J. Exp. Sci. 22 2008; 89-93) have synthesised carbon nanomaterial from tea leaves as an anode in Lithium secondary batteries. However the leaves used in the citation are tea leaves which have high commercial value. The current invention is based on the synthesis of highly conducting carbon and its nanocomposites with metal and metal oxides from readily available dead leaves. The process of the citation involves boiling leaves for about 1 hr. then dried at 100° C. for 3 hrs, washing several times and finally pyrolysis.
[0011] While in the current invention the leaves are washed, dried directly and then pyrolysed. Hence the invention is advantageous as compared to methods of prior art as it uses dead leaves instead of any starting material of commercial value and provide shorter process for synthesis of carbon nanomaterials employing lesser energy.
[0012] The functional carbon is normally synthesized by different chemical methods following complex steps using man-made chemical precursors, such as synthesis of functional carbon (graphene) by chemical vapor deposition using different waste materials such as lignocellulosic biomass, food, insects as the source of precursor vapor phase materials. In present case functional carbon forms as the residue of the pyrolysis process when the vapor phase precursors are removed, making instant process distinctly different as compared to what is reported. Further instant invention makes it possible to synthesize various nanocomposites in bulk form by our process, which cannot be the case with the reported publication. Moreover there are no reports on the use of plant dead leaves as a source of conducting carbon.
[0013] In view of above the present inventor addresses the technical constraints associated with the existing process such as cumbersomeness, toxicity of reagents, limited application, energy and time consuming, environmentally hazardous by-products, low surface area and capacitance of derived carbon material, expensive starting material etc. To overcome such problems the inventors have developed source of carbon nanomaterial by industrially feasible, cost-effective technique prepared from cheap, non-toxic, bio waste material such as plant dead leaves, that affords carbon nanomaterial with significant properties. Further the present inventors have succeeded to solve the problem related to waste material and pollution by employing waste organic material for the synthesis of valuable functional and device-worthy carbon materials.
OBJECTS OF THE INVENTION
[0014] Main objective of the present invention is to provide highly functional carbon nanomaterial or carbon based nanocomposite having improved or significant property(s) which is synthesized from organic waste material such as plant dead leaves.
SUMMARY OF THE INVENTION
[0015] Accordingly, present invention provides a carbon nanomaterial characterized by the surface area in the range of 700 to 1400 m 2 /g, electrical conductivity in the range of 2×10 −2 to 5×10 2 Scm −1 , capacitance in the range of 200-400 F/g and average pore diameter size in the range of 0.1 nm to 0.5 nm.
[0016] In an embodiment, present invention provides a process for synthesis of electronically conducting carbon nanomaterial as claimed in claim 1 , wherein said process comprising the steps of:
i. washing the dead leaves of plant with water followed by drying; ii. crushing the dried leaves to get fine powder of dead leaves; iii. pyrolysing the dead leaves powder at temperature in the rage of 600 to 1400° C. under argon atmosphere; iv. subsequently cooling the pyrolysed leaves at temperature in the rage of 20 to 30° C. to obtain electronically conducting carbon nanomaterial having high surface area, specific capacitance and conductivity.
[0021] In another embodiment of the present invention, the dead leaves are selected from the plant Neem ( Azadirachta indica ) and Ashoka ( Saraca asoca ).
[0022] In yet another embodiment of the present invention, in step (b) the dead leaf powder is optionally mixed with binder in the ratio ranging between 10:1 to 10:0.5 (w/w).
[0023] In yet another embodiment of the present invention, the conductivity value for the carbon synthesized with binder is in the range of 4×10 −2 to 8×10 −2 Scm −1 .
[0024] In yet another embodiment of the present invention, the dead leaf powder is optionally mixed with metal powder and binder in the ratio of ranging between 5.5 to 1 to 5:5:0.5 (w/w) respectively, to obtain carbon based metal nanocomposite.
[0025] In yet another embodiment of the present invention, metal used is selected from Fe and Cu or oxides thereof.
[0026] In yet another embodiment of the present invention, the binder used is selected from the group consisting of cellulose, methyl cellulose, gelatine, starch, polyvinylpyrrolidone (PVP) and polyethylene glycol (PEG) preferably polyvinylpyrrolidone (PVP).
[0027] In yet another embodiment of the present invention, said nanomaterial is useful as catalyst, super-adsorbents for toxic chemicals and dye remover; in high value added products to applications such as super-capacitor, super-adsorbent, battery, catalysis.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 depicts the process pathway for the synthesis of conducting carbon from dead leaves.
[0029] FIG. 2 depicts magnetic Fe-carbon nano-composites attracted towards magnet, wherein complete powder is attracted towards magnet which signifies the formation of a composite, and not a physical mixture of Fe and carbon.
[0030] FIG. 3 depicts XRD Spectra for carbon, Fe-carbon and Cu-carbon, wherein only carbon two broad peaks are present around 2θ=26° and 44° corresponding to graphitic form of carbon. In the case of Fe and Cu based composites the observed strong peaks correspond to metallic Cu and Fe. The carbon peaks are relatively small and can show up in the tog scale.
[0031] FIG. 4 depicts Raman Spectra of carbon, Fe-carbon and Cu-carbon, wherein the peak present around 1300 cm −1 corresponds to the D band and the peak at 1590 cm −1 corres p onds to the G band of carbon. In the case of Cu and Fe carbon composites both D and G bands are slightly shifted towards higher wave numbers. This shift is again due to the strain involved during the formation of the composites.
[0032] FIG. 5 depicts HR-TEM Images of porous carbon, wherein porous sheet like structures correspond to graphitic-carbon-like structures.
[0033] FIG. 6 depicts (a) FE-SEM images of Cu-carbon (b) FE-SEM images of Fe-carbon (c) HR-TEM images of Cu-carbon (d) HR-TEM images of Fe-carbon. Further the images show a uniform dispersion of Cu and Fe particles embedded in the carbon matrix.
[0034] FIG. 7 depicts EDAX Image of carbon from Neem leaf powder, wherein the synthesized carbon shows majority percentage and oxygen along with a few percent of Mg, Si, K and Ca which come from the oxide residues of Neem leaf.
[0035] FIG. 8 depicts BET adsorption isotherm of carbon, which show a Type-II adsorption desorption characteristics having mesoporous structures. The surface area is found to be 382 m 2 /g and the average pore diameter is measured 0.5 nm.
[0036] FIG. 9 depicts pore distribution plot of carbon, which shows a uniform pore distribution of carbon with or without binder. Further it represents the surface area 1231 m 2 /g for the case of carbon synthesized without binder which is considerably high as compared to the case with binder. The pore radius is again found to be 0.5 nm.
[0037] FIG. 10 depicts conductivity measurements of carbon synthesized with binder and without binder which shows the Current and Voltage plot (I-V Plot) of carbon synthesized with and without binder case respectively. The conductivity value for the carbon synthesized with binder is 5×10 −2 Scm −1 and without binder is 3.5×10 −2 Scm −1 . The high conducting nature of carbon is also observed in the case of carbon obtained by pyrolysis of Ashoka plant dead leaves by the instant process.
[0038] FIG. 11 depicts cyclic voltammetry measurements of carbon without binder cases at 50 mv/s scan rate, which represents an ideal supercapacitor. Also rectangular nature represents a perfect double layer formation.
[0039] FIG. 12 depicts Cyclic Voltammetry measurements of carbon without binder cases at different scan rates.
[0040] FIG. 13 depicts methylene blue dye removal by Fe-carbon composite.
[0041] FIG. 14 depicts the plot of specific capacitance with different current densities which shows even at very high current density (10 A/g) thr specific capacitance is still high as 290 F/g.
[0042] FIG. 15 depicts CV curve for the carbon synthesized from fresh green leaves which shows a specific capacitance of 195 F/g at a can rate of 20 mv/s. This value is lower than the carbon synthesized from the Neem dead leaves.
[0043] FIG. 16 depicts CV curve of Neem dry leaf without grinding at 20 mv/s in 1M H 2 SO 4 . The specific capacitance was calculated to be 373 F/g.
[0044] FIG. 17 depicts charge Discharge curve of Ashoka leaf derived carbon at 1 A/g and 0.5 A/g with 1M H 2 SO 4 . From the charge discharge curve the specific capacitance of Ashoka leaf derived carbon was calculated to be 250 F/g at a current density of 0.5 A/g which is lower than the Neem leaf carbon.
[0045] FIG. 18 depicts charge discharge data of Ashoka leaf derived carbon at 2 A/g current density in organic electrolyte. From the above curve the specific capacitance of Ashoka leaf derived carbon is calculated to be 21 F/g which is less than the neem leaf derived carbon.
[0046] FIG. 19 depicts BET surface area measurements of Ashoka leaf derived carbon. It shows a surface area of 705 m2/g and average pore radius of 0.2 nm.
[0047] FIG. 20 depicts Nyquist plot for carbon carbon electrode in 1M LiPF6 in EC: DEC (organic) [inset shows magnified high frequency region].
[0048] FIG. 21 depicts comparison of Nyquist plot for carbon electrode in 1M H 2 SO 4 (aqueous) and 1M LiPF6 in EC: DEC (organic).
DETAILED DESCRIPTION OF THE INVENTION
[0049] In the present specification, the following words and phrases are generally intended to have the meanings as set forth below, except to the extent that the context in which they are used indicate otherwise.
[0050] The term “carbon material” can also referred as “carbon particles” “carbon nanomaterial”, “carbon nanoparticle” “carbon composite” or “carbon powder”.
[0051] The present invention provides carbon nanomaterial having high surface area, electrical conductivity and capacitance obtained by pyrolysis of plant dead leaves. The dead leaves are fallen leaves or dry leaves of plant selected from Neem ( Azadirachta indica ) and Ashoka ( Saraca asoca ), wherein the dead leaves are individually selected from the plant Neem ( Azadirachta indica ) or Ashoka ( Saraca asoca ) or from both plants. Dead leaves of both the plants were collected from the compartment of NCL (National Chemical Laboratory), Dr. Homi Bhabha Road, Pune-411 008, India.
[0052] Present invention provides process for synthesis of carbon nanomaterial by pyrolysis of plant dead leaves, particularly dead leaves of Neem ( Azadirachta indica ) and Ashoka ( Saraca asoca ), wherein the derived carbon nanomaterial having high surface area, electrical conductivity and capacitance which is useful in high value added product applications such as super-capacitor, super-adsorbent, battery, catalysis, dye removal water purification etc.
[0053] In another aspect, the invention relates to synthesis of functional carbon material by pyrolysis of dead leaves in presence of binder.
[0054] In another aspect, the invention deals with the synthesis of carbon based metal nano-composites from the dead leaves which can be useful in the applications such as catalysis and super-adsorbent for toxic chemicals, dye removal.
[0055] The present invention provides carbon nanomaterial/particles having high surface area in the range of 700 to 1400 m 2 /g;, electrical conductivity in the range of 2×10 −2 to 5×10 −2 Scm − 1; capacitance in the range of 200-400 F/g and average pore diameter size in the range of 0.1 nm to 0.5 nm obtained by pyrolysis of plant dead leaves.
[0056] The process for the synthesis of functional carbon nano-material by pyrolysis of dead leaves of Neem ( Azadirachta indica ) and Ashoka ( Saraca asoca ) comprising the steps of:
[0057] a) washing the dead leaves of plant with water followed by drying;
[0058] b) crushing the dried leaves to get fine powder of dead leaves;
[0059] c) decomposing the dead leaves powder at high temperature (1000° C.±400° C.) under argon atmosphere; subsequently cooling at room temperature to obtain nanoparticles of carbon having high surface area and capacitance.
[0060] According to the process, the decomposition or pyrolysis of crushed dead leaves is carried out on alumina plate or crucible, wherein the dead leaves powder is heated at temperature range 600° C. to 1400° C. with heating rate in the range of 8-20° C. per minute wherein the crushing or grounding of dead leaves can be performed by known techniques by using crusher, mortar and pestle and like thereof.
[0061] It was demonstrated that the dead leaves without crushing or grinding i.e. as such dead leaves can also be used for the synthesis of carbon material via pyrolysis to give improved specific capacitance.
[0062] The synthesized carbon material containing reduced amount of the impurities which come from the oxide residues of plant leaf, wherein the impurities comprising of oxygen and few percent of Mg, Si, K and Ca, such impurities do not interfere the carbon nanomaterial conducting properties.
[0063] The average pore size of derived carbon particles is measured in the range of 0.1 nm to 0.5 nm, whereas the surface area of the carbon nanomaterial/nanoparticle is measured in the range of 700 to 1400 m 2 /g, particularly the surface area of the carbon powder derived from the dead leaves of Neem ( Azadirachta indica ) was observed in the range of 1000-1400 m 2 /g, whereas surface area of the carbon powder derived from Ashoka ( Saraca asoca ) is in the range of 700-1000 m 2 /g.
[0064] The specific capacitance of carbon material derived from dead leaves is evaluated in suitable aqueous electrolyte such as 1M H 2 SO 4 , or organic electrolyte such as ethylene and diethyl carbonates (EC-DEC) solutions of LiAsF 6 , LiClO 4 , LiBF 4 and LiPF 6 ; wherein the specific capacitance of derived carbon nanoparticles is measured in the range of 200-400 F/g.
[0065] In accordance with the specific capacitance, the carbon material derived from dead leaves of Neem exhibits nearly 290 F/g, and carbon particles derived from dead leaves of ashoka in aqueous electrolyte was measured about 250 F/g. Also the inventors have optionally derived carbon material from the dead or dry leaves of Neem without grinding, where the specific capacitance is evaluated nearly 373 F/g.
[0066] Alternatively, fresh green neem leaves pulp can also be subjected to the process according to the invention to obtain conducting carbon material, where the conductance is measured nearly 195 F/g. The chemical composition of fresh neem leaves is depicted in table 1.
[0067] The carbon material derived from dead leaves of plants in acidic medium preferably sulphuric acid with molar concentration 0.5M to 2M, particularly in presence of 1M sulphuric acid which shows high energy density i.e. more than 55.0 WhKg −1 and power density≧10 kWKg −1 which is comparatively higher than the other source of carbon materials, the comparison of energy density and power density of various carbon materials with dead leaf derived carbon is represented in Table 2.
[0068] The invention provides synthesis of carbon nanomaterial from dead leaves of Neem ( Azadirachta indica ) and Ashoka ( Saraca asoca ) in presence of binder; particularly the dead leaf powder is mixed with binder in the ratio of 10:0.5 (w/w) wherein the binder is selected from the group consisting of cellulose, methyl cellulose, gelatine, starch, polyvinylpyrrolidone (PVP) and polyethylene glycol (PEG); preferably polyvinylpyrrolidone (PVP).
[0069] Accordingly, the dead leaf powder was mixed with a PVP (poly vinyl pyrollidone) binder and formed as a pellet. The pellet was then placed on alumina plate and subjected to high temperature pyrolysis 1000° C. (±400 ° C.) under inert atmosphere for 2-10 hours at a heating rate of 5-15° C. per minute. The duration at the peak temperature was 1-10 hrs. The inert atmosphere is preferably argon.
[0070] The invention also provides evaluation of capacitance of carbon synthesized by both these cases, (with PVP binder and without binder) by means of carbon loaded electrodes in presence of alcohol and 1% Polytetrafluoroethylene (PTFE) solution under vacuum condition.
[0071] It was observed that for the carbon synthesized with binder a capacitance value of 120 F/g was realized at the scan rate of 50 mv/s, whereas for the carbon synthesized without binder the capacitance was found to have increased to 250 F/g (50 mv/s scan rate).
[0072] The conductivity value for the carbon synthesized from Neem leaves with binder is in the range of 4×10 −2 to 8×10 −2 Scm − and without binder is in the range of 2×10 2 to 5×10 −2 Scm − .
[0073] The invention provides carbon based metal nanocomposite from the dead leaves, wherein the dead leaves of neem or ashoka or both are mixed with a metal powder and binder.
[0074] The crushed dead leaves are mixed with metal followed by thoroughly blending with binder and made into pellets, subsequently the pellets are pyrolysed/decomposed at 1000° C. (±200° C.) in an inert atmosphere for 2-10 hours at a heating rate of 5-15° C. per minute.
[0075] The pallet can be prepared by mixing dead leaf powder and metal powder and binder in the ratio of 5:5:0.5 (w/w) which is further subjected to pyrolysis at high temperature.
[0076] The metal used in the nanocomposites is selected from the group consisting of Fe, Co, Cu, Zn, Al, Ni, Ti, Ag, Au, Pd, Pt like thereof or oxides, hydroxides thereof, preferably metal is Fe and Cu or oxides thereof; whereas the binder is particularly PVP.
[0077] It is noteworthy that the carbon nano-composites synthesized by instant process can be useful to generate carbon based application-worthy forms by addition of other molecules, polymers, metals, semiconductors, oxides or waste such as ash, fly ash and such like.
[0078] The Fe-carbon nanocomposite synthesized by the instant process was tested for dye removal wherein Fe-carbon composite was added to 10 −5 M methylene blue solution with stirring where the blue colour of methylene blue immediately disappeared, followed by separating Fe-carbon composites by means of maganet to get transparent solution. Further the adsorbed methylene blue solution can be recovered by putting the Fe-carbon composites into ethanol. The dye molecules immediately come out from the Fe-carbon composites.
[0079] The carbon composite and carbon based metal nanocomposite synthesized according to the instant process exhibit high value added products to many application but not limited to applications such as super-capacitor, super-adsorbents for toxic chemicals and dye remover, battery, catalysis, water purification and like thereof.
[0080] According to the invention the derived carbon composites and carbon based metal nanocomposites are characterized by using XRD, Raman spectra, HR-TEM, FE-SEM, EDAX, BET nitrogen adsorption isotherm, Current and Voltage plot.
[0081] The chemical composition of fresh neem leaves having more water content (>50.0%) and the comparison of carbon derives from dead leaves and other known material is represented in herein below table 1 and table 2 respectively.
[0000]
TABLE 1
Chemical composition of Fresh Neem Leaves
Moisture
59.4%
Proteins
7.1%
Fat
1.0%
Fibre
6.2%
Carbohydrates
22.9%
Minerals
3.4%
Vitamin C
218 Mg/100 g
Glutamic acid
73.30 Mg/100 g
[0000]
TABLE 2
Comparison of energy density and power density of
various carbon materials with dead leaf derived carbon
Max energy
Max Power
Materials
Medium
Density
Density
Activated carbon
1M H 2 SO 4
20 WhKg −1
—
from waste coffee
beans
Carbon from sea
1M H 2 SO 4
19.5 WhKg −1
—
weeds
Activated Carbon
1M H 2 SO 4
10 WhKg −1
—
from Sugarcane
bagasse
Binder free RGO-
1M H 2 SO 4
59.9 WhKg −1
250 WKg −1
CNT film
Ultrathin Graphene
2M KCL
15.4 WhKg −1
55 WKg −1
film
Graphene-CNT
0.5M H 2 SO 4
21.74 WhKg −1
78.29 kWKg −1
Carbon derived
1M H 2 SO 4
55.5 WhKg −1
10 kWKg −1
from Dead Leaves
EXAMPLES
[0082] The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
Example 1
Synthesis of Carbon Pellet with Binder
[0083] 10 g of dead leaf powder was mixed thoroughly with 500 mg PVP (poly vinyl pyrollidone) binder and then pellet sample was made. The pellet was placed on an alumina plate and was subjected to high temperature pyrolysis at 1000° C. under argon atmosphere for 5 hr at a heating rate of 10° C. per minute. The duration at the peak temperature was 3 hrs.
Example 2
Synthesis of Fe, Carbon Nanocomposites
[0084] 5g of leaf powder and 5 g of Fe metal were mixed thoroughly with 500 mg PVP to make a pellet and the same was subjected to high temperature pyrolysis as mentioned in example 1.
Example 3
Synthesis of Carbon Material
[0085] 10 g of dead leaf powder was heated in an alumina crucible at 1000° C. under argon atmosphere for 5 hr at a heating rate of 10° C. per minute and cooled to room temperature at natural rate to obtain black powders.
Example 4
Cyclic Voltammetry Measurements
Preparation of Electrodes
[0086] All the electrodes were prepared on Glassy carbon. Two glassy carbon substrates were used for each measurement. 6 mg of carbon was dispersed in 6 ml isopropanol and 200 pl of 1% PTFE solution was added to it. After proper dispersion this was drop-cast slowly on the glassy carbon till the loading was 1 mg. After making the electrodes they were dried in vacuum for 24 hrs at 60° C. Carbon synthesized by both these cases, (with PVP binder and without binder) were studied for super capacitor measurements.
Testing of Electrodes
[0087] All the Cyclic Voltammetry experiments were carried out using Auto Lab instrument in a potential window of 0-1V and in 0.5M H 2 SO 4 electrolyte. Measurements were taken at the scan rates of 10, 20 and 50 mv/s. The results are shown in FIG. 10 . It was observed that for the carbon synthesized with binder a capacitance value of 80 F/g was realized at the scan rate of 50 mv/s, whereas for the carbon synthesized without binder the capacitance was found to have increased to 120F/g (50 mv/s scan rate).
ADVANTAGES OF THE INVENTION
[0088] Invention provides efficient, cost-effective process for preparation of functional carbon nanoparticles by simple pyrolysis of biologically waste material.
[0089] The process also involves following significant advantages such as
[0090] a) Effective use of dead leaves,
[0091] b) Avoid environmental pollution,
[0092] c) Value-added carbon product from waste matter,
[0093] d) Carbon produces useful in various applications such as supercapacitors, superabsorbent, battery and catalysis,
[0094] e) Solution to waste management and control of pollutants.
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The present invention disclosed herein is carbon nanomaterial and carbon based nanocomposites by pyrolysis of dead leaves and other similar natural waste material. In particular, the invention relates to synthesis of valuable functional carbon materials and their nanocomposites from different waste materials such as plant dead leaves and their use in high value added product applications.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present document claims priority to Japanese Priority Document JP 2002-196279, filed in the Japanese Patent Office on Jul. 4, 2002, the entire contents of which are incorporated herein by reference to the extent permitted by law.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an optical pickup apparatus for writing or reading information signals on or from an optical disc as an optical recording medium and a signal recording and/or reproducing apparatus equipped with this optical pickup apparatus for recording or reproducing information signals on or from an optical disc.
[0004] 2. Description of Related Art
[0005] Conventionally, an optical pickup apparatus for writing or reading information signals on or from an optical disc as an optical recording medium has been proposed, and a signal recording and/or reproducing apparatus equipped with this optical pickup apparatus for recording or reproducing information signals on or from an optical disc has been proposed.
[0006] With respect to such an optical pickup apparatus, it is demanded that it support optical discs having a higher recording density for information signals for which it is necessary that the wavelength of the light emitted by the laser diode serving as a light source be shortened and numerical apertures (NA) of the objective lens be increased.
[0007] For example, according to an optical pickup apparatus that is configured using a high numerical aperture objective lens (an optical pickup apparatus for a high density phase change optical disc), which has been proposed in recent years, as shown in FIG. 9, a light beam emitted from a laser diode 101 is shaped into a parallel beam by a collimator lens 102 , and is further shaped by an anamorphic prism 103 into a light beam whose light intensity profiles in two orthogonal directions (the light intensity profile of the cross section of the light beam) are substantially equal before entering a beam splitter 104 .
[0008] The light beam, which has passed through the beam splitter 104 , passes through a beam expander for correcting spherical aberration including a concave lens 105 and a convex lens 106 , is deflected in a direction normal to an optical disc 109 by a reflecting mirror 107 and enters an objective lens 108 . The light beam entering the objective lens 108 is focused on a signal recording surface of the optical disc 109 as a minute light spot by this objective lens 108 .
[0009] In addition, in order to maintain the intensity of the emitted light from the laser diode 101 constant, the light beam reflected by the beam splitter 104 is received by an optical detector 110 so as to feedback-control the light emission output of the laser diode 101 based on the output of this optical detector 110 .
[0010] The light beam reflected by the signal recording surface of the optical disc 109 passes through the objective lens 108 again, is deflected by the reflecting mirror 107 , passes through the convex lens 106 and the concave lens 105 of the beam expander, and returns to the beam splitter 104 . At this beam splitter 104 , the reflected light from the optical disc 109 is reflected and deflected, and is focused, by a condenser 111 , on a light receiving surface of an optical detector 112 .
[0011] Optical elements constituting such an optical system are provided in an optical block 113 . As shown in FIG. 9 with arrow T, this optical block 113 is operated movably in a tracking direction, where the objective lens 108 moves towards or away from a spindle shaft 114 supporting a center portion of the optical disc 109 .
[0012] In such an optical pickup apparatus that supports optical discs with a high recording density, providing the anamorphic prism 103 and the beam expander makes the configuration of the optical system complicated and may cause the apparatus to become larger.
[0013] Further, in this optical pickup apparatus, because the entire optical block 113 has to be moved in order to access a given information track, quick activation and stopping of the apparatus cannot be achieved and there is the risk that the time taken to access a desired information track becomes longer.
[0014] As such, in recent years, for use in a signal recording and/or reproducing apparatus (i.e., a signal recording and/or reproducing apparatus for high density phase change optical discs), there has been proposed an optical pickup apparatus having a configuration in which, as shown in FIG. 10, the laser diode 101 as the light source, the beam splitter 104 , and the optical detectors 110 and 112 and the like are provided in a fixed optical block 115 , and only optical components such as the objective lens 108 and the reflecting mirror 107 are provided in the movable optical block 113 .
[0015] According to this optical pickup apparatus, in the fixed optical block 115 , a light beam that is emitted from the laser diode 101 is shaped into a parallel light beam by the collimator lens 102 , and is further shaped by the anamorphic prism 103 into a light beam whose light intensity profiles in two orthogonal directions (the light intensity profile of the cross section of the light beam) are substantially equal before entering the beam splitter 104 . In order to maintain the light emission intensity of the laser diode 101 constant, the light beam reflected by the beam splitter 104 is received by the optical detector 110 so as to feedback-control the light emission output of the laser diode 101 based on the output of this optical detector 110 .
[0016] The light beam that has passed through the beam splitter 104 is emitted from the fixed optical block 115 and enters the movable optical block 113 . Then, in this movable optical block 113 , the light beam passes through the beam expander for correcting spherical aberration composed of the concave lens 105 and the convex lens 106 , is deflected in a direction normal to the optical disc 109 by the reflecting mirror 107 , and enters the objective lens 108 . The light beam entering the objective lens 108 is focused on the signal recording surface of the optical disc 109 as a minute light spot by this objective lens 108 .
[0017] The light beam reflected by the signal recording surface of the optical disc 109 passes through the objective lens 108 again, is deflected by the reflecting mirror 107 , passes through the convex lens 106 and the concave lens 105 of the beam expander, is emitted from the movable optical block 113 and enters the fixed optical block 115 .
[0018] In the fixed optical block 115 , the reflected light from the optical disc 109 returns to the beam splitter 104 . At this beam splitter 104 , the reflected light from the optical disc 109 is reflected and deflected, and is focused, by the condenser 111 , on the light receiving surface of the optical detector 112 .
[0019] In this optical pickup apparatus, in order to access a desired track, as shown in FIG. 10 with arrow T, only the movable optical block 113 need be moved in the tracking direction, whereby the objective lens 108 is moved towards or away from the spindle shaft 114 supporting a center portion of the optical disc 109 . Therefore, in this optical pickup apparatus, the optical block 113 can be activated and stopped at high speed and it is possible to shorten the time taken to access a desired information track.
SUMMARY OF THE INVENTION
[0020] In a signal recording and/or reproducing apparatus using the optical pickup apparatus that is configured with a fixed optical block and a movable optical block as described above, the optical pickup apparatus is configured in such a manner that, as shown in FIG. 10, the fixed optical block 115 and the movable optical block 113 are aligned in the radial direction of the optical disc 109 . Therefore, the fixed optical block 115 is positioned on the outer side of the optical disc 109 . Accordingly, the outer housing of this signal recording and/or reproducing apparatus would have to be larger than a disc cartridge 116 , in which the optical disc 109 is housed, that is, the outer housing would have to be larger than an area substantially equal to a square circumscribing the optical disc 109 by at least the size of an area for housing the fixed optical block 115 .
[0021] For example, assuming that the diameter of the optical disc 109 is 50 mm, if one attempted to configure a small signal recording and/or reproducing apparatus, achieving a sufficient reduction in size becomes difficult since the apparatus would become considerably larger than the size of the disc cartridge 116 housing this optical disc 109 , namely, approximately 55 mm in both length and width.
[0022] A signal recording and/or reproducing apparatus using an optical pickup apparatus of the configuration above is described in the publication of Japanese Patent Application 1995-105565, however, a sufficient reduction in size in relation to the size of a disc cartridge housing an optical disc is not achieved.
[0023] The present invention has been made taking the foregoing problems into consideration and provides an optical pickup apparatus that supports an optical disc having a recording density that is higher than is conventional by shortening the light emission wavelength of a light source and increasing the numerical aperture (NA) of an objective lens, and which, at the same time, achieves a sufficient reduction in its size relative to the size of a disc cartridge housing such an optical disc.
[0024] In order to resolve the problems above, an optical pickup apparatus according to an embodiment of the present invention may include a fixed optical system having a light source and a collimator lens, and which is fixedly provided in a signal recording and/or reproducing apparatus. The optical pickup apparatus may also include a movable optical system having an objective lens, which is supported such that the optical axis of this objective lens is parallel to a shaft of a spindle motor that rotates an optical disc serving as a recording medium. The objective lens may be movable towards or away from the shaft of the spindle motor, and a parallel light beam from the light source that is emitted from the fixed optical system by way of the collimator lens enters the objective lens. The objective lens focuses this light beam on a signal recording surface of an optical disc that is rotated by the spindle motor. The optical pickup apparatus may also include light detecting means for detecting a reflected light beam, which is the reflection of the light beam focused on the signal recording surface of the optical disc by the objective lens. The parallel light beam that enters the movable optical system from the fixed optical system follows a light path that is parallel to the direction in which the objective lens is capable of moving, and enters the movable optical system from the side on which the spindle motor is provided.
[0025] According to this optical pickup apparatus, since the parallel light beam that enters the movable optical system from the fixed optical system follows a light path that is parallel to the direction in which the objective lens is capable of moving, and enters the movable optical system from the side on which the spindle motor is provided, the fixed and movable optical systems can be distributed in a substantially even manner relative to a center portion of the optical disc supported at this center portion by a shaft of the spindle motor, thereby making it possible to easily keep the fixed optical system and the movable optical system within an area corresponding to a disc cartridge housing this optical disc.
[0026] In addition, an embodiment of a signal recording and/or reproducing apparatus of the present invention may include a spindle motor for rotating an optical disc serving as a recording medium, and a fixed optical system having a light source and a collimator lens. The signal recording and/or reproducing apparatus may also include a movable optical system having an objective lens, which is supported such that the optical axis of the objective lens is parallel to a shaft of the spindle motor. The objective lens may be movable towards and away from the shaft of the spindle motor, and a parallel light beam from the light source that is emitted from the fixed optical system by way of the collimator lens enters the objective lens. The objective lens focuses this light beam on a signal recording surface of the optical disc rotated by the spindle motor. The recording and/or reproducing apparatus may also include light detecting means for detecting a reflected light beam, which is a reflection of the light beam focused by the objective lens on the signal recording surface of the optical disc; and signal processing means for signal-processing the light detection output from the light detecting means. The parallel light beam that enters the movable optical system from the fixed optical system follows a light path that is parallel to the direction in which the objective lens is capable of moving, and enters the movable optical system from the side on which the spindle motor is provided.
[0027] According to this signal recording and/or reproducing apparatus, since the parallel light beam that enters the movable optical system from the fixed optical system follows a light path that is parallel to the direction in which the objective lens is capable of moving, and enters the movable optical system from the side on which the spindle motor is provided, the fixed and movable optical systems can be distributed in a substantially even manner relative to a center portion of the optical disc supported at this center portion by a shaft of the spindle motor, thereby making it possible to easily keep the fixed optical system and the movable optical system within an area corresponding to a disc cartridge housing this optical disc.
[0028] Thus, according to an embodiment of the optical pickup apparatus and the recording and/or reproducing apparatus of the present invention, a significant reduction in size as compared to conventional optical pickup apparatuses can be achieved where, for example, each optical system can be kept within a projected area of a cartridge for an optical disc having a diameter of 50 mm or below.
[0029] In addition, according to the optical pickup apparatus and the signal recording and/or reproducing apparatus described above, since the movable optical system can be made lighter, seeking speed in the track direction can be made faster. Further, the laser driver, which is a heat source, can be fixedly provided within the signal recording and/or reproducing apparatus, and thus, it is possible to release heat towards the chassis or the like in a desirable fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a plan view showing the configuration of a main portion of an optical pickup apparatus and a signal recording and/or reproducing apparatus according to an embodiment of the present invention;
[0031] [0031]FIG. 2 is a side view showing the configuration of the main portion of the above-mentioned optical pickup apparatus and signal recording and/or reproducing apparatus;
[0032] [0032]FIG. 3 is a sectional view showing the configuration of a skew adjustment mechanism for the objective lens in the above-mentioned optical pickup apparatus;
[0033] [0033]FIG. 4 is a side view showing the configuration of a skew adjustment mechanism for the spindle motor in the above-mentioned signal recording and/or reproducing apparatus;
[0034] [0034]FIG. 5 is a plan view showing another example of the configuration of the above-mentioned optical pickup apparatus (one in which the deflection angle by a first deflection means is made smaller than 90 degrees) and the configuration of a main portion of the signal recording and/or reproducing apparatus;
[0035] [0035]FIG. 6 is a plan view showing another example of the configuration of the above-mentioned optical pickup apparatus (one in which the first deflection means is a pentaprism) and the configuration of a main portion of the signal recording and/or reproducing apparatus;
[0036] [0036]FIG. 7 is a plan view showing another example of the configuration of the above-mentioned optical pickup apparatus (one in which the first deflection means is made a part of a fixed optical system) and the configuration of a main portion of the signal recording and/or reproducing apparatus;
[0037] [0037]FIG. 8 is a block diagram showing the configuration of the above-mentioned signal recording and/or reproducing apparatus;
[0038] [0038]FIG. 9 is a plan view showing the configuration of a main portion of a conventional optical pickup apparatus (one that uses an integrated optical block) and signal recording and/or reproducing apparatus; and
[0039] [0039]FIG. 10 is a plan view showing the configuration of a main portion of a conventional optical pickup apparatus (one that uses a detached optical block) and signal recording and/or reproducing apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Embodiments of the present invention will be described below with reference to the drawings.
[0041] As shown in FIG. 1, an optical pickup apparatus according to an embodiment of the present invention includes: a fixed optical system 3 , in which a laser diode 1 as a light source is built-in and which is fixedly provided on a chassis 2 inside a signal recording and/or reproducing apparatus according to an embodiment of the present invention; and a movable optical system 5 which has an objective lens 4 , is provided in the signal recording and/or reproducing apparatus so as to be movable on the chassis 2 , and into which a light beam emitted from the laser diode 1 enters. The fixed optical system 3 and the movable optical system 5 are provided in a fixed optical block 3 a and a movable optical block 5 a , respectively. As shown in FIG. 2, the fixed optical block 3 a is fixedly provided on the chassis 2 .
[0042] In the fixed optical system 3 , as shown in FIG. 1, the light beam emitted from the laser diode 1 is shaped into a parallel light beam by a collimator lens 6 , and is further shaped by an anamorphic prism 7 into a light beam whose light intensity profiles in two orthogonal directions (the light intensity profile of the cross section of the light beam) are substantially equal before entering a beam splitter 8 . Then, in order to maintain the light emission intensity of the laser diode 1 constant, the parallel light beam that has passed through the beam splitter 8 is received by an optical detector 9 so as to feedback-control the light emission output of the laser diode 1 based on the output of this optical detector 9 .
[0043] The parallel light beam reflected at the beam splitter 8 is emitted from the fixed optical block 3 a . Further, the parallel light beam that is emitted from the fixed optical block 3 a enters the movable optical block 5 a.
[0044] The movable optical system 5 provided within the movable optical block 5 a is supported such that the optical axis of the objective lens 4 is parallel to a shaft of a spindle motor 10 rotating an optical disc 109 as a recording medium in the signal recording and/or reproducing apparatus, namely, a spindle shaft 10 a . Further, this movable optical system 5 , as shown in FIG. 1 by arrow T, is movable such that the objective lens 4 moves towards or away from the spindle shaft 10 a by having the movable optical block 5 a guided with a shaft 11 that is provided on the chassis 2 .
[0045] In addition, as shown in FIG. 2, a disc table 12 is attached to the tip end side of the spindle shaft 10 a , and this disc table 12 supports the center portion of the optical disc 109 . When the spindle motor 10 is driven and the spindle 10 a is rotated, the optical disc 109 rotates with the disc table 12 .
[0046] As shown in FIG. 1, the parallel light beam that enters the movable optical block 5 a hits a mirror 15 , which serves as first deflection means, after passing through a beam expander for correcting spherical aberration and which includes a concave lens 13 and a convex lens 14 . This mirror 15 deflects the parallel light beam emitted from the fixed optical system 3 and leads it in a direction that crosses the optical axis of the objective lens 4 .
[0047] As shown in FIG. 2, at the intersection between the light path of the parallel light beam that is deflected by the mirror 15 and the optical axis of the objective lens 4 is placed a reflecting mirror 16 as second deflection means. This reflecting mirror 16 deflects the light beam, which is led by the mirror 15 in a direction that crosses the optical axis of the objective lens 4 , in the direction of the optical axis of the objective lens 4 , namely, in a direction normal to a principal surface portion of the optical disc 109 and makes it enter the objective lens 4 . The parallel light beam that enters the objective lens 4 is focused as a minute light spot on a signal recording surface of the optical disc 109 by this objective lens 4 .
[0048] The light beam that is reflected by the signal recording surface of the optical disc 109 passes through the objective lens 4 again, is deflected by the reflecting mirror 16 , and is further deflected by the mirror 15 . Then, as shown in FIG. 1, the light beam passes through the convex lens 14 and the concave lens 13 of the beam expander, is emitted from the movable optical block 5 a and returns to the fixed optical block 3 a.
[0049] In the fixed optical system 3 within the fixed optical block 3 a , the reflected light from the optical disc 109 returns to the beam splitter 8 . In this beam splitter 8 , the reflected light from the optical disc 109 passes through a reflective surface which divides the light beam that goes to the optical detector 9 and the light beam that goes to the movable optical system 5 , is reflected and deflected by a surface other than this reflective surface, and is focused on a light receiving surface of the optical detector 18 serving as light detecting means. Thus, this optical detector 18 detects a light beam that is reflected by the signal recording surface of the optical disc 109 after being focused on the above-mentioned signal recording surface by the objective lens 4 .
[0050] In this optical pickup apparatus, in order to access a predetermined desired information track, as shown in FIG. 1 by arrow T, only the movable optical block 5 a need be moved in the tracking direction, where the objective lens 4 moves towards or away from the spindle shaft 10 a supporting the center portion of the optical disc 109 . Therefore, in this optical pickup apparatus, the movable optical system 5 can be activated and stopped at high speed and it is possible to shorten the time taken to access the desired information track.
[0051] Then, in this optical pickup apparatus, a parallel light beam that enters the movable optical system 5 from the fixed optical system 3 enters this movable optical system 5 via a light path L 1 parallel to the direction in which the objective lens 4 is movable as shown by arrow T in FIG. 1 and from the side on which the spindle motor 10 is provided. In other words, the fixed optical system 3 and the movable optical system 5 are arranged so as to face each other with the spindle motor 10 in between, such that they are on mutually opposite sides with respect to the spindle motor 10 .
[0052] Therefore, according to the optical pickup apparatus and the signal recording and/or reproducing apparatus, the fixed optical system 3 and the movable optical system 5 are placed so as to be substantially evenly distributed with respect to the center portion of the optical disc 109 that is supported at its center portion by the spindle shaft 10 a , and the fixed optical system 3 and the movable optical system 5 are kept within an area corresponding to a disc cartridge 116 in which this optical disc 109 is housed.
[0053] The disc cartridge 116 includes the optical disc 109 and a thin cartridge in which this optical disc 109 is housed rotatably. The cartridge has a principal surface portion substantially corresponding to a square that circumscribes the optical disc 109 .
[0054] Accordingly, the outer housing of this signal recording and/or reproducing apparatus can be made approximately the size of the disc cartridge 116 , namely, approximately the size of an area corresponding substantially to a square that circumscribes the optical disc 109 .
[0055] For example, if it is assumed that the diameter of the optical disc 109 is 50 mm, in configuring a small-sized signal recording and/or reproducing apparatus, the outer housing of this signal recording and/or reproducing apparatus can be made the size of a disc cartridge 116 in which the optical disc 109 is housed, that is, the outer housing of this recording and/or reproducing apparatus can be made to have a length of approximately 55 mm and a width of approximately 55 mm, thereby making it possible to reduce the size thereof sufficiently.
[0056] In this optical pickup apparatus and the signal recording and/or reproducing apparatus incorporating this optical pickup apparatus, a laser driver, which is a drive circuit of the laser diode, becomes a heat source. However, because this laser driver can be fixedly positioned within the signal recording and/or reproducing apparatus together with the fixed optical system 3 , it is possible to release heat from this laser driver to the chassis 2 of the signal recording and/or reproducing apparatus and the like in a desirable fashion.
[0057] The objective lens 4 in this optical pickup apparatus, as shown in FIG. 3, is supported on the movable optical block 5 a through a biaxial actuator 19 . This biaxial actuator 19 includes an actuator base 20 to be attached on the movable optical block 5 a and a lens holder 22 attached to this actuator base 20 through an elastic arm 21 and which holds the objective lens 4 . The lens holder 22 is capable of moving within a flat plane including two directions with respect to the actuator base 22 , namely, the optical axial direction of the objective lens 4 and the direction orthogonal to this optical axis, while elastically deforming the elastic arm 21 .
[0058] In this biaxial actuator 19 , a focusing coil and a tracking coil (not illustrated) are attached to the lens holder 22 . On the actuator base 20 , a magnet and a yoke (not illustrated) are attached. The magnet and the yoke form a magnetic circuit which places the focusing coil and the tracking coil inside a magnetic field it forms.
[0059] In this biaxial actuator 19 , when a drive current is supplied to the focusing coil, due to a mutual interaction between this current and the magnetic field formed by the magnetic circuit, the lens holder 22 is moved in the optical axial direction of the objective lens 4 , that is, in a focusing direction. In addition, in this biaxial actuator 19 , when a drive current is supplied to the tracking coil, due to a mutual interaction between this current and the magnetic field formed by the magnetic circuit, the lens holder 22 is moved in a direction orthogonal to the optical axial direction of the objective lens 4 , that is, in a tracking direction. In other words, in this biaxial actuator 19 , by feeding power to the focusing coil and the tracking coil, the lens holder 22 can move in any direction within a flat plane including the optical axial direction of the objective lens 4 and a direction orthogonal to this optical axis.
[0060] In this biaxial actuator 19 , the light beam that enters the objective lens 4 through the reflecting mirror 16 passes through a transmission hole 23 that is formed in a bottom plate portion of the actuator base 20 before entering the objective lens 4 .
[0061] In this biaxial actuator 19 , a focusing servo operation is performed by supplying to the focusing coil a drive current, which is based on a focus error signal indicating a distance in the optical axial direction of the objective lens 4 between a focal point of the objective lens 4 and the signal recording surface of the optical disc 109 . In addition, in this biaxial actuator 19 , a tracking servo operation is performed by supplying to the focusing coil and the tracking coil a drive current, which is based on a tracking error signal indicating a distance in the radial direction of the optical disc 109 between a focal point of the objective lens 4 and a recording track that is formed on the signal recording surface of the optical disc 109 . By performing such a focusing servo operation and tracking servo operation, the focal point of the objective lens 4 is always formed on a recording track on the signal recording surface of the optical disc 109 .
[0062] A skew adjustment mechanism for adjusting a skew (inclination) in the objective lens 4 with respect to the light beam that enters the objective lens 4 through the reflecting mirror 16 may be provided in this biaxial actuator 19 . This skew adjustment mechanism includes a spherical projection 24 formed in such a manner that the bottom surface portion of the actuator base 20 is spherically expanded to the side of the movable optical block 5 a , and a spherical seat 25 formed in a concave spherical shape for supporting the spherical projection 24 on the top surface portion of the movable optical block 5 a . Then, the actuator base 20 is pressed towards the side of the movable optical block 5 a at one end side as shown by arrow A in FIG. 3 by a compression coil spring 27 that is wound around a supporting column 26 that is provided on the movable optical block 5 a . At the same time, the actuator base 20 is supported, as shown by arrow B in FIG. 3, by having the other end side pulled to a certain position towards the side of the movable optical block 5 a by a pull screw 28 that is screwed into a screw hole that is formed in the top surface portion of the movable optical block 5 a.
[0063] In this skew adjustment mechanism, the position of the other end side of the actuator base 20 is determined by the position of the screw head of the pull screw 28 , and the spherical projection 24 and the spherical seat 25 are always in contact with each other due to the pressure exerted by the compression coil spring 27 . Accordingly, if such pull screws 28 are provided at positions in two or more directions from the optical axis of the objective lens 4 , it is possible to adjust the skew of the objective lens 4 with respect to the light beam that enters the objective lens 4 through the reflecting mirror 16 by adjusting the extent to which these pull screws are screwed into the screw holes in the movable optical block 5 a.
[0064] By virtue of this skew adjustment, a skew in the optical axis of the objective lens 4 with respect to the signal recording surface of the optical disc 109 can be prevented, and occurrences of aberration due to such skew can be suppressed.
[0065] Further, in this skew adjustment mechanism, assuming that the reflecting mirror 16 is also attached on the side of the actuator base 20 , it is possible to adjust the skew with respect to the signal recording surface of the optical disc 109 while keeping the positional relationship between the objective lens 4 and the reflecting mirror 16 constant. With such skew adjustment, it is possible to prevent the skew, with respect to the signal recording surface of the optical disc 109 , in the optical axis of the light beam that enters the objective lens from the reflecting mirror 16 , and it is possible to suppress occurrences of aberration due to such skew.
[0066] In addition, in this signal recording and/or reproducing apparatus, by inclining the spindle motor 10 with respect to the chassis 2 , the skew in the optical disc 109 with respect to the light beam emitted from the objective lens 4 may be adjusted. In this case, the spindle motor 10 , as shown in FIG. 4, is inserted and positioned in a transmission hole 29 , which is formed in the center portion of the chassis 2 , and is supported by the chassis 2 through an adjustment plate 30 that is attached to the bottom portion of the chassis 2 . The adjustment plate 30 can be easily deformed with one end side fixed to the chassis 2 , and by deforming this adjustment plate 30 , the inclination of the spindle motor 10 with respect to the chassis 2 can be adjusted. Then, in a state where the inclination of the spindle motor 10 with respect to the chassis 2 becomes optimum, the spindle motor 10 can be fixed by fixing a plurality of portions of the adjustment plate 30 to the chassis 2 by solder 31 so that the adjustment plate 30 cannot change its shape.
[0067] By way of such an adjustment of the inclination of the spindle motor 10 with respect to the chassis 2 , it is possible to prevent a skew in the signal recording surface of the optical disc 109 with respect to the optical axis of the light beam emitted from the objective lens 4 , and occurrences of aberration due to such skew can be suppressed.
[0068] In the above-described optical pickup apparatus, the angle by which the mirror 15 as the first deflection means deflects the parallel light beam is illustrated as 90 degrees. However, this angle is not limited to 90 degrees, and as shown in FIG. 5, the angle of the mirror 15 with respect to the light beam may be set to be smaller than 90 degrees or larger than 90 degrees.
[0069] In addition, the first deflection means, as shown in FIG. 6, may be a pentaprism 32 , which internally reflects the incident light beam twice before emitting it. This pentaprism 32 is a prism having the form of a pentangular column. The pentaprism 32 internally reflects the light beam entering from the first of the five peripheral surfaces with the third surface, internally reflects this light beam again with the fifth surface, and emits it from the second surface.
[0070] In this pentaprism 32 , the angle formed between the incident light beam and the emitted light beam is determined by the angle between the third surface and the fifth surface, by which the light beam is internally reflected, and thus is not affected by angle errors at attachment of the pentaprism 32 in the movable optical block 5 a . Accordingly, by making the first deflection means be the pentaprism 32 , it is possible to suppress occurrences of optical axis misalignment which are dependent upon the positional accuracy in attaching the pentaprism 32 to the movable optical block 5 a , and upon positional misalignment (movement) of the pentaprism 32 in the movable optical block 5 a due to environmental changes and changes over time.
[0071] Further, in the above-described embodiment, the second deflection means, which is the reflecting mirror 16 , may also be a pentaprism.
[0072] In addition, in the above-described embodiment, the first deflection means is provided in the movable optical system 5 . However, the first deflection means, as shown in FIG. 7, may be fixed at a position outside the movable optical system 5 , that is, it may be fixed as a part of the fixed optical system 3 .
[0073] In other words, in this case, the parallel light beam that is emitted from the beam splitter 8 of the fixed optical system 3 is reflected and deflected by the mirror 15 as the first deflection means that is fixed and provided in the signal recording and/or reproducing apparatus. Then, this parallel light beam is further reflected and deflected by a second mirror 15 a , which also serves as the first deflection means together with the mirror 15 , is led in a direction that crosses the optical axis of the objective lens 4 after traveling through a light path L 2 that is parallel to the direction in which the objective lens 4 is movable, and enters the movable optical system 5 from the side on which the spindle motor 10 is provided.
[0074] In addition, without using the first and second deflection means as described above, this optical pickup apparatus can be configured such that the parallel light beam, which has traveled through a light path parallel to the direction in which the objective lens 4 is movable, enters the movable optical system 5 from the side on which the spindle motor 10 is disposed. For example, the light beam emitted from the beam expander may be directly led to the objective lens 4 using a light guiding element such as an optical fiber.
[0075] The signal recording and/or reproducing apparatus according to the present invention, as described above, is equipped with the optical pickup apparatus and the spindle motor 10 on the chassis 2 , and further, as shown in FIG. 8, is equipped with an electronic circuit unit having a servo control circuit 33 and a system controller 34 and the like.
[0076] In this signal recording and/or reproducing apparatus, the spindle motor 10 is controlled by the servo control circuit 33 and the system controller 34 , and is driven at a certain rotation rate. An optical pickup apparatus 35 may write and read information signal on and from the optical disc 109 that is rotated by the spindle motor 10 . The movable optical system 5 of this optical pickup apparatus 35 is actuated by a motor 36 in a radial direction of the optical disc 109 that is mounted on the disc table 12 . The optical pickup apparatus 35 and the motor 36 are also controlled by the servo control circuit 33 .
[0077] The optical pickup apparatus 35 irradiates a light beam on the signal recording surface of the optical disc 109 , and by detecting a reflected light beam, it reads information signals from the signal recording surface. The signal that is read from the optical disc 109 by the optical pickup apparatus 35 is amplified by a preamplifier 37 and is transmitted to a signal modulation/demodulation and ECC (error correction code) block 38 and the servo control circuit 33 . The signal modulation/demodulation and ECC block 38 , in accordance with the kind of optical disc that is played, may add modulation, demodulation and ECC to the signal. In addition, the signal modulation/demodulation and ECC block 38 , based on the transmitted signal, may generate a focus error signal, a tracking error signal, a track identification signal, an RF signal or the like. The servo control circuit 33 may control the optical pickup apparatus 35 based on the focus error signal, the tracking error signal, the track identification signal, and the RF signal generated by the signal modulation/demodulation and ECC block 38 .
[0078] A signal that is demodulated by the signal modulation/demodulation and ECC block 38 may be transmitted to an external computer 40 or the like through an interface 39 if this signal is, for example, data for storage. In this case, the external computer 40 or the like is capable of receiving the signal recorded on the optical disc 109 as a reproduced signal.
[0079] In addition, the optical pickup apparatus 35 , based on the signal that is transmitted from the signal modulation/demodulation and ECC block 38 , may irradiate a light beam onto the signal recording surface of the optical disc 109 that is rotated by the spindle motor 10 . By way of such irradiation of a light beam, an information signal is written on the signal recording surface of the optical disc 109 .
[0080] Since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalents of the claims are intended to be embraced therein.
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While supporting an optical disc having a recording density that is higher than conventional optical discs by shortening the wavelength of the emitted light and increasing the numerical aperture (NA) of an objective lens, a reduction in the size of an optical pickup apparatus relative to the size of a disc cartridge that houses the optical disc is achieved. The present invention includes a fixed optical system having a built-in light source, and a movable optical system having an objective lens. A parallel light beam that enters the movable optical system from the fixed optical system enters the movable optical system via a light path that is parallel to the direction in which the objective lens is movable and from the side on which a spindle motor is provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to water-soluble synthetic glycosyl orthoesters of vitamin D, and their use in the regulation of calcium metabolism.
2. Description of the Background Art
Vitamin D 3 deficiency, or disturbances in the metabolism of vitamin D 3 cause such diseases as rickets, renal osteodystrophy and related bone diseases, as well as, generally, hypo- and hyper-calcemic states. Vitamin D 3 and its metabolites are therefore crucial in maintaining normal development of bone structure by regulating blood calcium levels.
Vitamin D 3 is rapidly converted to 25-OH-D 3 in the liver. In response to hypocalcemia, 25-OH-D 3 , the major circulating metabolite of the vitamin, undergoes further metabolism in the kidney to 1,25-(OH) 2 D 3 . 1,25-(OH) 2 D 3 acts more rapidly than either D 3 , or 25-OH-D 3 . Additionally, the dihydroxy form of the vitamin is 5-10 times more potent than D 3 , and about 2-5 times more potent than the monohydroxy form of the vitamin, in vivo, provided it is dosed parenterally and daily (Napoli, J. L. and Deluca, H. F., "Blood Calcium Regulators" and references cited therein in: Burger's Medicinal Chemistry, 4th Ed., part II, edited by Manfred Wolf, Wiley-Interscience, 1979, pp. 725-739).
Vitamin D 2 , vitamin D 3 or their metabolites which are hydroxylated at positions 1; 1,25; 1,24,25; 24,25; 25,26; or 1,25,26 are water-insoluble compounds. When a drug is relatively insoluble in an aqueous environment or in the gastrointestinal lumen, post-administration dissolution may become the rate-limiting step in drug absorption. On the other hand, with water-soluble drugs, dissolution occurs rapidly and thus facilitates transport through blood and to the site of activity. It would therefore be desirable to provide a form of vitamin D (D 3 or D 2 ) which is hydrophilic and/or water-soluble, yet preserves the normal biological properties of the water-insoluble drug.
The extracts from the leaves of a South American plant, Solanum malacoxylon (hereinafter "S.m."), have been demonstrated to contain a water-soluble principle which is different than 1,25(OH) 2 D 3 and which, upon treatment with glycosidase enzymes yields 1,25(OH) 2 D 3 , plus a water-soluble unidentified fragment. (See, for example, Haussler, M. R., et al., Life Sciences, Volume 18: 1049-1056 (1976); Wasserman, R. H., et al., Science 194: 853-855 (1976); Napoli, J. L., et al., The Journal of Biological Chemistry, 252: 2580-2583 (1977)).
A very similar water-soluble principle, which upon treatment with glycosidases also yields 1,25-dihydroxy vitamin D 3 , is found in the plant Cestrum diurnum (hereinafter "C.d."); Hughes, M. R., et al., Nature, 268: 347-349 (1977)). The water soluble extracts for S.m. or C.d. have biological activity which is similar to that of 1,25-dihydroxy vitamin D 3 .
The only evidence concerning the structure of the water-soluble fragment released during glycosidase treatment of the water-soluble principles from these plants is indefinite. The authors of the aforementioned publications have concluded that the structure is probably a glycoside, on the basis of enzymatic evidence, the water-solubility, and the use of chemical detection reagents (Peterlik, N. and Wasserman, R. H., FEBS Lett. 56: 16-19 (1973)). Humphreys (Nature (London) New Biology 246: 155 (1973)), however, has cast some doubt on this conclusion since he demonstrated that the Molisch carbohydrate test was negative for the principle.
Since it is known that the molecular weight of the water-soluble vitamin D 3 -containing principle, prior to enzymatic release, is considerably greater than 1000 (Humphreys, D. J., Nature (London) New Biology 246: 155 (1973)), the molecular weight of the water-soluble conjugated fragment released by enzymatic hydrolysis can be calculated to be considerably greater than 584, the molecular weight of dihydroxy vitamin D 3 being 416. Thus, if the water-soluble fragment released by enzymatic hydrolysis were in fact a glycoside, it would contain more than 3 glycosidic (glycopyranosyl or glycofuranosyl) units.
Moreover, the results of enzymatic release are fully consistent with a wide variety of structures. For example, Haussler, M. R., et al., Life Sciences 18: 1049-1056 (1976) disclose the use of mixed glycosidases derived from Charonia lampus to hydrolyze the water-soluble principle. This enzyme is really a mixture of enzymes, as follows (Miles Laboratories, 1977 catalog): β-glucosidase (11 units), α-mannosidase (33 units), β-mannosidase (5.2 units), α-glucosidase (4.8 units), β-galactosidase (44 units), α-galactosidase (26 units), α-fucosidase (24 units), β-xylosidase (8.2 units), β-N-acetylglucosaminidase (210 units), α-N-acetylgalactosaminidase (41 units), and β-N-acetyl-galactosaminidase (25 units). Peterlik, M., et al. (Biochemical and Biophysical Research Communications, 70: 797-804 (1976)) in their study of the S.m. extract with β-glucosidase (almond) from Sigma Chemical Company, utilized an enzyme that also contained β-D-galactosidase, and α-D-mannosidase activities (Sigma Chemical Company, February 1981 Catalog; see also, Schwartz, J., et al., Archives of Biochemistry and Biophysics, 137: 122-127 (1970)).
In sum, the results observed by these authors are consistent with a wide range of structures, none of which have been well characterized but which, even if proven to be glycosides, contain at least more than 3 glycosidic units per vitamin D unit.
Holick, et al., U.S. Pat. No. 4,410,515 describe water-soluble glycoside derivatives of Vitamin D which are biologically active. Furst, et al., Helv. Chim. Acta, 66: 2093 (1983) have also synthesized Vitamin D glycopyranosyl derivatives.
A need, however, continues to exist for other well-defined, well-characterized water-soluble forms of vitamin D, which will be hypocalcemically active and maintain calcium and phosphorus homeostasis.
SUMMARY OF THE INVENTION
The present invention thus provides:
A synthetic compound which is biologically active in maintaining calcium and phosphorous homeostasis in animals, selected from the group consisting of formula (IA) and (IB): ##STR3## wherein the bond between carbons C-22 and C-23 is single or double; Y is hydrogen, F, --CH 3 or --CH 2 CH 3 ;
Z is F, H or X;
Y' is H, --CH 3 or --CH 2 CH 3 ;
Z' is F or H;
Q a is CF 3 or CH 2 X;
Q b is CF 3 or CH 3 ;
wherein X is selected from the group consisting of hydrogen and --OR 1 , where --R 1 is hydrogen or an orthoester glycoside moiety of the formula (II) ##STR4## where A represents a glucofuranosyl or glucopyranosyl ring; R 2 is hydrogen, lower alkyl, aralkyl, or aryl (including both endo and exo isomers); and R 3 is hydrogen or a straight or branched chain glycosidic residue containing 1-100, especially 1-20 glycosidic units per residue;
with the proviso that at least one of said R 1 is an orthoester glycoside moiety of formula (II).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides well-defined water-soluble forms of vitamin D 3 and D 2 , as well as hydroxylated derivatives of these vitamins. The compounds of the present invention may in many instances be crystalline.
By glycosidic units are meant glycopyranosyl or glycofuranosyl, as well as their amino sugar derivatives. The residues may be homopolymers, random, or alternating or block copolymers thereof. The glycosidic units have free hydroxy groups, or hydroxy groups acylated with a group ##STR5## wherein R 2 is hydrogen, lower alkyl, aryl or aralkyl. Preferably R 2 , as defined previously, is C 1 -C 6 alkyl, most preferably acetyl or propionyl; phenyl, nitrophenyl, halophenyl, lower alkyl-substituted phenyl, lower alkoxy substituted phenyl, and the like; or benzyl, nitrobenzyl, halobenzyl, lower alkyl-substituted benzyl, lower alkoxy-substituted benzyl, and the like.
When the compounds of formula (I) have a double bond at position C-22, they are derivatives of vitamin D 2 ; whereas, if the bond at that position is single, and there is a lack of a C 24 alkyl they are derivatives of vitamin D 3 . The latter are preferred.
The compounds of the invention contain at least one orthoester glycoside moiety of formula (II) at positions 1, 3, 24, 25 or 26. They may, however, contain more than one, and up to five such radicals simultaneously. The orthoester moiety of formula (II) may comprise a glucofuranosyl moiety or a glucopyranosyl moiety in its first unit.
A glucopyranosyl moiety results in an orthoester moiety of formulae (III), (IV) or (V): ##STR6## where R 4 is R 2 or R 3 , and where R 2 and R 3 have the meanings given above.
A glucofuranosyl moiety results in an orthoester radical of formulae (VI) or (VII): ##STR7## where R 4 is R 2 or R 3 , and R 2 and R 3 have the meanings given above.
Preferred are those compounds derived from vitamins D 3 or D 2 ; 1-hydroxy-vitamins D 3 or D 2 ; 1,25-dihydroxy vitamins D 3 or D 2 ; 24,25-dihydroxy vitamins D 3 or D 2 ; 25,26-dihydroxy vitamins D 3 or D 2 ; 1,24,25-trihydroxy vitamins D 3 , or D 2 . Most preferred among these are vitamins D 3 or D 2 ; 1-hydroxy-vitamins D 3 or D 2 ; and 1,25-dihydroxy-vitamins D 3 or D 2 .
In the case of multihydroxylated forms of the vitamins (e.g.: 1,25-dihydroxy-vitamin D 3 has three hydroxy groups, at positions 1, 3 and 25), the preferred compounds of the invention are those wherein less than all of the multiple hydroxy groups are substituted with a radical of formula (II).
The glycoside residues R 3 can comprise up to 100, especially up to 20 glycosidic units. Preferred, however, are those having less than 10, most preferred, those having 3 or less than 3 glycosidic units. Specific examples are those containing 1 or 2 glycosidic units in the glycoside residue R 3 .
The glycopyranose or glycofuranose rings or amino derivatives thereof, whether part of the moiety of formula (II) or part of the glycosidic residue R 3 , may be fully or partially acylated or completely deacylated. The completely or partially acylated glycosyl orthoesters are useful as intermediates for the synthesis of the deacylated materials.
Among the possible glycopyranosyl structures useful in R 3 are glucose, mannose, galactose, gulose, allose, altrose, idose, or talose. Among the glycofuranosyl structures useful in R 3 , the preferred ones are those derived from fructose, or arabinose. Among preferred diglycosides are sucrose, cellobiose, maltose, lactose, trehalose, gentiobiose, and melibiose. Among the triglycosides, the preferred ones may be raffinose or gentianose. Among the amino derivatives are N-acetyl-D-galactosamine, N-acetyl-D-glucosamine, N-acetyl-D-mannosamine, N-acetylneuraminic acid, D-glucosamine, lyxosylamine, D-galactosamine, and the like.
Among the possible glycopyranosyl structures useful in moiety (II) are glucose, galactose or gulose. Among the glycofuranosyl structures useful in moiety (II) are those derived from arabinose. Diglycosides useful in moiety (II) include cellobiose, maltose, lactose, gentiobiose and meliobiose. Among the triglycosides useful in moiety (II) are maltotriose, cellotriose, and panose. An example of an amino derivative is 3-amino-3,6-dideoxy-D-galactose.
When more than one glycosidic unit per R 3 is present on a single hydroxy group (i.e., di or polyglycosidic residues), the individual glycosidic rings may be bonded by 1-1, 1-2, 1-3, 1-4, 1-5 or 1-6 bonds, most preferably 1-2, 1-4, and 1-6. The linkages between individual glycosidic rings may be alpha or beta.
The configuration of the oxygen linkage of a hydroxy group, or orthoester glycoside moiety (II) attached to the Vitamin D 3 or D 2 molecule may be either alpha (out of the plane of the paper) or beta (into the plane of the paper). It is preferred if the configuration of the 3-hydroxy or orthoester glycoside moiety (II) at C-3 be beta, and that, independently or simultaneously, the configuration of the hydroxy or orthoester glycoside moiety (II) at C-1 be alpha. It is also preferred that the configuration around C-24 be R. When, at C-24, X=H and R 2 =--CH 3 or --CH 2 CH 3 , the configuration at C-24 is preferably S.
In one embodiment, the carbon at position 24 of the Vitamin D moiety may be substituted by two F atoms. In another embodiment, the 26 and 27 methyl groups of the Vitamin D moiety are replaced by CF 3 groups, and X at position 25 is an OR 1 group.
Specific examples of compounds of the invention are:
1α-(α-D-maltosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-(α-D-lactosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-(α-D-gentiobiosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α,25-dihydroxyvitamin D 3 , 3β-(a-D-glycopyranosyl-1',2'-orthoacetate);
1α,25-dihydroxy-26,27-hexafluorovitamin D 3 , 3β-(α-D-glucopyranosyl-1',2'-orthoacetate);
1α,25-dihydroxy-24,24-difluoro Vitamin D 3 , 3β-(α-D-glucopyranosyl-1',2'-orthoacetate);
1α-(α-D-glucopyranosyl-1',2'-orthoacetate)-25-hydroxy-Vitamin D 3 ;
1α-hydroxy, 25-(α-D-cellobiosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-hydroxy, 25-(α-D-maltosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-hydroxy, 25-(α-D-lactosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-hydroxy, 25-(α-D-gentiobiosyl-1',2'-orthoacetate)-Vitamin D 3 ;
Vitamin D 3 , α-D-glucopyranosyl-1',2'-orthoacetate;
Vitamin D 3 , α-D-cellobiosyl-1',2'-orthoacetate;
Vitamin D 3 , α-D-maltosyl-1',2'-orthoacetate;
Vitamin D 3 , α-D-lactosyl-1',2'-orthoacetate;
Vitamin D 3 , α-D-gentiobiosyl-1',2'-orthoacetate;
1α-hydroxyvitamin D 3 , 3β-(α-D-glucopyranosyl-1',2'-orthoacetate);
1α-hydroxyvitamin D 3 , 3β-(α-D-cellobiosyl-1',2'-orthoacetate);
1α-hydroxyvitamin D 3 , 3β-(α-D-maltosyl-1',2'-orthoacetate);
1α-hydroxyvitamin D 3 , 3β-(α-D-gentiobiosyl-1',2'-orthoacetate);
1α-(α-D-glucopyranosyl-1',2'-orthoacetate)-Vitamin D 3 ;
1α-(α-D-cellobiosyl-1',2'-orthoacetate)-Vitamin D 3 .
All of the aforementioned derivatives can also be prepared with Vitamin D 2 .
The derivatives of Vitamins D of the present invention can be prepared by standard synthetic methods well known to those skilled in the art. These methods depend on whether the starting Vitamin D 3 or Vitamin D 2 contains one or more hydroxy groups. When the vitamin contains only one hydroxy group, the syntheses are straightforward, since the monohydroxylated Vitamin D (hydroxylated at position 3) is treated with silver trifluoromethanesulphonate (triflate) and the proton acceptor 2,4,6-trimethylpyridine (collidine) in an inert solvent such as dichloromethane, benzene or toluene, to which is added a fully acylated glycoside or fully acylated straight or branched chain glycosidic polymer, either of these containing an appropriate leaving group (L.G.) at position C-1' of the terminal ring (or on the single ring, as called for). Condensation occurs according to the following reaction, indicated here for a single glycosyl orthoester for the purpose of illustration only: ##STR8##
In this reaction sequence, R 2 is as defined previously, LG is a common leaving group such as bromine, chlorine, iodine, p-toluenesulfonyl, and the like, capable of being replaced in a bimolecular nucleophilic substitution reaction.
When the Vitamin D 3 or D 2 is reacted with a glycosidic polymer, one or more of the OCOR 2 groups in the glycopyranoside or glycofuranoside rings is replaced by a fully acylated glycosidic unit, with the proviso that the total number of glycosidic units not exceed 100, preferably 20.
The reaction is carried out at from -70° C. to room temperature or above for a period of 1-10 hours, and is thereafter cooled and filtered to remove the silver salt. The filtrate is dried and the inert solvent is evaporated. The resulting product can be purified by any of the standard modern purification methods such as high performance liquid chromatography, silicic acid chromatography, thin layer preparative chromatography, and the like.
After separation of the individual products, the glycosidic residues are deacylated in base, such as with a strong base ion exchange resin, such as Amberlyst A-26(OH). Further purification by high performance chromatography is usually indicated to obtain the highly purified product.
When the starting Vitamin D (D 3 or D 2 ) carries two hydroxy groups (such as in 1-hydroxy Vitamin D 3 , or 25-hydroxy Vitamin D 3 ) one of these may need to be selectively protected with a protecting group which can be ultimately removed after the condensation, and before, during and after the deacylation of the glycosidic residues. The same is true if three or more hydroxy groups are present in the vitamin starting materials, and less than all of these require to be glycosylated.
The selective protection of hydroxy groups in the starting materials can be carried out by using standard protection and deprotection reactions, well known to those skilled in organic chemistry.
Because each of the hydroxyl groups on the Vitamin D molecule have different reactivities either due to the fact that they are either primary (e.g., 26-OH), secondary (e.g., 24-OH), 3β-OH, etc.) or tertiary (e.g., 25-OH) hydroxyl functions, selectivity can be achieved. Furthermore, because of steric considerations the 3β-OH has different reactivity than the 1 --OH which is both a vicinyl hydroxyl function as well as sterically hindered by the exocyclic C 19 methylene function on C 10 . A good example of these reactivities is illustrated in Holick et al., Biochemistry: 10, 2799, 1971, where it is shown that the trimethylsilyl ether derivative of 1,25-(OH) 2 -D 3 can be hydrolyzed in HCl--MeOH under mild conditions to yield 3,25-disilyl ether, and 25-monosilyl ether derivatives of 1,25-(OH) 2 -D 3 . Furthermore, to obtain a 1,25-(OH) 2 -D 3 whereby the 3 and 1 hydroxyls are protected, the 25-monosilyl ether derivative of 1,25-(OH) 2 -D 3 can be acetylated to form the 1,25-(OH)-2-D 3 -1,3-diacetyl-25-trimethyl silyl ether. Because the acetates are quite stable to acid hydrolysis, this derivative can be acid hydrolyzed to yield 1,3-diacetoxy-25-hydroxyvitamin D 3 . An alternative approach would simply be to acetylate 1,25-(OH) 2 -D.sub. 3 in acetic anhydride in pyridine at room temperature for 24 to 48 h. to yield 1,3-diacetoxy-25-hydroxyvitamin D 3 .
For protecting the 25-hydroxyl group for 25-hydroxyvitamin D 3 the following can be done: 25-OH-D 3 can be completely acetylated in acetic anhydride and pyridine under refluxing conditions for 24 h. The 3-Ac can be selectively removed by saponification (KOH in 95% MeOH-water) at room temperature for 12 h.
Once the desired protected Vitamin D derivative is prepared, the same is reacted with silver triflate and collidine or other methods for coupling (as described e.g. by Igarashi, K., in Advances in Carbohydrate Chemistry and Biochemistry," Vol. 34, 243-283, or Banoub, J., Can. J. Chem., 57: 2091-2097 (1979), and the glycosidic or polyglycosidic residue as in scheme I above, followed by deacylation, deprotection and purification. Among the starting vitamin D derivatives which are readily available, are, for example:
Vitamin D 3 ;
Vitamin D 2 ;
1-hydroxy-Vitamin D 3 ;
1-hydroxy-Vitamin D 2 ;
25-OH-Vitamin D 3 ;
25-OH-Vitamin D 2 ;
1,24-(OH) 2 -Vitamin D 3 ;
1,25-dihydroxy-Vitamin D 3 ;
1,25-dihydroxy-Vitamin D 2 ;
24,25-dihydroxy-Vitamin D 3 ;
25,26-dihydroxy-Vitamin D 3 ;
24,25-dihydroxy-Vitamin D 2 ;
1,24,25-trihydroxy-Vitamin D 3 ;
1,25,26-trihydroxy-Vitamin D 3 .
Some materials, such as 25,26-Vitamin D 2 , 1,24,25-trihydroxy Vitamin D 2 or 1,25,26-trihydroxy Vitamin D 2 have not yet been fully identified in the art, but can nevertheless be used if synthetically prepared.
The acylated glycoside containing a leaving group at position C-1' of the first (or only) glycosidic ring can be prepared, for example, by the methods of Fletcher, H. G., Jr., Methods in Carbohydrate Chemistry 2: 228 (1963), or Bonner, W. A., Journal of Organic Chemistry 26: 908-911 (1961), or Lemieux, R. U., Methods in Carbohydrate Chemistry, Vol. II, 221-222.
The 26,26,26,27,27,27 hexafluoro, 1α,25 dihydroxy Vitamin D 3 can be made according to the method of De Luca et al., Belgium BE No. 896,830.
Oligosaccharide intermediates can be prepared, for example, by the methods of Lemieux, R. U., J. of Amer. Chem. Soc. 97: 4063-4069 (1975); or Frechet, J. M. J., Polymer-Supported Reactions in Organic Synthesis (1980) 407-434, or Kennedy, J. F., Carbohydrate Chemistry 7:496-585 (1975).
Commercially available sugars include (Pfanstiehl Laboratories, Inc.): Pentoses, such as: D-Arabinose, L-Arabinose, D-Lyxose, L-Lyxose, D-Ribose, D-Xylose, L-Xylose; Hexoses, such as: Dextroses, D-Fructose, D-Galactose, α-D-Glucose, β-D-Glucose, L-Glucose, Levulose, D-Mannose, L-Mannose, L-Sorbose; Heptoses, such as: D-Glucoheptose, D-Mannoheptulose, Sedoheptulosan; Disaccharides, such as: Cellobiose, 3-O-β-D-Galactopyranosyl-D-arabinose, Gentiobiose, Lactoses, α-Lactulose, Maltose, α-Melibiose, Sucrose, Trehalose, Turanose; Trisaccharides, such as: Melezitose, Raffinose; Tetrasaccharides, such as: Stachyose; Polysaccharides and derivatives, such as: Arabic Acid, Chitin, Chitosan, Dextrin, Cyclo-Dextrins, Glycogen, and Inulin.
Alternatively, the whole synthetic sequence (protection, condensation and deprotection) can be carried out starting with a Δ 5 ,7 steroidal diene which is a provitamin D of any D compound. After orthoesterification, the provitamin is ring-opened photochemically, and the resulting previtamin is thermally rear-ranged to yield orthoesterified vitamin.
It is known (Napoli, J. L. and DeLuca, H. F., in Burger's Medicinal Chemistry 4th Ed., part II, page 728 ff) that the active form of Vitamin D is 1,25-dihydroxy-Vitamin D 3 . When 1,25-dihydroxy-Vitamin D 3 orthoester is used in the treatment of hypocalcemic states, or in the regulation of phosphorus and calcium metabolism in an animal, especially in a human, endogenous hydrolysis, some of which by enzymes of the animal, directly release the active form of the vitamin. On the other hand, when non-hydroxylated derivatives of the vitamin are used (such as, e.g., Vitamin D 3 orthoester), release of the hydroxylated vitamin is followed by hydroxylation in the liver and then in the kidney in order to form the active 1,25-dihydroxy Vitamin.
The water-soluble Vitamin D conjugates of the present invention include hydrophilic derivatives of good water solubility to derivatives of excellent water solubility. They can be used generally in any application where the use of Vitamin D 3 , Vitamin D 2 or hydroxylated derivatives thereof has been called for in the prior art. The advantage of the conjugates of the invention resides in their water-solubility and thus their ease of administration in aqueous media such as, for example, saline or aqueous buffers. This allows the utilization of these conjugates in such devices as Vitamin D releasing in-line pumps, intravenous dispensation and the like. Other advantages include treatment of fat malabsorption syndromes, as well as release of the biologically active form of Vitamin D 3 in the gut, e.g. 1,25-(OH) 2 -D 3 glycosyl orthoester→gut→1,25(OH) 2 -D 3 →biological action.
The conjugates of the invention can be administered by any means that effect the regulation of calcium and phosphorus homeostasis and metabolism in animals, especially humans. For example, administration can be topical, parenteral, subcutaneous, intradermal, intravenous, intramuscular, or intraperitoneal. Alternatively, or concurrently, administration can be by the oral route. The dosage administered will be dependent upon the age, health and weight of the recipient, kind of concurrent treatment if any, frequency of treatment, and the nature of the effect desired. Generally, from 0.01 μg to 10 μg per kg per application, in one or more applications per therapy, is effective to obtain the desired result.
An additional, unexpected property of the compounds of the invention is that some of them may demonstrate promotion of calcium absorption through the intestine without effecting calcium mobilization brought about by calcium release from bones. Calcium mobilization by bone release is a common feature of 1,25-dihydroxy vitamin D 3 . Its selective absence in some of the compounds of the invention has a beneficial therapeutic consequence by promoting an increase in serum calcium levels by stimulating intestinal calcium transport. It is disadvantageous for patients with severe bone disease to maintain serum calcium levels at the expense of mobilizing calcium from their wasting bones.
The compounds can be employed in dosage forms such as tablets, capsules, powder packets or liquid solutions, suspensions or elixirs for oral administration, or sterile liquids for formulations such as solutions or suspensions for parenteral use. In such compositions, the active ingredient will ordinarily always be present in an amount of at least 1×10 -6 % by wt. based upon the total weight of a composition, and not more than 90% by wt. An inert pharmaceutically acceptable carrier is preferably used. Among such carriers are 95% ethanol, vegetable oils, propylene glycols, saline buffers, etc.
Having now generally described this invention, a more complete understanding can be obtained by reference to certain examples, which are included herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
Preparation of Vitamin D 3 , α-D-glucopyranosyl-1',2'orthoacetate
Reaction of Vitamin D 3 with Acetobromoglucose
To a solution of Vitamin D 3 (38.5 mg., 0.100 mmole) in dry CH 2 Cl 2 (2 ml) was added silver trifluoromethanesulphonate (56.5 mg, 0.220 mmole), 2,4,6-trimethylpyridine (30 μl, 0.227 mmole), and a solution of acetobromoglucose (80.3 mg, 0.195 mmole) in CH 2 Cl 2 (3 ml). After stirring in the dark under N 2 for 2 h. at 0° and then 4 h. at room temperature, the suspension was diluted with CH 2 Cl 2 and filtered through Celite. The filtrate was washed successively with H 2 O, 0.1M H 2 SO 4 , saturated KHCO 3 , and H 2 O and then co-evaporated with 100% EtOH under N 2 . The resulting oil was purified by preparative thin-layer chromatography using 20% EtOAc in hexane, giving 25.2 mg (35.2%) of Vitamin D 3 3',4',6'-tri-O-acetyl-α-D-glucopyranosyl-1',2'-orthoacetate (R f 0.28). Its UV spectrum in CH 3 OH had an absorbance maximum of 265 nm and an absorbance minimum of 228 nm, characteristic of the 5,6-cis-triene chromophore in Vitamin D. Its mass spectrum exhibited a peak for the parent molecular ion at m/e 714. Its 1 HMR spectrum (CDCl 3 ) showed the signal for H-1' as a doublet at 5.70 with a coupling constant of 5.12 Hz. Other characteristic 1 HMR signals are as follows: 0.54 (s, 3H, Me-18); 0.86 and 0.88 (2s, 6H, Me 2 -26,27); 0.92 (d, 3H, J 5.92 Hz, Me-21); 1.76 (s, 3H, C--CH 3 ); 2.10, 2.12, 2.14 (3s, 9H, AcO-); 4.35 (m, 1H, H-3); 3.81-5.20 (m, 6H, H-2', H-3', H-4', H-5', 2H-6'); 4.81 (bs, 1H, H-19); 5.03 (bs, 1H, H-19); 6.01 and 6.21 (AB quasi , 2H, J 11.12 Hz, H-6,7).
Deacetylation
The strong base ion-exchange resin, Amberlyst A-26 (OH), obtained by treating Amberlyst A-26 with NaOH soln., was used for deacetylation because it avoids the problem of removing ionic salts (which accompany deacetylation) from a water-soluble product. A mixture of Vitamin D 3 3',4',6'-tri-O-acetyl-α-D-glucopyranosyl-1',2'-orthoacetate (35.2 mg, 0.0492 mmole) and Amberlyst A-26 (OH) (185 mg) in 15 ml of CH 3 OH was refluxed under N 2 for 4 h. The resin beads were filtered off, and the filtrate was concentrated under N 2 . The resulting oil was purified by preparative thin-layer chromatography using 5% hexane in ethyl acetate, giving 22.5 mg (83.5%) of the product (R f 0.5). The UV spectrum of Vitamin D 3 α-D-glucopyranosyl-1',2'-orthoacetate, had λ max 265 nm and λ min 228 nm. The 1 HMR signal for H-1' was a doublet at δ 5.67 with a coupling constant of 5.63 Hz. Other 1 HMR signals (CD 3 OD) include: δ 0.55 (s, 3H, Me-18); 0.86 and 0.89 (2s, 6H, Me 2 -26,27); 0.94 (d, 3H, J 6.14, Me-21); 1.68 (s, 3H, C--CH 3 ); 3.30-3.87 (m, 6H,H-2',H-3',H-4',H-5',2H-6' ); 4.25 (m, 1H, H-3); 4.74 (d, 1H, J 1.4 Hz, H-19); 5.03 (bs, 1H, H-19); 6.03 and 6.21 (AB quasi , 2H, J 11.00 Hz, H-6,7).
The Vitamin D3,α-D-glucopyranosyl-1',2'-orthoacetate and the 25 OH derivative were tested for biological activity. Male weanling rats from Holtzmann Company, Madison, Wisc., U.S.A., were fed a Vitamin D deficient diet that was adequate in phosphorus and low in calcium (0.02%) for 31/2 weeks. Groups of five animals received orally either 0.25 μg in 50 μl of 95% ethanol, or vehicle alone. 24 hours later the animals were sacrificed and the small intestine and blood were collected. Intestinal calcium transport studies were performed by the everted gut sac technique, and blood was used for serum calcium determinations.
The results are shown in the following Table 1:
TABLE 1______________________________________BIOASSAYCompound I/O Serum Calcium______________________________________Control 1.7 ± 0.12 4.7 ± 0.1Vitamin D.sub.3 (325 pmoles) 3.3 ± 0.2 5.7 ± 0.16Vitamin D.sub.3 -α-D-glucopyranosyl- 3.0 ± 0.2 5.0 ± 0.11',2'-orthoacetate (325 pmoles)25-OH--D.sub.3 -α-D-glucopyranosyl- 3.7 ± 0.1 6.6 ± 0.21',2'-orthoacetate (325 pmoles)______________________________________
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A compound which is biologically active in maintaining calcium and phosphorous metabolism in animals, selected from the group consisting of formula (IA) and (IB): ##STR1## wherein the bond between carbons C-22 and C-23 is single or double; Y is hydrogen, F, --CH 3 or --CH 2 CH 3 ; Z is F, H or X; Y' is H, --CH 3 or --CH 2 CH 3 ; Z' is F or H; Q a is CF 3 or CH 2 X; Q b is CF 3 or CH 3 ; X is selected from the group consisting of hydrogen and --OR 1 , wherein R 1 is hydrogen or an orthoester glycoside radical of the formula (II) ##STR2## where A represents a glucofuranosyl or glucopyranosyl ring; R 2 is hydrogen, lower alkyl, aralkyl, or aryl; and R 3 is hydrogen or a straight or branched chain glycosidic residue containing 1-100 glycosidic units per residue; with the proviso that at least one of the R 1 is an orthoester glycoside moiety of formula (II).
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BACKGROUND OF INVENTION
Power supplied to an integrated circuit (IC) occurs through a power distribution network. The power distribution network starts with a power supply that generates an appropriate DC voltage. The power supplied to the IC must traverse from the power supply across the power distribution network before the power reaches the IC. The power distribution network has characteristics that may affect the operation of the IC.
FIG. 1 shows a conventional printed circuit board system ( 10 ). The printed circuit board system ( 10 ) includes a printed circuit board (PCB) ( 12 ). The PCB ( 12 ) is a central platform on which various components are mounted. The PCB ( 12 ) has multiple layers that contain traces that connect the power supply and signals to the various components mounted on the PCB ( 12 ). Two layers, a system power supply layer ( 14 ) and a system ground layer ( 16 ), are shown in FIG. 1 .
The system power supply layer ( 14 ) and the system ground layer ( 16 ) provide power to an IC ( 20 ). The power supplied to the IC ( 20 ) traverses the system power supply layer ( 14 ) and the system ground layer ( 16 ) from a DC source (not shown) to a package ( 18 ) on which the IC ( 20 ) is mounted. Other components are also mounted on the PCB ( 12 ) that generally attempt to maintain a constant voltage supplied to the IC ( 20 ). These components may include, but are not limited to, an air-core inductor ( 24 ), a power supply regulating integrated circuit ( 26 ), switching transistors ( 28 ), a tantalum capacitor ( 30 ), and electrolytic capacitors ( 32 ).
A variety of different types and different locations of capacitors are used to help maintain a constant voltage supplied to the IC ( 20 ). Electrolytic capacitors ( 32 ) mounted on the PCB ( 12 ) connect between the system power supply layer ( 14 ) and the system ground layer ( 16 ). The package ( 18 ), similar to the PCB ( 12 ), may include multiple planes and interconnections between the planes to provide a connective substrate in which power and data signals traverse. Ceramic capacitors ( 22 ) mounted on the package ( 18 ) connect between a package power supply signal (not shown) and a package ground signal (not shown).
Due to active switching of circuit elements on the IC ( 20 ), the power required by the IC ( 20 ) changes. The active switching causes power supply noise. Additional components may be included to minimize such power supply noise. For example, ceramic capacitors ( 22 ) near the IC ( 20 ) act as local power supplies by storing and dissipating charge as needed.
The addition of components reduces the power supply impedance at most frequencies; however, localized impedance peaks may exist. The impedance peaks indicate a power supply resonance. The power supply resonance is formed when parasitics in the power distribution network and components connected to the power distribution network are excited at a particular frequency. The parasitics include the inherent inductance, resistance, and capacitance that may exist in the IC ( 20 ) (or other integrated circuits), the package ( 18 ), and the power distribution network. In particular, the power supply resonance may be formed from the power distribution network and a “parasitic tank circuit” that includes the IC capacitance and package inductance.
FIG. 2 shows a schematic of a power distribution network for a package ( 296 ). The power distribution network is represented by impedances Z 1 ( 204 ), Z 2 ( 206 ), and Z 3 ( 208 ). Each of these impedances ( 204 , 206 , 208 ) may include resistive, inductive, and/or capacitive elements. Two power supply lines ( 292 , 294 ) supply power to the package ( 296 ) located between the two power supply lines ( 292 , 294 ). The impedances ( 204 , 206 , 208 ) model both the inherent parasitics of the power distribution network and added components.
On the package ( 296 ), various forms of capacitance may be used to further stabilize the power supply. Low equivalent series resistance (ESR) local decoupling capacitors are modeled by resistor ( 262 ) and capacitor ( 264 ). High ESR global decoupling capacitors are modeled by resistor ( 266 ) and capacitor ( 268 ). Non-switching logic disposed on an IC in the package ( 296 ) is modeled by resistor ( 270 ) and capacitors ( 272 , 274 ). Switching logic disposed on the IC in the package ( 296 ) is modeled by variable resistors ( 276 , 278 ) and capacitors ( 280 , 282 ).
In FIG. 2 , the schematic of the power distribution network may be used to simulate the power supply impedance observed by the IC in the package ( 296 ), as represented by “Z.” To measure the power supply impedance, a 1 Ampere AC current source ( 290 ) injects current onto power supply line ( 292 ). The measured voltage, V M , between the two power supply lines ( 292 , 294 ) may be used to calculate the power supply impedance. The impedance Z is equal to V M divided by the 1 Ampere AC current source ( 290 ). By varying the frequency of the 1 Ampere AC current source ( 290 ), a frequency versus impedance relationship may be determined.
A representative graph of power supply impedance is shown in FIG. 3 . Over a particular range of frequencies for the switching logic on the IC ( 296 ), the power supply impedance increases because the circuit formed by an IC and a package resonates. A spike in a power supply impedance curve ( 302 ), or a power supply resonance frequency, has the effect of current-starving the IC in the package ( 296 in FIG. 2 ). When the IC is current-starved, some voltage potentials on the IC in the package ( 296 in FIG. 2 ) may shift from their desired values. Accordingly, an increase in the power supply impedance may cause undesired operation of the IC in the package ( 296 in FIG. 2 ).
SUMMARY OF INVENTION
According to one aspect of the present invention, a power supply resonance compensation system comprising a power distribution network arranged to propagate from a power supply at least one voltage potential to an integrated circuit; a resonance detector operatively connected to the at least one voltage potential and arranged to detect power supply resonance; and a damping circuit external to the integrated circuit operatively connected to the resonance detector and the power distribution network where the damping circuit is arranged to dampen the power supply resonance under control of the resonance detector.
According to one aspect of the present invention, a method for reducing power supply resonance comprising propagating at least one voltage potential from a power supply to an integrated circuit; transmitting data to a receiving circuit from the integrated circuit; detecting whether a particular level of power supply resonance exists; and damping the power supply resonance dependent on the detecting where the damping occurs external to the integrated circuit.
According to one aspect of the present invention, an apparatus for reducing power supply resonance comprising power distribution means for propagating power to an integrated circuit; means for detecting power supply resonance on the power distribution means; and means for damping power supply resonance under control of the means for detecting where the means for damping resides external to the integrated circuit.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a prior art integrated circuit system.
FIG. 2 shows a schematic of a power distribution network for an integrated circuit.
FIG. 3 shows a graph depicting power supply system impedance.
FIG. 4 shows a graph of I/O bit patterns in accordance with an embodiment of the present invention.
FIG. 5 shows a block diagram of a power supply resonance compensation system in accordance with an embodiment of the present invention.
FIG. 6 shows a block diagram of a resonance detector system in accordance with an embodiment of the present invention.
FIG. 7 shows a block diagram of a resonance detector system in accordance with an embodiment of the present invention.
FIG. 8 shows a schematic of a resonance detector and damping circuit in accordance with an embodiment of the present invention.
FIG. 9 shows a schematic of a resonance detector and damping circuit in accordance with an embodiment of the present invention.
FIG. 10 shows a schematic of a resonance detector and damping circuit in accordance with an embodiment of the present invention.
FIG. 11 shows a graph depicting power supply system impedance in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
Embodiments of the present invention relate to a method for reducing power supply resonance.
Conventional approaches have focused on the clock frequency's relationship to the power supply resonance frequency. Much of the switching logic will operate at the clock frequency. So if the clock frequency closely matches the power supply resonance frequency of the power distribution network, power supply resonance can be observed. However, even if the clock frequency is significantly different than the power supply resonance frequency, certain patterns of transmitted bits may occur at the power supply resonance frequency, causing power supply resonance effects in a system.
FIG. 4 shows several exemplary bit patterns based on a 100 MHz clock frequency that may excite a circuit at frequencies other than 100 MHz. The clock signal ( 402 ) is shown on the top line of the graph in FIG. 4 . Transmitted data bits in the clock's system, for example, are sent every 10 nanoseconds (at 5 ns, 15 ns, 25 ns, etc. in FIG. 4 ). The data is held steady during the positive transition clock edges.
The second line ( 404 ) on the graph in FIG. 4 shows an alternating bit pattern: “0101010101.” If a binary one is sent every other clock cycle, energy is input to the system every other clock cycle, for a resulting frequency of 50 MHz. The third line ( 406 ) on the graph in FIG. 4 shows the bit pattern: “0100100100,” inputting energy every third clock cycle. With the bit pattern, energy is input to the system at 33 MHz. The fourth line ( 408 ) on the graph in FIG. 4 shows a bit pattern with a binary one every fourth clock cycle, inputting energy at 25 MHz. The fifth signal ( 410 ) on the graph in FIG. 4 shows a different 25 MHz signal. The bit pattern is “0011,” and the bit pattern duty cycle is 50%. Bit patterns with a 50% duty cycle have the strongest effect in inciting power supply resonance. If any of the frequencies generated by a particular bit pattern matches the power supply resonance frequency of the IC, the IC may malfunction.
Data to be transmitted between integrated circuits passes through high power transmission amplifiers before being transmitted from one integrated circuit to another. These signals are greatly amplified on an integrated circuit and may have a relatively large effect on a power distribution network. If a frequency of data transmitted between integrated circuits occurs at a power supply resonance frequency, the power distribution network may excite the power supply impedance spike described above. Accordingly, integrated circuits connected to the power distribution network may be current-starved and may malfunction. Data transmitted between integrated circuits is a significant contributor to switching-induced power supply resonance.
FIG. 5 shows a block diagram of an exemplary power supply resonance compensation system ( 500 ) in accordance with an embodiment of the present invention. In FIG. 5 , a transmitting IC ( 510 ) is connected to a power supply ( 502 ) with two power supply lines ( 520 , 522 ). The transmitting IC ( 510 ) transmits data to a receiving IC ( 516 ) on line ( 518 ). The parasitic impedances Z 1 ( 504 ), Z 2 ( 506 ), and Z 3 ( 508 ) ( 204 , 206 , and 208 , respectively, shown in FIG. 2 ) are shown.
Embodiments of the present invention use a damping circuit ( 514 ) that does not reside on the transmitting IC ( 510 ) to dampen a power supply resonance. A resonance detector ( 512 ) determines when the damping circuit ( 514 ) should be activated. The resonance detector ( 512 ) uses line(s) ( 524 ) to control the damping circuit ( 514 ). Under non-resonant conditions, the damping circuit ( 514 ) approximates an open circuit, thereby dissipating no power when power supply resonance damping is not needed. The resonance detector ( 512 ) may monitor transmissions between the integrated circuits ( 510 , 516 ) on line ( 518 ) and determine whether a transmission will cause a power supply resonance condition. If the transmission is determined to cause a power supply resonance condition, the resonance detector ( 512 ) will activate the damping circuit ( 514 ) so that the damping circuit ( 514 ) may damp the power supply resonance.
Furthermore, the resonance detector ( 512 ) may be arranged to detect a voltage potential sag of a voltage potential on at least one of the power supply lines ( 520 , 522 ). Accordingly, if the voltage potential sag is detected, the resonance detector ( 512 ) will activate the damping circuit ( 514 ) so that the damping circuit ( 514 ) may damp the power supply resonance (which may cause the voltage potential sag). One of ordinary skill in the art understands that a threshold may be set such that the voltage potential sag must cross the threshold to activate the damping circuit ( 514 ).
According to one or more embodiments of the present invention, the resonance detector ( 512 ) may store a list of bit patterns known to cause power supply resonance. Transmissions monitored by the resonance detector ( 512 ) would be compared to the list of offending bit patterns. Upon discovery of such a pattern, the resonance detector ( 512 ) enables the damping circuit ( 514 ) to dampen the impending power supply resonance caused by the offending bit pattern.
Because the first bit of an offending bit pattern may come at any time in a series of bits, a shift register may be used as part of the pattern detecting system. The bits to be transmitted may be fed through the shift register so that the pattern being transmitted could be “moved” and compared with respect to the offending bit pattern. If at any time during the transmitted pattern's traversal of the shift register, the transmitted pattern matches the offending bit pattern, the resonance detector ( 512 ) has detected an offensive bit pattern.
According to one or more embodiments of the present invention, the resonance detector ( 512 ) may perform a frequency analysis on the transmitted data signal. A frequency analysis algorithm may be used to determine the frequency content of the signal. Fourier analysis (e.g., Fast Fourier Transform) or wavelet analysis may be used to determine the frequency content of the signal. After determining the power supply resonance frequency of an integrated circuit and power distribution network combination, frequencies generated by offending bit patterns are programmed into the resonance detector ( 512 ). During operation, bit patterns are transformed into the frequency domain, and the resonance detector ( 512 ) in turn looks for frequency content near the power supply resonance frequency. The damping circuit ( 514 ) may be activated if the signal contains enough energy near the power supply resonance frequency to induce power supply resonance.
Signal frequency content near harmonics of the power supply resonance frequency (i.e., frequencies that are integer multiples of the power supply resonance frequency) may also cause power supply resonance. In one or more embodiments, a frequency analysis-based resonance detector may be programmed to be responsive to harmonic frequencies of the power supply resonance frequency as well as the power supply resonance frequency itself.
In FIG. 5 , the resonance detector ( 512 ) is shown as a part of the transmitting IC ( 510 ). One of ordinary skill in the art will understand that the resonance detector ( 512 ) may also be included as a part of the receiving IC ( 516 ), or the resonance detector ( 512 ) may be included on a third IC (not shown) separate from the transmitting IC ( 510 ) and the receiving IC ( 516 ). The resonance detector ( 512 ) may also be a separate IC on the package of either the transmitting IC ( 510 ) or the receiving IC ( 516 ).
FIG. 6 shows a block diagram of an exemplary resonance detector system in accordance with an embodiment of the present invention. Data transmitted on line ( 604 ) is sent to the resonance detector ( 602 ). The resonance detector ( 602 ) includes a data buffer that latches the transmitted data for analysis. The transmitted data is then passed on to the intended receiver on line ( 606 ). If the resonance detector ( 602 ) determines that a transmission will cause power supply resonance, the resonance detector ( 602 ) activates the damping circuit (not shown) using line ( 608 ). Data, for the purposes of the present invention, includes any information that may be transmitted between at least two integrated circuits.
One of ordinary skill in the art will understand that other configurations are possible. FIG. 7 shows a block diagram of an exemplary resonance detector system in accordance with an embodiment of the present invention. The resonance detector ( 702 ) may monitor transmissions between integrated circuits without being disposed between a transmitter (not shown) and a receiver (not shown) as in FIG. 6 . One of ordinary skill in the art will understand that lines ( 704 ), ( 706 ), and ( 708 ) represent the same electrical node. Data to be transmitted is sent on line ( 704 ), which splits into lines ( 706 ) and ( 708 ). Line ( 708 ) continues to carry the data on to the intended receiver, while line ( 706 ) supplies the data to the resonance detector ( 702 ). If the resonance detector ( 702 ) determines that a transmission will cause power supply resonance, the resonance detector ( 702 ) activates the damping circuit (not shown) using line ( 710 ).
As shown in FIG. 8 , according to an embodiment of the present invention, an exemplary damping circuit ( 802 ) may be a resistor ( 804 ) in series with a PMOS transistor ( 806 ) operating as a switch. A resonance detector ( 814 ) supplies a high voltage potential to the gate of the transistor under power supply non-resonant conditions, so that the damping circuit ( 802 ) is essentially an open circuit. When a power supply resonance inducing event is detected, the resonance detector ( 814 ) supplies a low voltage potential to the transistor ( 806 ) using line ( 808 ), causing the transistor ( 806 ) to behave as a short circuit, thereby creating a resistance between power supply lines ( 810 , 812 ). The resistor ( 804 ) between the power supply lines ( 810 , 812 ) will dampen the power supply resonance. When the power supply resonance-inducing event is over or damping is no longer required, the resonance detector ( 814 ) will turn “off” the transistor ( 806 ).
One of ordinary skill in the art will understand that an NMOS transistor could also be used instead of the PMOS transistor ( 806 ). The NMOS transistor may connect to power supply line ( 812 ) an in series with the resistor ( 804 ) connected to power supply line ( 810 ). The resonance detector ( 814 ) applies a high voltage potential to the gate of the NMOS transistor while a power supply resonance inducing event is detected.
Those skilled in the art will note that the control scheme used for a switch-mode operation is called “bang-bang control” because the control signal “bangs” between two discrete values (i.e., ON and OFF) as some parameter (e.g., frequency of transmitted bits, or voltage potential sag of at least one power supply line) enters and leaves an appropriate operating range (e.g., near power supply resonance, or voltage potential difference from an expected value).
As shown in FIG. 9 , according to an embodiment of the present invention, a damping circuit ( 902 ) may be a digital potentiometer ( 904 ) under control of a resonance detector ( 914 ). The resonance detector ( 914 ) sends control information on line(s) ( 908 ) to the digital potentiometer ( 904 ) that controls the resistance between the two power supply lines ( 910 , 912 ). For proper operation under power supply non-resonant conditions, the digital potentiometer ( 904 ) may be set to a very high resistance so that the digital potentiometer ( 904 ) may act as an open circuit.
The digital potentiometer ( 904 ) is tunable and may be continuously variable. If the resonance detector ( 914 ) detects a condition that may cause a small power supply resonance, the resonance detector ( 914 ) may respond appropriately by setting the digital potentiometer ( 904 ) to a slightly lower value than the digital potentiometer's ( 904 ) open circuit mode. Accordingly, the power supply resonance is effectively damped while the damping circuit ( 902 ) dissipates as little power as necessary. If the resonance detector ( 914 ) detects an event that will induce a relatively large power supply resonance, the resonance detector ( 914 ) may set the digital potentiometer ( 904 ) to relatively low resistance value to dampen the power supply resonance.
In one or more embodiments, various different control schemes may be used to control the damping circuit ( 902 ). Proportional, integral, differential (PID) control is one control method that could be employed by the resonance detector ( 914 ). The resonance detector's ( 914 ) PID parameters may be selected to optimize at least one aspect of the system's performance. Depending on the application, the goal of the optimization may be to minimize the amplitude of a power supply resonance, to minimize the duration of a power supply resonance, or to minimize power dissipated by the damping circuit.
One of ordinary skill in the art will understand that there are many other potential embodiments of a damping circuit. The minimum requirements are that the damping circuit be controllable by a resonance detector, and that the damping circuit be able to dampen a power supply resonance. In one or more embodiments, the power supply resonance is dampened by lowering a power supply impedance.
As shown in FIG. 10 , according to an embodiment of the present invention, a damping circuit ( 1002 ) may be under control of a resonance detector ( 1014 ). The resonance detector ( 1014 ) sends control information on line(s) ( 1008 ) to the damping circuit ( 1002 ) that controls the impedance on power supply line ( 1010 ). For proper operation under power supply non-resonant conditions, the damping circuit ( 1002 ) may be set to a very low impedance.
The damping circuit ( 1002 ) is tunable and may be continuously variable. If the resonance detector ( 1014 ) detects a condition that may cause a small power supply resonance, the resonance detector ( 1014 ) may respond appropriately by setting the damping circuit ( 1002 ) to a slightly higher impedance value. Accordingly, the power supply resonance is effectively damped while the damping circuit ( 1002 ) dissipates as little power as necessary. If the resonance detector ( 1014 ) detects an event that will induce a relatively large power supply resonance, the resonance detector ( 1014 ) may set the damping circuit ( 1002 ) to relatively high impedance value to dampen the power supply resonance.
In one or more embodiments, various different control schemes may be used to control the damping circuit ( 1002 ). PID control is one control method that could be employed by the resonance detector ( 1014 ). The resonance detector's ( 1014 ) PID parameters may be selected to optimize at least one aspect of the system's performance. Depending on the application, the goal of the optimization may be to minimize the amplitude of a power supply resonance, to minimize the duration of a power supply resonance, or to minimize power dissipated by the damping circuit.
One of ordinary skill in the art will understand that there are many potential embodiments of a damping circuit. The minimum requirements are that the damping circuit be controllable by a resonance detector, and that the damping circuit be able to dampen a power supply resonance. In one or more embodiments, the power supply resonance is dampened by increasing a power supply impedance.
FIG. 11 shows a graph depicting an exemplary power supply system impedance in accordance with an embodiment of the present invention. A power supply impedance curve ( 1102 ) displays a power supply impedance without the influence of the present invention as shown in the power supply impedance curve ( 302 ) in FIG. 3 . Power supply impedance curve ( 1106 ) shows a relationship of impedance to frequency under the influence of the present invention. Away from the power supply resonance frequency, the two power supply impedance curves ( 1102 , 1106 ) are approximately equivalent. Accordingly, a damping circuit is an open circuit at these frequencies. In other words, at such power supply non-resonant frequencies, the damping circuit, e.g., damping circuit ( 802 in FIG. 8 ), has no effect on the power distribution network. Near the power supply resonance frequency, the resonance detector activates the damping circuit, e.g., damping circuit ( 802 in FIG. 8 ), and the power supply resonance is attenuated.
Advantages of the present invention may include one or more of the following. In one or more embodiments, the present invention may dampen a power supply resonance in a power distribution network, thereby improving system performance.
In one or more embodiments, the present invention may limit the amount of power dissipated by the damping circuit while still effectively damping power supply resonance.
In one or more embodiments, the present invention may allow control over how a power supply resonance is damped. Amplitude of the power supply resonance, duration of the power supply resonance, or power dissipated by the damping circuit may be minimized.
Some power supply resonance-inducing transmissions may occur unpredictably. In one or more embodiments, the present invention may detect such power supply resonance-inducing transmissions, and the resulting power supply resonance may be damped. In one or more embodiments, the present invention may detect a voltage potential sag on at least one power supply line and damp a power supply resonance.
In one or more embodiments, the present invention's damping circuit will only dissipate power when a power supply resonance exists and requires damping, thereby dissipating power only when needed.
In one or more embodiments, a damping circuit may not be close to other circuits; therefore, heat produced/dissipated by damping may not affect the other circuits. A separate component used for the damping circuit may be less expensive to implement.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A computer system uses a power distribution network arranged to propagate at least one voltage potential to an integrated circuit. A resonance detector is arranged to detect a power supply resonance. A damping circuit is operatively connected to the resonance detector and the power distribution network. The damping circuit resides external to the integrated circuit and dampens the power supply resonance under control of the resonance detector.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of copending application Ser. No. 8,490, filed Jan. 29, 1987.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and method for withdrawing a continuously advancing yarn with a suction device which removes the yarn in an air stream. More particularly, the present invention relates to an apparatus and method for threading up a freshly spun synthetic filament yarn onto fast moving machine parts, and as the yarn continuously advances from a spinneret.
The design and construction of yarn suction devices, such as the so called suction guns, have been a source of difficulty, since they are unable to provide adequately high yarn tensions where the yarn speeds are greater than about 4,000 meters per minute (65-70 meters per second). Such suction guns generally serve the purpose of withdrawing a continuously advancing yarn, particularly synthetic filament yarn, when the spinning operation is interrupted, for example, in order to doff packages, and the withdrawn yarn is diverted to a waste container. In such suction guns, the yarn is subjected to a strong air current. However, the applicability of such devices is limited to yarn speeds of about 4,000 meters per minute, since at these high speeds, the present suction devices are not able to provide the required yarn tension in order to thread up the yarn on the feed godet or take-up device of the spinning machine. With inadequate tension, it is likely that the yarn will form a lap on the godet or take-up device. In addition, the compressors or vaccuum pumps which are required at these high yarn speeds, become a significant cost factor by reason of their large power requirement, even though these devices are needed only temporarily when the operations are interrupted. Further, the efficiency of the known suction guns and air injectors is so low that their use becomes uneconomical at high yarn speeds.
To overcome the limitations of the known yarn suction devices as outlined above, it has been suggested that the suction current be generated by a liquid, such as water, and with pressures of about 80 bar and above. However, this method has not proven to be successful, since the requirement of removing the required quantities of water without undue expense has presented a difficult problem. In addition, hydraulic problems developed, since even a pressure of 51 bar is necessary for a frictionless flow of fluid in order to obtain a velocity flow of about 6,000 meters per minute (100 meters per second). Further, it is necessary that the yarn be first advanced by an air suction current, and then by a fluid current, which further complicates the design.
It is accordingly an object of the present invention to provide a yarn withdrawal apparatus and method which overcomes the above noted limitations of the prior systems, and which is adapted to withdraw a yarn at high speed and relatively high yarn tension, and so as to facilitate its thread-up onto the rapidly moving components of the spinning machine.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are achieved in the embodiments illustrated herein by the provision of a yarn withdrawal apparatus and method which comprises yarn advancing means which includes at least one rotatable roll which is adapted to be looped by the advancing yarn, drive means for rotating the at least one roll at a predetermined rotational speed, and suction means having an inlet opening closely adjacent the yarn advancing means for withdrawing the yarn which is looped about the yarn advancing means. Thus in accordance with the present invention, the yarn advancing means directly precedes the suction means, and the inlet opening is arranged directly adjacent the surface of the roll and preferably tangent to the same. Also, the yarn advancing means, drive means, and the suction means are all mounted to a common support structure, which in turn may be either fixed to the spinning machine or configured to permit it to be manipulated by the machine operator in the manner of a suction gun.
The present invention includes provision for avoiding the formation of laps on the yarn advancing means, and to this end, one embodiment of the invention provides for two advancing rolls which are slightly spaced apart from each other and which rotate in the same direction, with at least one of the rolls being driven, and with the axes of the rolls intersecting each other at an acute angle. The yarn is guided over the advancing rolls so that it initially contacts the rolls in the area of the large separation between the axes, and the suction means is positioned in the area where the distance between the axes is least. By this arrangement, the suction means may follow the yarn advancing rolls in a substantially axial direction, and partially enclose the end of the advancing rolls, in which case a yarn guide is provided for preventing the yarn from unwinding overhead from the advancing rolls. Alternatively, the suction means may be disposed transversely to the axes of the rolls, and so that the yarn is tangentially withdrawn from the rolls.
In another embodiment, the formation of laps is prevented in that the yarn advancing means is composed of one roll which has a conical configuration. In this instance, the roll is mounted from its large end in cantelever fashion, and so that the laps which may form slide downwardly to the small end, where they can be removed. Further, the conical configuration provides for a constant, axial or helical advance of the yarn along its surface, and so that each winding does not superpose another. In this respect, the conical roll is similar to the system utilizing two rolls, the axes of which intersect in the manner described above.
As indicated above, the yarn withdrawal apparatus of the present invention may be mounted to the processing machine as a stationary unit, in which event both mechanical and pneumatic means may be provided for threading the yarn into the yarn advancing apparatus. However, the apparatus may alternatively be designed as a portable, hand-held device, which is similar in size to existing suction guns.
In accordance with the present invention, several different devices and methods are available for threading a yarn into the yarn advancing apparatus. When the roll or rolls of the yarn advancing means are mounted in a depending arrangement, and the suction means is positioned in the area of the bearing end, the following method is suggested in the case of man made fiber spinning operations. Specifically, the yarn advancing from the spinneret at a relatively low speed is first engaged by the suction device, so that it is withdrawn under a tension which can be produced by the suction device alone. The roll or rolls of the yarn advancing means are rotated at a circumferential speed which is at least equal to the circumferential speed of the godet or winding device on the processing machine upon which the yarn is to be threaded, and the apparatus then is moved so that the roll or rolls of the yarn advancing means are moved in a circular motion a number of times about the thread line. As a result, the yarn forms several loops on the roll or rolls. At the end of the procedure, the apparatus should be held so that the yarn advances substantially tangentially to the roll or rolls. In this manner, the contact point of the yarn on the advancing means is prevented from moving in the axial direction. In this condition, the yarn withdrawal apparatus can exert a sufficiently high tension on the yarn so that the yarn can be placed on high speed machine parts, such as godets and/or take-up systems, while effectively avoiding the risk of laps.
The thread-up of the yarn may also be effected by mechanical arrangements. In this case, the procedure is that the yarn is first caught by the suction device, and then a mechanical thread-up device becomes operative for looping the yarn about the roll or rolls of the yarn advancing means. This method is particularly suitable in spinning plants for catching a yarn advancing from the spinneret. After the yarn has been looped about the advancing means of the withdrawal apparatus, the yarn can be placed on high speed machine parts, such as godets and/or take-up systems.
When the yarn is looped about the roll or rolls of the yarn advancing means, it is withdrawn from the spinneret at a relatively high tension, with the level of the tension being a function of the torque of the drive motor and the number of loops of the yarn about the roll or rolls. The torque characteristic of the motor and the number of loops need to be coordinated so that yarn breakage can be avoided. The suction device then serves the purpose of applying relatively low tension in the exiting yarn end, and such tension need be only so high that an adequate tension in the entering yarn end is provided by the looping friction. In addition, a slight tension of the exiting yarn end may be compensated by additional yarn loops.
A further possibility of adjusting and/or regulating the yarn tension is provided in that the contact point of the yarn may be axially adjustable, here the advancing means comprises a conical roll.
Mechanical devices may also be provided for moving the apparatus about the yarn axis after the yarn is caught by the suction system, to loop the yarn about the withdrawal means. However, one embodiment of the present invention includes a mechanically simple and reliable looping device. In particular, the looping device comprises a yarn guide, which rotates or loops about the yarn advancing means, and so as to traverse the thread line in the area of the suction device. As it does so, the yarn guide preferably also imparts an axial advance to the yarn. The guide may for example be a flyer type guide, which is pivotal about an axis which is coaxial or parallel to the roll axis, or which lies in a plane defined by the roll axes in the case of the embodiment consisting of two rolls. The axial advance of the looped yarn may be effected by supporting the flyer in a screw thread, or the guide may be configured to include a helical external arm which performs this function.
As an alternative to the above, the present invention may incorporate pneumatic means, which cooperates with the suction system to loop the yarn about the yarn advancing means. In one such embodiment, which permits high yarn speeds and catches the yarn safely, and which is also easy to operate and may be constructed as a compact hand-operated device, the air stream which entrains the yarn is guided tangentially to the roll, looped about the same, and then tangentially withdrawn. The roll is constantly driven in the rotary direction of the looping air stream and yarn and at a circumferential speed which is at least equal to the circumferential speed of the godet or winding device of the processing machine, upon which the yarn is to be threaded. Where the roll is conical, the air stream is directed so as to impact on the periphery of the roll in a normal plane and in the area of the larger diameter end. In this yarn entry plane, the circumferential speed of the roll is at least equal to the yarn speed. The air stream then moves toward the smaller end of the conical roll.
In one efficient embodiment, the roll is enclosed by an air channel which serves to generate an air vortex, and the channel forms a narrow gap which is spaced from the roll so that the yarn can pass through the channel. The channel may for example be defined by a helically curved, slotted tube. It may b desirable to surround the roll with a casing, and such that the inside surface of the casing forms a narrow gap between the casing and the roll, with the width of the gap being dimensioned so that the yarn can form a small lap on the roll. The helical channel may then be formed on the inside surface of the casing, and so as to extend about the roll for at least half a loop. The yarn inlet and outlet passages which extend through the casing terminate respectively so as to be aligned with the respective ends of the helical channel. Again, the roll may be constructed to have a conical configuration for the purpose of axially advancing the yarn loops, and the interior wall of the casing may have a corresponding conical configuration.
The use of a conical roll has the advantage that the yarn tension adjusts itself automatically. More particularly, as soon as a certain tension is exceeded, the yarn windings slip toward the area of the smaller end, and thus to the area where the circumferential speed is lower. As noted above, this effect may also be intentionally accomplished by the adjustment of the contact point of the yarn with the roll.
Another embodiment which involves pneumatic threading means, comprises a roll which is mounted in a casing, with the casing being adapted to the roll circumference with a gap therebetween. The yarn inlet passage and the yarn outlet passage terminate in the casing, with each of the passages extending along a tangent to the roll. The remainder of the inside surface of the casing is smooth. The direction of rotation is in this case selected so that the periphery of the roll and the air are unidirectional. Thus, the air stream generated by the suction system is deflected as the roll rotates to form an air loop, with the so called Coanda effect playing a role. As the air is sucked in, the yarn is first guided in an air loop around the roll, before it is grasped by the suction system. Surprisingly, it has been found that this embodiment is very reliable in catching the yarn.
Where the roll of the above embodiment is conical, it is possible to effect a multiple looping of the roll in that the yarn suction passage is offset relative to the yarn inlet passage in the axial direction toward the small end. The downward slippage of the yarn windings insures that the free yarn end caught by the roll reaches the area of the yarn suction duct, and is there withdrawn.
In another embodiment which involves pneumatically threading the yarn onto the yarn advancing means, a conical roll is mounted in an overhung or cantilever fashion. More particularly, the yarn suction duct is positioned on a tangent of the roll in the area of its free end, and so that the entrance of the yarn suction duct does not impede the slippage of the yarn wound on the roll toward the free end. The opening of the suction duct is shaped so that it surrounds the free end of the roll in the form of a plate or cup. During threading, the yarn is first brought into circumferential contact with the conical roll, and it forms windings on the roll which slide downwardly toward the free smaller end. As they do so, the downwardly sliding windings drop into the plate or cup shaped opening of the yarn suction duct, from which they are withdrawn by the suction system until the yarn is drawn out smoothly and unwinds tangentially from the conical roll.
The present invention is based upon the recognition that there is no problem with catching an advancing yarn end by means of a suction gun or an air stream, and in particular when the yarn is freshly spun and advances from the spinneret. The tension which is necessary to prevent laps from forming on the feed system below the spinneret may be achieved with the mechanical assistance of the yarn advancing means in accordance with the present invention. In addition, the use of the conical roll of the present invention has the advantage that the formation of laps on the advancing means is effectively avoided, in that possible laps on the conical roll slide downwardly and are entrained with the air flow as it moves through the yarn outlet passage.
To facilitate the removal of laps, the conical roll may be mounted in an overhung or cantilever fashion, and so that the casing of the roll is open adjacent the free end. As a result, possible laps slide downwardly and over the free end of the roll and can fall from the casing or be pulled from the same. It is also possible to provide another suction duct at the open end of the casing, which leads to a waste container.
In accordance with the present invention, the conical roll may take a form which has a constantly decreasing diameter from a normal plane at the point of yarn contact to a normal plane at which the yarn suction duct is located. Thus the shape may include not only truncated cones, but also paraboloids, truncated hyperboloids, and the like.
A high speed electric motor may be provided to drive the yarn advancing means. Alternatively, it may be advantageous to use an air turbine. When the yarn is pneumatically threaded on the advancing means, a control system may be employed, by which the air turbine of the yarn advancing means is operated alone at first. When the yarn advancing means reaches a desired speed, the compressed air may then be supplied to the suction system. In so doing, the yarn advancing means may idle or continue to operate with a reduced air requirement, so that the necessary suction energy is available. After the suction system is also connected, the yarn is taken in, brought into contact with the advancing means, and removed by suction. At this point, the air turbine may again be supplied with a larger portion of the available quantity of pressurized air, so that the advancing means can apply the desired tension. Also, only a lesser energy is necessary for removing the yarn from the advancing means by suction. This control system prevents the yarn from being brought into circumferential contact with the advancing means before the advancing means has reached a desired speed, thereby making the thread-up more reliable and reducing the risk of laps.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when taken in conjunction with the accompanying drawings, in which
FIG. 1 is a sectional side elevational view of a yarn withdrawal apparatus which embodies the present invention;
FIG. 2 is a view similar to FIG. 1 and illustrating another embodiment of the invention;
FIGS. 3A, 3B, and 3C are perspective views of another embodiment, and illustrating a mechanical means for looping the yarn about the delivery roll of the yarn advancing means;
FIG. 4 is a perspective view of another embodiment of the invention;
FIG. 5 is a sectional view of still another embodiment of the present invention;
FIG. 5A is a schematic illustration of an air control system for the embodiment of FIG. 5;
FIG. 6 is an end view of the apparatus shown in FIG. 5;
FIG. 7 is a sectional view taken substantially along the lines 7--7 of FIG. 5;
FIG. 8 is a sectional view of a further embodiment of the present invention; and
FIG. 9 is a partly section view of still another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to the embodiment of the present invention illustrated in FIG. 1, there is illustrated a yarn withdrawal apparatus, which comprises a yarn advancing means 1 and a suction means 24 which includes a suction tube 16 and an air injector nozzle which has an annular duct 23 which is connected via the line 22 to a source of pressurized air. Air channels 21 extend from the duct 23 into the yarn outlet passage 31, where the pressurized air exiting from the channels 21 generates a strong suction current in the direction of the arrow. Positioned adjacent the inlet opening of the tube 16 is the yarn advancing means 1. The advancing means is supported by a holder 40 which is connected via an extension 41 with the wall of the suction tube 16. Supported by the holder 40 are two rolls 32, 33 in such a manner that their axes 45, 46 extend at an acute angle 34 relative to each other, and intersect. It is advantageous to arrange the advancing means 1 adjacent the inlet opening of the suction tube 16, so that the axis 48 of the tube 16 extends substantially in a plane tangent to both rolls 32, 33. Furthermore, the axis 48 of the tube 16 communicates with the yarn advancing means 1 at the unwinding area 27, whereas a substantial portion of the longitudinal length of the advancing means 1 laterally projects beyond the suction tube 16. Thus the yarn will be seen to unwind from the advancing means 1 in the area of the lesser separation between the roll axes.
The yarn outlet passage 31 of the suction means is connected to a flexible tube, which leads to a waste container. Also, the entire apparatus takes the form of a unit having a handle (not shown) which permits it to be manipulated by the operator. Specifically, the suction duct 16 and/or the yarn outlet passage 31 may serve as a handle.
A high speed electric motor is mounted in a casing 8 and drives the roll 32. The motor casing 8 is mounted on the holder 40, and the ro1 33 is supported for free rotation by the holder 40.
When a yarn is to be threaded, such as a yarn advancing from the spinneret 57, the yarn is first taken directly into the suction tube 16 of the suction means 24, and so that the yarn moves along the path 20.1 as shown in dashed lines in FIG. 1. In so doing, it should be noted that the yarn does not advance from the spinneret 57 at a defined speed, and as a result, the suction forces applied by the suction means 24 suffice to withdraw the yarn and so as to avoid the formation of tangles and knots. In the meantime, the roll 32 has been brought to a rotational speed which is sufficiently high so that its circumferential speed corresponds substantially to the operational speed of the yarn and to the circumferential speed of the feed godet 30 of the spinning machine, to which the yarn advancing from the spinneret is to be supplied. Prior to bringing the yarn into circumferential contact with the feed godet 30, the yarn withdrawal apparatus is moved in a generally circular fashion about the yarn axis, and the yarn, which until then has advanced in a straight line, is looped one or several times about the two rolls 32, 33 of the advancing means 1. As the looping increases, the advancing means and particularly the driven roll 32 exert an increasing frictional force on the yarn, so that the yarn is then withdrawn at substantially the operational speed of the godet 30 and at a high tension. At this point, the yarn withdrawal apparatus is guided several times around the feed godet 30, thereby threading the yarn with the desired number of loops onto the godet 30, so that the thread line 20.2 results. The yarn can then be threaded by the apparatus on a take-up system or winder 49, which is schematically indicated in the drawing, and such that the yarn passes along the thread line 20.3.
In the embodiment of FIG. 2, the advancing means 1 and the suction means 24 are substantially coaxial or parallel, with the unwinding end 47 of the advancing means 1 being received in the inlet opening portion of the widened suction tube 16. As illustrated, the unwinding portion 47 extends into the inlet opening of the tube 16, and it is also possible, as is illustrated in FIGS. 3A-3C, that the inlet opening of the suction duct 16 terminates at a location which is parallel and offset from the axes 45, 46 of the two rolls. As illustrated in FIG. 2, the holder 40 in which the rolls 32, 33 are supported, is connected via extensions 41 with the wall of the inlet portion of the suction tube 16. Also in this embodiment, the two axes 45, 46 of the rolls extend at an acute angle with respect to each other as indicated at 34. A cap 43 supports the rolls at their free ends and forms an abutment which covers the opposite ends of the two rolls in such a manner that the abutment effectively prevents the yarn from slipping off the ends of the rolls.
The suction tube 16 is connected to a suction means 24, which again comprises an annular duct 23 and connection 22 for the air line, and air channels 21. The entering air thus produces a strong suction current in the tube 16, and the yarn leaving the outlet passage 31 is guided to a waste container.
When threading a yarn onto the godet 30, the yarn advancing from the spinneret is first delivered into the suction tube 16 by the suction means 24, and withdrawn in a straight line as shown by the dashed thread line 20.1 in FIG. 2. The yarn withdrawal apparatus is then rotated several times in such a manner that the axis 48 of the tube performs a circular movement about the thread line 20.1, and so that a desired number of windings is formed on the advancing means 1. The rolls 32 and 33 are put into operation by an air turbine which is housed in the holder 40, and as a result, the yarn is then withdrawn from the spinneret at a speed and under a tension determined by the air turbine, and the extension 41 serves as a yarn guide which prevents the yarn from being withdrawn overhead from the advancing means by the suction force of the means 24. The yarn can then be brought into circumferential contact with the godet 30 along the thread line 20.2.
Aside from the fact that the yarn unwinding from the advancing means 1 is received by the suction means 24, tangentially in FIG. 1, or axially in FIG. 2, the cooperation of the advancing means 1 and the suction means 24 is substantially identical in the two embodiments. The yarn to be withdrawn is in either case looped several times about the two rolls 32, 33 to form windings 36 and withdrawn under an increased tension as a result of the thereby developed frictional contact between the rolls 32, 33 and the yarn. The positioning of the two rolls 32, 33 at an angle 34 facilitates the axial displacement of the individual windings 36, and in the area of the unwinding end 47, the yarn is caught by the suction current of the tube 16, and removed.
In FIGS. 1 and 2, the axes 45, 46 of the two rolls 32, 33 form an acute angle 34. However, they may also be arranged so that their axes extend in planes substantially parallel to each other and are so aligned with each other that they intersect at an acute angle in the projection of one of the two planes.
At least one of the two rolls 32, 33 is driven at high speed, and such that the circumferential speed corresponds at least to the speed of the advancing yarn. This may, for example, be accomplished by an air turbine which is accommodated in the holder 40, or by an electric motor as noted above.
The apparatus of the present invention permits a yarn to be threaded on godets and other yarn advancing systems, such as a yarn take-up or winding system, at circumferential speeds which are far above 4,000 meters per minute and for example up to 7,000 meters per minute. Its utility is based upon the fact that the required yarn tension can be generated by the yarn advancing means 1, and can be adjusted sufficiently high so that no laps form on the godet or take-up winding system. The removal of the yarn unwinding from the advancing means 1 requires high velocities of flow, but only relatively small tension forces.
FIGS. 3A-3C illustrate a yarn withdrawal apparatus in accordance with the present invention, and which incorporates a mechanical threading means for looping the yarn about the yarn advancing means 1. In this embodiment, the rolls 32, 33 of the yarn advancing means 1 are rotatably supported in a holder 40. The roll 33 is driven by a turbine positioned in the housing 8. The axes of the rolls 32 and 33 intersect at an acute angle, and both rolls are supported in the holder 40 so that the distance between their axes decreases from their free ends toward their bearing ends in the holder 40. The direction of drive of the roll 33 is indicated by the arrow 35. The suction means is positioned in the holder 40, and the suction tube 16 is located between the two rolls 32 and 33 and above the plane connecting the roll axes. As previously described in conjunction with the embodiments of FIG. 1 and 2, the suction means includes an annular duct which surrounds the suction tube 16 and which is connected to the tube 16 via air channels. Pressurized air is supplied to the annular duct through an inlet end 22, which also extends through a handle 39. The duct system inside the holder 40 is not shown in detail.
The yarn threading device is a U-shaped, bent rod 50, one end of which is pivotally mounted in the holder 40 and is disposed substantially parallel to the angle bisector between the two roll axes. Further, both the bearing in the holder 40 and the bearing end of the rod 50 are provided with the coarse thread for the purposes described below. Mounted on the other end of the rod 50 is a yarn guide 52. This yarn guide is a so-called "sawtooth" guide, i.e. it has a catching slot in which the yarn can enter laterally, but once caught it can not leave the same. The yarn guide 52 is pivotable about the axis of the post 53, but is not axially movable. The rod 50 can be pivoted in the direction of the arrow 54, i.e., in the direction of rotation of the yarn advancing rolls 32, 33.
The suction means exhausts through a yarn outlet passage 31 which leads to a waste bag 44 which is clamped thereto. The coarse thread 51 of the rod 50 is so designed that when the rod pivots in the direction of the arrow 54, it performs an axial movement in the direction of arrow 55, note FIG. 3B.
To catch a yarn and thread it onto a godet 30 of the processing machine, the yarn withdrawal apparatus of FIGS. 3A-3C is operated as follows. Initially, the yarn advancing from a spinneret is brought to the area of the opening of the suction tube 16, and drawn off. This is possible, since the yarn does not advance from the spinneret at a defined or very high speed. In the meantime, the air turbine in the housing 8 is actuated by pressurized air, and as a result, the roll 33 is caused to rotate, and so that it is driven substantially at the operational speed of the godet 30 on which the yarn is to be threaded. The yarn then advances along the thread line 20.1 as seen in FIG. 3A. The rod 50 is then rotated in the direction of arrow 54, and as seen in FIG. 3B, the yarn guide 52 will adjust itself to the yarn by rotating about the axis of the post 53. As the rod 50 rotates in the direction of arrow 54, the yarn is looped around the rolls 32 and 33, and since it rotates in the direction 54, the rod 50 also performs an axial movement in the direction of the arrow 55 by reason of the pitch of the coarse thread 51. Thus several axially displaced yarn windings will be looped around the rolls 32, 33 in the manner shown in FIG. 3C. The resulting thread line 20.3 is characterized in that the advancing yarn is first guided through the guide 52, deflected by the guide toward the roll 33, and then guided in two substantially complete windings around the rolls 32 and 33, and is subsequently removed from the roll 33 in its unwinding area 47 and drawn into the suction opening 16 for removal to the waste bag 44. The yarn can then be threaded onto the godet 30 which rotates at a high circumferential speed, and it may possibly also be wound onto a subsequent winding system of the yarn processing machine. By reason of the fact that the axes of the rolls 32, 33 intersect at an acute angle, the yarn windings 36 are axially separated so that no lap can form.
The yarn withdrawal apparatus as shown in FIG. 4 is provided with only one rotatably driven, cylindrical roll 33, which serves as the yarn advancing means which is supported in the holder 40. The suction tube 16 of the suction means terminates in the area of the unwinding end portion 47 of the roll 33. The roll 33 is driven in the direction 35, and an air turbine may serve as the drive for the roll 33, with the turbine being supplied with pressurized air in the same manner as the suction device, which is through the connection 22. The suction means is, for example, constructed in the manner described above with respect to FIGS. 1-3.
The mechanical threading device in the embodiment of FIG. 4 again comprises a U-shaped rod 50, with one flank supported coaxially through the roll 33, but rotatable independently of the roll in the direction 54. The other free flank of the rod 50 mounts a helically shaped yarn guide 56. To catch the yarn, the yarn is first drawn into the opening 16 of the suction means, and withdrawn in a thread line 20.1. The rod 50 is then rotated to position 50.1, in which the yarn guide 56 reaches the thread line 20.1, and as the rod 50 is further rotated in the direction 54, the yarn moves in the threads of the guide 56 upwardly in the direction of the arrow 55. As a result, the yarn is looped around the roll 33 in a number of windings, and otherwise is held in the thread line 20.3 by the wire guide 56. It should be noted that only a few windings are possible on the cylindrical roll, since otherwise there may be a risk of laps forming. However, it is also possible to use a conical roll for this threading apparatus, and it should be further noted that in the later embodiment, the flank of the rod 50 which is rotatably supported may alternatively be disposed along an axis which is parallel but offset from the axis of the roll 33.
The embodiment of FIGS. 5-7 is characterized by a pneumatic system for threading the yarn onto the advancing roll of the apparatus. More particularly, the yarn advancing system 1 of the apparatus comprises a conical roll 33a which is mounted to a shaft 2 which is rotatably supported in bearings 4 for rotation in the housing 5. A turbine 3 is fixedly mounted to the opposite end of the shaft 2. The housing 5 comprises a roll housing portion 6, a bearing housing portion 7 and a drive housing portion 8. A conical bore 9 is positioned in the housing portion 6, which terminates in a cylindrical bore 10. The conical bore 9 surrounds the conical roll 33a, leaving a narrow gap 11.
The shaft 2 may for example have a diameter of about 1 mm, and the inside wall of the conical bore 9 includes a helical channel 12. Also, the wall of the housing includes an inlet opening 13 which communicates with one end of the channel 12, and an outlet opening 15 which communicates with the opposite end of the channel 12 and which also serves as the inlet opening of the suction tube 16.
A yarn inlet housing is mounted adjacent the inlet opening 13, and the housing includes a yarn inlet passage 14 which communicates with the opening 13. The housing also includes injector nozzles 17, which are supplied with air via a connection 18 and an annular duct 19. The injector nozzle 17 generate a partial vacuum at the entry end of the inlet passage 14, so that the advancing yarn end 20 will be drawn inwardly.
A suction means 24 is positioned downstream of the roll, and for this purpose, the yarn duct 16 is provided with injector nozzles 21, which are similarly directed in the direction of material flow, and which are supplied with pressurized air through the tube 22 and the annular duct 23. The suction means generates, or assists in generating a suction air current in the inlet passage 14, channel 12, and the yarn suction tube 16.
The turbine wheel 3 comprises two end plates 25, with a number of turbine blades 26 mounted therebetween, for example by welding, note FIG. 7. The front end plate 25 of the turbine 3 is fixedly connected to the shaft 2, and the turbine housing forms an annular chamber 80 about the turbine. A compressed air passage 27 terminates in the chamber 80, and is directed substantially tangentially into the same. The configuration of its outlet opening is conventional and is generally known in the air turbine art, and is thus not described in greater detail herein. The required air pressure can build up in the annular chamber 80, and so that the turbine wheel can be driven at speeds up to 10,000 revolutions per second.
In the center of the turbine 3, the blades leave an open discharge passage 28. On the bearing side, the passage 28 is closed by the front plate 25, and in the opposite direction the passage 28 communicates with an axial air outlet opening 29 in the housing, and through an opening in the rear disc 25.
Based upon existing experience, it should be noted that the channel 12 in the wall of the bore 9 is suited for assisting in threading the yarn about the roll, and also for a reliable and reproducible catching of the yarn. This is achieved in that the channel serves to develop a high energy flow field in its cross sectional area, the direction of flow being well defined by the channel geometry. Thus it is accomplished that the yarn is advanced from the intake passage 14 and the inlet opening 13 of the channel to the outlet opening 15 of the channel and thus also into the yarn suction tube 16.
To describe the operation of the embodiment of FIG. 5, pressurized air is supplied to the passage 27, and as a result, the turbine 3 and the shaft 2 and the conical roll 33a are caused to rotate until the circumferential speed of the godet 30 is reached. Thereafter, the injector nozzles 17 and 21 receive pressurized air via the passages 18 and 22, respectively. As a result, a suction air current develops at the entry to the yarn inlet passage 14, which continues as a looping flow about the conical roll and then exhausts in the outlet tube 16. The velocity of the air is preferably higher than the yarn speed, and to catch a yarn advancing from a spinneret, it is only necessary that the air flows at least at the yarn speed. It is not necessary that high tension forces be exerted on the yarn. In a fraction of a second, the yarn is looped around the conical roll, and in so doing, the yarn is brought into contact with the surface of the roll. As a result, the yarn is withdrawn by the frictional contact with the surface of the roll.
It should be noted that the circumferential speed of the conical roll 33a is, in the area of the yarn contacting plane, at least equal to the yarn speed which is established by the feed godet 30. Preferably, the circumferential speed of the conical roll is also greater than such yarn speed in the area of the outlet opening 15. The roll therefore exerts a considerable friction force on the yarn, and this frictional force suffices to impart a sufficiently high yarn tension so that the yarn can be threaded onto the feed godet 30 without risk of lap formation.
FIG. 5A illustrates a manually operable control system for the delivery of pressurized air from a common source to the embodiment of FIG. 5. In the nonoperative condition, the air supply is stopped, which is illustrated by position I. In the manually adjusted position II of the valve, the pressurized air is supplied only the air turbine via line 27. The valve may then be switched to the operating position III, wherein the suction means 24 receives a substantial portion of the available amount of pressurized air via line 22, whereas the turbine is supplied with a reduced quantity by reason of a throttle. It is also possible to entirely disconnect the supply line to the turbine via the throttle. To form a yarn winding on the advancing means, it will usually suffice if the yarn advancing means idles. In the position IV, the valve is switched so that the suction means 24 receives limited air via another throttle, whereas a substantial portion of the air is supplied to the turbine.
As previously mentioned, the channel 12 in the wall of the housing assists in the formation of a loop in the advance of the yarn and an axial feed, as well as in an increased, reliable catching of the yarn. However, tests have unexpectedly shown that a good reliable catching is also achieved when the inside wall of the housing 9 is smooth.
The rotation of the roll 33a of the advancing means 1 contributes to the formation of the looping air whirl and the advance of the yarn from the yarn inlet opening 13 to the yarn outlet opening 15, and it is possible to arrange the yarn inlet opening on the same normal plane as the yarn outlet opening. In such case, however, there will be a greater risk of lap formation. As shown in FIG. 5, an axial advance of the feed is achieved and the yarn inlet opening 13 and the yarn outlet opening 15 are axially displaced relative to each other, and with the yarn suction duct being located downstream of the roll so that a defined suction current extends from the yarn inlet opening to the yarn outlet opening, thereby lessening the risk of lap formation.
After the yarn is caught, the air flow in the path extending from the yarn inlet passage 14, channel 12, and suction tube 16 can be substantially reduced, since the yarn is then advanced substantially by reason of its frictional contact with the surface of the conical roll.
It is preferable that the conical roll 33a has a diameter which constantly decreases toward its free end during the portion which is engaged by the yarn, and that it have a friction coefficient and an angle of cone which are adapted to each other so that the yarn cannot be held on the surface by self engagement, but will slide downwardly when it is under an appropriate yarn tension. For this reason, the formation of a lap on the conical roll is effectively precluded, and a lap will automatically slide toward the free end of the roll, and in so doing, it will necessarily pass the opening 15, i.e. the entry of the suction tube 16. Most laps will be caught here, and removed through the suction tube 16 by means of the injectors 21. If a lap should form which is not removed at this point, it will continue to slide to the free end of the conical roll, where it either drops out of the housing or can be readily removed. As indicated at 31, a flexible hose may be connected to this portion of the housing and which leads to a waste container. By reason of the fact that there is a considerable air pressure in the gap 11 between the inside wall 9 of the housing and the surface of the conical roll 33a as a result of the air flow in the inlet passage 14, channel 12, and yarn outlet tube 16, there will be an adequate air flow in this gap 11 toward the free end of the roll so as to remove remnants of yarns and laps. Moreover, it has been found that a possible lap clogs the gap 11 like a piston, and is advanced by the air pressure which builds up behind it, in the direction of the free end.
Further embodiments which are adapted for pneumatically threading the yarn are shown in FIGS. 8 and 9. In the embodiment of FIG. 8, the housing 5 is provided with a bore which is tapered in its lower portion 9, and the upper front end of the housing is closed by a cover 77 which is connected with the housing by bolts 74. A housing 8 on the cover 77 is concentric with the bore 9 in the housing 5 and mounts the bearing 4 of the conical roll 33b. The roll 33b is a component part of a structural unit which comprises a shaft 2, turbine 3, and the roll 33b. The shaft 2 is fixedly connected to one plate 25 of the turbine, and is freely rotatable in the housing 8 by means of two ball bearings. The blades 26 of the turbine 3 are mounted between the two end discs 25, note again FIG. 7. Mounted on one of the plates 25 is the advancing roll 33b, and the roll has substantially the same conical configuration as the bore 9 in the housing 5. As a result, the winding members form with the bore and annular yarn chamber 9, which also tapers toward the free end of the advancing roll 33b. The angle of the cone of the roll 33b is smaller than the angle of cone of the bore 9, and as a result, the width of the chamber 9 narrows toward the end of the roll. At its upper mounted end, the advancing roll is provided with a lip 38, which forms with the cylindrical portion of the bore in the housing 5 a narrow passage in the form of an annular nozzle 79.
The upper cylindrical portion of the bore in the housing 5 forms an annular chamber 80, which houses the turbine 3. A compressed air channel terminates in this annular chamber 80, and the passage 27 is directed substantially tangentially into the chamber 80. Since the lip 38 of the roll 33b forms a strong throttling resistance with the cylindrical chamber wall of the housing, the necessary air pressure can build up in the annual chamber 80, and the turbine can be driven at speeds up to 10,000 revolutions per second.
The blades 26 of the turbine are open in the center thereof to define a discharge passage 28, and the discharge passage is closed toward the bearing end by one of the plates 25. The passage 28 communicates with a central duct 81 which extends through the roll 33b, via a large opening in the other disc 25. The post 73 in the center of the turbine 3 is shaped so that the air passing through the blades 26 is deflected in the direction of the central duct 81 in the roll 33b.
A yarn inlet passage 14 is positioned in the housing 5 on the side of the lip 38 facing away from the annular chamber 80. The yarn inlet passage 14 is disposed on a plane substantially tangent to the advancing roll 33b, and it is possible to arrange the yarn inlet passage 14 on a normal plane of the roll. However, the passage 14 may also be arranged so that it crosses, in the projection of FIG. 8, the axis of the roll at an obtuse angle. In other words, the yarn advancing through the passage 14 may have a component of movement in the direction toward the free end of the roll.
An end piece 68 is attached to the housing 5 and includes a conical, rounded and closed cavity 69. The end piece 68 is further provided with a wide opening 70 on its side, and this opening is rounded toward the cavity and extends in a normal plane in the area adjacent the smallest end of the roll 33b. The opening 70 also is aligned with the suction tube 16, which includes a flange which is joined to the end piece 68 of the housing and which is provided with air injectors 21. The cross section of the yarn tube 16 is adapted substantially to the cross section of the opening 70, at the point where the opening 70 communicates with the tube 16.
To describe the operation of the embodiment of FIG. 8, the same sequential operation is used for threading the yarn as in the embodiments of FIGS. 5 and 5A. Initially, the turbine rotation is started, and the supply of pressurized air to the turbine is substantially restricted, and the suction means in the suction tube 16 is supplied with pressurized air. At this time, the yarn is held in front of the inlet passage 14, and so that it will be drawn therein. The circumferential speed of the roll 33b corresponds at least to the yarn speed, and the yarn is thus brought into circumferential contact with the roll and formed into windings, which extend around the roll. As a result of the conical configuration of the roll and the air flow which proceeds from the annular chamber 80 around the lip 38, the windings will advance toward the small end of the roll, where they accumulate. Also by reason of the air flow from the turbine 3 and the air flow in the yarn chamber 9, the yarn tangle falling from the roll is not only collected in the cavity 69, but it is also advanced in the direction of the opening 70 and suction tube 16, as a result of the air flow in the suction tube 16. In the tube 16, the yarn tangle is engaged by the air from the injectors 21, and brought under tension, by which the tangle is again straightened to a smooth yarn. Since the suction tube 16 is located in a normal plane, which intersects the roll in the area of its smallest end, the yarn will then be tangentially withdrawn from the roll, as indicated by the line 71. Thereafter, a substantial portion of the pressurized air is again supplied to the turbine 3, and the suction means receives only so much of the air to assure an adequate tension is produced in the yarn unwinding from the roll, and so as to produce a tension in the yarn advancing to the roll 1 which develops from the loops.
The yarn windings which are formed on the roll 33b in the normal plane of the yarn inlet passage, continue to slide along the conical roll, due to low friction and the air flow. The yarn tension upstream of the inlet passage 14 may be adjusted by the adjustment of the speed and the torque of the roll, to be sufficiently high so that the yarn may be threaded on the godet, without laps being formed. The yarn windings which slide downwardly on the conical roll, lose their tension however, so that the yarn can be easily transported into the suction tube 16. The necessary suction flow can be easily generated by the injectors 21.
The embodiment of FIG. 8 is also suitable for depositing a yarn in the form of a web, felt, or as waste.
The embodiment of FIG. 9 corresponds substantially to that of FIG. 8 with respect to the advance of the yarn, and this embodiment may be used in particular for the waste removal or also for the further processing of the yarn. The arrangement of the yarn withdrawal means of FIG. 9 corresponds to that described in conjunction with FIG. 8, with the following addition. In particular, the housing 5 is provided on its circumference with a wide slot 61 which extends over a portion of the circumference and along a sector angle, such that the yarn can be inserted through this slot and looped about the advancing roll 33c of the yarn advancing means 1. A jacket 62 is slideably mounted on the housing 5, and a spring 63 pushes the jacket to its extreme right hand position. Also, the jacket is provided on its periphery with a yarn intake device which includes an inlet passage 14.
The yarn intake device is directed substantially tangentially to the periphery of the roll 33c, and its yarn passage 14 also extends through the jacket 62. The device may be equipped with injectors as indicated at 18, which produce a suction current in the passage 14. Also, the device is disposed so that it is located in its extreme right hand position, which is illustrated in FIG. 9, and substantially in the normal plane and the working area of the advancing roll 33c, which has the largest diameter. A yarn guide 65 is also attached to the jacket 62, and the yarn 59 advancing from a spinneret and which is to be threaded onto the feed godet 30 is tensioned between the stationary yarn guides 66 and 67, as well as by the guide 65 which moves with the jacket 62. As a result, the jacket is displaced to the left against the force of the spring 63, as the yarn tension increases. Stationary is here meant that the yarn guides 66 and 67 are not movable relative to the housing 5 of the apparatus.
To describe the operation of the embodiment of FIG. 9, it will be understood that the operation is substantially the same as for the embodiment of FIG. 8, with the following variations. The engagement of the yarn in the circumferential contact with the roll 33c is facilitated when the jacket 62 is displaced against the force of the spring 63 and toward the left as seen in FIG. 9, so that the yarn contacts the roll 33c initially at a smaller diameter. Once the yarn is caught, the jacket is released to its extreme right hand position, which is defined by the spring 63 and a stop. Since the suction tube 16 extends in a normal plane which intersects the roll 33c in the area of its smaller diameter, the yarn is tangentially withdrawn from the roll, as is indicated by the line 71.
The yarn windings on the roll 33c will slide further downwardly, due to the conical configuration and low friction, and it is possible to adjust the yarn tension in front of the inlet passage 14, not only by the adjustment of the speed of the roll 33c, but also by the displacement of the jacket 62 and thus the point of contact of the yarn with the roll, and such that the yarn can be placed on the feed godet 30 which operates at a constant, high circumferential speed, without risk of laps. However, the windings which slide downwardly on the roll lose their yarn tension, so that the yarn which advances, for example, to a waste container or a container for collection or transport, can be easily advanced in the suction tube 16, and the required air flow can be easily produced by the injectors 21.
As is also indicated in FIG. 9, the yarn can be withdrawn by an additional delivery system. Furthermore, the yarn withdrawal apparatus may serve to control the yarn tension between the feed godet 30 and the yarn withdrawal apparatus. To this end, the yarn is guided in the illustrated manner over the yarn guides 66, 67, 65 which serve to monitor the yarn tension.
The width of the slot 61 defines the working range in which the yarn contact point of the roll 33c can be displaced. Depending on the position of the yarn guide 65 and the yarn intake device, the yarn is wound on the roll 33c at a higher or lower winding speed, thus making it possible to control and regulate the yarn tension by adjusting the position of the jacket 62. When the yarn tension increases, the yarn guide 65 and thus also the jacket 62 are displaced to the left, whereby the yarn intake device comes to lie in a normal plane having a smaller diameter. Consequently, the winding speed is lowered and the yarn tension is reduced. An equilibrium is thus obtained between the yarn tension, and the force of the spring 63. It is therefore possible to preset a desired value of the yarn tension by adjusting the force of the spring 63, and thus insuring that the yarn tension which the yarn withdrawal apparatus imparts to the yarn, is always adequate to avoid laps on the feed roll 30, or to exert constant forces on the yarn for influencing its properties.
In the drawings and specification, there has been set forth preferred embodiments of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only, and not for purposes of limitation.
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A yarn withdrawal apparatus is disclosed for temporarily withdrawing a freshly spun and continuously advancing yarn to a waste container when the spinning operation is interrupted, and for thereafter threading the yarn onto the feed godet or winder of the spinning machine. The apparatus includes a yarn advancing means in the form of one or more rolls and which is adapted to have the yarn looped thereabout. Drive means is provided for rotating the roll or rolls of the advancing means, and a suction means is provided for withdrawing the yarn from the advancing means. In one embodiment, the yarn is initially drawn into the suction means, and then looped about the rotating roll of rolls which serve to frictionally engage the yarn and apply a high yarn tension, and so that the yarn is then in condition to be threaded onto the feed godet of the spinning machine. In another embodiment, a pneumatic system is provided which serves to loop the yarn about a single rotating roll and then guide the yarn into the suction means, and so that the roll again serves to impart a high degree of tension to the yarn.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a system and method for detecting objects under the surface of the ground, and in particular, to three-dimensional imaging to detect an underground target item such as a mine.
[0003] 2. Background of the Invention
[0004] Buried mines on, e.g., a beachhead, are a major threat to amphibious landing forces and a severe obstacle to a rapid amphibious landing. Clearing mines prior to a full-scale landing is a slow and tedious process that requires manual location and neutralization of the individual mines. This process includes the use of heavy machinery to detonate anti-personnel mines while, at the same time, facing the threat of larger anti-tank mines.
[0005] Ground penetration radar systems using transistor generated short pulses have been in use for decades for geophysical applications. These systems can be relatively compact, approximately the size of a lawn mower, and are generally pulled along the ground with the radar signal directed downwardly into the ground.
[0006] Recently, airborne (e.g., from an aircraft) synthetic aperture radar (SAR) has also been used in mine detection. SARs typically are side-looking radar which produce a two-dimensional image of the earth's surface. In the past, SARs operated with bandwidth up to 500 mHz 1 GHz resulting in range resolution of 6 inches.
[0007] In addition to aircraft-based radar systems, ground-based two-dimensional SAR imaging systems have been used to locate buried mines. These ground-based SAR systems use an impulse radar disposed on an elevated platform and operated in a side-looking mode.
[0008] One disadvantage with current radar-based mine detecting systems is that these systems tend to be limited to generating only a two-dimensional image rather than a three-dimensional image. A two-dimensional imaging system has limited capabilities with respect to the accuracy and precision by which the mine detection system operates when compared with that potentially available with three-dimensional imaging system.
[0009] An additional disadvantage with current SAR systems is that these systems produce an image of limited resolution. Since SARs have operated at bandwidths up to 16 Hz, SAR range resolution is limited to about six inches, as indicated above. Consequently, the six-inch imaging resolution reduces the applicability of SARs in buried mine imaging, detection and classification because mines tend to be 3 inches to a foot in diameter.
BRIEF SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, an aerially disposed three-dimensional SAR system is provided which enables subsurface (i.e., underground) object detection. Such objects include, but are not limited to, mines. The three-dimensional SAR includes a radar transmitter and an array of receiving antennas which are aerially translatable, i.e., which are mounted on an aircraft so as to be transported with the aircraft. Three-dimensional SAR imaging is obtained from a reflected radar signal detected by the antenna array as the array traverses over a target area.
[0011] According to one aspect of the invention, a radar system includes an aircraft for detecting buried objects from the air, for overflying a target area of interest, a radar transmitter, carried by the aircraft, for producing a radar signal of a frequency or at least three gigahertz, a plurality of radar receiving antennas, carried by the aircraft and forming an antenna array, for receiving a reflected signal produced by reflection of said radar signal, and a processor for generating a three-dimensional image of said object from the reflected signal.
[0012] According to another aspect of the invention, a method is provided for detecting a subsurface object in a target area from an aircraft. The method includes transmitting a pulsed radar signal having a frequency of at least three gigahertz using a radar transmitter dispersed on the aircraft, receiving a return of the transmitted signal reflected by the subsurface object with a plurality of radar receiving antennas disposed on the aircraft and forming a receiving antenna array, and generating a three-dimensional image based on the received return of the transmitted signal.
[0013] An advantage of the present invention concerns the use of an aerial translatable three-dimensional synthetic aperture radar for the detection of buried objects such as mines.
[0014] An additional advantage of the present invention concerns enhanced image resolution compared with conventional SAR systems by implementing SAR using a radar signal having a frequency of at least three gigahertz.
[0015] Yet another advantage of the present invention concerns the use of various types of wide band radar signals such as impulse radar signals and frequency-stepped pulse compression radar signals.
[0016] Further features and advantages of the present invention will be set forth in, or apparent from, the detailed description of preferred embodiments thereof which follows.
BRIEF DESCRIPTION OF THE DRAWING
[0017] [0017]FIG. 1( a ) is an elevational view of an aircraft-mounted radar system according to a preferred embodiment of the present invention, with the aircraft shown in a tilted position for illustrative purposes;
[0018] [0018]FIG. 1( b ) is a perspective view of the radar system of FIG. 1( a ); and
[0019] [0019]FIG. 2 is a schematic diagram, partially in block form, of the basic operation of the system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring now to the drawings, and in particular to FIGS. 1 ( a ) and 1 ( b ), illustratively depicted therein is radar system 10 according to the present invention. Radar system 10 includes radar transmitter 12 which generates radar signal 14 of at least three gigahertz, corresponding to the S-band and X-band carrier frequencies. Preferably, the frequency is within the range of three to ten gigahertz to provide good resolution with acceptable signal attenuation. However, higher frequencies can be used to provide enhanced resolution where signal attenuation is accommodated.
[0021] The radar signal 14 is directed towards the surface 16 of the underlying ground 18 of a target area denoted 19 . Radar signal 14 penetrates surface 16 and reflected signals 22 are produced by the radar signal 14 reflecting off of the surface of buried objects indicated at 20 .
[0022] An antenna array 24 is formed of a plurality of receiving antennas 26 which receive reflected signal 22 . Receiving antennas 26 are disposed along wings 28 of an aircraft 30 . The real aperture, a r of antenna array 24 is defined by the diameter of the individual receiving antennas 26 . A horizontal aperture for the radar system 10 is defined by the width D of the antenna array 24 . The height of the aircraft 30 is indicated as h.
[0023] To enhance the horizontal aperture of the radar system, some of the receiving antenna 26 are located on extendible booms 32 located at the opposite ends of wings 28 . As will be obvious to one of ordinary skill in the art, the lengths of the booms 32 may be extended or varied in order to produce larger or variable horizontal apertures as necessary.
[0024] To further aid in an understanding of the implementation of radar system 10 , FIG. 2 provides a block diagram which schematically depicts the operation of radar system 10 . As described above, during the operation thereof, radar transmitter 12 generates and directs radar signal 14 toward the surface 16 of ground area 18 . The radar signal 14 is reflected off of the surface of a buried object 20 thereby forming reflected signal 22 . A portion of reflected signal 22 is received by the antenna array 24 .
[0025] When radar system 10 is deployed in mine detection, carrier frequencies above L-band yield depth penetration beneath the surface 16 while also providing attenuation of backscattering from material at depths greater than typical, standard mine deployment. Three-dimensional SAR imaging is achieved from radar system 10 by aerially traversing target area 19 while transmitting a radar signal 14 thereto and receiving a reflected signal 22 therefrom by means of receiving array 24 .
[0026] Three-dimensional images may be generated from radar system 10 of varying resolution based on radar frequency, along track real receiver aperture dimension (a) cross track array aperture, and altitude h of aircraft 30 . More specifically, three-dimensional imaging is obtained from reflected signal 22 from range resolution, along-track resolution, and cross-track resolution. The range resolution is obtained from reflected signal 22 , independently of the height h of aircraft 30 . The along-track resolution is obtained through standard SAR processing known in the art. The along-track resolution obtained by synthetic aperture processing is also independent of the height h of aircraft 30 , but limited by the along-track real aperture size a r . Table 1 shows various along-track resolutions obtainable at different radar frequencies.
TABLE 1 Achievable Resolutions Range Res. Along Track Cross Track Freq. (GHz) Alt. (FT) (IN) Res. (IN) Res. (IN)* 1 40 4.5 3 4.5 1 80 4.5 3 9.0 3 40 1.5 1.5 1.5 3 80 1.5 1.5 3.0 9 80 1 1 1 9 240 1 1 3
[0027] Cross-track resolution is determined by the array aperture size, i.e., based on width D of antenna array 24 and is given by:
[0028] Δy=hλ/2D where
[0029] Δy=Cross-track resolution,
[0030] h=Height of aircraft,
[0031] D=Width of antenna array, and
[0032] λ=Wavelength.
[0033] Table 1 above shows cross-track resolutions for a 40 foot wide antenna array at various altitudes and radar frequencies. During three-dimensional image processing, a processor 32 on board aircraft 30 receives a signal over connection 34 from receiving array 24 . Processor 32 then generates a three-dimensional image which may be stored in a memory 36 also located aboard aircraft 30 . Further, processor 32 may also be used to determine the identity of an object corresponding to the image. For example, the three-dimensional image generated by processor 32 may be compared to a previously stored image of a mine in an attempt to determine whether the received image is that of the mine.
[0034] Alternatively, an off-board processor 40 can be used to produce the three-dimensional image and may be able to identify objects corresponding to the received images thereof. Processor 32 transmits data via data link formed by antennas 42 to off-board processor 40 . Further, off-board processor 40 can generate the image for viewing on an associated display 44 .
[0035] Radar system 10 allows for the mapping of a subsurface minefield by detecting a three-dimensional section of the minefield layout. Such three-dimensional resolution imaging provides advantages not possible with conventional two-dimensional surface SAR, including the ability to obtain depth information and to provide classification of mines according to shape. In addition, radar system 10 provides radar cross-section (RCS) detection and identification of the interior metal components of plastic mines. Further, the radar system 10 enables the rejection of ground surface reflections, a.c. polarization diversity can be used for image enhancement and the rejection of ground surface reflections.
[0036] An example of a preferred implementation of radar system 10 will now be considered. It will be understood to that this example is provided to enhance understanding of the present Invention and not to limit the scope or adaptability thereof.
[0037] The necessary calculation to determine power requirements for a three-dimensional SAR in a ground penetrating mode of the present invention is provided by the formula:
P T = S N R ( 4 π ) 3 h 4 k T L N F L r e f A τ G T G R σ λ 2
[0038] where
[0039] SNR=signal to noise ratio per pulse (frequency) from receive array=10 dB
[0040] h=height=80 ft
[0041] k=Boltzmann Constant=1.38×10 −23 J/K
[0042] T=antenna noise temperature=400K
[0043] L=system losses=10 dB
[0044] N f =receive noise figure=7 dB
[0045] L ref =reflection at earth's surface=10 dB
[0046] A=earth attenuation=10 dB
[0047] τ=pulse width=0.5 μs
[0048] G T =transmit gain=15.8 dB
[0049] G R =receive gain=32.2 dB
[0050] σ=Radar cross section=0.01 m 2
[0051] λ=0.1 m (Frequency=3 GHz)
[0052] P peak =61.0 mW
[0053] P av =9.5 mW for duty factor 0.155
[0054] In this example, the radar transmitter 12 operates at S-band. Ground attenuation and reflection from surface 16 are factored in when considering the necessary power requirement. The typical peak and average transmit power requirements are in the milliwatt range.
[0055] In this example, the target volume, i.e., the three-dimensional target swath, is 1 nautical mile×320 feet×1 foot deep. The on-board processor 32 comprises a 1 gigahertz Pentium PC with a 20 gigabyte storage memory device 38 . If all data collected from the three-dimensional swath is transmitted in real-time to an off-board processor, a data link of 5.4 MBPS is provided. One example of an applicable datalink is the high bandwidth data link (CHBDL) which is used by the U.S. Navy and which has a capacity of 274 MBPS. If all the data is stored on-board aircraft 30 , and then transferred off-board for processing after the aircraft lands, the on-board storage memory requirement is about 0.4 gigabytes.
[0056] In order to effectively discriminate between mines and other debris such as rocks and roots, the present radar system operates at high frequencies. However, at such high frequencies, ground attenuation increases dramatically as the radar frequency increases. Therefore, it is preferable to select a desired frequency by factoring in ground attenuation when maximizing image resolution.
[0057] A second area of concern is that the reflection from the surface 16 will disrupt three-dimensional imaging. The reflection produces a large return which must be range-gated out in order for the smaller return radar signal from the buried mine or other target to be discernable. Therefore, it is advantageous for processor 32 to provide range gating.
[0058] In a test of the range gateout functions of the present radar system, a small metal plate was buried in a bucket of moist sand which was illuminated with an impulse-modulated X-band radar. It was determined that the surface of reflection could be ranged out by an on-board processor 32 and/or off-board processor 40 . The soil attenuation at X-band was measured and found to be 114 dB/m. A 114 dB/m attenuation is within an acceptable range for a three-dimensional SAR imaging system. Therefore, land mines buried up to one foot in depth may be readily detected from an aircraft flown above a target area using the present system's three-dimensional SAR.
[0059] As discussed above, prior to the present invention, no other SAR system operated in high frequencies such as S-band and X-band as it was believed that ground attenuation would be too severe. However, the inventors have determined that attenuation effects at S-band and X-band were acceptable when using the present system for mines buried at shallow depths. Further, the high frequencies used by the present invention permit the fine resolution necessary for mine classification.
[0060] In addition to detecting mines, the present system may be adapted for use in detecting other objects buried near the surface of the ground. Further, the present system can be used to detect objects beneath the surface of fresh water. Other uses of the present invention include archeological exploration at the surface, detection of buried bunkers, and walls and the detection of buried persons.
[0061] Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.
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A radar system for generating a three-dimensional image includes a radar transmitter which is operable to produce a radar signal of a frequency of at least three gigahertz. A plurality of radar receiving antennas from an antenna array. The antenna array is aerially translatable. For example, in one embodiment, the antenna array is disposed along the wings of an aircraft which, in operation, flies over the intended target area. A three-dimensional image is generated from a reflected radar signal returned from the surface of an object in response to the transmitted radar signal. The radar system may be incorporated into an aircraft and adapted to detect subsurface objects such as mines buried beneath the surface of the ground as the aircraft traverses over a target area.
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BACKGROUND OF INVENTION
This invention relates to the dual use of a memory storage function and a processing function as a means of programming the configuration of a telephone. The Dial Pulse Rate, Dial Pulse Make/Break Ratio, DTMF Duration, DTMF Inter Digit Delay, Pause Duration and other telephone configuration parameters are typically set during the design phase and are not programmable after manufacture. The configuration parameters set signal timing for country specific applications, audio volume levels for ringing and control tones, telephone keypad illumination timing, and automatic channel select control for applications involving the operation of cordless phones in close proximity to sources of interference. In particular, this invention provides a means to program all of the aforementioned telephone configuration parameters and more which were not mentioned using the telephone keypad or other input means.
THE PRIOR ART
It is well known in the art that microprocessors can be used in telecommunications as shown by Subhash Bal, "New Generation Microprocessor for Telecommunication Applications." Proceedings 1980 International Conference on Communications, Seattle, Wash., (Jun. 8-12, 1980) pages 11.5.1-11.5.4. It is also well known that dial memory registers are used to store commonly used telephone numbers. The dial memory registers are activated through separate buttons or switches and the telephone number (address) is entered into memory through the telephone keypad. However, the prior art does not teach the use of the aforementioned microprocessor and dial memory register(s) as a means to program the configuration parameters of a telephone.
The following is a list of the configuration parameters of a telephone and the definition of each:
1) Dial Mode: the dialing mode, either dual tone multi-frequency dialing (DTMF) or pulse dialing, of a telephone which facilitates communication with the main office.
2) Dial Pulse Rate: the frequency of loop current interruptions, measured in pulses per second (pps), made during the pulse dialing process.
3) Dial Pulse Make/Break Ratio: the ratio of the time that loop current flows to the time that loop current does not flow during the pulse dialing process.
4) Pulse Inter-Digit Delay: the amount of time, in milliseconds, required between bursts of pulses during the pulse dialing process.
5) DTMF Duration: the amount of time, measured in milliseconds (ms), required for the main office to correctly interpret a DTMF tone generated by a caller's telephone during the DTMF dialing process.
6) DTMF Inter-Digit Delay: the amount of time, measured in milliseconds (ms), required between DTMF tones during the DTMF dialing process.
7) Pause Duration: in an application where a first key digit must be depressed to gain access to an outside telephone line, the amount of time, in milliseconds, required between the first key digit and the rest of a telephone number.
8) Flash Duration: an amount of time where there is a simulated depression of a hook switch, in milliseconds, which induces call waiting or conference call operation.
9) Ringer mode: a mode indicating that a telephone ringer is inhibited or permitted.
10) Ringer Tone: the audible frequencies emitted from a telephone of a called party indicating an incoming call.
11) Ringer Volume: the audible intensity level of a telephone ringing mechanism.
12) Ring Pattern Ignore: in an application, for example, where in-house phone calls have one ring pattern and outside calls have another ring pattern; the ability to inhibit a telephone ringer based on an incident ring pattern.
13) Key Beep Tone: the tone of an audible feedback signal emitted from a caller's receiver when a key is depressed.
14) Key Beep Volume: the audible intensity level of a feedback signal which emanates from a caller's receiver when a key is depressed.
15) Key Beep Duration: the amount of time that a feedback signal is emitted from a caller's receiver when a key is depressed.
16) Receiver Volume: the intensity level of any audible signal which is emitted from a telephone receiver.
17) Key Pad Illumination Duration: the amount of time, measured in seconds, that a keypad of a telephone remains illuminated after it is activated.
18) Automatic Channel Select Mode Enable/Disable: a signal which enables or disables an automatic carrier frequency selection process for the transmit/receive channel of a cordless telephone.
19) Automatic Channel Select Permit/Inhibit: a plurality of signals which selectively permit or inhibit the availability of a specific transmit/receive channel of a cordless telephone.
The aforementioned configuration parameters of a telephone can be categorized into the three groups shown below in Table 1. Additionally, as an illustration, the configuration parameter values of a cordless telephone used on average by a person in North America are shown. It is noted that user specific and cordless specific configuration parameters are more likely to be programmed by an end user than a manufacturer. The manufacturer is likely to program the location specific configuration parameters.
TABLE 1______________________________________Illustrative example of the configurationparameter values of a cordless telephone used inNorth America.Category Configuration Parameter Value______________________________________location Dial Mode DTMFSpecific Dial Pulse Rate 10 pps Dial Pulse Make/Break Ratio 40/60 Pulse Inter-Digit Delay 700 ms DTMF Duration 50 ms DTMF Inter-Digit Delay 50 ms Pause Duration 400 ms Flash Duration 400 msuser Ringer Mode permittedspecific Ringer Tone standard Ringer Volume med. high Ring Pattern Ignore inhibit Key Beep Tone tone 1 Key Beep Volume low Key Beep Duration long Receiver Volume med. high Key Pad Illumination Duration 10 seccordless Automatic Channel Select Mode Enabledspecific Automatic Channel Select Ch1 permitted______________________________________
The operation of a cordless phone, specifically regarding an automatic channel select feature, is presented and discussed in detail in the prior art U.S. Pat. No. 5,044,010. Cordless telephones are discussed herein because their higher complexity over corded phones gives rise to a presentation of additional configuration parameters. This invention is suited to being used with both cordless and corded telephones.
SUMMARY OF THE INVENTION
The present invention is directed towards a system which provides a means for programming the configuration parameters of a telephone. The invention generally consists of a control means, memory means and modified telephone hardware of the prior art. Most of the telephone hardware of the prior art, whether for a corded telephone, cordless telephone or a cellular telephone, will allow implementation of the present invention; however some circuits of the prior art may require slight modifications to accept signals which alter their transfer functions in accordance with this invention. The memory means is used for the dual purpose of providing a user accessible storage medium for storing telephone configuration parameter data and dialing digits of a commonly called telephone number. In alternate embodiments the memory means may be solely used to store telephone configuration parameter data. The control means has resident software which facilitates interpretation of the data of the dual memory means, transitions between normal operating modes and the configuration parameter programming mode, and the alteration of the transfer functions of some telephone circuitry in accordance with generated control signals.
DESCRIPTION OF THE DRAWING
The invention can be better understood when considered with the following drawings wherein:
FIG. 1 is a block diagram of a cordless telephone which is suited to incorporate the configuration parameter programmability of the present invention;
FIG. 2 is a high level diagram of a dual dial memory register of the present invention; and
FIG. 3a through 3f is a software flow diagram which defines a portion of the actions taken by the control unit of the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is directed to providing a telephone with a means to enable a service person or an end user to program the configuration parameters of a telephone for its use in a particular application. This invention makes dual use of a dial memory register, found in most telephones. This dual dial memory register is used to store commonly called telephone numbers and configuration parameter data of the telephone. In alternate embodiments a memory means which is only used to store the configuration parameters of a telephone may be employed.
This embodiment discusses using the invention in a cordless telephone. The advantages over the prior art that this invention provides are not limited to cordless telephone applications. Although corded telephones are also suited to using this invention, the higher complexity of a cordless telephone introduces more configuration parameters than that of a corded model and, therefore, facilitates a broader discussion of the invention.
FIG. 1 shows a block diagram of a cordless telephone employing the configuration programming means of the present invention. As shown, the cordless telephone generally comprises a handset unit 10 and a base unit 15 which are both operable on a plurality of communication channels. Included in the handset unit 10 is a control unit 110 which provides a number of control functions. This control unit 110 may be implemented through the use of a microcomputer containing read-only-memory (ROM), random-access-memory (RAM) and through the use of proper coding. Such a microcomputer is known in the art and is readily available from semiconductor manufacturers such as Philips, Intel and AMD.
The control unit 110 configures a radio frequency (RF) transmitter 113 and an RF receiver 114 for operation on each of a plurality of channels, thus allowing the automatic channel select configuration parameters to be programmed. Prior art U.S. Pat. No. 5,044,010 presents the automatic channel select feature of a cordless telephone in detail. The transmitter 113 and the receiver 114 respectively transmit signals to and receive signals from the base unit 15 with the control unit 110 providing the appropriate channel control information to both units.
The transmit and receive signals of the handset unit 10 are coupled to a duplexer 117 which permits the transmitter 113 and the receiver 114 to both simultaneously operate over antenna 119 while preventing the output of transmitter 113 from being coupled directly to the input of the receiver 114. The receiver 114 demodulates voice signals transmitted by the base unit 15 and couples these signals to a loudspeaker 121. The control unit 110 also configures the output stage of the receiver 114 such that the receiver audible volume level is acceptable to the user. Key Beep Tone, Key Beep Volume and Key Beep Duration are also adjusted in accordance with commands of the control unit 110 to the receiver 114. A receiver (not shown) such as the Motorola MC3361B is used with additional circuitry as described in the Motorola data book, LINEAR AND INTERFACE INTEGRATED CIRCUITS, 8-56, 57, (Rev. 3 1990) to provide the needed function of the present invention. The transmitter 113 has speech signals as inputs from a microphone 122 which it transmits to the base unit 15.
A battery 120, a keypad 111, an illumination driver 130 and a ringer circuit 140 are also part of the handset unit 10. The battery 120 provides operating power for all circuitry in the handset unit 10. The key pad 111 is used for entering dial digits and control functions executable by the control unit 110 or transmitted to the base unit 15. The illumination driver 130 provides illumination power to the keypad. The illumination power is controlled via the control unit 110 to be present or not present depending on the needs of a particular user.
The ringer circuit 140 and the loudspeaker 141 provide an audible tone which indicates an incoming call. The ringer circuit is comprised of a transistor amplifier responsive to control signals from the control units 110 and 150. The amplifier gain and output frequency content are alterable according to one or more input signals. Thus, Ringer Mode, Ringer Tone and Ringer Volume are configuration parameters which are controlled through the interaction between the ringer circuit 140 and the control unit 110.
Referring next to the base unit 15, there is shown a control unit 150 which interfaces with the control unit 110 in the handset 10. This control unit 150 compares a received security code from the handset unit 10 with a stored security code during the establishment of a two-way communications link between the handset unit 10 and the base unit 15. A favorable comparison of the two security codes must be achieved in order for the base unit 15 to respond to a request-for-service signal from a handset unit 10. This control unit 150 also receives and processes opcode data provided by the handset unit 10 in dialing and providing signaling information out to a central office via a telephone circuit 151 and tip-ring lines 101 and 102. Like the control unit 110, this control unit 150 may be implemented through the use of a microcomputer containing ROM, RAM and through the use of proper coding. A suitable microcomputer is known in the art and is readily available from semiconductor manufacturers such as Philips, Intel and AMD.
Communications with the handset unit 10 are provided via transmitter 152 and receiver 153 in the base unit 15. The output of the transmitter 152 and input for the receiver 153 are commonly coupled to an antenna 154 through a duplexer 155. The telephone circuit 151 serves as a "plain old telephone service" (POTS) interface for signals on the tip-ring lines and for those signals received by the receiver 153 or transmitted by the transmitter 152. Command signals to the telephone circuit 151 from the control unit 150 program the Flash Duration of the system. An integrated circuit (not shown) such as the Motorola MC34013A is used in the telephone circuit 151 with the additional circuitry as described in the Motorola data book, TELECOMMUNICATIONS DEVICE DATA BOOK, 2-278, 292, (Rev. 2 1989) to achieve the needed function of the present invention.
An integrated circuit (not shown) such as the Motorola MC34012-1 is used with the additional circuitry as described in the Motorola data book, TELECOMMUNICATIONS DEVICE DATA BOOK, 2-270, 277, (Rev. 2 1989) to achieve the ring pattern ignore function of the present invention. The MC34012-1 is part of the telephone circuit 151 and detects a ringing pattern on the tip 101 and ring 102 lines. The control unit 150 monitors the output of the integrated circuit to ensure the ringing pattern is a permitted one. If the ringing pattern is permitted, ring signals are sent to the ringer circuit 140 via the control unit 110.
Responsive to the control unit 150, a generator 156 which is configured to either generate DTMF signals or pulse signals (Dial Mode) provides signaling to the telephone circuit 151 for dialing over the tip-ring lines 101 and 102 which connect to the central office or other appropriate switch. Dial Pulse Rate, Dial Pulse Make/Break Ratio, Pulse Inter-Digit Delay, DTMF Duration and DTMF Inter-Digit Delay are also configured via the command link between the control unit 150 and the generator 156. A generator (not shown) such as the Motorola MC145412 is used with the additional circuitry as described in the Motorola data book, TELECOMMUNICATIONS DEVICE DATA BOOK, 2-443, 449, (Rev. 2 1989) to achieve the needed function of the present invention.
The control unit 110 of the handset unit 10 and the control unit 150 of the base unit 15 contain the circuitry known in the art to provide a dial memory register function. At least one dual dial memory register 2 (FIG. 2) of the present invention, or a first portion thereof, is contained within the control unit 110 of the handset unit 10. Alternate embodiments may have at least one dual dial memory register 2a, or a second portion thereof, contained within the control unit 150 of the base unit 15.
The control unit 110 and/or 150 is used in conjunction with a software program to provide for the interpretation of data stored in the dual dial memory register 2 and/or 2a. The data stored in the dual dial memory register 2 and/or 2a are user-defined digits, a first subset of which causes the control unit 110 and/or 150 to place a call or alter the configuration of the telephone while in a configuration parameter programming mode. When the configuration parameter programming mode is entered, the configuration parameters of the telephone are programmed according to a second subset of the user-defined digits.
FIG. 2 shows a dual dial memory register 2 which comprises five special sequence digits 4 and fourteen configuration digits 6, labeled CF0-CF13. Having nineteen user-defined digits in the dial register is not a requirement for the operation of the invention, however this number of digits suits this particular embodiment. Also, it is noted that several dial memory registers may be designed into the telephone; however, it may only be necessary to designate one memory register as having the dual purpose described above.
A first subset of the user-defined digits, comprising five special sequence digits 4 of the dual dial memory register 2, is used by the control units 110 and 150 respectively as an indicator of how the second subset of user-defined digits is to be used. The second subset of user-defined digits, comprising the next fourteen digits in the dual dial memory register 2, may be interpreted as at least a portion of the digits of a commonly called telephone address or configuration digits depending on the special sequence digits 4.
In this embodiment, the special sequence digits 4 must all be `9` for the respective control units 110 and 150 to interpret the digits, labeled CF0-CF13, as configuration digits 6 which alter the configuration of the telephone. A special sequence of `9,9,9,9,9` is chosen because it is unlikely for this sequence to be used while dialing a telephone address. If the special sequence digits 4 are not all `9`, then the control units 110 and 150 interpret at least a portion of the dual dial memory register 2 digits as those of a commonly called telephone number and the telephone configuration remains unchanged.
Once the respective control units 110 and 150 enter the configuration parameter programming mode and all the special sequence digits 4 are verified to be `9`, each of the configuration bits 8 are processed. In this embodiment, the configuration digits 6 are between zero and seven and, therefore, only three configuration bits 8 are required to represent each of them.
The control units 110 and 150 associate each configuration digit 6 with at least one configuration parameter and each configuration bit, or pair of configuration bits, with a particular value that the configuration parameter takes.
Table 2 through Table 19 define the configuration parameter values assigned to the configuration bits 8 of the preferred embodiment of the present invention. The information of Table 2 through Table 19 is part of the software program which is used in the interpretation of the configuration digits 6.
TABLE 2______________________________________Dial Mode Truth TableCF0 Bit0 Dial Mode______________________________________0 DTMF1 Pulse______________________________________
TABLE 3______________________________________Dial Pulse Rate Truth Table(CF0 bit1, CF0 bit2) Dial Pulse Rate______________________________________(0,0) 10 pps(0,1) 8 pps(1,0) 12 pps(1,1) 20 pps______________________________________
TABLE 4______________________________________Dial Pulse Make/Break Ratio Truth Table Dial Pulse Make/(CF1 bit0, CF1 bit1) Break Ratio______________________________________(0,0) 40/60(0,1) 30/70(1,0) 66/34(1,1) 70/30______________________________________
TABLE 5______________________________________Pulse Inter-Digit Delay Truth Table Pulse Inter-(CF1 bit2, CF2 bit0) Digit Delay______________________________________(0,0) 500 ms(0,1) 700 ms(1,0) 900 ms(1,1) 1200 ms______________________________________
TABLE 6______________________________________DTMF Duration Truth Table(CF2 bit1, CF2 bit2) DTMF Duration______________________________________(0,0) 70 ms(0,1) 50 ms(1,0) 125 ms(1,1) 200 ms______________________________________
TABLE 7______________________________________DTMF Inter-Digit Delay Truth Table DTMF Inter-(CF3 bit0, CF3 bit1) Digit Delay______________________________________(0,0) 75 ms(0,1) 50 ms(1,0) 125 ms(1,1) 200 ms______________________________________
TABLE 8______________________________________Pause Duration Truth Table(CF3 bit2, CF4 bit0) Pause Duration______________________________________(0,0) 600 ms(0,1) 400 ms(1,0) 1200 ms(1,1) 2500 ms______________________________________
TABLE 9______________________________________Flash Duration Truth Table(CF4 bit1, CF4 bit2) Flash Duration______________________________________(0,0) 600 ms(0,1) 400 ms(1,0) 1200 ms(1,1) 2500 ms______________________________________
TABLE 10______________________________________Ringer Mode Truth TableCF5 bit0 Ringer Mode______________________________________0 Inhibited1 Permitted______________________________________
TABLE 11______________________________________Ringer Tone Frequency Truth Table(CF5 bit1, CF5 bit2) Ringer Tone______________________________________(0,0) Standard Freq.(0,1) Frequency 1(1,0) Frequency 2(1,1) Frequency 3______________________________________
TABLE 12______________________________________Ringer Volume Truth Table(CF6 bit0, CF6 bit1) Ringer Volume______________________________________(0,0) Low(0,1) Medium Low(1,0) Medium High(1,1) High______________________________________
TABLE 13______________________________________Ring Pattern Ignore Truth Table Ring Pattern(CF6 bit2, CF7 bit0) Ignore______________________________________(0,0) Pattern 0(0,1) Pattern 1(1,0) Pattern 2(1,1) Inhibited______________________________________
TABLE 14______________________________________Key Beep Tone Truth Table(CF7 bit1, CF7 bit2) Key Beep Tone______________________________________(0,0) Tone 0(0,1) Tone 1(1,0) Tone 2(1,1) Tone 3______________________________________
TABLE 15______________________________________Key Beep Volume Truth TableCF8 bit0 Key Beep Volume______________________________________0 High1 Low______________________________________
TABLE 16______________________________________Key Beep Duration Truth TableCF8 bit1 Key Beep Duration______________________________________0 Standard1 Long______________________________________
TABLE 17______________________________________Receiver Volume Truth Table(CF8 bit2, CF9 bit0) Receiver Volume______________________________________(0,0) Low(0,1) Medium Low(1,0) Medium High(1,1) High______________________________________
TABLE 18______________________________________Key Pad Illumination Duration Truth Table Key Pad Illumination(CF9 bit1, CF9 bit2) Duration______________________________________(0,0) 5 Sec(0,1) 0 Sec(1,0) 10 Sec(1,1) 20 Sec______________________________________
TABLE 19______________________________________Automatic Channel Select Truth Table Status______________________________________Automatic Channel 0 EnabledSelect Mode 1 DisabledCF10 bit0Automatic Channel 0 PermittedSelect, Ch1 1 InhibitedCF10 bit1Automatic Channel 0 PermittedSelect, Ch2 1 InhibitedCF10 bit2Automatic Channel 0 PermittedSelect, Ch3 1 InhibitedCF11 bit0Automatic Channel 0 PermittedSelect, Ch4 1 InhibitedCF11 bit1Automatic Channel 0 PermittedSelect, Ch5 1 InhibitedCF11 bit2Automatic Channel 0 PermittedSelect, Ch6 1 InhibitedCF12 bit0Automatic Channel 0 PermittedSelect, Ch7 1 InhibitedCF12 bit1Automatic Channel 0 PermittedSelect, Ch8 1 InhibitedCF12 bit2Automatic Channel 0 PermittedSelect, Ch9 1 InhibitedCF13 bit0Automatic Channel 0 PermittedSelect, Ch10 1 InhibitedCF13 bit1Reserved 0CF13 bit2 1______________________________________
If the user-defined digits stored in the dual dial memory register are 9,9,9,9,9,0,0,5,2,5,1,5,5,7,2,0,0,0,0 then the control units 110 and 150 interpret the digits, in accordance with the information of Table 2 through Table 19 of the software program, and program the configuration parameters of the telephone as defined by Table 1. When the control units 110 and 150 enter the configuration parameter programming mode and receive the above mentioned, user-defined digits of the dual dial memory register 2, the control units 110 and 150 recognize the first five special sequence digits 4 as all being `9`. The control units 110 and 150 interpret the three bits of the configuration digits 6 as shown in Table 20.
TABLE 20______________________________________Significant Bits of the ConfigurationDigits of this embodiment.Configuration Decimal Configuration BitsDigit Value Bit2 Bit1 Bit0______________________________________CF0 0 0 0 0CF1 0 0 0 0CF2 5 1 0 1CF3 2 0 1 0CF4 5 1 0 1CF5 1 0 0 1CF6 5 1 0 1CF7 5 1 0 1CF8 7 1 1 1CF9 2 0 1 0 CF10 0 0 0 0 CF11 0 0 0 0 CF12 0 0 0 0 CF13 0 0 0 0______________________________________
A portion of the software programming code of the handset control unit 110 and the base control unit 150 is defined by FIG. 3a through 3f. The configuration parameter programming mode is entered periodically in accordance with a main software program of the control units 110 and 150. In this embodiment of the present invention, the configuration parameter programming mode is entered at least 20 times each minute. With reference to FIG. 3a, the control unit 110 reads the contents of the dual dial memory register 2 (an example of user defined digits are shown). If the first five digits of the dual dial memory register 2 are `9`, the control units 110 and 150 extract the configuration bits 8 from the configuration digits 6. When the first five digits of the dual dial memory register are not all `9`, the control units 110 and 150 read a set of default configuration digits from a permanent memory means (not shown) and extract the configuration bits, CF0 bit0 through CF13 bit2, from the configuration digits.
With reference to FIG. 3b, CF0 bit 0 is compared with the configuration parameter template defined by Table 2 to determine the Dial Mode and the appropriate I/O signal is generated to configure a first part of the generator circuit 156. CF0 bit 1 and CF0 bit 2 are compared with the configuration parameter template defined by Table 3 to determine the Dial Pulse Rate and the appropriate I/O signals are generated to configure a second part of the generator circuit 156. CF1 bit 0 and CF1 bit 1 are compared with the configuration parameter template defined by Table 4 to determine the Dial Pulse Make/Break Ratio and the appropriate I/O signals are generated to configure a third part of the generator circuit 156. Likewise, CF1 bit 2 and CF2 bit 0 are compared with the configuration parameter template defined by Table 5 to determine the Pulse Inter-Digit Delay and the appropriate I/O signals are generated to configure a fourth part of the generator circuit 156.
With reference to FIG. 3c, CF2 bit 1 and CF2 bit 2 are compared with the configuration parameter template defined by Table 6 to determine the DTMF Duration and the appropriate I/O signals are generated to configure a fifth part of the generator circuit 156. Likewise, CF3 bit 0 and CF3 bit 1 are compared with the configuration parameter template defined by Table 7 to determine the DTMF Inter-Digit Delay and the appropriate I/O signals are generated to configure a sixth part of the generator circuit 156. CF3 bit 2 and CF4 bit 0 are compared with the configuration parameter template defined by Table 8 to determine the Pause Duration and the appropriate signals are generated within the control units 110 and 150 to facilitate a pause between two consecutive dial digits. CF4 bit 1 and CF4 bit 2 are compared with the configuration parameter template defined by Table 9 to determine the Flash Duration and the appropriate I/O signals are generated to configure the telephone circuit 151.
With reference to FIG. 3d, CF5 bit 0 is compared with the configuration parameter template defined by Table 10 to determine the Ringer Mode and the appropriate I/O signal is generated to configure a first part of the ringer circuit 140. CF5 bit 1 and CF5 bit 2 are compared with the configuration parameter template defined by Table 11 to determine the Ringer Tone and the appropriate I/O signals are generated to configure a second part of the ringer circuit 140. Likewise, CF6 bit 0 and CF6 bit 1 are compared with the configuration parameter template defined by Table 12 to determine the Ringer Volume and the appropriate I/O signals are generated to configure a third part of the ringer circuit 140. CF6 bit 2 and CF7 bit 0 are compared with the configuration parameter template defined by Table 13 to determine the ring pattern to be ignored and the appropriate signals are generated within the control units 110 and 150 to ensure the desired telephone operation.
With reference to FIG. 3e, CF7 bit 1 and CF7 bit 2 are compared with the configuration parameter template defined by Table 14 to determine the Key Beep Tone and the appropriate I/O signals are generated to configure the control unit 110. CF8 bit 0 is compared with the configuration parameter template defined by Table 15 to determine the Key Beep Volume and the appropriate I/O signal is generated to configure the control unit 110 for proper volume levels. CF8 bit 1 is compared with the configuration parameter template defined by Table 16 to determine the Key Beep Duration and the appropriate I/O signal is generated to configure the control unit 110 for proper audible tone durations. CF8 bit 2 and CF9 bit 0 are compared with the configuration parameter template defined by Table 17 to determine the Receiver Volume and the appropriate I/O signals are generated to configure the receiver 114.
With reference to FIG. 3f, CF9 bit 1 and CF9 bit 2 are compared with the configuration parameter template defined by Table 18 to determine the Keypad Illumination Duration and the appropriate I/O signals are generated to configure the illumination driver 130. CF10 bit 0 through CF13 bit 1 are compared with the configuration parameter template defined by Table 19 to determine the Automatic Channel Select Mode and permitted Automatic Channel Select channels and the appropriate I/O signals are generated to configure the respective receivers 114 and 153, and respective transmitters 113 and 152. The telephone returns to the main software program to execute further instructions and enters the configuration parameter programming mode again several seconds later.
The following patent is hereby incorporated into this patent specification by reference:
U.S. Pat. No. 5,044,010.
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A configuration parameter programming system of a telephone is presented which is executable by an end user or service person. The configuration parameter programming system is accessed through the use of a dial memory register or other data transfer means, and a control means. In this way, the Dial Pulse Rate, Dial Pulse Make/Break Ratio, DTMF Duration, DTMF Inter Digit Delay, Pause Duration and other configuration parameters of a telephone are programmable after manufacture without requiring hardware modification.
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This is a national stage of PCT/EP08/006609 filed Aug. 11, 2008 and published in German, which has a priority of German no. 20 2007 014 853.4 filed Oct. 24, 2007, hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a pelletizer preferably in the form of an underwater pelletizer. In particular, the invention relates to a cutter and/or grinding head for such pelletizer, including a tool carrier which can be rotatably driven about a tool carrier axis of rotation, and at least one cutting and/or grinding tool, which is attached to the tool carrier and is spaced from the tool carrier axis of rotation, for knocking off plastic melt emerging from a pelletizer die plate and/or for grinding the pelletizer die plate.
2. Description of the Related Art
Pelletizers, such as underwater pelletizers, usually have a pelletizer die plate with a plurality of bores or channels, through which plastic melt is pressed in the form of a strand. On the outlet side, the emerging strands of plastic melt are knocked or cut off by a rotating cutter head, so that plastic pellets are obtained, which in the case of an underwater pelletizer are carried away by the process fluid flowing around the cutting head.
Some of the factors that affect the quality of the plastic pellets and of the pelletizing process include the shape and surface accuracy of the die plate on its outlet side, and the precise geometrical interaction between the outlet side of the die plate and the cutting or knock-off tools passing over the same. If wear results in irregularities on the die plate outlet side, the plastic material can start to smear on the die plate outlet side, impairing the neat cutting or knocking off of the pellets. One known approach to avoid or correct this problem has been to surface-grind the die plate of the pelletizer from time to time and, instead of the cutter head, use a grinding head with an end-face abrasive coat which is urged against the outlet side of the die plate in order to surface-grind the latter. However, the surface accuracy and fineness that can be achieved is limited and, due to the usual uniaxial rotatory grinding movement, annular ridges can be cut into the die plate surface.
In addition to wear on the die plate, wear on the cutting tools also can impair the pelletizing process. Usually, cutting plates which can be mounted in cutting plate holders at the desired angle are used as cutting tools so that they can pass over the die plate in the specified angular position, in order to knock off the emerging melt. In this regard, it is known to use turnover plates, i.e. cutting plates that can be turned over in the cutting plate holders, so that both sides of the usually rectangular cutting plates can be used, until they must be discarded due to excessive wear. The stability of the cutting plates is, however, limited and, when changing the cutting surface, differences in shape with respect to the ground outlet side of the die plate sometimes are obtained.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing problems by creating an improved pelletizing device and an improved cutter and/or grinding head for a pelletizer, which avoid the disadvantages of the prior art and develop the latter in an advantageous way. In particular, an improved tool head is provided which equally allows both grinding of the outlet side of the die plate of the pelletizer and cutting or knocking off of the plastic melt emerging from the die plate. The tool head in accordance with the present invention also exhibits improved service life with more favorable wear properties of the working tool.
In accordance with the present invention, therefore, an improved cutting and/or grinding head is provided for a pelletizer, preferably an underwater pelletizer, and a pelletizer having such a head. The head includes a tool carrier to be driven rotatably about a tool carrier axis of rotation, and at least one cutting and/or grinding tool for knocking off plastic melt emerging from a pelletizer die plate and/or for grinding the pelletizer die plate. The cutting and/or grinding tool is rotatably mounted on the tool carrier about an axis of rotation spaced from the tool carrier axis of rotation. The axis of rotation of the cutting and/or grinding tool extends substantially parallel to the tool carrier axis of rotation. The cutting and/or grinding tool includes a substantially planar end face extending perpendicular to the tool's axis of rotation, for bearing against the pelletizer die plate, with the end face being adapted to be provided with an abrasive coat and/or an abrasive structure. The cutting and/or grinding tool is rotatably supported on the tool carrier free from a rotatory drive in a freely self-rotating manner.
Thus, it is proposed to attach the at least one cutting and/or grinding tool to the tool carrier not rigidly in a specified position, but to provide the same with an additional degree of freedom or an additional axis of movement with respect to the tool carrier, so that the cutting and/or grinding tool can move with respect to the tool carrier. In accordance with the invention, the cutting and/or grinding tool is rotatably mounted on the tool carrier about an axis of rotation spaced from the tool carrier axis of rotation. This provides a second component of movement for the cutting and/or grinding tool. On the one hand, the cutting and/or grinding tool rotates together with the tool carrier about its tool carrier axis of rotation, and on the other hand, the cutting and/or grinding tool can rotate about its own axis of rotation relative to the tool carrier. The tool carrier has a pivot bearing for the cutting and/or grinding tool, by means of which the cutting and/or grinding tool can rotate about itself.
Due to the additional component of movement of the cutting and/or grinding tool, the wear of the cutting and/or grinding tool itself can be rendered more uniform, as different portions are worn depending on the rotary position, which in the course of time adds up to a uniform wear. In addition, especially in the grinding process, when the grinding and/or cutting tool is used for grinding, the superimposed component of movement can prevent the formation of annular ridges around the tool carrier axis of rotation. On the outlet side of the die plate, a much finer surface of greater shape accuracy is achieved. Furthermore, the rotary movement of the grinding and/or cutting tool about itself can also be utilized for a better removal of the pellets knocked off, and for cutting or knocking off the next strand of plastic melt as a fresh portion of the tool is effectively made available.
The axis of rotation of the cutting and/or grinding tool in accordance with the present invention advantageously extends substantially parallel to the tool carrier axis of rotation. The tool axis of rotation may also be slightly inclined with respect to the tool carrier axis of rotation, which can be advantageous for generating the rotary movement of the cutting and/or grinding tool. What is preferred, however, is a parallel arrangement of the axis of rotation of the cutting and/or grinding tool with respect to the tool carrier axis of rotation.
In accordance with a development of the present invention, the axis of rotation of the cutting and/or grinding tool is aligned on the tool carrier to be directionally stable. Alternatively, the axis of rotation of the cutting and/or grinding tool can be arranged or mounted so as to be tiltable to a limited extent, in order to achieve a self-adjustment of the cutting and/or grinding tool or to compensate for minor alignment errors. The cutting and/or grinding tool can be self-adjusting, so to speak, so that it can slightly tilt with respect to the tool carrier. To achieve a simple, stable mounting, the directionally stable mounting of the axis of rotation on the tool carrier as described above, however, is preferred.
In accordance with an advantageous development of the present invention, the cutting and/or grinding tool is mounted on the tool carrier free from a rotatory drive so as to be freely self-rotating. In operation of the cutter and/or grinding head, the cutting and/or grinding tool remains rotatable, wherein the desired rotary movement is obtained by the cooperation of the cutting and/or grinding tool with the die plate, in particular by the different peripheral speeds of different portions of the cutting and/or grinding tool relative to the die plate. When the cutting and/or grinding tool passes around the tool carrier axis of rotation on a circular path as a result of the rotation of the tool carrier, a portion of the cutting and/or grinding tool located radially further to the outside has a greater peripheral speed than a portion located closer to the inside. This difference leads to a rotation of the cutting and/or grinding tool during operation about its own axis of rotation. As an alternative to such drive-free mounting and self-rotating configuration of the cutting and/or grinding tools, a drive for the forced driving of the cutting and/or grinding tool relative to the tool carrier might be provided, for instance in the form of an intermediate transmission, which derives the corresponding rotary movement of the cutting and/or grinding tool from the rotary movement of the tool carrier. In this way, higher relative speeds can be achieved between the tool and the die plate surface. What is preferred, however, is the above-described drive-free and self-rotating configuration of the cutting and/or grinding tool, as a certain irregularity in the rotary speed can provide advantages with respect to an accurately ground die plate surface.
In accordance with another development of the present invention, the axis of rotation of the cutting and/or grinding tool is arranged at a fixed distance from the tool carrier axis of rotation. This fixed distance advantageously is chosen such that the cutting and/or grinding tool passes over the pelletizer die plate in the vicinity of at least one associated outlet bore or melt passage outlet duct.
In accordance with an alternative embodiment of the present invention, an adjusting device for the distance of the axis of rotation of the cutting and/or grinding tool can, however, also be provided, so that the distance of the axis of rotation of the cutting and/or grinding tool from the tool carrier axis of rotation is adjustable. With such adjustability, the cutting or grinding head can be used for different pelletizer die plates. When using a pelletizer die plate with a larger hole center distance, for example, the cutting and/or grinding tool merely is moved further to the outside on the tool carrier, i.e., the tool is moved further away from the tool carrier axis of rotation, so that the tool is adapted to the corresponding geometry of the pelletizer die plate.
In principle, the adjusting device for the distance of the axis of rotation of the cutting and/or grinding tool can be formed differently. For instance, the tool carrier can include a slotted longitudinal guideway in the form of an oblong-hole guideway in which the cutting and/or grinding tool can be moved in order to adjust the distance of the tool from the tool carrier axis of rotation. In accordance with a preferred development of the present invention, the adjusting device also can include a swivel arm configured to be pivotally attached to the body of the tool carrier and to carry the cutting and/or grinding tool and its axis of rotation. When the swivel arm is swiveled further to the outside, the distance of the cutting and/or grinding tool mounted thereon from the tool carrier axis of rotation is increased. Conversely, the distance between the cutting and/or grinding tool and the tool carrier axis of rotation can be reduced by swiveling the swivel arm to the inside.
Advantageously, a fixing device is associated with the adjusting device, by means of which at least two different distances of the tool axis of rotation from the tool carrier axis of rotation can be fixed. The fixing device can include, for example, a positive locking device and/or a clamping device, for instance in the form of a clamping screw bolt.
In principle, the rotatably mounted cutting and/or grinding tool can have different geometries and configurations. In accordance with a development of the present invention, the cutting and/or grinding tool can have a substantially planar end face for bearing against the pelletizer die plate so that the planar end face does not need to extend over the entire cross-section of the working head of the cutting and/or grinding tool. For instance, the working head of the cutting and/or grinding tool can also have an annular end face and a concave recess in the center of the end face, so that only the annular surface bears against the die plate. Advantageously, at least the annular end face is formed flat and extends in a plane vertical to the axis of rotation of the tool.
For surface grinding the pelletizer die plate, the end face of the cutting and/or grinding tool can be provided with an abrasive coat and/or an abrasive structure. For instance, an abrasive coat can be applied in the form of a diamond grain carpet on the end face of the cutting and/or grinding tool. Alternatively, or in addition, the end face of the cutting and/or grinding tool can also be provided with a microstructure incorporated in the material of the working head. The microstructure may, for example, be in the form of fishscales with corresponding cutting or grinding edges, which provide for a machining, abrasive removal of material on the die plate. Alternatively or in addition, a grinding fluid or emulsion containing abrasive grains can also be applied to the die plate or between the die plate and the grinding head, in order to achieve an abrasive effect without requiring an abrasive coat on the end face of the working head.
To be able to selectively also operate only as a cutting tool for knocking off the strands of plastic melt, the abrasive coat can be releasably connectable with the end face of the tool working head, for instance be clampable onto a backing pad in the manner of a grinding wheel. Alternatively, or in addition, the cutting and/or grinding tool can releasably and replaceably be mounted on the tool carrier, so that a grinding tool with abrasive coat and a cutting tool without abrasive coat can selectively be mounted on the tool carrier. Independent of the exchangeability of different types of tool, the replaceability of the cutting and/or grinding tool on the tool carrier is advantageous, in order to avoid the need to replace the entire cutting or grinding head in the case of wear.
Depending on the plastic melt to be pelletized, different configurations and geometries of the cutting and/or grinding tool can be advantageous. In particular, differently formed cutting or knock-off edges can be used, in order to pelletize the emerging strands of plastic melt in the desired way. In an advantageous embodiment of the present invention, the cutting and/or grinding tool is formed symmetrical with respect to its axis of rotation and/or have segments which can be made to coincide by rotation about the axis of rotation, so that there is no continuous rotation symmetry, so to speak, but a symmetry upon rotation about a predetermined angular amount. The tool can have a pitch and be divided into segments which can be made to coincide by rotating the same by the corresponding pitch angle.
In particular, the cutting and/or grinding tool can have a rotationally symmetric working head with circular cross-section in accordance with a preferred development of the invention, so that the cutting and/or grinding tool can rotate and wear with near complete uniformity, having a working edge uniform over 360° for knocking or cutting off the plastic strands during pelletizing.
Alternatively, however, the working head can also have a cross-section different from the circular shape, in particular in the form of a peripheral contour with pitch-symmetrically identically shaped segments, as mentioned above. When providing a plurality of congruent peripheral segments, different working head geometries can be chosen. For instance, the working head can have a generally blossom- and/or flower-shaped contour which is divided into a plurality of arcuate peripheral segments. Alternatively, or in addition, the working head of the cutting and/or grinding tool also can have a polygonally profiled contour with preferably rounded transitions between the polygon portions. For example, a substantially polygonal, such as a hexagonal or octagonal working head, with rounded transitions between the segments can be provided.
To cleanly cut and pelletize the plastic strands emerging from the melt ducts of the die plate, the cutting and/or grinding tool has a peripheral flank constituting a cutting and/or knock-off edge in accordance with a development of the present invention. The cutting and/or knock-off edge advantageously extends around the tool axis of rotation, and in particular with a circular cross-section of the working head, can form an annular flank which defines a cutting or knock-off edge extending over 360°. Alternatively, a segmental configuration of the cutting and/or knock-off edge can be provided, which in terms of a pitch angle advantageously is congruent, for instance in the above-mentioned blossom shape or traverse shape with rounded transitions, so that cutting and/or knock-off edge segments are provided, which extend over six times 60°.
Depending on the plastic melt to be cut, different angles of inclination of the peripheral flank or of the cutting and/or knock-off edge formed by the flank can be advantageous. In accordance with a development of the present invention, the peripheral flank includes a flank angle in the range from 110° to 30° with respect to an end plane of the working head vertical to the axis of rotation. In accordance with a preferred development of the present invention, the flank angle can lie in the range from 90° to 45°, in particular about 90° to 75°.
As viewed in a longitudinal section including the axis of rotation of the tool, the peripheral flank can have different shapes, for instance be formed convex or also concave. Depending on its configuration, such curved shape of the flank can effect a sharper separation of the melt strands or a more impulsive or forceful knocking off. In accordance with a preferred development of the present invention, however, the peripheral flank as viewed in a longitudinal section including the axis of rotation of the tool has a straight flank, which can be inclined at the aforementioned flank angles with respect to the vertical end plane.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will subsequently be explained in detail with reference to preferred embodiments and associated drawings.
FIG. 1 is a schematic, perspective representation of a cutting and grinding head of an underwater pelletizer on the pelletizer die plate in accordance with an advantageous embodiment of the present invention.
FIG. 2A is a top view of the cutting and grinding head of a first embodiment of the underwater pelletizer of FIG. 1 .
FIG. 2B is a side view of the cutting and grinding head shown in FIG. 2A .
FIG. 2C is a perspective view of the cutting and grinding head shown in FIGS. 2A and 2B .
FIG. 3A is a side view of a second embodiment of the cutting and grinding head of the pelletizer shown in FIG. 1 in which the cutting and knock-off flank of the cutting and grinding tool has a flank angle of 75°.
FIG. 3B is a perspective view of the cutting and grinding head shown in FIG. 3A .
FIG. 4A is a top view of a third embodiment of the cutting and grinding head of the pelletizer shown in FIG. 1 in which the cutting and knock-off flank of the cutting and grinding tools has a flank angle of 90°.
FIG. 4B is a side view of the cutting and grinding head shown in FIG. 4A .
FIG. 4C is a perspective view of the cutting and grinding head shown in FIGS. 4A and 4B .
FIG. 5A is a side view of a first tool geometry of the cutting and grinding heads of the rotatably mounted cutting and grinding tool in accordance with the present invention.
FIG. 5B is a side view of a second tool geometry of the cutting and grinding heads of the rotatably mounted cutting and grinding tool in accordance with the present invention.
FIG. 5C is a side view of a third tool geometry of the cutting and grinding heads of the rotatably mounted cutting and grinding tool in accordance with the present invention.
FIG. 5D is a side view of a fourth tool geometry of the cutting and grinding heads of the rotatably mounted cutting and grinding tool in accordance with the present invention.
FIG. 6A shows a top cross-sectional view of a first peripheral contour of a cutting and grinding head of the cutting and grinding tool in accordance with the present invention.
FIG. 6B shows a top cross-sectional view of a second peripheral contour of a cutting and grinding head of the cutting and grinding tool in accordance with the present invention.
FIG. 6C shows a top cross-sectional view of a third peripheral contour of a cutting and grinding head of the cutting and grinding tool in accordance with the present invention.
FIG. 6D shows a top cross-sectional view of a fourth peripheral contour of a cutting and grinding head of the cutting and grinding tool in accordance with the present invention.
FIG. 6E shows a top cross-sectional view of a fifth peripheral contour of a cutting and grinding head of the cutting and grinding tool in accordance with the present invention.
FIG. 7 is a perspective view of a cutting and grinding head of an underwater pelletizer in a further advantageous embodiment of the invention, according to which the tool carrier includes an adjusting device in the form of swivel arms for adjusting the distance of the axes of rotation of the cutting and grinding tools from the tool carrier axis of rotation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
In the embodiment illustrated in FIG. 1 , the only partly represented pelletizing device 1 includes a cutting and grinding head 2 that includes a substantially plate-like, ring-shaped tool carrier 3 . The tool carrier 3 can be rotatably driven about a tool carrier axis of rotation 4 by a drive shaft (not shown). In the illustrated embodiment of the device 1 , the tool carrier 3 has a central, hub-like recess 5 , by means of which the tool carrier 3 can be mounted on the drive shaft or on a cutting and grinding head bearing provided thereon.
As shown in FIGS. 1 to 4C , the tool carrier 3 carries a plurality of cutting and grinding tools 6 spaced from the tool carrier axis of rotation 4 , which are arranged on the end face of the tool carrier 3 and axially protrude beyond the body of the tool carrier 3 . Advantageously, between two and ten, and preferably between two and six, cutting and grinding tools 6 are provided. In the illustrated embodiment, four of such cutting and grinding tools 6 advantageously are attached to the tool carrier 3 . The cutting and grinding tools 6 can be formed differently. Advantageously, however, identically formed cutting and grinding tools are attached to the tool carrier 3 .
In accordance with the embodiments illustrated in FIGS. 1 to 4C , the cutting and grinding tool 6 includes a rotationally symmetric, approximately plate-shaped working head 7 , which in the illustrated embodiments as shown in FIGS. 1 to 4C has a circular cross-section. The cutting and grinding tools 6 each are rotatably mounted on the tool carrier 3 . The pivot bearings 8 provided for this purpose advantageously each have an axis of rotation 9 , which extends substantially parallel to the central tool carrier axis of rotation. The pivot bearings 8 are preferably recessed or integrated in the body of the tool carrier 3 .
As shown in FIGS. 5A to 5D , the cutting and grinding tools 6 can include a bearing portion 10 molded to the working head 7 , which can have the shape of a bearing pin or another suitable form of bearing member. In general, the cutting and/or grinding tool 6 thereby obtains a generally mushroom-like configuration.
The cutting and grinding tools 6 are freely rotatable on the tool carrier 3 by means of the pivot bearings 8 . Although the tools 6 are mounted on the tool carrier 3 free from drive, they nevertheless perform a rotary movement in operation. As shown in FIG. 1 , the cutting and grinding tools 6 are spaced from the tool carrier axis of rotation 4 such that they approximately come to lie on the melt passages 11 of the pelletizer die plate 12 or on the outlets thereof. In the illustrated embodiment as shown in FIG. 1 , the melt passages 11 in the pelletizer die plate 12 are arranged on a circle or arranged in an annular portion, which slightly protrudes with respect to the remaining body of the pelletizer die plate 12 and forms a flat end face of the pelletizer die plate 12 .
The substantially flat end face of the cutting and grinding tools 6 is seated on a ring portion 13 of the pelletizer die plate 12 . When rotating together with the tool carrier 3 about its tool carrier axis of rotation 4 , different portions of the tools 6 undergo different peripheral speeds which effects a self-rotation of the cutting and grinding tools 6 about their respective axes of rotation 9 . The cutting and grinding tools 6 thus perform two superimposed rotary movements, namely the rotary movement about the tool carrier axis of rotation 4 and the superimposed self-rotation about the respective tool axes of rotation 9 .
As shown more clearly in FIGS. 5A-5D , the working heads 7 of the cutting and grinding tools 6 have a flat end face 14 , which possibly can be ring-shaped, as is shown in FIG. 5C . The end face 14 is surrounded by an annular peripheral flank 15 , which forms a cutting or knock-off edge for cutting off or separating the strands of plastic melt emerging from the melt passages 11 . In principle, the working head 7 can have a substantially cylindrical contour, as is also shown in FIGS. 4A-4C as well as FIGS. 5B , 5 C and 5 D. In the case of a cylindrical contour, the peripheral flank 15 is inclined at an angle of 90° with respect to an end-face plane of the respective working head 7 , which is vertical to the axis of rotation 9 (see FIG. 4B ).
Alternatively, the working head 7 can also be conical with a peripheral flank 15 that is inclined at an acute angle with respect to the end-face plane. FIGS. 2A-2C show a conically formed working head 7 with a flank angle of about 45°, whereas the embodiment of FIGS. 3A and 3B shows a conical working head with a flank angle of about 75°. The smaller the flank angle 16 , the sharper the melt strands are cut through, whereas with a more vertical peripheral flank they are knocked off impulsively, i.e., with greater force or energy.
The height of the working head 7 of the cutting and grinding tools 6 , as measured in the direction of the axis of rotation 9 , can be adapted to the different plastic melts to be pelletized and can vary. In accordance with a preferred development of the invention, the height 17 of the working head 7 is smaller than the diameter of the working head 7 as shown in FIG. 5D . With this configuration, the height 17 preferably is less than half the diameter, in particular less than one third of the diameter of the working head 7 . For instance, the height 17 can lie in the range from about one tenth to about one third of the diameter of the working head 7 .
The diameter of the working head 7 of the cutting and grinding tools 6 likewise can be adapted to the different pelletizing conditions and, in particular, to the geometry of the pelletizer die plate 12 . In accordance with an advantageous embodiment, the working head diameter can be about 10% to 150%, preferably about 30% to 100%, and most preferably about 50% to 75% of the distance of the axes of rotation 9 from the central tool carrier axis of rotation 4 . In principle, the axes of rotation 9 of the cutting and grinding tools 6 can be arranged at different distances from the central tool carrier axis of rotation 4 , in particular when the pelletizer die plate 12 includes more than one melt passage circle. In accordance with the illustrated embodiment, however, the cutting and grinding tools 6 advantageously can all be arranged at the same distance from the central tool carrier axis of rotation 4 .
FIG. 7 shows another advantageous embodiment of the present invention, according to which the tool carrier 3 is adjustable with respect to the distance between the axis of rotation 9 of the cutting and grinding tools 6 and the central tool carrier axis of rotation 4 . In the illustrated embodiment, the corresponding adjusting device 18 includes swivel arms 19 . One end of the swivel arms is pivotally attached to the body of the tool carrier 3 , namely about swivel axes which extend parallel to the central tool carrier axis of rotation 4 . The other protruding end of the swivel arms 19 carries the cutting and grinding tools 6 together with their axes of rotation 9 and the associated pivot bearings 8 . When the swivel arms 19 are swiveled further to the outside, the distance of the cutting and grinding tools 6 from the tool carrier axis of rotation 4 is increased. Conversely, the distance between the cutting and grinding tools 6 and the tool carrier axis of rotation 4 can be reduced by swiveling the swivel arms 19 to the inside. The cutting and grinding tools 6 advantageously can be adjusted individually, so that different distances can be adjusted for different cutting and grinding tools 6 , for instance such that every second cutting and grinding tool 6 is running further on the outside than every third cutting and grinding tool. The adjusting device 18 includes a fixing device for fixing the respectively desired position. In the illustrated embodiment, the fixing device includes clamping bolts 20 for clamping the swivel arms 19 in the respective swivel position.
As shown in FIGS. 6A to 6E , the working head 7 can have different cross-sections, for instance a circular cross-section in accordance with an advantageous development of the invention shown in FIG. 6A . Alternatively, blossom- or flower-shaped peripheral contours can be specified as shown in FIGS. 6B and 6E . As a further alternative, polygonal peripheral profiles, preferably with rounded transitions, are possible as shown in FIGS. 6C and 6D .
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims.
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A pelletizer, preferably in the form of an underwater pelletizer, having a cutter and/or grinding head and a tool carrier is provided. The tool carrier can rotatably be driven about a tool carrier axis of rotation, and at least one cutting and/or grinding tool, which is attached to the tool carrier and is spaced from the tool carrier axis of rotation, is used to knock off plastic melt emerging from a pelletizer die plate and/or for grinding the pelletizer die plate. In one embodiment, the cutting and/or grinding tool rotates together with the tool carrier about its tool carrier axis of rotation, and in another embodiment, the cutting and/or grinding tool can rotate about its own axis of rotation relative to the tool carrier.
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SUMMARY OF THE INVENTION
The present invention relates to a device for attaching a shoe to a bicycle pedal.
More particularly, the invention relates to a device of the type comprising:
a pedal body with an upper bearing surface,
a counter-member which is fixed to the sole of the shoe and can be fitted on to the upper bearing surface of the pedal body,
rapid-attachment means for establishing firm mutual engagement of the pedal body with the counter-member,
the pedal body including a toe piece adapted to house a front portion of the counter-member when the pedal body and the counter-member are in the mutually coupled condition so as to prevent the upward detachment of the front portion of the counter-member from the upper bearing surface of the pedal body.
The object of the invention is to provide a device of the type defined above which has a simple, light structure and which enables the shoe to be locked on to to and to be released from the pedal quickly and easily.
According to the present invention, this object is achieved by the provision of an attachment device of the type specified above, characterised in that:
a) the counter-member has a step which is fixed to the member and is adapted to engage beneath a corresponding fixed step in the pedal body, the step being formed in a region of the pedal body which is spaced rearwardly of the toe piece so as completely to prevent the upward detachment of the counter-member from the upper bearing surface of the pedal body in the mutually coupled condition;
b) the rapid-attachment means comprise:
mutual coupling surfaces formed in the counter-member and in the pedal body respectively and extending essentially in planes parallel to the length of the counter-member and of the pedal body, one of the surfaces having a recess and the other a tooth which can engage in the recess in the coupled condition as a result of a movement of the counter-member relative to the pedal in a direction transverse its length,
a thrust member which is urged by a spring and is carried by the pedal body or by the counter-member and adapted --in the coupled condition --to exert a transverse force on the other member so as to prevent the recess and the tooth from moving apart when they are subjected to a force below a predetermined value which tends to move them apart; the member which is not provided with the thrust member having a cam surface for cooperating with the thrust member when the counter-member is fitted on to the upper surface of the pedal body so as first to cause the retraction of the thrust member and then to snap engage the tooth in the recess under the force returning the thrust member to its projecting position.
The device according to the invention ensures that the shoe is fixed to the pedal whatever movement occurs during pedalling. Release is achieved by a simple transverse rotary movement of the heel of the shoe away from the bicycle.
Further characteristics and advantages of the present invention will become clear from the detailed description which follows with reference to the appended drawings, provided by way of non-limiting example, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a device according to a first embodiment of the invention,
FIG. 2 is a perspective view of the device of FIG. 1 during the engagement stage,
FIG. 3 is a side view, partially in section, of the device shown in FIG. 1, the section being taken along the longitudinal centerline of the FIG. 1 device in assembled and locked position.
FIGS. 4 and 5 are partially-sectioned plan views of the device of FIG. 1 in two different configurations,
FIGS. 6 and 7 are views corresponding to FIGS. 4 and 5, relating to a second embodiment of the device according to the invention,
FIG. 8 is a view taken on the arrow VIII of FIG. 6 during the engagement stage,
FIG. 9 is a perspective view of a third embodiment of the device according to the invention,
FIG. 10 is a partially-sectioned plan view of the device of FIG. 9, and
FIG. 11 is a side view, partially in section, of the device shown in FIG. 9, the section being taken along the longitudinal centerline of the FIG. 9 device in assembled and locked position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawings, a left-hand bicycle pedal is indicated 1 and has a body 2 which is rotatably mounted, in known manner, on a pin 3 with a threaded end 4 for connection to the respective pedal crank (not shown).
In the present description and in the following claims, geometric references are intended to relate to the normal operating position of the pedal mounted on the bicycle.
The pedal body 2 has a flat upper surface 5 on which the flat undersurface 6 of a counter-member 7 bears, in use. The counter-member 7 has three slots 8 for its fixing to the sole of a shoe 9 which can be seen in FIGS. 2 and 3. The counter-member 7 is fixed to the sole of the shoe 9 by means of screws 10 which pass through the slots 8 with the interposition of washers 11.
The counter-member 7 has a rounded front portion 12 which, in known manner, engages a toe piece 13 formed in the front part of the pedal body 2.
An anchoring block 15 is fixed to the lower surface 6 of the counter-member 7 by means of a screw 14.
Alternatively, the block 15 could be formed integrally with the counter-member 7.
The block 15 is inserted in a seat 16 formed in the rear of the pedal body 2 and, in the manner which will better be explained below, establishes the engagement of the counter-member 7 with the pedal body 2.
A tooth 18 is formed on one side 17 of the block 15 and has a stop surface 19 which extends perpendicular to the surface 6 of the counter-member 7. In its wall 20 which faces the side 17 of the block 15, the seat 16 of the pedal body 2 has a recess 21 which extends perpendicular to the surface 5 of the pedal body 2 and has a shape corresponding to that of the tooth 18. The stop surface 19 of the tooth 18 and the corresponding surface 22 of the recess 21 are inclined towards the rear of the pedal body 2 (see FIGS. 4 and 5) and constitute a restraint against the release of the block 15 towards the rear of the pedal. The wall 20, at the opening into the seat 16, has a connecting part 23 with a large radius of curvature which facilitates the insertion of the block 15 into the seat 16.
The block 15 has a step 24 in its front wall which cooperates with a corresponding step 25 formed in the facing wall of the seat 16 so as to define a stop which prevents the raising of the block 15 (see in particular FIG. 3).
As seen in FIGS. 4 and 5, the block 15 is generally wedge-shaped in plan and a vertical groove is formed in its inclined side 26. The wall, indicated 28 in the drawings, of the seat 16 facing the inclined side 26 of the block 15 is formed with a bore 29 which communicates at its rear end with a larger-diameter bore 30. A pin 31 is slidable in the bore 29 and has an enlarged head 32 situated in the bore 30. The bore 30 is closed at one end by a grub screw 33 and houses a helical spring 34 between the grub screw 33 and the head 32. The spring 34 urges the pin 31 towards its most outwardly projecting position defined by the abutment of its head 32 against the end of the bore 30.
The pin 31 has a circumferential groove 35 in its shank which, when the pin is in the position shown in FIG. 5 corresponding to the engagement of the block 15 in the seat 16, is acted on by a ball 36 situated in a hole 37 and urged towards the groove 35 by a spring 38. The ball 36 allows the pin 31 to move back into the bore 29 against the action of the spring 34 only when subjected to a force greater than a predetermined value.
The operation of the engagement device described is as follows.
The shoe 9 is engaged with the pedal 1 by the placing of the counter-member 7 on the upper surface 5 of the pedal body 2 with the front portion 12 of the counter-member 7 behind the toe piece 13. The counter-member 7 is then moved forwards, simultaneously bringing the front portion 12 into the toe piece 13 and the fixing block 15 into the seat 16. During this forward movement, the inclined surface 26 of the block 15 exerts a force on the pin 31 which overcomes the force exerted by the ball 36 and makes the pin 31 move back against the action of the spring 34. When the tooth 18 of the block 15 is in correspondence with the recess 21, the block 15 moves transversely under the action of the pin 31 and the tooth 18 thus engages the recess 21. In this condition, shown in FIG. 5, the end of the pin 31 is inserted in the groove 27 in the block 15 and the ball 36 is located in the circumferential groove 35 of the pin 31.
In the configuration shown in FIG. 5, the counter-member 7 is locked to the pedal body 2 whatever movement occurs during pedalling (movement forwards, backwards, upwards and inwards).
The counter-member 7 can be released from the configuration shown in FIG. 5 by the transverse rotation of the heel of the shoe 9 in the sense indicated by the arrow A in FIG. 5. During this movement, the counter-member 7 rotates about its front portion 12, which is held by the toe piece 13, and the block 15 exerts a force on the pin 31 which tends to make it retract. When this force exceeds a predetermined value which is sufficient to release the pin 31 from the action of the ball 36, the pin 31 moves inwardly of the bore 29. The tooth 18 is thus released from the recess 21 and it is then possible to move the shoe 9 backwards, releasing the shoe completely from the pedal.
FIGS. 6 to 8 show a second embodiment of an attachment device according to the present invention. The elements which correspond to those described above are indicated by the same reference numerals below.
The device shown in FIGS. 6 to 8 differs from that described above essentially in that the step 24 is situated on the side 17 of the block 15 instead of being in the front of the latter. As can be seen from FIG. 8, the side 26 of the block 15 and the lower part of the step 24 are connected to the lower wall of the block 15 by means of surfaces indicated 50 and 51 respectively.
By virtue of this shaping of the block 15, the latter can be engaged in the seat 16 by means of a downward movement of the block 15 from above, as well as by means of the forward movement described in connection with the first embodiment. In this case the shoe 9 is engaged with the pedal body 2 by the insertion of the front portion 12 of the counter-member in the toe piece 13 followed by the downward movement of the block 15 so as to insert it in the seat 16. During this movement, the connecting surface 50 urges the projecting end of the pin 31 backwards. When the block 15 is inserted in the seat 16 the action of the pin 31 brings the tooth 18 into engagement with the recess 21.
With reference to FIGS. 9 to 11, a third embodiment of the device according to the invention will now be described.
In this case, the counter-member 7 has a peripheral wall 60 at its rear end which extends vertically towards the lower side of the counter-member 7. As shown in FIG. 10, the cross-section of the wall 60 is U-shaped and can be seen to include a central portion 61 and two side arms indicated 62 and 63. The central portion 61 of the wall 60 has a lower step 64 which cooperates with a rear portion 65 of the pedal body 2 so that, together with the front portion 12 inserted in the toe piece 13, it prevents the counter-member 7 from being released upwardly from the pedal body 2.
In this third embodiment of the device according to the invention, the tooth 18 is formed in the arm 62 of the peripheral wall 61. The tooth 18 is inserted in the recess 21 formed in the side portion of the pedal body 2 by means of a forward movement of the counter-member 7 relative to the pedal body 2. As in the previous embodiments, the pin 31 situated in the pedal body 2 is made to retract by the arm 63 of the wall 60.
In this case the counter-member 7 is also released from the pedal body 2 by a movement of the shoe in the sense indicated by the arrow A in FIG. 10.
In the above description only the left hand pedal has been described, since the right hand pedal is specularly identical thereto.
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A device for attaching a shoe to a bicycle pedal, comprising a pedal body and a counter-member fixed to the sole of the shoe and adapted to be fitted to the body of the pedal. Attachement is achieved by means of a tooth which is carried by the counter-member and engages a recess formed in the body of the pedal so as to prevent the backwards displacement of the counter-member relative to the body of the pedal. A step carried by the counter-member cooperates in the body of the pedal and prevents the upward detachment of the counter-member.
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BACKGROUND
The object of this invention is a device to introduce the upper thread into the eye of the needle of a sewing machine.
It is difficult, especially for older persons, to thread a needle with a necessarily very small eye. For one thing, one has to have a very steady hand and for another thing the end of the thread to be pushed through the eye must be free of frayed fibers. For this tedious work, there have been devices introduced that thread the eye partially by hand using an assisting device, or filly automatically with the touch of a button. Regardless of whether the threading is done by hand or automatically using a suitable device, a very fine hook is always necessary to grasp the thread on the other side of the eye and to form a loop of thread when pulled through the eye. For fine needles, such as those in common use for household sewing machines, the thickness of the hook is approximately 0.2 mm. This results in the smallest forces exerted on the hook bending it, thus rendering the entire device to which the hook is anchored unusable. These forces exerted on the hook can occur if, for example, the sewing needle is slightly bent and the eye is not in the prescribed position as a result so that the hook tilting into it hits the needle. For this reason, most known threading devices have guide clips or plates to the side of the hook with conically diverging ends.
An example of this can be found in U.S. Pat. No. 2,538,395. The interior sides of the guide clips, i.e. the two surfaces opposite one another, extend parallel to one another and have a separation that is slightly larger than the thickness of the needle. This means that for each needle size, the right size guide clips must be provided. For a thicker needle, it would not be possible for it to be placed in between the guide clips, and for a thinner needle, it would not be centered and thus the hook would be bent. In order to counteract the bending of the hook and to guide a slightly bent needle in between the two guide clips, the threader is hung elastically. The elastic support protects the hook, but—as already mentioned above—not against bending when a non-centered thin needle is grasped.
From U.S. Pat. No. 5,615,629, another fully automatic threading device is known whereby the two guide clips are produced from an elastic sheet material and whose interior sides run parallel to one another. The ends of the two guide clips can be deflected outward and thus enable a centering with respect to the needle. Most fine hooks are, however, not protected against bending by this known device since the needle cannot be exactly centered in the middle between the two guide clips when, as shown explicitly in an example of U.S. Pat. No. 5,615,629 in FIG. 6, one clip deviates, thus no longer guaranteeing that it will meet the eye of the needle lying in the middle.
SUMMARY
The object of this invention is to create a device to introduce the upper thread into the eye of the needle, wherein the hook always lies exactly in the middle between the two guide clips regardless of the position of the needle and regardless of its thickness.
This object is met by a device with guide clips that include two first sections that are parallel to one another and two second sections that converge together at an angle and are adjacent to the first sections. The second sections transition into curved fourth sections whose peaks have a smaller distance from one another than the adjacent first sections. The curved fourth sections are followed by diverging fifth sections. Advantageous embodiments of this invention are further described below.
The similar design of the two guide clips located to the side of the hook, as well as their symmetric suspension makes it possible to always hold the hook located between them exactly at the same distance from the two interior sides of the clips and thus to introduce it into the eye of the needle without contact. Furthermore, the tilting suspension of the plate carrying the guide clips enables an essentially frictionless centering of the two guide clips with respect to the axis of the needle and thus with respect to the eye of the needle. A bent needle will tilt the plate until the guide clips lie symmetric to the needle. The separation of the guide clips at its narrowest point is smaller than the diameter of the thinnest needle. This makes it possible to acceptably center onto the eye of the needle.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is explained in more detail based on a preferred embodiment. In the drawings:
FIG. 1 is a partial view of a sewing machine at the front end of the upper and lower arm with needle post and push sole,
FIG. 2 is an enlarged representation of the needle post and the stem with the threader,
FIG. 3 is a horizontal section view taken along line III—III in FIG. 8 through the threader and the needle when the two guide clips are centered about the needle.
FIG. 4 is a view similar to FIG. 3, but prior to the first contact of the grasping clips with the needle,
FIG. 5 is an enlarged portion of FIG. 1 with the hook already passed through the eye of the needle,
FIG. 6 is a view of the swivel arm with the tilt plate hinged to it and tilted to the side by angle alpha,
FIG. 7 is an enlarged view of the swivel arm and the plate shortly before the needle centers the guide clips,
FIG. 8 is a view of the device with the upper thread in place,
FIG. 9 is a view of the device after the thread hook has grasped the upper thread,
FIG. 10 is a side view of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the front ends of the lower arm 1 , the upper arm 3 , the needle holder 5 and the needle 7 are shown, as are a push sole 9 and the push shaft 11 of a household sewing machine, for example. Indicated below the push sole 9 are the openings 13 for the conveyer as well as the stitch hole 15 for the needle 7 . To the side of the needle 7 and the needle holder 5 is a threader 19 represented that is fixed, preferably onto the stem 17 , said stem 17 moveable vertically at the lower end. The stem 17 with the threader 19 can be lowered to the height of the needle eye 25 by means of a hand lever 21 fastened to the lower end of an actuator 23 (see FIG. 2 ), and can be rotated in the lowered position about axis A. This rotation is done by means of a coulisse 24 located at the upper section of the actuator 23 . A pin 26 that is fastened to the stem 17 engages this coulisse.
Lowering and tilting the threader 19 in the described manner is known from the state of the art. Therefore, it is not described in further detail. A known arrangement can be found in DE 914815.
The device, abbreviated as “threader 19 ”, includes a support 27 , which in the embodiment shown in FIG. 3 is cylindrical, with which the threader 19 can be coupled to the lower end of the stem 17 . A swivel arm 29 is attached to the support 27 . The support 27 and the swivel arm 29 are preferably manufactured in a single piece and are preferably made of plastic. A thread guide sheet 31 wraps around both the support 27 to some extent as well as the swivel arm 29 and extends out tangentially over the support 27 , in the shape of a downward-facing support bracket 33 , and ends to the side of and away from the end of the swivel arm 29 as a bent angled section 35 acting as an feed plate 37 . An open V-shaped slit 39 with an adjacent guide curve 41 is mortised into the feed plate 37 (see FIG. 6 ). The guide curve 41 is shaped like a “V” placed on end as seen from the side. The thread guide sheet 31 is held on the rear of the swivel arm 29 with suitable fasteners. For example, nubs formed on the swivel arm 29 can be provided as the fasteners, said nubs passing through holes 43 in the thread guide sheet 31 and that are connected to the latter by ultrasonic welds.
A tilting U-shaped plate 45 is fastened (see FIG. 6 also) to the thread guide sheet 31 , with the plate being wrapped around the thread guide sheet 31 from below with some play. The plate 45 can be hinged by means of bulges 47 formed on both of its sides 45 ′ and 45 ″ that lie opposite to one another, for example. These bulges 47 mate with a hole (not shown) in the thread guide sheet or in recesses attached to it accordingly. At the side 45 ″, two guide clips 49 and 51 that are at right angles to the surface of the side 45 ″, are being stamped out of the plate 45 , which is made of sheet material. See FIG. 7 . The two first sections 49 ′ and 51 ′ of the guide clips 49 , 51 that directly attach to the side 45 ″ of the plate run parallel and are made from an elastic material. Adjacent to these are the two sections 49 ″ and 51 ″, which converge in a cone shape. Adjacent to this are two curved sections 49 ′″ and 51 ′″ whose peaks S′ and S″ are separated from one another by distance a, shown in FIG. 6 . This distance a represents the narrowest point between the two guide clips 49 , 51 . The two end sections 53 , 55 of the guide clips 49 , 51 come after the peaks (S′ and S″) diverging along a V shape. End section 55 at the right side can be somewhat longer than end section 53 at the left side in a preferred embodiment. Lying in plane E exactly in the center between the two first sections 49 ′, 51 ′ is a thread hook 57 (FIG. 6 ). The thread hook 57 is not located exactly between the guide clips 49 , 51 , but is below them and its rear end is fastened to the side 45 . The hook 57 is of a very fine design so that it can be passed through the eye 25 of even very thin needles 7 , for example of only 0.6 mm width. The thickness of the hook 57 is of the order of magnitude of 0.2 mm. The hook 57 is made of sheet material.
The U-shaped plate 45 is connected at a point far enough from the lower edge 59 of the thread guide sheet 31 so that the plate 45 can be tilted about its tilt axis B, which is formed by the bulge 47 and the hole behind it, within a prescribable range. The tilt range is a few degrees, for example +/−3 degrees.
Below, the functioning of the threader 19 is described in more detail. In a known fashion, the stem 17 , along with the hook 57 fastened to its lower end and the two guide clips 49 and 51 , is lowered by pushing down on the hand lever 21 and rotated clockwise shortly before reaching the lowest position. This rotation is accomplished by means of the partially shown coulisse 24 at the upper end of the stem 17 . If an unbent needle 7 is present, the two ends 53 , 55 of the two guide clips 49 , 51 meet the needle 7 at the same time and symmetrically. When the stem 17 is further turned, the two guide clips 49 and 51 are spread apart at the same time and in the same amount and the hook 57 located between the two guide clips 49 and 51 can pass through the eye 25 of the needle 7 without touching it. This ideal initial position is not shown in the figures. If the axis of the needle, however, is located offset with respect to the intended position (see FIG. 3 ), guide clip 49 encounters the needle first. Due to the force acting on the guide clip 49 in the direction of the arrow x (FIG. 4 ), the plate 45 , to which the two guide clips 49 and 51 as well as the hook 57 are fastened, tilts in a counter clockwise fashion about axis B and centers the two guide clips 49 and 51 about the needle 7 . By further rotating the stem 17 , the hook 57 , which now lies exactly in front of the eye 25 due to the tilting motion of the plate 45 , is pushed through it and extends through the eye 25 , as shown in FIG. 10 .
An upper thread 63 , which is held in a thread guide 61 at the needle holder 5 of the sewing machine, can be threaded through to the slot 41 under the support bracket 33 and the two guide clips 49 and 51 , as shown in FIG. 8 . By means of the V-shaped design of the slot 41 , the upper thread 63 approaches the hook 57 from below, as shown in FIG. 9 . As soon as the pressure is let off of the hand lever 21 , the stem 17 tilts back and the hook 57 grasps the upper thread 63 and pulls it through the needle eye 25 and throws it upward after rotating by a few degrees of angle and beginning its vertical motion. The loop formed by the hook 57 can be grasped by hand and the end of the thread can be pulled through the needle eye 25 . The threader 19 returns by spring force to its raised protected position beneath the upper arm 3 .
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A device to introduce the upper thread into the eye of the needle ( 7 ) of a sewing machine which includes two guide clips ( 49, 51 ) having two inlet sections ( 53, 55 ) ending in a narrow point. The two guide clips ( 49, 51 ) are generally identical and can spread evenly when encountering the needle. The grasping hook ( 57 ) that lies in a plane in the center of the two guide clips ( 49, 51 ) is always guided exactly centered into the eye ( 25 ) of the needle ( 7 ). In addition, the two guide clips ( 49, 51 ) are mounted for tilting movement about a horizontal axis (B).
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BACKGROUND OF THE INVENTION
The invention relates to a ventilator roof for vehicles having a roof opening formed in a fixed roof surface, which can be closed by means of a cover that can be swung, by pivoting around a pivot axis, at, or near its rear edge, into a ventilation position in which the cover front edge is at a distance below the fixed roof surface while the rear edge of the cover is kept approximately at the height of the fixed roof surface, so that a ventilation gap is formed between the cover front edge and the front edge of the roof opening.
Such roofs are known from U.S. Pat. No. 4,911,497, as well as from U.S. Pat. No. 4,978,165. A common drawback of these prior art ventilator roofs is that they only provide a passive ventilation of the vehicle interior, due to negative pressure occurring above the fixed roof surface during vehicle movement, or due to the rising of warmer air from the vehicle interior, With the vehicle standing, the ventilation effect, thus achieved, is unsatisfactory.
Vehicle roofs with active ventilation have already been developed. Thus, it is known (published German Application DE 36 43 436 A1, FIGS. 1, 2 and 5) to integrate a cross current blower into the cover of a lifting roof, whereby the cover is provided with an air passage slit extending over a major portion of its width and whose edge is encircled by the housing of the cross current blower on both sides, from above and below. The blower housing forms a radial suction channel or exhaust channel on the cover's inner side, and forms a tangentially directed exhaust or suction channel on the outer cover side.
In accordance with another embodiment that German Application (FIGS. 3, 4 and 6), the cross current blower, in similar manner, is disposed in a wind deflector which is placed in front of the front edge of the roof opening on the fixed roof surface. In these known designs, the blower housing represents an add-on which projects upwardly above the roof surface. For reasons of visual esthetics and aerodynamic considerations (increased CD value), such an arrangement is not desirable.
Moreover, if the blower is integrated into the cover, sealing the roof against rain and wash water becomes a problem; the cover weight increases, and the cover mechanism must be stronger. If the blower is disposed above the roof surface in the wind deflector, ventilation with the cover closed is not possible.
It is also known (published German Application 35 40 546 A1 and Gebrauchsmuster 88 08 782 U1) to attach a motor powered ventilator and a solar energy source powering it to a vehicle lifting roof beneath a translucent cover on a wide carrier element which extends in the medial region of the roof opening in the driving direction of the vehicle. In another embodiment of this lifting roof, a radial ventilator and an associated solar energy source are attached at the underside of the translucent lifting cover (German Begraushsmuster 88 15 676 U1), so that they also are induced into executing the swing movement when the cover is pivoted.
A common drawback of such assemblies is that optical visibility is lost from a considerable portion of the cover area. Moreover, the overall headroom of the roof reaches dimensions which are undesirable for many applications in practice.
SUMMARY OF THE INVENTION
The invention, therefore, has a primary objective to provide a ventilator roof of the kind mentioned above, which not only permits passive ventilation, bu facilitates, in an unobtrusive and space-saving manner, a means of active ventilation which is comfortable and pleasant for the passengers of the vehicle.
This objective is achieved by this invention in that at least one blower, which is powered by an electric motor, is built into a ventilation channel leading from the ventilation gap into the vehicle interior.
In the ventilator roof in accordance with the invention, active ventilation does not require any roof add-on structures which are undesirable from a visual or aerodynamic aspect. The utilizable roof opening and transparent roof surface can be fully sustained regardless of the provisions to obtain active ventilation. The blower is disposed in front of the roof opening and thus at a location, which, with regard to low headroom is not critical. Once the blower is activated, the air flows along the inside of the vehicle's front windshield, thereby preventing air being blown directly onto the vehicle passengers. Due to the lower air resistance in the ventilation channel, the blower located in the ventilation gap can be designed for a lower input power than the existing vehicle blowers.
Preferably, the design is such that the ventilation channel connects the ventilation gap, formed between the front edge of the lowered cover and the front edge of the roof opening, with an air passage-in-a fixed roof liner which is mounted to the underside of the roof surface, below the roof opening. This ensures a particularly attractive appearance for the vehicle interior.
At least one ventilation screen can be inserted into the air passage, and the blower and the ventilation screen can be combined into a single unit. Specifically, the blower may have a housing which is formed of one piece with the ventilation screen, so that the blower housing can be designed as an exchangeable part with a simple ventilation-screen, as utilized with ventilator roofs without active ventilation. Accordingly, the ventilator roof can be easily designed either with or without active ventilation, without changing the visual appearance of the vehicle interior.
In accordance with another embodiment, the blower housing can also be formed by a roof frame which is mounted to the underside of the fixed roof surface and which carries the cover and its associated operating parts.
The cover can be designed as a solar module which supplies current to the electrically powered blower. An example of such a solar module is shown in copending, commonly assigned U.S. patent application Ser. No. 07/663,611 now abandoned. The solar module can be of known construction and a contact device can be provided, in the electric circuit between the solar module and the blower, which closes automatically, whereby the current device can also be designed such that it likewise keeps the electric circuit closed between the solar module and the blower when the cover is in the closed position. An example of a roof with a solar module for supplying current to electric power consuming devices of the vehicle is shown in co-pending, commonly assigned U.S. patent application Ser. No. 723,905, filed Jul. 1, 1991 on.
The blower can be connected to the on-board power supply, in which instance a monitoring step is provided for preventing excessive discharge of the on-board power supply by separating the blower from the on-board power supply when the charge of the on-board power supply falls below a preset threshold value.
At least one time-switch can be disposed in the control circuit of the blower to facilitate activation and/or deactivation of the blower at a predetermined time; or, over a predetermined period, e.g., a gradual deactivation over a period of time.
A thermal switch can be provided for controlling the blower, which automatically effects the active ventilation when a predetermined temperature limit value is surpassed in the vehicle interior. Specifically, the blower can be a cross-current blower or an axial blower. At least one such blower can be medially disposed in the ventilation channel, transverse to the vehicle direction, whereby, free ventilation openings remain at both sides of the blowers. The configuration, however, also can be such that, in the transverse direction, at least one blower, respectively, is arranged on both, the right and left sides, of the ventilation channel, and free ventilation openings remain therebetween.
In order to also provide active ventilation when the cover is closed, ventilation slits can be provided in the rear portion of the vehicle roof which are connected with a compartment between the roof surface and a roof liner. Air from the vehicle interior can be discharged by the blower via this compartment and the ventilation slits, when the cover is in the closed position.
Preferably, the cover, as is known as such from U.S. Pat. No. 4,911,497, can be extended above the roof surface, and can be rearwardly displaced below or above the roof surface into an open position, in which the cover at, least partially, exposes the roof opening.
Further objects, features and advantages of the ventilator roof in accordance with the invention are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2 and 3 are schematic longitudinal sections through a ventilator roof, with the cover depicted in the closed position; the ventilator position; and with the cover pushed back;
FIG. 4 is a top view onto the ventilator roof according to FIGS. 1 to 3;
FIG. 5 is a sectional view taken along line V--V of FIG. 4;
FIG. 5A is a section through a ventilator screen without blower;
FIG. 6 is a top view similar to FIG. 4, showing a different embodiment of the ventilator roof;
FIG. 7 is a sectional view taken along line VII--VII of FIG. 6;
FIG. 8 is a partial, longitudinal sectional view through a variation of a ventilator roof with an axial blower, with the cover in the ventilator position;
FIGS. 9, 10, 11 are schematic, longitudinal sections through a ventilator roof in various cover positions, indicating the construction of a contact device, which automatically closes when the cover changes into the ventilator position;
FIGS. 12, 13, 14 are various embodiments for the supply and control circuits of the blower;
FIG. 15 is a schematic, longitudinal sectional view of another embodiment of a roof;
FIGS. 16, 17, 18 are schematic, longitudinal, sectional views, similar to those in FIGS. 1, 2 and 3, for a ventilator roof, in which the cover can be pushed rearwardly above the fixed roof surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The ventilator roof depicted in FIGS. 1 to 5 has a cover 10 made of transparent or translucent material, for instance, glass, which is carried on an encircling cover carrier 11. A sealing profile 12 is disposed on a projecting outer edge of carrier 11 for sealing an edge gap between the outer edge of the cover 10 and the adjacent edge of roof opening 13 in the cover's closed position (FIG. 1). The roof opening 13 is formed in the front part of the fixed roof surface 14 and can be selectively closed by means of cover 10, or can, at least partially, be exposed.
Secured below the roof surface 14, there are disposed a roof frame 15 and a fixed roof headlining 16 defining an opening 17 which is located below the roof opening 13. This opening can be covered by way of a sliding roof headliner 18 (FIGS. 1 and 2).
Cover 10, by way of a displacement mechanism 20, indicated in FIG. 4 only schematically, with associated threaded cables 30, and powered by a drive motor 21, can be pivoted into the FIG. 2 ventilator position around an pivot axis (imaginary), at or, near its rear edge 22, into the FIG. 2 ventilator position, in which the cover front edge 23 is below fixed roof surface 14. To this end, the cover rear edge 22 is at least approximately kept at the height of the roof surface. If, during the movement of the vehicle, there is a negative pressure at the outer side of the roof surface 14, relative to that prevailing in the vehicle interior, an air current is formed which is indicated at numeral 24 in FIG. 2. To this end, the air current 24 traverses a ventilation channel 25 which connects a ventilation gap 27, between the front edge 23 of the lowered cover 10 and the front edge 26 of roof opening 13, with an air passage 28 of roof lining 16. The air passage 28 is below the fixed roof surface 14 and in front of front edge 26 of roof opening 13. A ventilator screen 29 is inserted into air passage 28.
The roof opening 13, in the front part of roof surface 14, can be at least partially opened, whereby the rear edge 22 of cover 10, preferably starting from the FIG. 2 ventilator position, is lowered below the roof surface 14 by an amount which, preferably, is less than the downward slant of the cover front edge 23 in the ventilator position (FIG. 2). In this preferred operational sequence, the cover front edge 23, previously lowered into the ventilator position, is simultaneously lifted into an intermediate position between the ventilator position (FIG. 2) and the closed position (FIG. 1). In this manner, cover 10 is brought into a sliding position, in which it is essentially parallel to roof surface 14 (FIG. 3). Subsequently, cover 10, by means of longitudinal guides 31 (FIG. 4) extending along both sides of roof opening 13 and extending rearwardly therefrom, can be pushed underneath roof surface 14 into an open position in which cover 10 opens the roof opening 13 to a varying degree (FIG. 3). Hereby, cover 10 is received in a compartment 32 between that portion of surface 14 which is rearward of roof openings 13, 17 and the roof lining 16 lying beneath it.
While cover 10 is in the (FIG. 1) closed position, in the (FIG. 2) ventilator position, or in between these two positions, the sliding headliner 18 can be selectively shifted into a position between its closed position (FIG. 1) and a pushed back position (FIG. 3) by grasping a grip molding 33 in order to influence the incidence of light into the vehicle interior through cover 10. As is known from prior art (U.S. Pat. No. 4,312,533), a mechanism can be provided to facilitate the taking along of sliding headliner 18 when cover 10 is moved back into compartment 32. Appropriately, a wind deflector 34 is provided which changes from its rest position (FIGS. 1 and 2) into a working position (FIG. 3) when the cover is slid back. The displacement mechanism 20 can be constructed as described in U.S. Pat. No. 4,911,497 or in copending, commonly assigned U.S. patent application Ser. No. 07/525,603 now U.S. Pat. No. 5,069,500 and, therefore, needs no further detailed explanation.
In the illustration of the ventilation channel 25 depicted in FIGS. 4, 5 and 5A an electrically powered cross current blower 35 is built on its right and left hand sides, respectively, whereby ventilation openings 36 remain open between the two lateral cross current blowers 35. In the example depicted, the cross current blower 35 and the ventilation screen 29 are combined into one structural unit, designated in its entirety with reference numeral 37, whereby blowers 35 have a housing 38 which is connected, as a one piece unit, with the ventilating screen 29. Appropriately, unit 37 with ventilation screen 29 can be designed as an exchangeable part for a simple ventilation screen, as it is used with a ventilator roof which does not have a blower built into the ventilator channel U.S. Pat. No. 4,911,497 (Published German Applications 38 40 694, A1, P 39 39 054.4 and P 39 30 755.17 and U.S. patent application Ser. No. 07/525,603 now U.S. Pat. No. 5,069,500. It is to be understood that the ventilation screen 29 also may be designed such that it is divided longitudinally, e.g. may have a two-part or multiple-part configuration.
In a different embodiment, illustrated according to FIGS. 6 and 7, a cross current blower 35 is medially arranged in the ventilation channel 25 in the transverse direction of the vehicle, whereby open ventilation openings 36 remain at both sides of blower 35. In this variation, housing 38' of cross current blower 35 is formed by the roof frame 15', which surrounds the underside of roof opening 13 and carries cover 10, as well as the associated operating parts. In the air passage 28 defined by roof frame 15', a ventilation screen 29' is inserted which, in the area of the cross current blower 35, forms an air inlet for the blower housing 38'.
In a variation of this design, a roof frame forming the blower housing can also be provided for a configuration incorporating multiple blowers, like those, for instance, as depicted in FIG. 4. Conversely, it is also possible to provide a ventilation screen 29, forming the blower housing, with a medial arrangement of the cross current blower, in accordance with FIG. 6.
FIG. 8 shows a still further variation of the ventilator roof, in which one or several axial blowers 35' are arranged in the ventilator channel 25 adjacent to each other int he transverse direction of the vehicle. In the FIG. 8 configuration, the axial blower 35' or the axial blowers 35' are installed at the ventilation screen 29". Alternatively, it is possible to design the roof frame 15 in such a manner that it constitutes the axial blower housing or the axial blower housings.
Advantageously, cover 10 can be designed as a solar module which provides power for the blowers 35 or 35'. Such a cover 10, designed as a solar module, together with an associated contact device 40, is schematically depicted in FIGS. 9, 10 and 11. Cover 10, here, has an outer glass layer 41 and a translucent solar cell layer 42, contacting the inner side of the glass outer layer, which solar cell layer 42 can be supported on a carrier layer at that side which faces away from the of glass layer 41. The solar cell layer 42 may consist of amorphous or crystalline semiconductor material. The construction of such a solar module is known per se and by itself forms no part of this invention and, therefore, does not require further detailed discussion here. An example of such a solar module is shown in copending, commonly assigned U.S. patent application Ser. No. 07/663,611. Contact device 40 has a contact plate 43 on the underside of cover 10 which is electrically connected with the solar cell layer 42, and further, has a spring contact 44 on the roof frame. The contact device 40 is located in a circuit 45 between the solar cell layer 42 and the electronically powered blower 35, and is schematically indicated in FIG. 10. After cover 10 has been brought into the ventilator position (FIG. 10), contact plate 43 contacts spring contact 44; the circuit 45 between the solar module and the blower 35 is closed; and the blower is in operation. In all other cover positions (for instance, the positions according to FIGS. 9 and 11), circuit 45 is open, in this embodiment.
Alternatively, contact device 40 can be designed such that the spring contact 44 is kept in engagement with contact plate 43, in all of the FIGS. 9, 10 and 11 cover positions, as well as in all intermediate positions between these cover positions, and opens contact device 40 only when cover 10 is pushed back toward a position corresponding to that of FIG. 3. In this connection it is to be understood that designs of the contact device 40, other than those indicated in FIGS. 9-11, may be considered. For instance, contact devices may be used which principally have designs which are similar to those described in greater detail in the above-noted, commonly assigned co-pending U.S. application Ser. No. 723,905.
An example of a circuit 45 between the solar module of cover 10 and the electrically powered blower 35 or 35' is shown in FIG. 12, in which the motor driving blower is indicated at "M". As long as radiation is prevailing, the solar module emits a direct voltage between terminals 46 and 47, which can be applied at the blower motor "M" via two leads 48 and 49. In each of the two leads 48, 49, there is a contact mechanism, which automatically closes, at least when cover 10 has been brought into the ventilator position (FIGS. 2, 8 and 10). The contact device 40 employed, for instance, can be of the kind shown in FIGS. 9 to 11. In series with contact device 40, in lead 48, there is an ON/OFF switch 50, while int he other lead 49, in addition to the contact device 40, there is a fuse 51. The ON/OFF switch 50 can be designed for manual operation. Alternatively, or additionally, it can be provided that switch 50, after each cover 10 movement, is placed in the OFF mode, which eliminates unwanted blower actuations, at the very start and also prevents blower motor "M" from starting operation when cover 10 is driven from the closed into the opened position (and vice versa). Thus, the cover traverses the ventilator position, thereby closing the contact device 40. For such an OFF mode, switch 50, as indicated at 52, is connected with the roof drive 20, 21. In place of ON/OFF switch 50, or additionally in series thereto, a thermal circuit breaker 53 can be provided, which is open at relatively low temperatures, and which closes when the vehicle interior temperature surpasses an adjustable or specific predetermined threshold value.
However, the blowers 35 or 35' may also be connected to the on-board vehicle power supply. A simple block diagram therefor is depicted in FIG. 13, whereby the battery 55 feeding the on-board power supply is connected with the one terminal of blower motor "M" via the fuse 51 and is connected via a switching series consisting of the ONOFF switch 50 and a cover position switch 56 with the other terminal of blower motor "M". Switch 50 has a function which is illustrated by way of FIG. 12. The cover position switch 56, dependent upon the respective position of the cover 10, is automatically brought into the closed position, at least, when cover 10 reaches the ventilation position. The respective cover position can be queried via a microswitch, proximity switch, or the like, directly at the cover. Alternatively, it is also possible to detect the cover position immediately at the roof drive 20, 21.
In accordance with FIG. 14, the circuit layout along the lines of FIG. 13 can be further refined. In the control circuit of blowers 35 or 35', there is, additionally, a monitoring unit 57 that separates the blower from the on-board power supply when the charge of the on-board power source (battery 55) falls below a preset threshold value. This eliminates an undue progressive discharge of the on-board power source by the blower. Two time-switches 58 and 59 are also arranged in series with the monitoring unit 57. One time switch 58 detects the time and can be adjusted such that at preselected times it closes and/or opens. The other time switch 59 closes for a preselected time period. The time switches 58 and 59 permit, among other functions, intake operation of blowers 35, 35' at a predetermined time and/or a gradual deactivation stage over a certain time period. In addition to the time switches or alternatively thereto, a thermal circuit breaker 53, as described by way of FIG. 12, can be provided as indicated. Also, selectively supplying the blowers from either the on-board power supply or from a solar current source is another option.
While in the embodiments according to FIGS. 1, 2 and 3, the compartment 32 which receives the pushed back cover 10 is closed to the rear, FIG. 15 shows a variation thereof in which ventilation slits 61 are provided in the rear portion of the vehicle roof. Ventilation slits 61 communicate with the compartment 32 between the fixed roof surface 14 and the roof lining 16. In this embodiment, the blowers 35 or 35' can be utilized to discharge air from the vehicle interior via the ventilation slits 61, while cover 10 is in the closed position.
The embodiment, in accordance with FIGS. 16, 17, and 18, is essentially different from the configuration in FIGS. 1, 2 and 3, in that the cover 10, for the purpose of opening the roof opening 13, is not lowered rearwardly and subsequently slid below the roof surface, but instead, is tilted with its rear edge 22 above roof surface 16 and, then, in the manner of a spoiler roof, is shifted rearwardly over the fixed roof surface 14. A displacement mechanism that is suitable for such a movement sequence is described in U.S. Pat. No. 4,978,165 and does not require further discussion here. In this roof, also, at least one electrically powered blower 35 or 35' is built into the ventilation channel 25 leading from the ventilation gap 27 into the vehicle interior which, especially, can provide active ventilation of the interior of a standing vehicle.
In particular, in this embodiment, while cover 10 is in the closed position, the blowers 35 or 35' can be utilized to discharge air from the vehicle interior into a compartment 32', that is located between the cover 10 and the cover inside headliner 18. From compartment 32', the discharged air is able to flow back into the vehicle interior space via ventilation slits 61' that are provided in the rear area of the roof openings 13, 17. In this way, air is dischargable from a front portion of the vehicle interior space by the blower and recirculated back to the vehicle interior space via compartment 32' and the ventilation slits 61' in order to make the vehicle interior space more comfortable when the vehicle is stopped.
While we have shown an described various embodiments in accordance with the present invention, it is understood that the same is not limited thereto, but is susceptible of numerous changes and modifications as known to those skilled in the art, and we, therfore, do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims.
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Ventilator roof for use in motor vehicles with a roof opening in a fixed roof surface which can be closed by a cover. The cover can be swung by pivoting around a pivoting axis, at, or near its rear edge, into a ventilation position in which the cover front edge is below the roof surface, while the cover rear edge is kept at the height of the roof surface, and a ventilation gap is formed between the cover front edge and the front edge of the roof opening. At least one electrically powered blower is built into a ventilation channel leading from the ventilation gap into the vehicle interior. The blower can be powered by solar cells or the on-board vehicle power unit (battery) with safeguards to prevent use when the vehicle power unit lacks sufficient charge. In some embodiments, arrangements are also provided to enable the blower to provide ventilation of the interior space of the vehicle even when the cover is closed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of application Ser. No. 11/691,099 filed on Mar. 26, 2007 and published as US2008/0236832 on Oct. 2, 2008, the disclosures of which are incorporated herein by reference in their entirety; this application also claims priority under 35 U.S.C. §365(a) to P.C.T. Application Number PCT/RU2009/000477 entitled Method For Treating Subterranean Formation With Degradable Material At Low Temperature filed on Sep. 16, 2009.
FIELD OF THE INVENTION
The present invention relates to the art of treating subterranean formations and more particularly, to a method of delivering a fluid treatment composition with base mixture and a degradable material into a formation for low temperature application. The invention is particularly applicable to methods of delivering low viscosity viscoelastic surfactant compositions that are capable of transporting large size proppants but break cleanly without the need for pre flushes or post flushes.
BACKGROUND
Hydraulic fracturing of subterranean formations has long been established as an effective means to stimulate the production of hydrocarbon fluids from a wellbore. In hydraulic fracturing, a well stimulation fluid (generally referred to as a fracturing fluid) is injected into and through a wellbore and against the surface of a subterranean formation penetrated by the wellbore at a pressure at least sufficient to create a fracture in the formation. Usually a “pad fluid” is injected first to create the fracture and then a fracturing fluid, often bearing granular propping agents, is injected at a pressure and rate sufficient to extend the fracture from the wellbore deeper into the formation. If a proppant is employed, the goal is generally to create a proppant filled zone from the tip of the fracture back to the wellbore. In any event, the hydraulically induced fracture is more permeable than the formation and it acts as a pathway or conduit for the hydrocarbon fluids in the formation to flow to the wellbore and then to the surface where they are collected.
The fluids used as fracturing fluids have also been varied, but many if not most are aqueous based fluids that have been “viscosified” or thickened by the addition of a natural or synthetic polymer (crosslinked or uncrosslinked) or a viscoelastic surfactant (VES). The carrier fluid is usually water or a brine (e.g., dilute aqueous solutions of sodium chloride and/or potassium chloride).
The viscosifying polymer is typically a solvatable (or hydratable) polysaccharide, such as a galactomannan gum, a glycomannan gum, or a cellulose derivative. Examples of such polymers include guar, hydroxypropyl guar, carboxymethyl guar, carboxymethylhydroxyethyl guar, hydroxyethyl cellulose, carboxymethylhydroxyethyl cellulose, hydroxypropyl cellulose, xanthan, polyacrylamides and other synthetic polymers. Of these, guar, hydroxypropyl guar and carboxymethylhydroxypropyl guar are typically preferred because of commercial availability and cost performance.
In many instances, if not most, the viscosifying polymer is crosslinked with a suitable crosslinking agent. The crosslinked polymer has an even higher viscosity and is even more effective at carrying proppant into the fractured formation. The borate ion has been used extensively as a crosslinking agent, typically in high pH fluids, for guar, guar derivatives and other galactomannans. Other crosslinking agents include, for example, titanium, chromium, iron, aluminum, and zirconium.
Viscoelastic surfactant fluids are normally made by mixing into the carrier fluid appropriate amounts of suitable surfactants such as anionic, cationic, nonionic and zwitterionic surfactants. The viscosity of viscoelastic surfactant fluids is attributed to the three dimensional structure formed by the components in the fluids. When the concentration of viscoelastic surfactants significantly exceeds a critical concentration, surfactant molecules aggregate into micelles, which can become highly entangled to form a network exhibiting elastic behavior.
Viscoelastic surfactant solutions are usually formed by the addition of certain reagents to concentrated solutions of surfactants, frequently consisting of long-chain quaternary ammonium salts such as cetyltrimethylammonium bromide (CTAB). Common reagents that generate viscoelasticity in the surfactant solutions are salts such as ammonium chloride, potassium chloride, sodium salicylate and sodium isocyanate and non-ionic organic molecules such as chloroform. The electrolyte content of surfactant solutions is also an important control on their viscoelastic behavior.
During hydraulic fracturing treatments, control of fracture height growth can be an important issue. In situations where the water table is close to the fracturing zone, or where the fracture zones have low stress barriers, where fracture height growth can result in screen outs, control of the fracture height may be critical. A common technique for the control of fracture height control is to use fluids with lower viscosity, such as VES surfactants. Lower viscosity fluids however, do not transport the large sized proppants effectively in the fracture.
One method of addressing the issue has been the incorporation of fiber into the surfactant fluids. However, the breaking of fiber and of fiber bearing VES fracturing fluid can be still be problematic especially without pre or post flushes. Polylactic acid (PLA) fibers have been shown to degrade into soluble materials under temperature and with time. However, all applications are limited to temperatures above 82° C. based on the rate of degradation. At temperatures below 82° C., PLA fibers degrade too slowly to be useful for those oilfield applications. It would be helpful to have a VES fluid which would transport the large sized proppants effectively and still break under low temperature conditions (below 82° C., for example 50° C. or 60° C.), leaving little or no residue solids in the fracture.
SUMMARY
In one embodiment, the invention provides a method for treating a subterranean formation penetrated by a wellbore which comprises providing a treatment fluid comprising a viscoelastic surfactant having at least one degradable linkage, a hydrolysable material, and a pH control material, wherein the pH control material has a pH equal or greater than about 9 and comprises a strongly alkaline material and an oxidizing agent; and injecting into the subterranean formation the treatment fluid.
In another embodiment, the invention provides a method for treating a subterranean formation penetrated by a wellbore which comprises injecting into the subterranean formation a treatment fluid made of a viscoelastic surfactant having at least one degradable linkage, a hydrolysable material and a pH control material, wherein the pH control material is an amine additive.
In some embodiments, the hydrolysable material is a hydrolysable fiber for example selected from the group consisting of polyesters, polyamides, and polylactides. The hydrolysable fiber and the viscoelastic surfactant may form non-solid products upon hydrolysis.
In some embodiments, the oxidizing agent and/or strongly alkaline material and/or the amine additive may be encapsulated.
In another embodiment, the strongly alkaline material has a pH of at least about 11. The strongly alkaline material may be selected from the group consisting of metal hydroxide, metal oxide, calcium hydroxide, metal carbonates, and metal bicarbonates. The metal hydroxide can be NaOH, Ca(OH) 2 , Mg(OH) 2 or KOH and the metal oxide can be CaO, MgO or ZnO. The oxidizing agent may be persulfate ammonium or calcium peroxide. The amine additive may be selected from the group consisting of urea, dimethylolurea, 1,1-diethylurea, 1,1,3,3-tetramethylurea, 1,3-diethylurea, hydroxyurea, 1,3-diallylurea, ethylurea, 1,1-dimethylurea, 4-dimethylaminopyridine (DMAP) and 1,8-diazabicylo(5.4.0)undec-7-ene (DBU). The amine additive may further have a salt, for example potassium carbonate.
Unless otherwise specifically stated, all percentages herein are percentages by weight
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph plotting fiber dissolution over time in hours at 75° C.
FIG. 2 is a graph plotting PLA fiber degradation after 18 h 30 min at 50° C.
FIG. 3 is a graph plotting PLA fiber degradation after 4 h at 50° C.
FIG. 4 is a graph plotting PLA fiber degradation with different oxidizing agents at 50° C.
FIG. 5 is a graph plotting conductivity of Fores 12/18 proppants with fiber and different amount of sodium hydroxide.
FIG. 6 is a graph plotting degradation of fibers with various urea additives and amine additives at 66° C. and 100° C.
FIG. 7 is a graph plotting degradation of fibers as a function of DBU concentration at 50° C. and 66° C.
FIG. 8 is a graph plotting degradation of fibers with DMAP as a function of DBU concentration at 50° C. and 66° C.
FIG. 9 is a graph plotting degradation of fibers with DMAP at 50° C. for 58 hours.
FIG. 10 is a graph plotting degradation of fibers with DMAP at 66° C. for 21 hours.
FIG. 11 is a graph plotting degradation of fibers with DBU at 50° C. for 68 hours.
FIG. 12 is a graph plotting degradation of fibers with DBU at 66° C. for 21 hours.
FIG. 13 is a graph plotting degradation of fibers with 1,1-diethylurea at 50° C. for 5 hours.
FIG. 14 is a graph plotting degradation of fibers with 1,1-diethylurea at 66° C. for 21 hours.
DETAILED DESCRIPTION
At the outset, it should be noted that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. The description and examples are presented solely for the purpose of illustrating the preferred embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. While the compositions of the present invention are described herein as comprising certain materials, it should be understood that the composition could optionally comprise two or more chemically different materials. In addition, the composition can also comprise some components other than the ones already cited.
In the summary of the invention and this description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific data points, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors have disclosed and enabled the entire range and all points within the range.
A first embodiment is an oilfield treatment method including providing a fluid viscosified with a viscoelastic surfactant, including a degradable material and a base mixture for hydrolysis of PLA at low temperature.
According to some embodiments, degradable material is a degradable fiber or degradable particle. For example, degradable fibers or particles made of degradable polymers are used. The differing molecular structures of the degradable materials that are suitable for the present embodiments give a wide range of possibilities regarding regulating the degradation rate of the degradable material. The degradability of a polymer depends at least in part on its backbone structure. One of the more common structural characteristics is the presence of hydrolyzable and/or oxidizable linkages in the backbone. The rates of degradation of, for example, polyesters, are dependent on the type of repeat unit, composition, sequence, length, molecular geometry, molecular weight, morphology (e.g., crystallinity, size of spherulites, and orientation), hydrophilicity, surface area, and additives. Also, the environment to which the polymer is subjected may affect how the polymer degrades, e.g., temperature, presence of moisture, oxygen, microorganisms, enzymes, pH, and the like. One of ordinary skill in the art, with the benefit of this disclosure, will be able to determine what the optimum polymer would be for a given application considering the characteristics of the polymer utilized and the environment to which it will be subjected.
Suitable examples of polymers that may be used in accordance with the embodiments herewith include, but are not limited to, homopolymers, random aliphatic polyester copolymers, block aliphatic polyester copolymers, star aliphatic polyester copolymers, or hyperbranched aliphatic polyester copolymers. Such suitable polymers may be prepared by polycondensation reactions, ring-opening polymerizations, free radical polymerizations, anionic polymerizations, carbocationic polymerizations, coordinative ring-opening polymerization for, such as, lactones, and any other suitable process. Specific examples of suitable polymers include polysaccharides such as dextran or cellulose; chitins; chitosans; proteins; aliphatic polyesters; poly(lactides); poly(glycolides); poly(ε-caprolactones); poly(hydroxy ester ethers); poly(hydroxybutyrates); polyanhydrides; polycarbonates; poly(orthoesters); poly(acetals); poly(acrylates); poly(alkylacrylates); poly(amino acids); poly(ethylene oxide); poly ether esters; polyester amides; polyamides; polyphosphazenes; and copolymers or blends thereof. Other degradable polymers that are subject to hydrolytic degradation also may be suitable. Of these suitable polymers, aliphatic polyesters are preferred. Of the suitable aliphatic polyesters, polyesters of α or β hydroxy acids are preferred. Poly(lactide) is most preferred. Poly(lactide) is synthesized either from lactic acid by a condensation reaction or more commonly by ring-opening polymerization of cyclic lactide monomer. The lactide monomer exists generally in three different forms: two stereoisomers L- and D-lactide; and D,L-lactide (meso-lactide). The chirality of the lactide units provides a means to adjust, inter alia, degradation rates, as well as the physical and mechanical properties after the lactide is polymerized. Poly(L-lactide), for instance, is a semicrystalline polymer with a relatively slow hydrolysis rate. This could be desirable in applications where slow degradation of the degradable material is desired. Poly(D,L-lactide) is an amorphous polymer with a much faster hydrolysis rate. This may be suitable for other applications. The stereoisomers of lactic acid may be used individually or combined for use in the compositions and methods of the present embodiments. Additionally, they may be copolymerized with, for example, glycolide or other monomers like e-caprolactone, 1,5-dioxepan-2-one, trimethylene carbonate, or other suitable monomers to obtain polymers with different properties or degradation times. Additionally, the lactic acid stereoisomers can be modified by blending high and low molecular weight polylactide or by blending polylactide with other aliphatic polyesters. For example, the degradation rate of polylactic acid may be affected by blending, for example, high and low molecular weight polylactides; mixtures of polylactide and lactide monomer; or by blending polylactide with other aliphatic polyesters.
One guideline for choosing which composite particles to use in a particular application is what degradation products will result. Another guideline is the conditions surrounding a particular application. In choosing the appropriate degradable material, one should consider the degradation products that will result. For instance, some may form an acid upon degradation, and the presence of the acid may be undesirable; others may form degradation products that would be insoluble, and these may be undesirable. Moreover, these degradation products should not adversely affect other operations or components.
The physical properties of degradable polymers may depend on several factors such as the composition of the repeat units, flexibility of the chain, presence of polar groups, molecular mass, degree of branching, crystallinity, orientation, etc. For example, short chain branches reduce the degree of crystallinity of polymers while long chain branches lower the melt viscosity and impart, inter alia, extensional viscosity with tension-stiffening behavior. The properties of the material utilized can be further tailored by blending, and copolymerizing it with another polymer, or by a change in the macromolecular architecture (e.g., hyper-branched polymers, star-shaped, or dendrimers, etc.). The properties of any such suitable degradable polymers (such as hydrophilicity, rate of biodegration, etc.) can be tailored by introducing functional groups along the polymer chains. One of ordinary skill in the art, with the benefit of this disclosure, will be able to determine the appropriate functional groups to introduce to the polymer chains to achieve the desired effect.
In one embodiment, the method employs degradable fiber when exposed to high pH conditions for a period of time. Examples of such fibers include, but are not limited to polyesters, polyamides, polylactides and the like.
In one embodiment, the method employs polylactic acid, which undergoes a hydrolysis to form a liquid when exposed to a high pH environment as shown in the following reaction scheme:
In order to provide a pH environment suitable for the hydrolysis of the fiber to occur at low temperature (as low as 40° C. and up to 85° C.), a base mixture is used. The base mixture can be a pH control agent.
Useful pH control agents will vary with the specific degradable fiber selected for use, but generally may include those agents which are strongly alkaline materials that may provide a high pH environment. Generally, pH control agents having a pH of 9 or more are considered to be strongly alkaline materials. Examples of such strongly alkaline materials include, but are not limited to, metal hydroxides, metal oxides, calcium hydroxide, metal carbonates or bicarbonates, and the like. For example, the strong alkaline material can be CaO, Ca(OH) 2 , MgO as well as liquid additives such NaOH and KOH.
The pH control agent may also contain oxidizing agents such as (NH 4 ) 2 S 2 O 4 and CaO 2 . The oxidizing agents were found to increase rate of fiber degradation when used in conjunction with metal oxide.
The pH control agent may also contain amines base additives such as urea and its derivatives, as well as nucleophilic amines such as 4-dimethylaminopyridine (DMAP) and 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU). In one embodiment, the pH control agent may also contain a combination of amines with potassium carbonate (K 2 CO 3 ).
In a first embodiment, the pH control agent is made of a strongly alkaline material and an oxidizing agent. In a second embodiment, the pH control agent is made of an amine additive. The amine additive can be an amine base and/or a nucleophilic amine. In one embodiment, the amine additive may also be a amine and a salt. In a third embodiment, the pH control agent is made of a strongly alkaline material, an oxidizing agent and an amine additive.
The amount of pH control agent required to provide hydrolysis at low temperature will vary with the particular control agent selected and with the system, but generally, the pH control agent may comprise from about 0.5 weight percent to about 15 weight percent of the treatment fluid. In one embodiment, the fluid may contain from about 1 weight percent to about 10 weight percent. In another embodiment, the fluid may contain about 3 weight percent to about 10 weight percent. In yet another embodiment, the fluid may contain from about 3 weight percent to about 7 weight percent.
When fluids are viscosified by the addition of viscoelastic surfactant systems, the viscosity increase is believed to be due to the formation of micelles, for example worm-like micelles, which entangle to give structure to the fluid that leads to the viscosity. In addition to the viscosity itself, an important aspect of a fluid's properties is the degree of viscosity-recovery or re-healing when the fluid is subjected to high shear and the shear is then reduced. For VES fluids, shear may disrupt the micelle structure, after which the structure reforms. Controlling the degree of reassembling (re-healing) is necessary to maximize performance of the surfactant system for different applications. For example, in hydraulic fracturing it is critical for the fluid to regain viscosity as quickly as possible after exiting the high-shear region in the tubulars and entering the low-shear environment in the hydraulic fracture. On the other hand, it is beneficial in coiled tubing cleanouts to impart a slight delay in regaining full viscosity in order to “jet” the solids more efficiently from the bottom of the wellbore into the annulus. Once in the annulus the regained viscosity ensures that the solids are effectively transported to the surface. Controlling the viscosity-recovery and the time required for such recovery is therefore desirable.
Many viscoelastic surfactants may be used in this application. Surfactants with a degradable linkage in the molecule will hydrolyse to separate the hydrophilic head and the hydrophobic tail. While not wishing to be bound by theory, it is believed that such separation will degrade the micelles formed by the VES surfactant.
Exemplary cationic viscoelastic surfactants include the amine salts and quaternary amine salts disclosed in U.S. Pat. Nos. 5,979,557, and 6,435,277 which have a common Assignee as the present application and which are hereby incorporated by reference.
In one embodiment, the viscoelastic surfactant has an amide linkage in the head group, according to the scheme
XX Examples of suitable cationic viscoelastic surfactants include cationic surfactants having the structure:
R 1 N + (R 2 )(R 3 )(R 4 )X −
in which R 1 has from about 14 to about 26 carbon atoms and may be branched or straight chained, aromatic, saturated or unsaturated, and may contain a carbonyl, an amide, a retroamide, an imide, or an amine; R 2 , R 3 , and R 4 are each independently hydrogen or a C 1 to about C 6 aliphatic group which may be the same or different, branched or straight chained, saturated or unsaturated and one or more than one of which may be substituted with a group that renders the R 2 , R 3 , and R 4 group more hydrophilic; the R 2 , R 3 and R 4 groups may be incorporated into a heterocyclic 5- or 6-member ring structure which includes the nitrogen atom; the R 2 , R 3 and R 4 groups may be the same or different; and X − is an anion. Mixtures of such compounds are also suitable. As a further example, R 1 is from about 18 to about 22 carbon atoms and may contain a carbonyl, an amide, or an amine, and R 2 , R 3 , and R 4 are the same as one another and contain from 1 to about 3 carbon atoms. Cationic surfactants having the structure R 1 N + (R 2 )(R 3 )(R 4 )X − may optionally contain amines having the structure R 1 N(R 2 )(R 3 ). It is well known that commercially available cationic quaternary amine surfactants often contain the corresponding amines (in which R 1 , R 2 , and R 3 in the cationic surfactant and in the amine have the same structure). As received commercially available VES surfactant concentrate formulations, for example cationic VES surfactant formulations, may also optionally contain one or more members of the group consisting of solvents, mutual solvents, organic acids, organic acid salts, inorganic salts, and oligomers, polymers, co-polymers, and mixtures of these members. They may also contain performance enhancers, such as viscosity enhancers, for example polysulfonates, for example polysulfonic acids, as described in copending U.S. Patent Application Publication No. 2003-0134751 which has a common Assignee as the present application and which is hereby incorporated by reference.
Another suitable cationic VES is erucyl bis(2-hydroxyethyl) methyl ammonium chloride, (“EMHAC”), also known as (Z)-13 docosenyl-N—N-bis(2-hydroxyethyl) methyl ammonium chloride. It is commonly obtained from manufacturers as a mixture containing about 60 weight percent surfactant in a mixture of iso-propanol, ethylene glycol and water. In this patent, when we refer to “EMHAC” we mean such a solution. Other suitable amine salts and quaternary amine salts include (either alone or in combination), erucyl trimethyl ammonium chloride; N-methyl-N,N-bis(2-hydroxyethyl) rapeseed ammonium chloride; oleyl methyl bis(hydroxyethyl) ammonium chloride; erucylamidopropyltrimethylamine chloride, octadecyl methyl bis(hydroxyethyl) ammonium bromide; octadecyl tris(hydroxyethyl) ammonium bromide; octadecyl dimethyl hydroxyethyl ammonium bromide; cetyl dimethyl hydroxyethyl ammonium bromide; cetyl methyl bis(hydroxyethyl) ammonium salicylate; cetyl methyl bis(hydroxyethyl) ammonium 3,4,-dichlorobenzoate; cetyl tris(hydroxyethyl) ammonium iodide; cosyl dimethyl hydroxyethyl ammonium bromide; cosyl methyl bis(hydroxyethyl) ammonium chloride; cosyl tris(hydroxyethyl) ammonium bromide; dicosyl dimethyl hydroxyethyl ammonium bromide; dicosyl methyl bis(hydroxyethyl) ammonium chloride; dicosyl tris(hydroxyethyl) ammonium bromide; hexadecyl ethyl bis(hydroxyethyl) ammonium chloride; hexadecyl isopropyl bis(hydroxyethyl) ammonium iodide; and cetylamino, N-octadecyl pyridinium chloride.
Zwitterionic viscoelastic surfactants are also suitable. Exemplary zwitterionic viscoelastic surfactants include those described in U.S. Pat. No. 6,703,352 which has a common Assignee as the present application and which is hereby incorporated by reference. Exemplary zwitterionic surfactants have the structure:
in which R 1 is a hydrocarbyl group that may be branched or straight chained, aromatic, aliphatic or olefinic and contains from about 14 to about 26 carbon atoms and may include an amine; R 2 is hydrogen or an alkyl group having from 1 to about 4 carbon atoms; R 3 is a hydrocarbyl group having from 1 to about 5 carbon atoms; and Y is an electron withdrawing group. More particularly, the zwitterionic surfactant may have the betaine structure:
in which R is a hydrocarbyl group that may be branched or straight chained, aromatic, aliphatic or olefinic and has from about 14 to about 26 carbon atoms and may contain an amine; n=about 2 to about 4; and p=1 to about 5. Mixtures of these compounds may also be used.
Two examples of suitable betaines are, respectively, BET-O-30 and BET-E-40. The VES surfactant in BET-O-30 is oleylamidopropyl betaine. It is designated BET-O-30 here, because as obtained from the supplier (Rhodia, Inc. Cranbury, N.J., U.S.A.) it is called Mirataine BET-O-30; it contains an oleyl acid amide group (including a C 17 H 33 alkene tail group) and is supplied as about 30% active surfactant; the remainder is substantially water, sodium chloride, glycerol and propane-1,2-diol. An analogous suitable material, BET-E-40, was used in the experiments described below; one chemical name is erucylamidopropyl betaine. BET-E-40 is also available from Rhodia; it contains a erucic acid amide group (including a C 21 H 41 alkene tail group) and is supplied as about 40% active ingredient, with the remainder substantially water, sodium chloride, and iso-propanol. BET surfactants, and others that are suitable, are described in U.S. Pat. No. 6,703,352.
Certain co-surfactants may be useful in extending the brine tolerance, to increase the gel strength, to reduce the shear rehealing time, and/or to reduce the shear sensitivity of zwitterionic VES fluid systems, such as betaine VES fluids. An example given in U.S. Pat. No. 6,703,352 is sodium dodecylbenzene sulfonate (SDBS). Another example is polynaphthalene sulfonate. Zwitterionic VES surfactants may be used with or without this type of co-surfactant, for example those having a SDBS-like structure having a saturated or unsaturated, branched or straight-chained C 6 to C 16 chain; further examples of this type of co-surfactant are those having a saturated or unsaturated, branched or straight-chained C 8 to C 16 chain. Other suitable examples of this type of co-surfactant, especially for BET-O-30, are certain chelating agents such as trisodium hydroxyethylethylenediamine triacetate. Many suitable additives are known for improving the performance of gelled VES surfactant systems; any may be used; they should be tested for compatibility with the compositions and methods of the present embodiments before use; simple laboratory experiments for such testing are well known.
Zwitterionic surfactant viscoelastic systems typically contain one or more members of the group consisting of organic acids, organic acid salts, inorganic salts, and oligomers, polymers, co-polymers, and mixtures of these members. This member is typically present in only a minor amount and need not be present at all. The organic acid is typically a sulfonic acid or a carboxylic acid and the anionic counter-ion of the organic acid salts are typically sulfonates or carboxylates. Representative of such organic molecules include various aromatic sulfonates and carboxylates such as p-toluene sulfonate, naphthalene sulfonate, chlorobenzoic acid, salicylic acid, phthalic acid and the like, where such counter-ions are water-soluble. Most preferred are salicylate, phthalate, p-toluene sulfonate, hydroxynaphthalene carboxylates, e.g. 5-hydroxy-1-naphthoic acid, 6-hydroxy-1-naphthoic acid, 7-hydroxy-1-naphthoic acid, 1-hydroxy-2-naphthoic acid, preferably 3-hydroxy-2-naphthoic acid, 5-hydroxy-2-naphthoic acid, 7-hydroxy-2-naphthoic acid, and 1,3-dihydroxy-2-naphthoic acid and 3,4-dichlorobenzoate. The organic acid or salt thereof typically aids the development of increased viscosity that is characteristic of preferred fluids. The organic acid or salt thereof is typically present in the zwitterionic viscoelastic fluid (after the viscoelastic surfactant has concentrated sufficiently to viscosify the fluid) at a weight concentration of from about 0.1% to about 10%, more typically from about 0.1% to about 7%, and even more typically from about 0.1% to about 6%.
Inorganic salts that are particularly suitable for use in the zwitterionic viscoelastic fluid include water-soluble potassium, sodium, and ammonium salts, such as potassium chloride and ammonium chloride. Additionally, calcium chloride, calcium bromide and zinc halide salts may also be used. The inorganic salts may aid in the development of increased viscosity which is characteristic of preferred fluids. Further, the inorganic salt may assist in maintaining the stability of a geologic formation to which the fluid is exposed. Formation stability and in particular clay stability (by inhibiting hydration of the clay) is achieved at a concentration level of a few percent by weight. The inorganic salt is typically present in the zwitterionic viscoelastic fluid (after the viscoelastic surfactant has concentrated sufficiently to viscosify the fluid) at a weight concentration of from about 0.1% to about 30%, more typically from about 0.1% to about 10%, and even more typically from about 0.1% to about 8%. Organic salts, e.g. trimethylammonium hydrochloride and tetramethylammonium chloride, may also be used in addition to, or as a replacement for, the inorganic salts. Optionally, these systems may be formed in dense brines, including brines containing polyvalent cations.
As an alternative to the organic salts and inorganic salts, or as a partial substitute therefore, one can use a medium to long chain alcohol (preferably an alkanol), preferably having five to ten carbon atoms, or an alcohol ethoxylate (preferably an alkanol ethoxylate) preferably of a 12 to 16 carbon alcohol and having 1 to 6, preferably 1-4, oxyethylene units.
Amphoteric viscoelastic surfactants are also suitable. Exemplary amphoteric viscoelastic surfactants include those described in U.S. Pat. No. 6,703,352, for example amine oxides. One useful amine oxide surfactant has the formula:
wherein R 1 , R 2 , and R 3 are independently selected from alkyl, alkenyl, arylalkyl, or hydroxyalkyl groups wherein each of said alkyl groups contain from about 8 to about 24 carbon atoms and may be branched or straight chained and saturated or unsaturated
Mixtures of zwitterionic surfactants and amphoteric surfactants are also suitable. An example, called BET-E-40/AO here, is a mixture of about 13% iso-propanol, about 5% 1-butanol, about 15% ethylene glycol monobutyl ether, about 4% sodium chloride, about 30% water, about 30% cocamidopropyl betaine, and about 2% cocamidopropylamine oxide.
The fluid may be used, for example in oilfield treatments. As examples, the fluid may be used as a pad fluid and as a carrier fluid in hydraulic fracturing, as a carrier fluid for lost circulation control agents, and as a carrier fluid for gravel packing.
The optimal concentration of a given rheology enhancing additive for a given choice of VES surfactant fluid system at a given concentration and temperature, and with given other materials present, can be determined by simple experiments. The total viscoelastic surfactant concentration must be sufficient to form a viscoelastic gel under conditions at which the surfactants have sufficient aggregation tendency. The appropriate amounts of surfactant and rheology enhancer are those necessary to achieve the desired viscosity and shear recovery time as determined by experiment. In general, the amount of surfactant (as active ingredient) is from about 1 to about 10%. Commercially available surfactant concentrates may contain some materials that we have found may be used as rheology enhancers, for example for concentrate freezing point depression, but normally the amount of such material is not sufficient, when the concentrate is diluted, in the final fluid. The amount of rheology enhancer used, in addition to any that may be already present in the as-received surfactant concentrate, is from about 0.1 to about 6%, for example from about 0.25 to about 3.5%, most particularly from about 0.25 to about 1.75%. Mixtures of surfactants and/or mixtures of rheology enhancers may be used.
EXAMPLES
The present embodiments can be further understood from the following examples:
FIG. 1 shows the results of PLA fiber (3.6 kg/m 3 ) degradation in polymer solution with different amount of NaOH added, at temperature of 75° C. Table 1 shows the results of fiber degradation in fluids at 60° C. prepared with 3.6 kg/m 3 PLA fiber and different amounts of CaO and Ca(OH) 2 . As can be seen, higher concentration of CaO and Ca(OH) 2 resulted in faster degradation of PLA fibers.
TABLE 1
Degradation time,
Chemical
Concentration, g/L
days
CaO
1
>10 days
CaO
3
7
CaO
5
2
Ca(OH) 2
1
>10 days
Ca(OH) 2
3
7
Ca(OH) 2
5
2
Additives such as CaO or Ca(OH) 2 can either be made large mesh size or encapsulated to avoid fast dissolution in fracturing fluids during pumping and flowback (dissolution constant for Ca(OH) 2 is 6×10 −6 mol 3 /L 3 ). FIG. 2 demonstrates PLA fiber degradation at low temperature (bottles heated from room temperature to 50° C.) in the presence of Ca(OH) 2 (fine powder and encapsulated in paraffin (hydroxide:paraffin ratio is 1:1)). Also, degradation in the presence of encapsulated Ca(OH) 2 with hexane (oil mimic) is shown.
The use of pre-heated sample at 50° C., Ca(OH) 2 slurry showed even higher degradation rates ( FIG. 3 ). Also, positive influences of peroxide type oxidizers on the degradation rate were also observed.
FIG. 4 shows that MgO did not have significant impact on PLA degradation at 50° C. However, when mixed with oxidizing agents such as ammonium persulfate and calcium peroxide, MgO significantly increases the rate of degradation of PLA. Interestingly, addition of the non-generating oxidizer sodium bromate to MgO did not have any impact on PLA degradation at the same temperature. It is expected that the amount of fiber degraded will have a significant impact on the fracture conductivity as shown in FIG. 5 .
A series of amines derivatives were also evaluated in order to increase the degradation rate of the polymer. Nucleophilic bases were chosen and in particular amines bases. Amongst them, urea and its derivatives were assessed. Indeed, urea and its derivatives self-decompose and liberate ammonia which reacts rapidly with ester bonds, leading to amide terminated oligomers. The nucleophilic attack of the amine together with a high pH environment accelerates the degradation rate of the fibers as shown in FIG. 6 . In all of the experiments a loading of fibers of 1 kg/m 3 of fluid was used.
Some derivatives such as 4-dimethylaminopyridine (DMAP) and 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU) accelerate significantly the degradation rate at 66° C. Further experiments were then carried out to further study the action of DMAP and DBU on the degradation of fibers at low temperatures. FIG. 7 , shows the influence of DBU (with various concentrations) on the degradation of the fibers at 50° C. and 66° C. It appears that a concentration of 0.5 mol/L gives full degradation at 66° C. after 21 h. Much higher concentrations are required to achieve full degradation at 50° C.
The results obtained with the addition of DMAP are presented in FIG. 8 . As compared to DBU, DMAP accelerates more significantly the degradation at low temperatures. A concentration of 0.2 mol/L to 0.5 mol/L of DMAP gives significant degradation of the fibers. The combination of these derivatives with the presence of a base such as K 2 CO 3 was also investigated and results are shown on FIGS. 9 and 10 .
FIGS. 9 and 10 show the influence of the presence of various amounts of K 2 CO 3 together with DMAP (at 0.01M). The experiments were performed at 66° C. for 21 h and 50° C. for 68 h. Results show that there is an increase of degradation of the fibers when using the combination of the two products. K 2 CO 3 is a base which helps maintaining a high pH environment. As the degradation of the polymer occurs, lactic acid is generated which decreases the overall pH of the solution. In acidic environment protonation of the amine can occurs which will then limit its activity on the degradation process. Therefore keeping the pH alkaline is a much better option to insure faster degradation.
Similar results were obtained with DBU and 1,1-diethyl urea as shown in FIGS. 11 , 12 , 13 and 14 .
The foregoing disclosure and description of the invention is illustrative and explanatory thereof and it can be readily appreciated by those skilled in the art that various changes in the size, shape and materials, as well as in the details of the illustrated construction or combinations of the elements described herein can be made without departing from the spirit of the invention.
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A method for treating a subterranean formation penetrated by a wellbore is provided. The method includes providing a treatment fluid containing a viscoelastic surfactant having at least one degradable linkage, a hydrolysable material, and a pH control material, and injecting the treatment fluid into a subterranean formation. The pH control material may have a pH equal or greater than about 9 and may include a strongly alkaline material and an oxidizing agent.
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This is a continuation of application Ser. No. 08/164,333, filed on Dec. 9, 1993, U.S. Pat. No. 5,415,005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for determining periodic power consumption of an electrically operated appliance and more particularly relates to a device and method for activating an electric component of the electrically operated appliance in response to the determined periodic power consumption of the electrically operated appliance.
2. Description of the Related Art
A refrigerator typically is provided with a defrosting control system for removing frost which has accumulated on the evaporator coils of a refrigerator during a cooling cycle. A typical defrosting control system is illustrated in FIG. 1 and generally includes a motor driven switch timer (10) which effectively counts the cumulative running time of a compressor (12) so as determine when the cooling cycle is to be terminated so as to initiate a defrosting cycle. The refrigerator circuit, including the motor driven switch timer (10), is activated when a freezer temperature control switch (16) closes, caused generally by the refrigerator having a storage compartment temperature above a prescribed value. When switch (16) opens, the refrigerator is in effect off. A defrost heater (14) is provided for thawing the frost accumulated on the evaporator coils (not shown) along with a defrost terminator (18) for detecting the temperature of the evaporator coils so as to disable the energization of the defrost heater (14).
The defrosting operation is controlled and carried out periodically by the motor driven switch timer (10) which is typically detachably coupled to the control circuitry of the refrigerator at quick-connect terminals to facilitate replacement if necessary. The duty cycle of refrigeration to defrost is fixed by the refrigerator manufacturer and implemented in the motor driven switch timer (10), with generally six hours of cooling to thirty minutes of defrosting. There are no adjustments to compensate for variations in the operating environment, and as such the same ratio is used in a refrigerator disposed in Alaska as compared to a refrigerator used in Florida.
In operation, when the freezer temperature control switch (16) closes, the cooling compressor (12) is activated, and the cumulative running time of compressor (12) is counted by the motor driven switch timer (10). After the compressor (12) has been energized for a prescribed period of time, such as, e.g., six hours, the motor driven switch timer (10) immediately de-energizes the compressor (12) and consequently energizes the defrost heater (14) through the provision of an internal switch (10a). The motor driven switch timer (10) thereafter enables the defrost heater (14) to be energized when the defrost terminator (18) is in a closed position. Typically, the defrost terminator (18) will be in a closed position when the temperature of the evaporator coils are below a prescribed value (e.g., 20° F.). In particular, the motor driven switch timer (10) enables the defrost heater (14) to be energized only during a defrosting duty cycle which is typically a thirty minute period which is prescribed by the motor driven switch timer (10). While the defrost heater (14) is energized, any frost on the evaporator coils are gradually thawed by radiant heat from the defrost heater (14). The accumulation of ice and frost on the evaporator coils restricts the coils from drawing heat out of the food compartment since the ice acts as an insulator, thus lowering the efficiency of the coils, and consequently, the refrigerator. In accordance with the energization of the defrost heater (14), the temperature of the evaporator coils gradually rises. In this time period, (such as, e.g., a half hour) the defrost terminator (18) detects the temperature of the evaporator coils. When the temperature of the evaporator coils reaches a prescribed value, (such as, e.g., 50° F.) the defrost terminator moves to an open position and the defrost heater (14) is deenergized, whereafter the compressor (12) is returned to an operational state by the motor driven switch timer (10) after the half hour duty cycle of the defrost heater (14) has expired.
In typical refrigerator control systems, such as illustrated in FIG. 1, the motor driven switch timer (10) only operates when the refrigerator's settable freezer temperature control switch (16) is closed (usually when the temperature in the storage compartment of the refrigerator is above a prescribed temperature, e.g., 50°). As illustrated in FIG. 2, a defrost cycle must always interrupt and supersede a cooling cycle. Further, the cooling cycle may not be resumed, (regardless of the position of the defrost terminator (18), until after the defrost duty cycle, as prescribed in the motor driven switch (10), has expired. FIG. 2 illustrates a refrigerator energy consumption graph including a defrost cycle consisting of thirty minutes which comprises regions (2) and (3). Only after expiration of the defrost duty cycle, may the motor driven switch timer (10) initiate a cooling cycle, as indicated by regions (4),(5) and (6) in FIG. 2, and as seen, during region (3) the refrigerator is effectively off.
The above defrost scheme is disadvantageous in that the defrost cycle is only initiated by the interruption and consequent termination of a cooling cycle. This results in a high energy consumption by the refrigerator along with the degradation of food stored within the refrigerator. In particular, the refrigerator consumes a large amount of energy since the compressor must not only lower the temperature of the storage compartment to below a prescribed temperature, but must now additionally compensate for the further rise in compartment temperature which is attributable to the defrosting cycle. Thus, the further rise in the compartment temperature along with the longer time period required by the compressor to lower the compartment temperature, gives rise the degradation of food which may be stored within a storage compartment of the refrigerator.
Furthermore, it has been found that there are a greater number of cooling cycles, and cooling cycles of longer duration, required during times of high ambient temperatures and high door opening activity, (e.g., dinner time during a hot humid day in August) and less cooling cycles during lower ambient temperatures and low door opening activity, (e.g., 3 a.m. in the morning). Therefore, the existing defrost scheme utilized by refrigerators tends to drive initiation of a defrost cycle toward the power utility's peak load period. Additionally, more cooling cycles and cycles of long duration are required during brown outs or immediately following a power outage, and therefore, a high probability of a defrost cycle being initiated exists at those times. Thus, there is no relationship of initiation of the defrost cycle as to the amount of frost on the evaporator coils, since the defrost cycle is not altered based on how much ice is melted, and the initiation time of the defrost cycle is unrelated to the needs of the power utility company.
A typical example of the above method is disclosed in U.S. Pat. No. 4,528,821 to Tershak et al. wherein the defrost cycle is executed while the operation of the cooling cycle is switched from the "on" state to the "off" state or during a period when the temperature within the refrigerator is at the upper end of its range at which foods deteriorate.
A still further type of defrost control is disclosed in U.S. Pat. No. 4,251,988 to Allard et al. This defrost control is referred to as an "adaptive" defrost control since it establishes the time between succeeding defrosting cycles as a function of the length of time that the defrost heater was energized during the first defrosting cycle. Another type of adaptive defrost control is disclosed in U.S. Pat. No. 4,481,785 to Tershak et al. This adaptive defrost control varies the length of an interval between defrosting cycles in accordance with the number and duration of compartment door openings, the duration of a previous defrosting cycle as corrected by the temperature of the evaporator coils prior to a defrost cycle and the length of time the compressor has been energized. However, the decrementing of the number and duration of refrigerator door openings does not result in an entirely accurate representation of the amount of frost which has formed on the evaporator coils due to the moisture introduced into the refrigerator while the refrigerator door is open. Accordingly, this results in a less-than-optimal defrost interval.
Thus, a common disadvantage with prior defrost systems is that they do not initiate a defrost cycle during an optimal time period according to the energy efficiency of the refrigerator, the peak demand loading needs of power utility companies and the degradation of food caused by a defrosting cycle being initiated during a warm ambient temperature period.
Furthermore, the above mentioned adaptive defrost controls are unable to be readily adapted for retrofit into existing refrigerator control systems. Rather, the control circuitry of refrigerators must be designed and configured for the implementation of such adaptive defrost controls.
Accordingly, there exists a need to provide a defrost system that will conserve energy and prevent the degradation of food by initiating a defrost cycle during an optimal time period which is most energy efficient after the completion of a cooling cycle.
It is an object of the present invention to initiate a defrosting cycle in a refrigerator during an off-peak demand period of utility companies which is most energy efficient for the refrigerator while also preventing the degradation of food stored within the refrigerator.
Further, there exists a need to provide a defrost control system that is configured to be readily adapted into existing refrigerators while being simple and inexpensive to manufacture.
SUMMARY OF THE INVENTION
Generally, in a refrigeration system, a compressor provides for cooling the food compartment in conjunction with evaporator coils which draw heat out of the food compartment to assist the compressor in the cooling function. During cooling, frost and ice tend to accumulate on the evaporator coils which decreases the efficiency of the refrigerator. It is desirable to defrost the accumulated frost and ice only as often as is necessary to maintain an efficient cooling system. This objective dictates that a balance be struck between the competing considerations of system operation with frosted evaporator coils, the energy consumed in removing a frost load from the evaporator coils and the acceptable level of temperature fluctuation within the refrigerated food compartments as a result of a defrosting operation.
To accomplish the objects described above, the present invention provides a novel defrost control device which is dimensioned and configured so as to be detachably engaged with the refrigeration components of a commercially available refrigerator. Typically, a commercially available refrigerator comprises at least one enclosed compartment for storing items, such as food. Means for cooling the at least one enclosed compartment, such as a compressor and evaporator, are also typically provided. Additionally means are provided for heating the evaporator, (i.e., a defrost heater) so as to remove accumulated frost from the evaporator.
The novel control device is configured so as to initiate a defrost cycle, whereby the initiation of the defrost cycle is responsive to the daily power consumption of the refrigerator. In particular, the control device of the present invention includes a microprocessor which is preprogrammed with a mathematical scheme so as to determine the time of day without the usage of clock by analyzing the energy consumption of the refrigerator during a 24 hour period.
By determining the approximate time of day, the microprocessor is enabled to initiate a defrost cycle during the off-peak energy power consumption time of the local utility company. This is advantageous since the off-peak energy power consumption time typically coincides with the time period corresponding to the period of least usage of the refrigerator (the opening and closing of doors). Further, this time period coincides with a relatively low ambient temperature which the refrigerator will be exposed to during a 24 hour period. Thus, the initiation of a defrosting cycle during this time period conserves energy while also having the smallest impact on food stored within the refrigerator. The microprocessor can anticipate the initiation of the next cooling cycling starting a defrost cycle just prior to the predicated start thus, a cooling cycle will never be interrupted. Furthermore, the microprocessor constantly monitors the operating frequency of the defrost heater so as to ensure that a defrost cycle is only initiated when it is needed and only during a time period which is most efficient for the refrigerator and the local utility company.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention will become more readily apparent from the following detailed description of the invention taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a simplified schematic circuit illustrating a refrigerator circuit utilizing a prior art defrost time which is used to defrost the refrigerator;
FIG. 2 is a graph illustrating the energy consumption of a refrigerator having a circuit using the prior art defrost timer of FIG. 1;
FIG. 3 is a perspective view of a refrigerator in partial cut-away illustrating components of the refrigerator with which the present invention is used;
FIG. 4 is a schematic circuit diagram illustrating a defrost control system according to the present invention; and
FIGS. 5-12 are flow charts explaining the operation of the microprocessor of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 3, there is illustrated a refrigerator 50 within which the present invention is intended to be used with. Generally, such a refrigerator 50 includes a fresh food compartment door 52 and a frozen food compartment door 54 which are pivotably connected to a body portion 56 which defines, respectively, a fresh food compartment 58 and a frozen food compartment 60.
The respective food compartments 58, 60 are refrigerated by passing refrigerated air therein which is cooled by a cooling apparatus which comprises an evaporator 62, a compressor 64 and a condenser 66. The cooling apparatus also includes a condenser fan, an evaporator fan and a heater or accumulator (not shown), as is conventional.
The evaporator 62 is periodically defrosted by a defrost heater 68 which is to be operated by the control of the present invention. The defrost heater 68 may be configured as of the ordinary resistive type or may be configured as any other type of heating element configured to accomplish such a task.
A temperature sensing device generally in the configuration of a defrost terminator 70 (such as, i.e., a thermostat) is disposed in heat-transfer relationship with the evaporator 62. More specifically, the defrost terminator 70 is mounted directly on the evaporator 62 as to detect the temperature thereof. Additionally, at least one temperature control switch (not shown) is utilized in at least one food compartment 58, 60 so as to detect the temperature of one or both of the respective food compartments 58, 60.
Turning now to FIG. 4, there is illustrated a schematic circuit diagram of the control system 100 according to the present invention, which is constructed to replace the prior art electromechanical timer (1) as shown in the circuit of FIG. 1. The control system 100 is preferably disposed within the body portion 56 or outside of the body portion 56 of the refrigerator 50. As described in more detail below, the control 100 is configured to detachably engage with the above-mentioned components of an existing refrigerator 50 (FIG. 3), such as that shown in FIG. 4 and schematically depicted as block 101.
In general, the control 100 comprises a microprocessor 102 together with circuitry for controlling the compressor 64 and the defrost heater 68 of the refrigerator 50. The microprocessor is provided with a clock input 105 configured to connect to a clock source, such as an oscillator (not shown), as is conventional.
Further, the microprocessor 102 samples the AC line, via resistor R2, to obtain precise time periods, designated "ticks" block 512 as illustrated in FIG. 5 and further discussed below.
The various components of the control 100 illustrated in FIG. 4 receive DC voltage from a rectifier 103 which is directly coupled, via line 104, to an AC voltage source. In particular, the AC voltage source may originate from the power circuitry of the refrigerator 50 or from any other source, such as a conventional wall outlet. A filter apparatus 106 is coupled to the rectifier 103 so as to reduce the ripple of the terminal voltage from the rectifier 103, and additionally, to smooth out any voltage surges being effectuated from a compressor/defrost relay 108 being coupled in parallel relationship to the filter 106. The compressor/defrost relay 108 comprises a dry switch 134 and a relay coil 136, the significance of which will be described in greater detail below.
A solid state relay control 110 couples to the filter apparatus 106 and to the compressor/defrost relay 108. The solid state relay control 110 is configured to either energize or de-energize the compressor/defrost relay 108 upon a command signal which is generated from the output terminal 120 of the microprocessor 102 which is coupled, via line 112, to the solid state relay control 110.
The microprocessor 102 is powered by line 114 which is coupled from rectifier 103. A zener diode DC regulated power supply 116 is provided in line 114 so as to regulate the voltage between the rectifier 103 and the input supply voltage terminal 118 of the microprocessor 102.
An input terminal 122 of the microprocessor 102 is coupled, via line 126, to a filter and peak detector 124. The filter and peak detector 124, via line 128, is coupled to a toroid transformer 130. As will be described in greater detail below, the filter and peak detector 124 provides the microprocessor 102 with the information which in turn is utilized by the microprocessor so as to formulate when a defrosting cycle is to be initiated in the refrigerator 50.
The toroid transformer 130, via line 132, is in electrical communication with an AC switched line voltage supply of the refrigerator 50. Specifically, the AC switched line voltage supply, via line 132, provides an energizing current when the temperature control switch of the refrigerator 50 is in a closed position. Typically, the temperature control switch is in a closed position when a respective food compartment 58, 60 of the refrigerator 50 has a temperature which is greater than a prescribed value (such as, e.g., 30° F.). Conversely, when a respective food compartment 58, 60 of the refrigerator 50 has a temperature which is less than the above mentioned prescribed value, the temperature control switch moves to an open position so as to prevent an energizing current to flow from the AC switched line voltage supply to the line 132 of the control system 100.
As mentioned above, the compressor/defrost relay 108 comprises a dry switch 134 and a relay coil 136. The line 133 is coupled to the dry switch 134. The dry switch 134 is configured to be actuable by a command signal from the microprocessor 102, via the relay coil 136. The dry switch 134 is actuable between an activated position and a de-activated position. When the dry switch 134 is de-activated, it effectively couples the AC switched line voltage supply by line 135 to the compressor 64 of the refrigerator 50. Conversely, when the dry switch 134 is activated, it effectively couples the AC switched line voltage supply by line 137 to the defrost heater 68 of the refrigerator 50. It is particularly noted that the dry switch 134 may only be switched from the de-activated position to the activated position when the compressor 64 is not energized (generally when a temperature control switch is disposed in an open position, as mentioned above).
The toroid transformer 130 is configured to sense the flow of energizing current, via lines 132 and 133, from the AC switched line voltage supply of the refrigerator 50 to the dry switch 134 of the compressor/defrost relay 108. Thus, when the temperature control switch of the refrigerator 50 is disposed in a closed position, the toroid transformer 130 effectively detects the flow of energizing current from the AC switched line voltage supply, via line 132, to either the compressor 64 or the defrost heater 68, depending upon the position of the dry switch 134. The toroid transformer 130 couples this sensed energizing current flow, via line 128, to the filter and peak detector 124.
The filter and peak detector 124, via line 126, is coupled to an input terminal of the microprocessor 102. As will be discussed in much greater detail below, the microprocessor 102 processes this received information from the filter and peak detector 124, and subsequently formulates when it is most efficient to initiate a defrosting cycle in the refrigerator 50.
When the microprocessor 102 determines that a defrost cycle should be initiated, an "ON" signal is sent from the output terminal 120 of the microprocessor 102 to the solid state relay control 110. The solid state relay control 110 relays the "ON" signal to the relay coil 136 of the compressor/defrost relay 108 which effectuates the dry switch 134 to be "activated", thereby enabling the AC switched line voltage supply to be coupled to the defrost heater 68 of the refrigerator 50.
In contrast, when the microprocessor 102 determines that the defrost cycle is to be terminated, an "OFF" signal is sent from the output terminal 120 of the microprocessor 102 to the solid state relay control 110. The solid state relay control 110 relays the "OFF" signal to the relay coil 136 of the compressor/defrost relay 108 which effectuates the dry switch to be "de-activated", thereby enabling the AC switched line voltage supply to be coupled to the compressor 64 of the refrigerator 50.
Referring now to FIGS. 5-12, there is illustrated a flow chart of the programming utilized the programming of the microprocessor 102 for implementing the control of the instant invention.
The microprocessor program starts immediately after the completion of power on reset timing circuit (not shown).
The parameters of APC (Actual Recorded Hourly Power Consumption), TTDC (Time to Defrost Control), defrost mode, various recorded times, Tdefrostactual, defrost time and others not described, are initialized (step 510). During the first days (e.g. five days) of operation while the proposed device is determining the operational time of day for the refrigerator, it will operate as a conventional defrost timer. The defrost period will be fixed at a 13 hour elapsed time period or, if an alternate configuration is implemented, jumpers positioned within the microprocessor circuity will be read by the microprocessor for various common time periods such as 6, 8, 12, and 16 hours. Referring to FIG. 5, a clock in the microprocessor is initially set for zero (step 500) and will start counting when a tick occurs after every 1 second of the system clock event. If a tick is detected, the control system 100 will measure the toroid current sensor 130 and determine if the current in the defroster or compressor has changed state (steps 512 and 514). If no change in the measured current is detected, the system repeats steps 512 and 514 until a current change is detected. Once a current change is detected, a defrost mode flag is read to determine if the change detected occurred while the defrost heater was energized or the compressor was energized (steps 516 and 518). If the defrost mode flag was set the defrost process of FIG. 6 is performed (step 520).
The defrost process, illustrated in FIG. 6, is implemented such that the microprocessor 102 records the defrost time, as referenced to the clock ticks (step 610) and reads the toroid current sensor 130 to determine if current is sensed (step 620). If current is sensed, the time recorded was a defrost start and the defrost process returns to the main loop (step 620 of FIG. 6 and step 520 of FIG. 5). If no current is sensed by the toroid current sensor 130, the time recorded was a defrost termination requiring the defrost mode flag to be cleared (step 630) and the dry switch 134 of the common relay contact 108 is switched to activate the compressor (step 640) so that the next time the refrigerator temperature control supplies power to the common relay contact 108 the compressor will actuate. Once the relay 108 is switched, the defrost process returns to the main loop at step 520 of FIG. 5.
Returning to step 518 of FIG. 5, if the defrost mode flag is not set (step 518), the compressor process is performed (steps 518 and 522). The compressor process is illustrated in FIG. 7 and comprises the steps of recording the time (step 710) as being referenced to the clock ticks. The current sensor (step 720), via the toroid transformer 130 (FIG. 4), is read to determine if current is sensed. If current is sensed, time is recorded as a compressor start (step 720) and the compressor process returns to the common loop of FIG. 5 (steps 518 and 522). If no current is sensed, the time recorded is of compressor power consumption being terminated (step 730). The APC memory array contains a 24 hour record of averaged power consumption. The APC is updated with smoothing (step 740) by adding a percentage of the latest compressor power consumption to the complementary percentage K1 of the averaged power consumption for the respective time period. The TTDC counter is decremented (740) by an amount equal to the stop time minus the start time (compressor on duration). The TTDC counter is initially set to 13 hours, equivalent to approximately 8 hours of compressor run time as would be measured by a conventional timer, during the conventional defrost program operation. Other times may be selected if the alternate jumper configuration (not shown) is used. If the TTDC has expired, (step 750) the relay is switched to the defrost position (step 760) and a defrost will be initiated the next time the temperature control supplies power to the relay common terminal. If the TTDC has not expired, the program will not allow initiation of defrost at this time and the program returns to the common loop (steps 518 and 522).
Returning to FIG. 5, if the clock has not ticked (step 512), the program determines if a Continuous Next Step Time of Day (524) is required. Turning to FIG. 8, the Present Hour Complete Flag is tested to determine if all calculations for the present hour are complete (step 810). If not, another single element of the 24 element typical hourly power consumption is subtracted from an element of the 24 element actual element power consumption array (step 820), the result squared and added to a running sum for the appropriate time element. This function (step 820) is the calculation of at least means square fit, also referred to as a correlation, of a mathematical representation of the typical hourly power consumption expected of a typical refrigerator in a typical family residence to that of the refrigerator containing the device 100 of the present invention.
As there are 24 by 24, or 576 calculations, only one calculation is performed per pass through the loop. If all 576 calculations are not complete (step 830) the program returns. If all are complete the program calculates the time of day by adding the time offset determined (step 820) to the clock (step 840). The present hour complete flag is set (step 850) and the program returns (step 526).
Referring to FIG. 8, if the Present Hour Complete Flag is set, there will be no more calculations until a new hour occurs (step 860). At the start of a new hour the indexes for the 576 calculations are initialized (step 870), the Present Hour Complete Flag is cleared (step 880) and the program returns to the common loop (step 526).
Returning to FIG. 5, as the amount of compressor power consumption data increases, the estimates of time of day will become closer to actual. When the error corrections to time of day become small (step 526), and the refrigerator is not in defrost mode (step 528) and there is sufficient time (step 530) until the middle of the off peak period, about 3 AM, the program is allowed to calibrate the defrost operation to determine the thermal overhead, as illustrated in FIG. 9.
Referring to FIG. 9, the calibration process requires two defrosts closely spaced. The process is directed by a CALLOOP count (step 902). The first defrost is set to occur at 1 AM (step 906). While waiting for the defrost to occur, the clock ticks (step 910), sensor change (step 912) time of day calculations (step 914), defrost (steps 916 and 920), compressor (step 918) are utilized similarly to those in conventional operation mode (steps 512, 514, 518, 520 and 522). However, when the 1 AM defrost has completed (steps 922 and 924), CALLOOP is decremented to allow setup of the 5 AM defrost (step 908). Since only 4 hours of presumably little refrigeration activity exist between 1 and 5 AM, little frost should occur on the evaporation coils and the evaporation temperature should be predictable. Thus, the measured defrost time at 5 AM will be almost completely the thermal overhead of the defrost process (step 926) without ice. The ideal defrost time for the particular refrigerator is estimated to be the thermal overhead times a factor (step 928) greater than 1. The next defrost is scheduled to occur at 2 AM (step 930) and the program enters the process of FIG. 11.
Referring to FIG. 10, an alternate implementation is implemented by reading jumpers (step 1002) which directs the program to read predetermined values of ideal defrost time (step 1004). The TTDC is set to 2 AM (1006) the two calibration defrosts are not required and the program enters the process of FIG. 11.
Referring to FIG. 11, the clock tick (step 1102) sensor change (step 104), defrost mode (step 1106), process defrost (step 1110) and process compressor (step 1116) are all similar to those previously described. The TTDC is calculated (step 1114) at the end of each defrost (step 1112). Referring to FIG. 12, the difference between the actual defrost time and ideal time is an error value (ED) (step 1202). If the error value ED is very large (greater than a prescribed value in step 1206), then presumably a lot of ice was on the evaporator coils and three defrosts (step 1212) are required per day. Similarly, if the error is large (step 1206), two defrosts (step 1214) are required per day.
If the error is small (greater than a prescribed value in step 1208), then one defrost is required (step 1216) if the error is less than small (less than a prescribed value in step 1210), then defrost is every other day.
While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various modifications in form and detail may be made therein without departing from the scope and spirit of the invention. Accordingly, modifications such as those suggested above, but not limited thereto, are to be considered within the scope of the invention.
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A device and method is provided for automatically defrosting a refrigeration system. The present invention includes a microprocessor which initiates a defrost cycle during a time of day which is most efficient for the refrigerator and the utility company. Moreover, the defrost cycle is initiated during a time of day which has the least impact on food stored within the microprocessor. The microprocessor is programmed and enabled so as to analyze the power consumption of the refrigerator during a 24 hour period, and from this analysis, the microprocessor is able to determine the time of day and period(s) of time which will be most efficient for the initiation of a defrost cycle.
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BACKGROUND OF THE INVENTION
1. The Field of The Invention
The present invention relates to a cable harness assembly machine and in particular to a cable hold down and positioning device acting on multi-conductor flat flexible cable fed into the assembly machine.
2. The Prior Art
There are many well known cable harness assembly machines which are capable of sequentially applying a plurality of terminals to one end of a pre-formed cable. Such a machine is shown in U.S. Pat. No. 3,774,284. There are some machines that are capable of applying terminals intermediate the ends of the cable to form what is known as a daisy chain. U.S. Pat. No. 3,553,836 shows such a machine.
There is a number of problems associated with these known machines amongst which are difficulties in handling the cable prior to termination as well as difficulties involved in removing the cable from the machine after termination without damaging or misaligning the newly applied terminals. Also, these machines are relatively slow in that they sequentially apply terminals and to only one end of the cable at a time.
SUMMARY OF THE INVENTION
The present invention is intended to overcome the above discussed difficulties of the prior art. The subject machine has a press assembly including a front loading work station with at least one multi-terminal applicator positioned beneath the press. A terminal supply means feeds a continuous supply of terminals to each respective applicator. A cable hold down apparatus is movably mounted at the work station and adapted to secure a cable and hold it in a properly aligned position relative to the applicator while the terminals are applied to the cable end. The cable hold down is so arranged that after the cable has been terminated, the completed harness assembly is readily extracted from the machine without damage to any portion of the cable or the attached terminals.
It is therefore an object of the present invention to produce a cable harness assembly machine having an improved cable hold down and alignment means.
It is another object of the present invention to produce a cable harness assembly machine which can be used to apply multiple terminals to one or both ends of a flat flexible cable in a single operation.
It is still another object of the present invention to produce an improved cable hold down apparatus for a cable harness assembly machine in which the cable will be firmly secured in the correct position during the terminating operation and yet will be readily released upon completion of the termination.
It is a further object of the present invention to produce a cable harness assembly machine which is readily adjustable for various widths and lengths of cable.
It is a still further object of the present invention to produce a cable harness assembly machine which can be readily and economically manufactured.
The means for accomplishing these and other objects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description taken with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an entire cable harness assembly apparatus according to the present invention;
FIG. 2 is a top plan view, partially in section, of the cable harness assembly apparatus of FIG. 1;
FIG. 3 is a front elevation, partially broken away, of the cable harness assembly apparatus of FIG. 1;
FIG. 4 is a vertical section, taken along line 4--4 of FIG. 2;
FIG. 5 is an exploded perspective view of a cable hold down assembly according to the present invention;
FIG. 6 is a perspective view of the cable hold down assembly according to the present invention with a cable exploded therefrom;
FIG. 7 is a perspective view, similar to FIG. 6, showing a cable properly located and held in position by the subject cable hold down assembly;
FIG. 8 is a perspective view similar to FIGS. 6 and 7 showing, the hold down assembly actuated to release a terminated cable;
FIG. 9 is a transverse vertical section through an applicator of the cable harness assembly apparatus of FIG. 1 with the applicator positioned ready to apply terminals to a cable;
FIG. 10 is a section view similar to FIG. 9 showing the applicator at the point of shearing the terminals from their carrier strips;
FIG. 11 is a section view similar to FIGS. 9 and 10 showing the applicator in a terminal crimping condition; and
FIG. 12 is a section view similar to FIGS. 9 to 11 showing the applicator after termination of the cable but before release of the cable by the hold down assembly.
DETAILED DESCRIPTION OF THE INVENTION
The subject assembly apparatus 10 is shown in its entirety in FIG. 1 and includes a press assembly 12 mounted on a base 14 which contains a known press drive means (not shown). A substantially horizontal work table 16 is mounted on the base directed toward the press. At least one terminal applicator 18, 20 is mounted so as to be accessible from the work table and actuated by the press. Electrical and fluid control means for the press are schematically represented by boxes 22, 24, respectively.
A terminal supply assembly 26, 28 for each applicator 18, 20, respectively, extends to the rear of the apparatus 10. Each terminal supply assembly includes a reel support frame 30 one end of which is attached to base 14 by screw adjustment means (not shown) so that the frame can be moved sideways to maintain alignment with the respective applicator as the latter is moved as required for terminating cables of different lengths. Each terminal supply assembly 26, 28 has means 32 to support a reel 34 of terminals 36 in continuous strip form. Each terminal supply assembly can further include terminal separator tape takeup means (not shown) and terminal strip detector and guide means (also not shown).
Each terminal supply assembly has been shown with two reels each feeding a strip of terminals. This is a stacked carrier strip arrangement as described in U.S. Pat. No. 4,021,095 and is used to supply overlapping strips of terminals to have terminals on a closer center line spacing than is possible with a single strip of terminals.
Turning now to FIGS. 2 to 4 the subject machine is shown with left and right spaced applicators 18, 20 mounted on a single transverse guide rail 38 so that they can be moved relative to each other between the upper and lower plates 40, 42 of the press, which are connected by posts 44. Each applicator 18, 20 is connected to a respective terminal supply assembly 26, 28, as mentioned previously. The relative positioning of the applicators is controlled by a drive means (not shown) which will keep the applicators symmetrical with respect to the press.
A cable hold down assemblies 46, 48 is provided for each applicator 18, 20, respectively. A tie bar 50, having a handle 52, interconnects the hold down assemblies 46, 48 and has a projection 54 which is slidable along a guide groove 56 in the work table 16 between a loading position (FIG. 2) and a crimping position aligned with the respective applicators (FIG. 4) by detent means 58. Each cable hold down assembly 46, 48 is attached to a vacuum source (not shown) by means of flexible conduits 60, 62, respectively.
The left hand cable hold down assembly 46 is shown in FIGS. 5 to 8 and includes an elongated member 66 having a guide slot 68 in the base thereof and an elongated central chamber 70 with an upwardly directed opening 72. A plate 74 is detachably secured to the top of the member 66 and has an upwardly directed profiled surface 76 including a plurality of parallel spaced grooves 78 each with a centrally disposed slot 80 leading to the chamber 70. The plate 74 can be replaced by a similar plate having grooves and slots on different center line spacings. A manifold means 82, to which the source of vacuum is attached by coupling 84 and conduit 60, is adjustably attached to one end of member 66 with end surface 86 forming a cable edge guide. An adjustment screw 88 engages in member 66 and with manifold means 82 to control the relative positioning thereof and also the positioning of cable edge guide 86 with respect to the profiled surface 76 of plate 74. At the opposite end of the member 66 there is transverse slot 90 through which movable strip means 92 is selectively extended to lie against the profiled surface 76 of the plate 74 to close off a selected number of slots 80 thereby compensating for the width of cable to be secured by the hold down assembly 46. The strip means 92 preferably has a profiled bottom surface that corresponds to the profiled top surface 76 of plate 64. The hold down assembly 46 further includes a cable end stop member 94 having a profiled front surface 96 and a plurality of spaced, downwardly directed standoff pin means 98. This stop member 94 is pivotally attached to member 66 by pins 100 and is arranged to lie immediately adjacent the slotted plate 74 on stop blocks 102, 104 and serve as a cable end abutment. At one end of the vacuum chamber member 66 there is a fixed, vertically directed alignment cylinder 106.
The operation of the cable hold down means is shown in FIGS. 6, 7, and 8 with a cable 108 being shown spaced above the hold down assembly in FIG. 6. In FIG. 7 the cable 108 has been applied against profiled face 96, edge guide 86, the slotted plate 74, with the vacuum in chamber 70 holding the cable tightly in place with each conductor being held in a respective recess 78 in the profiled plate 74. One lateral edge of the cable is against the adjustable abutment 86 while the forward free edge is against the front face 96 of the pivotable stop member 94. The control strip 92 for the vacuum hold down assembly has been applied to the surface of plate 74 to adjust for the width of the cable.
FIG. 8 shows the cable after it has been terminated by crimping a terminal 110 onto each conductor (not shown). It will be appreciated from this figure that since the terminals project from the end of the cable which abuts face 96, it is necessary for the cable end stop member 94 to be swung upwardly to free the terminals. This movement can be arranged to cause the vacuum to be cut off so that the terminated cable 108 is released from the hold down assembly thereby allowing the completed cable harness to be removed from the machine.
FIGS. 9, 10, and 11 show the details of the termination operation performed by the applicator portion of the machine. In FIG. 9 the applicator 18 is in the ready condition with the upper sub assembly 112 formed by cable gripping member 114, crimp member 116, terminal guide pin 118, hold down guide pin 120 and terminal hold down member 122 in a raised condition. The intermediate sub assembly 124 formed by carrier strip support and guide member 126, shear member 128, and guide rail 130 with hold down assembly 46 positioned thereon, is in a raised condition due to the action of the springs schematically shown in FIG. 4. The terminal support member 132 and anvil 134 are in their fixed position. A single strip of terminals 112 is shown passing over support member 132 with the crimp portion 136 on anvil 134 and the carrier strip 138 on guide 126 beneath shear member 126. The hold down assembly 46 has been actuated to position the cable 108 in the applicator.
When the press is actuated (see FIG. 10) the upper and intermediate applicator sub assemblies 112, 124, respectively, are brought together. First the guide pin 118 engages in alignment holes (not shown) in the carrier strip 138 to center the terminals in the applicator. Next the guide pin 120 engages the sleeve 106 of the hold down assembly 46 to insure proper positioning of it with respect to the terminals 112. The gripping member 114 makes contact with the cable 108 and the terminal hold down member 122 makes contact with the terminals 112. Continued actuation of the press brings the upper and intermediate sub assemblies to the condition of FIG. 11. First the terminals 112 are sheared from the carrier strip 138 and then the insulation piercing tines of the crimp barrel 136 are driven into the cable 108 where the crimp member 116 crimps them into engagement with the conductors. This movement also causes a slight rocking of the cable end stop member 94. When the crimping is completed, FIG. 12, the press is withdrawn freeing both the cable hold down assembly 46 and the carrier strip 138 so that the terminated cable can be removed from the machine and the terminal strip fed forwardly to position further terminals at the work station. Feed of the terminal strip is accomplished by the known terminal feed assembly 140, shown in FIG. 4.
The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. The present embodiment should therefore be considered in all respects as illustrative and not restrictive of the scope of the invention.
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An improved machine is disclosed for forming cable harnesses by simultaneously terminating all conductors at one or both ends of a cable formed of a plurality of flat conductors embedded within a web of insulating material. The subject machine incorporates a cable positioning and hold down mechanism which both accurately positions the end of the cable to be terminated at a proper location relative to the terminals, which are subsequently gang applied thereto, as well as firmly holds the cable in position during termination. The subject hold down mechanism is adjustable for various widths of cable and the dual terminating machine is adjustable for cables of varying lengths.
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CLAIM OF PRIORITY UNDER 35 U.S.C. §119
The present Application for Patent claims priority to Indian Patent Application No. 395/CHE/2006 filed Mar. 7, 2006, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
The present Application for Patent claims priority to U.S. Provisional Application No. 60/793,489 entitled “A RESISTOR-LESS BANDGAP REFERENCE FOR MICRO-POWER MEMORIES and LOW-POWER LOW VOLTAGE MOSFET BASED VOLTAGE REFERENCE” filed Apr. 19, 2006, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
BACKGROUND
Conventionally, obtaining a sub-100 nA micro-power voltage reference for micro-power wide voltage range memory applications required very large matched resistors to achieve a low current, bipolar junction transistors (BJT), and an amplifier to generate a proportional to absolute temperature (PTAT) voltage. FIG. 1 illustrates a circuit schematic for a conventional band-gap voltage reference circuit 100 . The large resistors (R 1 and R 2 ) are not generally suitable as micro-power components. Furthermore, the use of BJTs 102 - 106 and resistors R 1 -R 2 introduces BJT mismatch and resistor mismatch.
One purpose of a band gap voltage reference is to balance the negative temperature coefficient of a P-N junction with the thermal voltage (V T , where V T =KT/q). In FIG. 1 , the reference voltage V bg can be expressed as follows:
V bg =V eb106 +K 1 *V T . (1)
The amplifier 108 generates a PTAT voltage across resistor 110 by equalizing nodes A and B. The current through resistor 110 can be expressed as follows:
I = Δ V R 1 R 1 = V eb 102 - V eb 104 R 1 = V T ln ( I / I S ) - V T ln ( I I S * K 2 ) R 1 , = V T ln ( K 2 ) R 1 ( 2 )
where the m-factor K 2 is equal to 8. V bg can alternatively be expressed as:
V bg =V eb106 +I*R 2. (3)
Upon substituting the expression of I from Equation 2 into Equation 3:
V bg =V eb106 +R 2 /R 1*ln(8)* V T (4)
Thus, it should be clear from Equation 4 that
K 1 =R 2 /R 1*ln( K 2 ) (5)
Thus, establishing a band-gap reference voltage in the conventional art depended heavily on the values of R 1 and R 2 .
Beta multiplier voltage references have been developed in the past that do not require the use of a BJT. FIG. 2 is a circuit schematic for one such conventional circuit 200 for generating a beta multiplier voltage reference. When MOSFETS 202 - 208 operate in the sub-threshold region, the relationship between I DS and V GS depends strongly on Vt variations with respect to temperature. Thus I DS at 90° C. would be greater than I DS at 27° C. On the other hand, when MOSFETS 202 - 208 operate in the strong inversion region, the relationship between I DS and V GS depends strongly on Mobility (u n ) variations with respect to temperature. Thus I DS at 90° C. would be less than I DS at 27° C.
FIG. 3 is an I DS vs. V GS curve illustrating a MOSFET's transfer characteristic for two different temperatures. The principle behind beta multiplier voltage references is that there exists a temperature-insensitive value of V GS for a given I DS . This point is denoted as point CP in FIG. 3 . However, the temperature insensitivities of circuits such as circuit 200 strongly depend on MOSFET modeling and do not account for threshold voltage and mobility variations with respect to temperature or the variations in resistance. Consequently, these circuits require a significant amount of on-chip trimming.
SUMMARY
Accordingly, embodiments of the present invention eliminate the need for the resistors and the amplifier discussed above and also reduce the number of BJTs required for a voltage reference circuit. Embodiments also help to eliminate excessive dependence on MOSFET models so as to eliminate the need for on-chip trimming.
An embodiment of the present invention is directed to a low power voltage reference circuit. The circuit includes a first circuit for generating a PTAT voltage without use of an operational amplifier. The reference circuit also includes a second circuit for generating the reference voltage. The first and the second circuit are resistor-free, e.g., they do not use resistors.
Another embodiment of the present invention is directed to a circuit for generating a band-gap voltage reference including a first transistor coupled with a first output of a current reference circuit. The first transistor is operable to generate a bias current that is proportional to a reference current of the current reference circuit. The reference current is proportional to a temperature measurement. The novel circuit also includes a diode-connected transistor coupled with the first transistor and a second transistor coupled with said first transistor and said second transistor, wherein said reference voltage is generated at a drain of said diode-connected transistor. The reference voltage is generated at a drain of the diode-connected transistor.
This embodiment of the present invention is capable of achieving a band-gap reference of minimal variation (1.24V+/−20 mV, for instance) across a wafer in the temperature range of −45° C. to 95° C., for instance. The voltage reference is achieved with an ultra low sub-100 nA operating current. This embodiment is applicable for micro-power applications requiring low standby current, for example.
Another embodiment of the present invention is directed to a circuit for generating a low-power, low-voltage voltage reference including a PMOS transistor coupled with an output of a current reference circuit. The current reference circuit generates a reference current that is proportional to a temperature measurement. The novel circuit also includes a diode-connected transistor coupled with the PMOS transistor. The voltage reference is generated at a drain of said diode-connected transistor.
This embodiment has several benefits over conventional voltage reference circuits. For example, the circuit's dependency on MOSFET models has been minimized and depends on Vt modeling. The circuit also has low power requirements (≦300 nA of current, for instance). The circuit can also operate at low voltage (up to Vt+300 mV, for instance). Additionally, in one embodiment, the circuit's temperature coefficient is less than 200 ppm/° C. Furthermore, the reference may be adaptive with respect to process.
Thus, embodiments of the present invention are able to advantageously provide a reference voltage without using resistors or amplifiers. As a result, circuit area and operating current are reduced. Moreover, problems associated with resistor matching are eliminated. These advantages translate generally into lower cost and lower power consumption compared to conventional voltage reference circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of embodiments of the invention:
FIG. 1 shows a circuit schematic of a conventional band-gap voltage reference.
FIG. 2 shows a circuit schematic of a conventional beta multiplier voltage reference.
FIG. 3 is an I DS vs. V GS curve, illustrating a temperature insensitive point in a MOSFET's transfer characteristic.
FIG. 4 shows an exemplary circuit schematic of a resistor-less current reference, in accordance with an embodiment of the present invention.
FIG. 5 shows an exemplary circuit schematic of a resistor-less band-gap voltage reference, in accordance with an embodiment of the present invention.
FIG. 6 shows an exemplary circuit schematic of a low power, low voltage MOSFET based voltage reference, in accordance with an embodiment of the present invention.
FIG. 7 illustrates a schematic for a band-gap voltage reference circuit 420 A, in accordance with various embodiments of the present invention.
FIG. 8 illustrates a schematic for a voltage reference circuit 420 B, in accordance with various embodiments of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the claims. Furthermore, in the detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
FIG. 4 illustrates a block diagram of a low power voltage reference circuit 400 , in accordance with various embodiments of the present invention. Circuit 400 may be well-suited for use in, for example, memory applications. In one embodiment, circuit 400 advantageously uses no resistors. As such, the problems associated with resistor mismatch of conventional designs are eliminated. Furthermore, circuit 400 has a smaller on-chip footprint than conventional circuits.
Circuit 400 includes a current reference circuit 410 . The current reference circuit 410 , which uses no resistors, is operable to generate a reference current. The current reference circuit 410 is also operable to generate a PTAT voltage (V ptat ) without using an operational amplifier. For example, in one embodiment, the current reference circuit 410 contains no operational amplifier.
FIG. 5 illustrates a block diagram of a current reference circuit 410 A, in accordance with various embodiments of the present invention, which may be used in circuit 400 . The current reference circuit 410 A includes a current mirror 510 for mirroring the reference current within the current reference circuit 410 A and to other circuits coupled with the current reference circuit 410 A. In one embodiment, the current reference circuit 410 A generates the output signal “bias_p,” which may be used by another circuit to mirror the reference current. The current reference circuit 410 A also includes a PTAT generator 520 coupled with the current mirror 510 . In one embodiment, the PTAT generator is operable to generate the PTAT voltage (V ptat ) without use of an operational amplifier. The PTAT generator may also be operable to generate the signal “bias_n,” which may be used to bias another circuit. The current reference circuit 410 A may also include a V-I converter 530 for converting a voltage signal to a current signal. In one embodiment, the V-I converter is coupled with the PTAT generator and is operable to convert V ptat to a PTAT current (I ptat ). The reference current of the current reference circuit 410 A may then be based on I ptat . The current reference circuit 410 A may also include a bias circuit 540 for biasing the V-I converter 530 .
FIG. 6 illustrates a detailed schematic of a current reference circuit 410 B, in accordance with various embodiments of the present invention, which may be used in circuit 400 . In current reference circuit 410 B, transistors 610 , 620 , and 630 act as a current mirror 510 A. Transistors 640 and 650 are coupled with transistors 610 and 620 respectively. In this configuration, transistors 640 and 650 operate in sub-threshold region and serve as a PTAT generator 520 A for generating the PTAT voltage V ptat , thereby eliminating the need for an amplifier. The current reference circuit 410 B also includes transistor 530 A, which is coupled with transistor 650 . As configured, transistor 530 A is operable to convert V ptat to I ptat . In one embodiment, transistor 530 A is a MOSFET operating in the linear region and thus taking the place of a resistor. The current reference circuit 410 B may also include a transistor 540 A, which may be used to bias transistor 530 A.
Consequently, the reference current through the current reference circuit 410 B is:
I= 8*β 530A *η 2 *V T 2* ln 2 ( S ) (6)
Ignoring the constant terms in Equation 6, the relationship can be reduced to:
I∝β 530A *V T 2 . (7)
Noting that β 530A ∝C OX *μ n , and μ n ∝T −1.6 , where T is Absolute Temperature, and V T ∝T, this relationship can be rewritten as:
I∝β 530A *V T 2 ∝C OX *T −1.6 *T 2 ∝C OX *T 0.4 (8)
Thus, the current is nearly constant across the Transistor Process Voltage and Temperature. Therefore, this current can be used to advantageously bias a voltage reference stage 420 of the circuit 400 .
With reference again to FIG. 4 , circuit 400 includes a voltage reference circuit 420 for generating a reference voltage V REF . Voltage reference circuit 420 advantageously uses no resistors.
In one embodiment, the reference voltage V REF is a band-gap reference (e.g., V bg ). FIG. 7 illustrates a schematic for a band-gap voltage reference circuit 420 A, in accordance with various embodiments of the present invention, which may be used by circuit 400 . Circuit 420 A includes a transistor 710 , which mirrors the current from circuit 410 (or circuit 410 A). The band-gap voltage reference circuit 420 A also includes a BJT 750 , which has an emitter voltage of V EB . Circuit 420 A also includes a diode-connected transistor 720 , which acts as a resistor. It should be appreciated that this configuration of transistor 720 therefore obviates the need for a resistor. The negative temperature variation due to the BJT 750 is cancelled by the positive temperature coefficient of the overdrive of transistor 720 .
In one embodiment, the band-gap voltage reference circuit 420 A also includes transistors 730 and 740 , which serve as a simple voltage follower and remove a V th component of the drain voltage of transistor 720 . The reference voltage V bg from FIG. 7 can be expressed as:
V bg =V EB +V GS720 −V GS730 . (9)
Here, V GS720 =V t +√{square root over (2*4*I/β 720 )} and V GS730 ≈V t . On substituting these V GS values into Equation 9,
V bg =V EB +√{square root over (2*4 *I/β 720 )}. (10)
In one embodiment, the transistors 710 and 720 of voltage reference circuit 420 A and transistor 530 A of current reference circuit 410 A are selected so that β 530A /β 720 =2 and K 3 =4. On substituting the I given in Equation 6 into Equation 10,
V bg =V EB +η*V T *ln(4)*√{square root over (2*2*4*8)} =V EB +19.2 *V T ≈1.24 V, (11)
at room temperature. Thus, by appropriate selection of transistors 530 A and 720 , the β terms can be cancelled out. In one embodiment, transistors 640 , 650 , 530 A, 540 A, and 720 - 740 in FIGS. 6-7 may be native NMOS transistors, which allows for lower supply voltage operation.
Thus, this embodiment of the present invention is capable of achieving a band-gap reference of minimal variation (1.24V+/−20 mV) across a wafer in the temperature range of −45° C. to 95° C., for instance. The voltage reference is achieved with an ultra low sub-100 nA operating current. This embodiment is applicable for micro-power applications requiring low standby current, for example.
FIG. 8 illustrates a schematic for a voltage reference circuit 420 B, in accordance with various embodiments of the present invention, which may be used in circuit 400 . Voltage reference circuit 420 B is particularly useful in low power applications and low voltage applications. It should be appreciated that voltage reference circuit 420 B does not require a resistor or a BJT to generate the voltage reference V REF . For example, transistor 820 is diode-connected and therefore operates similar to a resistor. Moreover, because BJTs can become inaccurate at sub-nA currents (e.g., 10 nA), it is therefore advantageous to generate V REF without using a BJT. In one embodiment, the current reference circuit 410 B of FIG. 6 is connected to the voltage reference circuit 420 B of FIG. 8 at the bias_p node. From FIG. 8 , the reference voltage V REF can be expressed as:
V REF =V t +√{square root over (2 *I/β 820 )} (12)
Upon substituting I from Equation 4 into Equation 10,
V REF =V t +√{square root over (2*8*β 530A /β 820 *ln 2 ( S ))}* V T (13)
V REF =V t +K 1 *V T (14)
By changing the sizes of transistors 530 A and 820 , the value of K 1 can be manipulated to cancel out the V t variations with respect to temperature. Assuming that V t variation with respect to temperature is mainly with Bulk Fermi Potential (2φ F ) and mathematics, the following expression for V REF can be derived:
V REF =V FB +Q B /C OX +V G0 +3 V T0 (15)
Where V G0 represents the extrapolated silicon band-gap at T=0° K. and V T0 represents the thermal voltage at room temperature. It is appreciated that the expression for the reference voltage in Equation 15 is substantially independent of temperature. The temperature dependent term (2φ F ) in the threshold voltage (V t ) is cancelled with weighted PTAT voltage from the current reference circuit 410 B. V REF is also substantially independent of external voltage because it is driven by the self-biased current reference 410 B. However, V REF does depend on process (1/C OX ), which is adaptive. In other words, the circuit will produce a higher V REF at slow PMOS and slow NMOS, and it will produce a lower V REF at fast PMOS and fast NMOS.
This embodiment has several benefits over conventional voltage reference circuits. For example, the circuit's dependency on MOSFET models has been minimized and depends on Vt modeling. The circuit also has low power requirements (≦300 nA of current). The circuit can also operate at low voltage (up to Vt+300 mV). Additionally, in one embodiment, the circuit's temperature coefficient is less than 200 ppm/° C. Furthermore, the reference may be adaptive with respect to process.
Thus, embodiments of the present invention are able to provide a reference voltage without using resistors or amplifiers. As a result, circuit area and operating current are reduced. Moreover, problems associated with resistor matching are eliminated. These advantages translate generally into lower cost and lower power consumption compared to conventional voltage reference circuits.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
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An embodiment of the present invention is directed to a low power voltage reference circuit. The circuit includes a first circuit for generating a PTAT voltage without using an operational amplifier. The circuit also includes a second circuit for generating the reference voltage. The first and the second circuit do not utilize a resistor.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a wire saw for cutting wafers from a workpiece, in particular a wire saw for producing semiconductor wafers. The wire saw comprises a cutting head in which at least two wire-guiding rollers are rotatably mounted in each case between a moveable bearing and a fixed bearing, with adjacent wire-guiding rollers, together with a wire wound around them, forming a wire web. The wire web is used with a sawing suspension and functions as a cutting tool. A sawing suspension may be dispensed with if a sawing wire having bonded cutting particles is used. The invention also relates to a repair station and to a maintenance and testing station for a wire-guiding-roller unit and to a method of exchanging the wire-guiding-roller unit.
2. The Prior Art
A wire saw for cutting wafers and having a cutting head in which the wire-guiding rollers are mounted between a moveable bearing and a fixed bearing in this cutting head, is described, in EP-733 429 A1. This wire saw can be used to cut a multiplicity of semiconductor wafers of a specific thickness from a piece of crystal during a cutting operation. The thickness of the semiconductor wafers is determined by the distance between the windings of the sawing wire in the wire web. This distance, in turn, is essentially predetermined by grooves which are located in the coating of the wire-guiding rollers and in which the wire runs. The wire saw also has a heating/cooling system for controlling the temperature of the wire-guiding rollers and of the moveable bearing and fixed bearing adjacent thereto. In this way, undesired sawing-wire displacement as a result of heat expansion of machine parts can be minimized.
Occasionally, it is necessary to change the coating of the wire-guiding roller or to change the wire-guiding roller itself. For example, change may be needed when the cutting results deteriorate as a consequence of the coating being worn. Change may also be necessary if it is intended that the thickness of wafers which are to be cut subsequently should be modified to a new value. Deterioration of the cutting result may also indicate damaged bearings.
If the coating or the bearings are changed, it is necessary for the wire-guiding roller or the bearings to be removed from the cutting head. Up until now, this has been very expensive and has resulted in the wire saw being out of service and at a standstill for long periods of time. Once a new wire-guiding roller or new or repaired bearings have been introduced, the wire saw then still requires additional time. During this certain period of time, the wire saw is test run and is brought to the operating temperature before stable operation is possible. After this, a test workpiece then usually has to be sawed before the actual production of the wafers can proceed.
SUMMARY OF THE INVENTION
It is an object of the present invention to shorten the period during which the wire saw has to be at a standstill in order that a wire-guiding roller or bearings can be changed, and to simplify the procedure for changing a coating.
The invention relates to a wire saw for cutting wafers in which each wire-guiding roller and the moveable bearing and fixed bearing adjacent to it form a wire-guiding-roller unit. This unit can only be removed from the cutting heads as an entire unit.
The wire-guiding roller and the bearing shafts also form a rigid unit. This rigid unit is balanced as such and the bearing seats of this unit and the coating mount of this unit can be produced in one operation.
With the prior art devices, the bearing shafts have to be separated from the wire-guiding rollers in order for the rollers to be moved. Any coolant located in the bearing shafts and in the wire-guiding roller flows into the sawing area. This coolant changes the composition of the sawing suspension, with the result that the sawing suspension may even become unusable. This cannot take place in the case of the present invention since the wire-guiding roller and bearing shafts are removed as a unit.
The combination of the wire-guiding roller and moveable bearing and fixed bearing form a wire-guiding-roller unit. This unit not only permits swift removal of the wire-guiding roller and of the bearings. But this unit also makes it possible for the wire-guiding roller which has been removed to be provided with a new coating in a repair station. This makes it possible, following this and the reinstallation of the wire-guiding-roller unit into the wire saw, to dispense with the warm up stage. Thus, the warm up operation of the wire saw can be omitted for the purpose of reaching the necessary operating temperature.
With the wire-guiding-roller/bearing design of the prior art, the wire-guiding rollers are fastened between the fixed-bearing shaft and moveable-bearing shaft. For this reason, the drive forces are transmitted, but the bearing shafts and wire-guiding roller do not form a single-piece, rigid unit. The fixed-bearing and moveable-bearing shafts are therefore each mounted with two bearing assemblies for stabilizing purposes.
The 3-part screwed arrangement of the bearing shafts and wire-guiding roller involves a high expense and results in misalignment and thus causes a stressing of the shaft system. This stressing, in turn results in shortening the service life of the bearings and in an uncontrolled heating of the bearings. Moreover, the geometry of the wafers which are to be cut is influenced by the erratic operation which occurs as a result of misalignment.
The present invention thus also achieves the object of avoiding misalignment, of simplifying the bearing design and of ensuring smooth running.
The present invention also relates to a repair station for a wire-guiding-roller unit with a wire-guiding roller, a moveable bearing and a fixed bearing, comprising
a) supporting surfaces for supporting the wire-guiding-roller unit;
b) retaining elements for fixing the wire-guiding-roller unit on the supporting surfaces;
c) a heating/cooling system for controlling the temperature of the wire-guiding-roller unit; and
d) means for detaching a covering from the wire-guiding roller.
The period during which the wire saw is at a standstill is shortened considerably if the wire-guiding-roller unit which has been removed from the wire saw is replaced by another wire-guiding-roller unit, which has previously been prepared for use in a fitting station.
It is also possible for the bearings of the wire-guiding-roller unit which has been removed from the wire saw to be repaired or exchanged outside the wire saw. It is also possible for the wire-guiding-roller unit to be run in a maintenance and testing station once the bearings have been repaired or changed. During this time, the wire saw can be used to produce wafers with a wire-guiding-roller unit which, for example, has been prepared and run in another maintenance and testing station. The elimination of a warm-up phase in the wire saw and the sawing of a test workpiece means the following. Thus, the period during which the wire saw is at a standstill and out of operation is shortened to the time taken to exchange wire-guiding-roller units.
The present invention thus also relates to a maintenance and testing station for a wire-guiding-roller unit with a wire-guiding roller, a moveable bearing and a fixed bearing, comprising
a) bearing supports for the bearings of the wire-guiding-roller unit;
b) a heating/cooling system for controlling the temperature of the wire-guiding-roller unit;
c) a drive for running-in the wire-guiding-roller unit; and
d) a device for monitoring the running-in operation of the wire-guiding-roller unit.
Lastly, the present invention relates to a method of exchanging a wire-guiding-roller unit of a wire saw for cutting wafers from a workpiece. The method is defined in that the wire-guiding-roller unit, which comprises a wire-guiding roller provided with a coating as well as a moveable bearing and a fixed bearing, is displaced axially from an operating position into a release position and is removed from the wire saw with the aid of a manipulator, and a wire-guiding-roller unit which has been temperature-controlled in advance is moved into the operating position.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings which disclose several embodiments of the present invention. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 shows a wire-guiding-roller unit installed in a wire-saw cutting head;
FIG. 2 shows the wire-guiding-roller unit according to FIG. 1 in a release position, in which it can be lifted out of the cutting head;
FIG. 3 shows the wire-guiding-roller unit according to FIG. 2 in a repair station according to the invention;
FIG. 4 shows the wire-guiding-roller unit according to FIG. 2 in an arrangement which is suitable for the purpose of repairing or changing the bearings; and
FIG. 5 shows the wire-guiding-roller unit according to FIG. 2 in a maintenance and testing station according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning now in detail to the drawings, FIG. 1 shows that wire-guiding roller 1 is rotatably mounted between a moveable bearing 2 and a fixed bearing 3 in a cutting head 4. Preferably 2 to 4 wire-guiding rollers are accommodated in the cutting head, and at least one of them is driven. The cylindrical body of the wire-guiding roller is tapered at the ends to form a bearing shaft 5. The moveable bearing 2 and the fixed bearing 3 are seated on the bearing shaft and form a wire-guiding-roller unit 6 within the wire-guiding roller 1. Located on the wire-guiding roller is a single-piece coating 7 which has guide grooves (not illustrated) and is centered by a releasable ring 8 and is secured against axial displacement. The wire-guiding roller illustrated is driven by a motor 9, of which the torque is transmitted directly via a coupling. According to the invention, it is unimportant for the wire-guiding roller to have its own drive. Pivot tensioners 10 are provided in order to safeguard against undesired axial displacement of the wire-guiding-roller unit. Clamping elements 11 are provided in order to fix the moveable bearing 2. These fix the wire-guiding-roller unit in the cutting head in an operating position. The pivot tensioners 10 and the clamping elements 11 are preferably moved hydraulically.
The temperature of the wire-guiding-roller unit is controlled with the aid of a heating/cooling system 12. This system comprises supply lines 13 and 14 which are connected to channels in the interior of the wire-guiding roller and the interior of the moveable bearing. This system will maintain circulation of temperature-controlling medium in the wire-guiding roller and in the moveable bearing. The heating/cooling system also comprises temperature-controlling segments 15 with corresponding supply lines 16 for controlling the temperature of the fixed bearing from the outside. These segments butt against the slightly conically designed lateral surface of the fixed bearing and are pressed against the lateral surface by springs. A constant airstream can be directed into the region of the fixed bearing with the aid of a sealed air line 17, and constituents of the sawing suspension or of the abraded material produced during the cutting operation are thus prevented from being able to penetrate into the fixed bearing.
A removal aid is provided for the purpose of removing the wire-guiding-roller unit from the wire saw. In the exemplary embodiment illustrated in FIG. 1, this removal aid comprises a linear carriage system 19 which is provided with a spindle drive 18 and by means of which the wire-guiding-roller unit 6 can be displaced axially into a release position. Prior to this, it is necessary for the sawing wire to be removed and for the arresting action of the pivot tensioners 10 and clamping elements 11 to be eliminated. Furthermore, the supply lines 13 and 14 have to be separated from the wire-guiding-roller unit, and independent closing valves are provided for this purpose at the separation points.
A situation in which the wire-guiding-roller unit is already located in the release position is illustrated in FIG. 2. The embodiment of the wire which is shown has a coupling between the drive and the fixed bearing. Upon displacement of the wire-guiding-roller unit into the release position, this coupling is automatically separated into a half 20 which remains in the saw head and a half 21 which remains connected to the wire-guiding-roller unit 6. The sealed air line 17 is likewise automatically separated during the displacement of the wire-guiding-roller unit. In the release position, it is possible, with the aid of a manipulator, for the wire-guiding-roller unit to be lifted out of the saw head in the direction of the arrow and transferred, for example, into a fitting station. In order to avoid longer periods during which the wire saw is at a standstill, another wire-guiding-roller unit, which has already been prepared for use, is moved into the operating position. This movement is preferably immediately after the original wire-guiding-roller unit has been removed, in the reverse order to which said removal operation takes place. Of course, it is possible that the wire-guiding-roller unit which has been remove can also be reconditioned. For example, this unit can be cleaned and provided with a new coating, and then replaced in its original position in the cutting head. When the wire-guiding-roller unit is installed, the temperature-controlling segments 15 automatically come into contact with the lateral surface of the fixed bearing 3 (FIG. 1). There is no need for any supply lines to be connected.
The coating of the wire-guiding roller is changed in a repair station provided for this purpose. FIG. 3 illustrates a repair station 22 with a wire-guiding-roller unit 6 accommodated therein and part of a manipulator which is suitable for moving the wire-guiding-roller unit. The manipulator preferably has grippers 23, which enclose the wire-guiding-roller unit laterally, and a pivot spindle 24, which allows the wire-guiding-roller unit to rotate through 90°. The wire-guiding-roller unit which has been removed from the cutting head is rotated through this angle and is set down. Alternatively, if appropriate, unit 6 can be fitted onto supporting surfaces 25 of the repair station and then is fixed thereon by retaining elements 26. The repair station 22 is provided with a heating/cooling system 27 for controlling the temperature of the wire-guiding-roller unit 6. This system 27 comprises supply lines 29 which are connected to channels in the interior of the wire-guiding roller and of the moveable bearing and of the fixed bearing. This system 27 maintains circulation of the temperature-controlling medium in the wire-guiding roller and in the moveable bearing and in the fixed bearing. Furthermore, the temperature of the moveable bearing is controlled from the outside via the supply lines 28. Temperature-controlling segments 30 with corresponding supply lines 31 are provided for controlling the temperature of the fixed bearing from the outside and can be moved up to the fixed bearing by means of linear advancement elements 32. Provided in the fitting station for the purpose of facilitating the operation of changing the coating 7 is a tool 33 which can detach the coating 7. In the exemplary embodiment illustrated coating 7 is molded onto a single-part sleeve 34, of the wire-guiding roller. The sleeve 34 is preferably produced from a CRP material (CRP=carbon-fiber-reinforced plastic). The sleeve is seated on a covering mount of the wire-guiding roller. It is also possible to manufacture the wire-guiding-roller unit entirely of a CRP material.
The heating/cooling system is used to control the temperature of the wire-guiding-roller unit in advance while it remains in the repair station. This has the result that, once it has subsequently been installed in the wire saw, there is no need for any warm-up phase during which the wire-guiding roller has to be brought to the operating temperature. All that is required in order to make the wire saw ready for operation again is to move the wire-guiding-roller unit into the operating position in the cutting head. This replacement occurs in the reverse order to which its removal operation takes place. Then it is necessary to provide the wire-guiding rollers with a new sawing wire.
The repair station may be constructed as a displaceable fitting carriage which, if required, is moved up to the wire saw. Another embodiment provides for the repair station and, if appropriate, also the manipulator to be positioned on the wire saw. Finally, it is also possible for the repair station to be constructed such that it can receive more than one wire-guiding-roller unit.
If it is necessary for the bearings of the wire-guiding-roller unit to be repaired or changed, the wire-guiding-roller unit is removed from the wire saw in the repair station as has already been described and is preferably arranged such that the bearings are freely accessible. Such an arrangement is shown in FIG. 4. The wire-guiding-rolling unit 6 is positioned outside of the wire saw on a repair bench 35 and is supported on the bench by means of supports 47. Once the necessary work has been completed, the wire-guiding-roller unit is transferred to a maintenance and testing station.
FIG. 5 shows a suitable maintenance and warming-up or testing station 36, in which the wire-guiding-roller unit 6 has been deposited on bearing supports 46. A motor 37 for driving the wire-guiding-roller unit is located in the station. The motor is coupled to the wire-guiding-roller unit by virtue of a displaceable linear guide 38 being moved into position. The repaired or exchanged bearings 2 and 3 are driven, with the aid of a motor, at certain rotational speeds in accordance with a specified program. During the test run, measurements are taken of the temperatures of the bearings and the vibration caused by the rotating wire-guiding-roller unit. The test run, which may last several hours, is carried out with the purpose of preparing the wire-guiding-roller unit for use in the wire saw. The intention, in particular, is to bring the wire-guiding-roller unit to a constant operating temperature and to achieve low-vibration rotary movement of the wire-guiding-roller unit. The test run is controlled by a device 41 for monitoring the warm-up operation of the wire-guiding-roller unit. In the same way as the repair station according to FIG. 3, the maintenance and testing station 36 is provided with a heating/cooling system 27 for controlling the temperature of the wire-guiding-roller unit 6. The temperatures of the moveable bearing and fixed bearing are measured by temperature sensors 39. These measurements are continuously passed onto the monitoring device 41 via signal lines 40. The signal lines 40 are connected to the temperature sensors via quick-action couplings 42. Once the wire-guiding-roller unit has been installed in the wire saw, it is also possible for the temperature sensors to be connected to a wire-saw control means via the quick-action couplings.
Also connected to the monitoring device 41 are vibration sensors 43, which monitor the development of vibration during running of the wire-guiding-roller unit. If vibration values which are considered to be permissible are exceeded, the test run is terminated and the wire-guiding-roller unit is balanced.
According to a preferred embodiment, the maintenance and testing station 36 also has means which can recondition a damaged or worn coating of the wire-guiding roller. These means may comprise, for example, a cylindrical-grinding tool 44 and a groove-grinding tool 45. The cylindrical grinding tool regrinds the covering, and the groove-grinding tool grinds guide grooves in the covering. The drive of the grinding tools is not illustrated in FIG. 5.
Once it has been installed in the wire saw and provided with sawing wire, a wire-guiding-roller unit which has been prepared for use in the maintenance and testing station can be used immediately for the purpose of producing wafers. Periods during which the wire saw is out of service and at a standstill can be reduced to the time taken to exchange wire-guiding-roller units. This is because once it has been removed from the wire saw, a wire-guiding-roller unit is immediately replaced by another wire-guiding-roller unit which has been prepared for use in the manner described. In this way, warming-up and testing phases for the wire saw and the cutting of test pieces are eliminated.
While several embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims.
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A wire saw for cutting wafers from a workpiece, has a cutting head in which at least two adjacent wire-guiding rollers are mounted rotatably in each case between a moveable bearing and a fixed bearing. These are adjacent wire-guiding rollers, together with a wire wound around them, form a wire web. Each wire-guiding roller and the moveable bearing and fixed bearing assigned to it form a wire-guiding-roller unit, which can only be removed from the cutting head as an entire unit. There is also a repair station and a maintenance and testing station for the wire-guiding-roller unit and a method of exchanging the wire-guiding-roller unit.
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BACKGROUND OF THE INVENTION
This invention relates in general to belt-type restraint devices for restraining a person by securing the wrists to a belt locked about the waist.
The advantages of the belt-type restraint devices, of which the present invention is intended as an improvement, are well known and include the fact that once properly secured, it is difficult to break loose or to do much damage while secured.
However, there are a number of disadvantages inherent in the belt-type restraint devices presently in wide-spread use. In general these devices are quite bulky and heavy. They require a lock to secure the girdling belt about the waist of the person and an individual lock for each shackle which secures the wrists to the belt. Additionally, the shackles are normally made of metal thereby adding to the bulk and weight of the restraint device. The prior art devices are therefore not only a bother to carry when not in use, but also are highly visible when in use. High visibility tends to result in "public relations" problems when a prior art restraint belt is utilized during the transportation of restrained persons by public transportation.
Accordingly, it is a major object of this invention to provide a belt-type restraint device which is lighter in weight and less bulky then are previously known devices and which is therefore easier to carry and simpler to use.
It is a further and related purpose of this invention to eliminate the metal shackles in order to achieve the above objectives.
It is a further purpose of this invention to provide this type of device which, in use, will attain the required restraing but which will make it feasible to restrain an individual who is then transported in public conveyances and in public places with minimum visibility as to the fact of the restraint.
It is also a purpose of this invention to achieve all of the above results in a device which is fully as secure as any previously known devices. Indeed, handcuffs, and to some extent metal shackles, permit a certain degree of mobility for the hands which at times allows the restrained individual to defeat and even break the devices. Accordingly, it is a purpose of this invention to reduce such mobility and thus enhance the security of the restraint device.
It is important that the restraint device be simple to use and that it be coupled to the individual being restrained by means of a single latching action. Accordingly, it is another purpose of this invention to provide a single latch restraint device.
BRIEF DESCRIPTION
In brief, the embodiment of the invention disclosed herein restrains a person by securing the person's wrists in loops of a fabric belt girdling the waist of the individual. The belt buckle is in the back, not in the front. The wrists of the individual are secured by two loops formed as a continuous part of the belt. This continuous construction results in a device wherein the tightening of the belt around the person's waist and the tightening of the wrist restraining loops occur simultaneously. The belt webbing is threaded through two separate metal grips at the front of the belt to form two separate wrist restraining loops. The two loops are spaced from one another by a non-adjustable portion of the belt extending between the two metal grips. The circumference of the belt is adjustable by means of passing the belt around a friction bar associated with the clip that latches into the buckle at the back of the belt. The wrist loops are threaded around cross bars at the two spaced apart metal grips and are adjustable. Tightening the belt around the waist of the person being restrained pulls the belt web through the metal grips thereby also tightening the wrist loops.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a belt-type restraint device according to the present invention.
FIG. 2 is an enlarged partial view in perspective of the device of FIG. 1, showing a wrist restraining loop and associated adjustment buckle in detail.
FIG. 3 is a view of the latch actuating surface of the latching buckle for the belt.
FIG. 4 is a perspective view of the adjustment buckle used to form the loop of FIG. 2 with the belt webbing removed to reveal the grip structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The FIGS. all refer to the same embodiment. As shown therein, the belt-type restraint device 10 of this invention includes a belt portion 12 having a buckle 14 and clip 16 so as to fasten the belt on an individual. The webbing 18 of the belt portion 12 is threaded through a friction bar (not shown) in the clip 16 so that the circumference of the belt portion 12 can be adjusted and the restraint device 10 thereby tightly drawn around the waist of the person being restrained.
The webbing 18 is threaded through two spaced apart metal grips 20 to form two spaced apart loops 22. These loops 22 are employed to tightly fasten the wrists of the individual being restrained to the belt at the position of the grips 20. The restraint device 10 includes a strap portion 24, which is made of the same type of webbing as the rest of the belt, but which is connected between the two grips 20 and which thereby fixes the distance apart of the two grips 20 and thus of the two loops 22. This fixed length strap portion 24 is overlayed by belt webbing 18 that is threaded through the grips 20. This overlayed portion of the belt 12 and the strap portion 24 are sewn together so that tension forces in the belt extend continuously through the webbing 18 that constitutes the belt portion 12, loop portion 22 and strap portion 24 of this restraint device.
The grips 20 are rectangular metal pieces, each having an inboard end bar 20a, an outboard end bar 20b, side bars 20s and a cross bar 26. The cross bar 26 is V-shaped in cross section and is positioned across the two side bars 20s so that the cross bar 26 is free to move along the side bars 20s. Thus the side bars 20s operate as rails along which the cross bar 26 can move.
The ends of the strap portion 24 are looped around the inboard ends 20a of the grips and sewn in place. The belt portion 12 is passed over the outboard end 20b of each grip, under and around the cross bar 26 and then along the front facing surface of the strip 24 where the belt webbing 18 and strap 24 webbing are sewn together. Tabs 28 in the form of loops are sewn to the belt portion of the webbing 18 at positions where the loops 22 are formed. These tabs aid the peace officer or the like to pull the restrained individual's wrists into position and also aid in releasing the wrists once the buckle has been opened.
The metal grip 20 is the same as a type of adjustment buckle frequently used on a parachute. It prevents a restrained person from opening the loops 22 by thrusting his wrists in an outboard direction. Thus, thrusting the wrists outboard will cause the webbing 18 to pull the movable cross bar 26 outboard thereby gripping the webbing between the outboard end bar 20b. It is for this reason that the jaw of the cross bar 26 faces the outboard end bar 20b. Yet once the buckle 14 in the back has been released, the wrist loops 22 can be opened by pulling the tabs 28 in an inboard direction (that is, toward each other). When this is done, the cross bar 26 moves inboard enough so that the webbing 18 can slide over the end bar 20b and around the cross bar 26 to open the loop 22.
The buckle 14 and clip 16 arrangement may be similar to that shown in U.S. Pat. No. 4,052,775 issued Oct. 11, 1977. However, in order to enhance security, the top of the buckle 14 is covered by a plastic face plate 30 having a small opening 30a so that the only access to the release lever is by way of a prod or key that is inserted through the opening 30a and pressed inward to depress the lever and release the clip. This prevents finger or thumb release of the buckle. Further, in order to enhance security, the top of the buckle 14, where access to the release lever is available, is turned inward against the body of the person being restrained rather than, as is usual, turned outward. Thus, to release the restraint device 10 one not only has to have a key available that will fit through the opening 30a but one also has to turn the buckle 14 and clip 16 around so as to have access to the opening 30a.
In operation, the arresting officer pulls the loops 22 open so that the hands of the person being restrained can be passed through the loops 22. The arms of the restrained person are preferably crossed so that his left wrist is held by the right loop 22 and vice versa. Loops 22 are then pulled reasonably tight and the belt portion 12 is drawn around the waist of the person being restrained. The end 12e of the belt is drawn through the clip 16 until the belt is as tight as desired around the person being restrained. The clip 16 and buckle 14 are fastened and the belt can continue to be drawn as tight as desired. The drawing of the belt tighter, sets up tension in the webbing 18 which is transmitted through the webbing to the loop portions 22 thereby pulling the loop portions 22 tight around the wrists of the person being restrained at the same time as the belt 12 is being pulled tight around the waist of the person. Wrist movement within the loops 22 by the person being restrained causes the cross bar 26 to jam against one end of the grip 20 thereby preventing the loops 22 from opening under pressure from forces generated within the loops 22.
Although a presently preferred embodiment of the invention has been described, there are certain variations that could be made without departing from the scope of this invention. For example, the adjustment buckle or grip 20 has been referred to as a grip because of the manner in which the movable cross bar 26 will serve to grip the webbing 18 when a restrained individual attempts to move his wrists in a outboard direction. However, depending on the precise function to be achieved and the trade-off between security and ease of use, the grip 18 might be replaced by any one of a number of types of adjustment buckles which permit and even facilitate movement of the webbing 18 therethrough under tension so that the wrist loops 22 can be tightened around the wrists of the restrained individual at the same time that the girdle portion of the belt 12 is tightened around the waist of the individual.
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A belt-type restraint device, for restraining a person, has a belt for forming a girdle about the waist of the person and restraint means for securing the wrists of the person to the front of the belt. The restraint means are formed of loops continuous with the webbing of the belt to allow a single latching buckle at the back of the belt to simultaneously adjust and lock both the belt and the loops.
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RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/668,881, filed Jul. 6, 2012, and entitled “CASE APPARATUSES FOR PORTABLE ELECTRONIC DEVICES,” which is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to portable electronic devices and, more specifically, to case accessories for portable electronic devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:
[0004] FIGS. 1A and 1B illustrate perspective views of an embodiment of a case for a portable electronic device consistent with embodiments of the present disclosure;
[0005] FIGS. 2A and 2B illustrate perspective views of an embodiment of a case with a portable electronic device stored within consistent with embodiments of the present disclosure;
[0006] FIGS. 3A and 3B illustrate plan views of an embodiment of a case for a portable electronic device consistent with embodiments of the present disclosure;
[0007] FIGS. 4A and 4B illustrate perspective views of an alternative embodiment of a case for a portable electronic device consistent with embodiments of the present disclosure;
[0008] FIGS. 5A and 5B illustrate perspective views of an alternative embodiment of a case with a portable electronic device stored within consistent with embodiments of the present disclosure;
[0009] FIGS. 6A and 6B illustrate plan views of an alternative embodiment of a case for a portable electronic device consistent with embodiments of the present disclosure;
[0010] FIG. 7 illustrates a perspective view of an embodiment of a case for a portable electronic device in a display configuration consistent with embodiments of the present disclosure; and
[0011] FIG. 8 illustrates a plan view of an embodiment for a case for a portable electronic device.
DETAILED DESCRIPTION
[0012] The proliferation of portable electronic devices (PEDs), including notebook and tablet computers (e.g., the Apple® iPad® and Samsung® Galaxy®), portable digital assistants (PDAs), an electronic book reader (e.g., the Amazon® Kindle® and smartphones (e.g., the Apple® Phone®, Google® Android®), has placed more computing power into the hands of users than the computing power of early computers that occupied an entire room. This portable computing power has enhanced both personal and business mobile productivity. Due to their portability, however, PEDs may be susceptible to damage and protecting an expensive electronic device is a priority to the user. Embodiments of the present disclosure provide an accessory case for a PED configured to protect the PED from damage. In various embodiments, the case may be configured to enclose and protect the PED in a closed position and support the PED upright and/or elevated (i.e., propped up) in an open position.
[0013] Embodiments may be best understood by reference to the drawings. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail. The case embodiments disclosed herein may include any number of buttons, apertures, grooves, slots, and the like to enable interaction, access, and viewing with corresponding input and output devices of a PED.
[0014] FIGS. 1A and 1B illustrate a case 100 for a PED (not shown) that is configured to receive the PED and retain, protect, carry, and secure the PED. FIG. 1A is referred to herein as the front side 102 which receives the PED and FIG. 1B is the back side 104 . As used herein, the PED may be any portable electronic device including, for example, a notebook computer, an electronic book reader (e.g., the Amazon® Kindle®), a smartphone (e.g., the Apple® iPhone®, the Motorola® Droid®, and the BlackBerry® Storm®) and/or a tablet computer (e.g., the Apple® iPad®, the HP® Slate, and the Samsung® Galaxy® Tablet). The PED may include on the front and/or the back face of the PED a display that is viewable in either a portrait orientation or a landscape orientation, a user input, and a data input/output port. In some embodiments, the case 100 may be configured such that the display, user input, and data input/output port are accessible by a user of the PED while the PED is disposed in the case 100 . Access may be provided by apertures or buttons, toggles, switches and the like which interact with corresponding PED controls. Further, in some embodiments, the case 100 may include a protective display disposed over the PED display.
[0015] The case 100 comprises a primary base surface 106 to support a backside of a PED and may define a generally rectangular shape, include a substantially planar member, may further include rounded corners, and may include one or more apertures for accessing the PED and/or to enable camera operation. In one embodiment, the primary base surface 106 covers a majority of a backside of a PED.
[0016] The case 100 includes a top wall 108 extending from a side of the primary base surface 106 which is intended to cover a top wall of a PED. Two primary sidewalls 110 extend from the primary base surface 106 and are substantially parallel to one another. Together, the sidewalls 108 , 110 and the base surface 106 define a recess 112 to receive a PED. The sidewalls 108 , 110 may be configured with apertures, grooves, switches, buttons, toggles, or the like to allow access to the PED. The sidewalls 108 , 110 may define a frame or window at least partially extending over the recess 112 to retain the PED while still allowing access to a PED. In one embodiment, the opposing and parallel sidewalls 110 may include a configuration or material to facilitate gripping of the case 100 . For example, the sidewalls 110 may include a semi-rigid and compressible material.
[0017] A fourth side 114 of the primary base surface 106 may not have a corresponding, extending sidewall and is designated the access side 114 . The primary base surface 106 and the sidewalls 108 , 110 are designated herein as the primary case member 116 .
[0018] The case 100 may include a secondary base surface 118 with a planar surface which supports a minority of a backside of a PED. The secondary base surface 118 may also define a substantially rectangular shape with rounded corners. The case 100 includes secondary sidewalls 120 and a bottom wall 122 which extend from the secondary base surface 118 . The walls 120 , 122 may include one or more apertures to enable access to the PED. In an alternative embodiment, the case 100 may not have a secondary base surface 118 but would still include the walls 120 , 122 .
[0019] A fourth side 124 of the secondary base surface 118 designated herein as the secondary access side, does not have a corresponding sidewall. The secondary base surface 118 and the secondary walls 120 , 122 are collectively referred to herein as the secondary case member 126 . The primary and secondary case members 116 , 126 may comprise various semi-rigid and/or rigid materials.
[0020] Two opposing stretchable strips 128 are coupled to the two parallel primary sidewalls 110 and two parallel secondary sidewalls 120 . The strips 128 may include any one of various elastic materials known in the art. The strips 128 may be coupled to the primary and secondary walls 110 , 120 adjacent the primary and secondary access sides 114 , 124 . The strips 128 provide sufficient strength to pull the primary and secondary case members 116 , 126 together adjacent one another in a closed configuration. In the closed configuration, the base surfaces 106 , 118 form a continuous planar member 106 , 118 to support the PED and the PED is contained within the walls 108 , 110 , 120 , 122 .
[0021] In one embodiment, the primary and secondary base surfaces 106 , 118 are configured with tongue and groove features to facilitate alignment of the base surfaces one another.
[0022] Referring to FIGS. 2A and 2B , the case 100 is shown with a PED 150 . FIG. 2A illustrates the front side 102 of the case 100 and FIG. 2B illustrates a back side 104 of the case 100 . In inserting a PED 150 into the case 100 , a user applies tension to the strips 128 to separate the primary and secondary case members 116 , 126 away from one another in an open configuration. The PED 150 is inserted through the access side 114 into the recess 112 defined by the primary base surface 106 and primary walls 108 , 110 . A user then releases tension on the strips 128 and the secondary base surface 118 and secondary sidewalls 120 , defining a secondary recess, receive a portion of the PED 150 . Thus inserted, the backside and sidewalls of the PED 150 are protected and a PED display is accessible.
[0023] In transitioning from a closed configuration to an open configuration, a user may apply tension to the strips 128 to separate the primary and secondary case members 116 , 126 . A user may then extract the PED 150 from the case 100 . Alternatively, a user may remove the secondary case member 126 to expose a side of the PED 150 while the primary case member 116 continues to retain a portion of the PED 150 . A user may thereby access a port on the exposed side to enable access such as for charging and/or data synchronization.
[0024] Referring to FIGS. 3A and 3B , front and back sides 102 , 104 of the case 100 are shown in a closed configuration with a PED 150 retained within. As illustrated, the PED display is accessible while the sides and back of the PED 150 are protected by the case 100 .
[0025] Referring to FIGS. 4A and 4B , perspective views of an alternative embodiment of a case 200 is shown for a PED. FIG. 4A is referred to herein as the front side 202 which allows access to a PED display and FIG. 2B is the back side 204 . As in other embodiments, the case 200 may be configured such that the display, user input, and data input/output port are accessible by a user of the PED while the PED is disposed in the case 200 . Access may be provided by apertures or buttons, toggles, switches and the like which interact with corresponding PED controls.
[0026] The case 200 comprises a primary base surface 206 to support a majority of a backside of a PED and may define a generally rectangular shape, include a substantially planar member, may further include rounded corners, and may include one or more apertures for accessing the PED and/or to enable camera operation. The case 200 includes a top wall 208 and two primary sidewalls 210 , substantially parallel to one another, extending from sides of the primary base surface 206 as shown. The walls 208 , 210 and the primary base surface 206 define a recess 212 to receive a PED. The walls 208 , 210 may be configured with apertures, grooves, buttons, switches, toggles, and the like to access or interact with the PED. The walls 208 , 210 may define a frame or window at least partially extending over the recess 212 to retain the PED while still allowing access to a PED.
[0027] A fourth side 214 of the primary base surface 206 may not have a corresponding, extending sidewall and is designated the access side 214 . The primary base surface 206 and the walls 208 , 210 are designated herein as the primary case member 216 . The primary base surface 206 may have a greater length than the sidewalls 210 and may therefore extend without corresponding sidewalls 210 .
[0028] The case 200 includes a secondary base surface 218 with a planar surface which supports a minority of a PED backside. The secondary base surface 218 may also define a substantially rectangular shape with rounded corners. The case 200 includes secondary sidewalls 220 and a bottom wall 222 which extend from the secondary base surface 218 . In one embodiment, the bottom wall 222 may only partially extend along the corresponding side of the secondary base surface 218 to thereby allow access to a power and data synchronization port of a PED. As illustrated, the bottom wall 222 extends for a minority of the length of the corresponding side.
[0029] The walls 220 , 222 may include one or more apertures, switches, toggles, buttons, and the like to enable access to the PED. A fourth side 224 of the secondary base surface 218 , designated herein as the secondary access side, does not have a corresponding sidewall. The secondary base surface 218 and the secondary walls 220 , 222 are collectively referred to herein as the secondary case member 226 .
[0030] Two opposing flexible strips 228 are coupled to the two parallel primary sidewalls 210 and two parallel secondary sidewalls 220 . The strips 228 may include any one of various pliable or elastic materials known in the art. With the application of pressure, the strips 228 provide pivotable separation of the case members 216 , 226 from one another to an open configuration wherein a PED may be inserted into the recess 212 . Without pressure, the strips 228 return to the original, closed configuration wherein the base surfaces 206 , 218 are disposed adjacent one another to support a back side of a PED. In the closed configuration, the base surfaces 206 , 218 may be separated from one another by a groove 229 which may also partially extend along opposing sides of the primary base surface 206 . The groove 229 provides unobstructed separation of the case members 216 , 226 as the members pivot relative to one another.
[0031] Referring to FIGS. 5A and 5B , the case 200 is shown in an open configuration with a PED 250 . FIG. 2A illustrates the front side 202 of the case 200 and FIG. 2B illustrates a back side 204 of the case 200 . In inserting a PED 250 into the case 200 , a user applies pressure to the strips 228 to separate the primary and secondary case members 216 , 226 away from one another. The PED 250 is inserted through the access side 214 into the recess 212 defined by the primary base surface 206 and primary walls 208 , 210 . A user then releases pressure on the strips 228 and the secondary base surface 218 and secondary sidewalls 220 , defining a secondary recess, receive a portion of the PED 250 .
[0032] In transitioning from a closed configuration to an open configuration, a user may apply pressure to the strips 228 to separate the primary and secondary case members 216 , 226 . A user may then extract the PED 250 from the case 200 . The open configuration may also be used to allow access to a port on a bottom side of the PED 250 which is appreciated in an embodiment where the bottom wall 222 would prevent access.
[0033] Referring to FIGS. 6A and 6B , front and back sides 202 , 204 of the case 200 are shown in a closed configuration with a PED 250 retained within. As illustrated, the PED display is accessible while the sides and back of the PED 250 are protected by the case 200 .
[0034] Referring to FIG. 7 , a perspective view of the case 200 of FIGS. 4A-6B is shown in an open configuration with the flexible strips 228 providing separation of the primary and secondary case members 216 , 226 relative to one another. The case 200 also provides a display configuration with the PED 250 and the secondary case member 216 resting on a horizontal surface to provide angled viewing of the PED 250 . The primary case member 216 secures the PED 250 while the secondary case member 226 provides an angled support.
[0035] Referring to FIG. 8 , a plan view of a case 300 is shown with the front side exposed. As in previous embodiments, the case 300 includes a primary base surface 306 , top side wall 308 , primary sidewalls 310 , primary recess 312 , primary case member 316 , secondary base surface 318 , secondary sidewalls 320 , bottom wall 322 , secondary case member 326 , and flexible strips 328 . The case 300 further includes sliders 340 that may be disposed on the primary base surface 306 to facilitate insertion of a PED into the recess 312 and reduce scratching of the PED. The sliders 340 further protrude from the base surface 306 and provide suspension of the PED once the PED is secured in the case 300 to enhance cushioning and protection. The sliders 340 may comprise an elastomeric material including thermoplastic elastomers (TPE), thermal plastic urethane (TPU), polyurethane, transpolyurethane, unsaturated and saturated rubbers, and the like.
[0036] A slider 340 may extend around the majority or the entirety of the border between the primary base surface 306 and the walls 308 , 210 . A slider 340 may be a single continuous member or may be disposed at discreet locations. For example, sliders 340 may only be disposed along the borders between the primary base surface 306 and the sidewalls 310 . A slider 340 may also extend around an aperture 342 , in the illustrated example a camera aperture, to provide cushioned support for the PED. One or more sliders 340 may also be disposed on the walls 308 , 310 to facilitate insertion and removal of the PED and cushioned support of the PED.
[0037] The cases disclosed herein provide separation of primary and secondary case members while still retaining connection between the case members. The primary and secondary case members define respective recesses to receive and support portions of a PED. The primary and secondary case members may also be referred to as primary and secondary shells.
[0038] It will be understood by those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles presented herein. In addition, any suitable combination of various embodiments, or the features thereof, is contemplated. Further, any methods disclosed herein may comprise one or more steps or actions for performing the described method. These method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified.
[0039] Throughout this specification, any reference to “one embodiment,” “an embodiment,” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment. Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles set forth herein.
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A case for a portable electronic devices such as smart phones includes upper and lower shells that are joined by elastic members. The upper shell includes a base surface and sidewalls to retain a portion of the portable electronic device and, likewise, the lower shell includes a base and sidewalls to retain a portion of the portable electronic device. The elastic members enable separation of the upper and lower shells to permit insertion of the portable electronic device and further provide biasing to move the shells together and retain the portable electronic device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the art of cutting glass and particularly to the art of scoring glass in the presence of a fluid.
2. Description of the Prior Art
The cutting of individual glass articles from a large glass sheet or ribbon is generally accomplished by moving a glass-cutting tool across the surface of the glass with sufficient force to effect a score in the surface of the glass. This may be done with no fluid (dry scoring) or in the presence of a fluid. Cutting fluids may be used for the purpose of lubricating the cutting wheel and axle and the glass, but are now generally used primarily to prevent or retard healing of the score. It is known that healing is retarded by excluding atmospheric moisture from a score. Therefore, cutting fluids are typically in the form of oils or oils mixed with solvents.
U.S. Pat. Nos. 3,894,456 and 3,914,180 to Boller et al. disclose a cutting fluid which comprises methyl chloroform and a non-volatile hydrocarbon oil. The methyl chloroform acts as a cutting tool lubricant, then, being highly volatile, evaporates. The hydrocarbon oil, being non-volatile, forms a residue which binds wing chips along the edge of the score thus preventing spalling. An emulsifying agent may be added to the cutting fluid to aid washability for removal of the non-volatile oil from the glass surface.
Belgian Pat No. 819,914 to Simpkin et al. discloses a cutting fluid comprising a hydrophobic cutting oil and a hydrophobic organic solvent. The oil is thought to reduce lateral cracks produced along the score by water vapor in the atmosphere and consequently to reduce the force required subsequently to snap the glass score while the solvent acts as a thinner and is removed by evaporation.
SUMMARY OF THE INVENTION
The present invention relates to an improved glass cutting fluid which contains no oil and leaves no residue on the glass surface, thereby eliminating the need for washing. More particularly, this invention relates to a method of cutting glass employing an oilless cutting fluid which produces a spall-free cut glass edge having increased edge strength over an edge cut by dry scoring and which also extends the useful life of the cutting tool.
The primary component of the improved glass cutting fluid of the present invention is a halogenated hydrocarbon. The cutting fluid of the present invention may consist essentially of a liquid halogenated hydrocarbon or may comprise a halogenated hydrocarbon and a paraffin, naphtha or aromatic solvent. The cutting fluid need not contain an emulsifying agent to render the fluid water-washable since the cutting fluid is essentially completely removed by evaporation. Solutions or blends are adjusted for evaporation rates to meet the specific conditions imposed by production procedures and both automatic and manual operation equipment.
The method of cutting glass of the present invention involves effecting a score on the surface of the glass in the presence of the cutting fluid of the present invention and propagating the score to produce a cut through the glass. The cut edge of glass scored by the method of the present invention has increased edge strength compared with a cut edge of glass scored in the absence of the cutting fluid of the present invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a cutting wheel performance chart which defines the working range of a cutting wheel as a function of wheel load. The minimum wheel load at which a fissure starts is shown at 1. The working range of the wheel is defined by 2 and 3, the range of wheel load at which a fissure which can consistently be opened is generated without the occurrence of instant healing (formation of lateral vents which erupt with the glass surface). The wheel load at which the glass surface is crushed is shown at 4.
FIG. 2 displays cutting wheel performance charts of 134°, 145° and 150° wheels scoring dry and scoring through a cutting fluid of the present invention. The same performance parameters are defined by points 1, 2, 3 and 4 as in FIG. 1.
FIG. 3 compares cut edge strength of glass obtained by dry scoring with cut edge strength of glass obtained by scoring with a cutting fluid of the present invention as a function of wheel load within the respective working ranges for dry and wet scoring shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A cutting fluid is applied at the interface of a scoring tool edge and a major surface of a sheet of glass, supported on a substantially flat surface, along the intended scoring path. The cutting fluid comprises a halogenated hydrocarbon, preferably a chlorinated hydrocarbon such as 1,1,1-trichloroethane or perchloroethylene. The halogenated hydrocarbon is preferably used in combination with a paraffin, naphtha or aromatic solvent in order to permit adjustment of evaporation rate, fire resistence, cost and the like to satisfy specific needs of a cutting operation. A naphtha solvent is preferred for cutting flat glass in a primary glass manufacturing factory in which high speed, automatic cutting is accomplished.
The cutting fluid preferably comprises from 2 to 98 percent by volume halogenated hydrocarbon and from 98 to 2 percent by volume solvent. Selection of cutting fluid components and proportions will vary with such factors as cutting process, design of cutting and wareroom systems and materials, and desired score quality and edge strength.
The cutting fluid may be applied as a liquid or mist according to any of the techniques known in the glass cutting art. Preferably, the cutting fluid is applied continuously, such as by flowing down the cutting tool and transferring to the glass surface being scored.
The cutting tool is preferably a cutting wheel made from steel or tungsten carbide or other material having suitable properties. The cutting wheel has a glass contact edge with a cutting angle preferably between about 115° and 155°. The cutting wheel is moved across the surface of the glass along the intended scoring path with sufficient force to effect a score, i.e., to produce a major vent in the glass essentially perpendicular to the glass surface.
The range of force sufficient to effect a score which can be consistently opened without causing lateral vents to erupt with the glass surface adjacent the score (spalling) is the working range of wheel load. Use of the cutting fluids of the present invention expands the working range by allowing the use of higher wheel loads. Since it has been found that wheel load must be increased as the wheel wears to obtain acceptable score quality, expansion of the working range as in the present invention extends the useful life of the cutting wheel.
After the glass surface is scored, the score is propagated to produce a cut through the glass such as by applying a bending moment about the score causing the glass to fracture with a resultant smooth, straight, strong, spall-free edge perpendicular to the major surfaces of the glass. Preferably the scored glass is opened either manually using glass cut-running pliers commonly employed in the art or is opened mechanically by snapping.
Since the cutting fluid of the present invention is completely removed by evaporation, the cut glass edge is free of any residue and does not require washing. The cut glass edge exhibits greater edge strength than the cut edge of glass scored without the cutting fluid of the present invention.
The invention may be further illustrated by the specific examples which follow.
EXAMPLE I
A cutting fluid is prepared having a composition of 75 percent by volume 1,1,1-trichloroethane and 25 percent by volume of a naphtha solvent available from Ashland Chemical Co. under the designation Rule 66 Mineral Spirits (7 percent aromatics). Test strips of 7/32 inch (6 millimeter) thick soda-lime-silica float glass measuring 4 by 26 inches (about 100 by 800 millimeters) are cleaned with a solution of a commercial glass cleaner. A test strip is placed atop a wooden sled which travels along the base of a scoring apparatus beneath a cutting head positioned midway down the length of the base. A six pound load is applied to the horizontal pan affixed to the top of the cutting head which is equipped with a 7/32 inch (6 millimeter) diameter tungsten carbide cutting wheel having a 180 grit surface finish (regular grind) and a 145° cutting angle. A film of cutting fluid approximately twice the width of the cutting wheel is applied at the midpoint of the width of the glass strip along its entire length. The sled bearing the glass test strip is then driven at a rate of 1 foot per second beneath the cutting wheel to effect a score on the glass surface along the path of the cutting fluid. The same procedure is carried out with additional test strips. After the scores are opened, using conventional glass score opening apparatus, the edge strengths of the cut edges are measured by beam load testing. The samples, which bear no residue since the cutting fluid is completely evaporative, are placed on a Baldwin Tester loading at a rate of 1000 pounds per square inch per minute until glass failure. The samples exhibit an average edge strength of 13,218 pounds per square inch, an increase of 43 percent over the edge strength of 9270 pounds per square inch measured for the cut edges of glass scored with no cutting fluid.
EXAMPLE II
A large sheet of 7/32 inch (6 millimeter) float glass is cleaned as in Example I. A cutting fluid essentially of dichlorobenzene of which about 80 percent is orthodichlorobenzene is applied to the surface defining a rectangular scoring pattern measuring 36 by 48 inches. The glass is cut by picture-frame scoring and opening using the same type cutting wheel and load (145° and 6 pounds) as in Example I. Edge strength of the cut edge is measured by thermal loading to permit effective measurement of 120 inches of cut edge as opposed to 10 inches by beam loading. Thermal loading is accomplished by placing on the sample a 341/2 inch by 461/2 inch heating blanket and electrically heating until glass failure. The stress at breakage is estimated from the mirror radius at the origin. The edge strength of the sample scored with dichlorobenzene is 9000 pounds per square inch compared with 6770 pounds per square inch for the cut edge of glass scored with no cutting fluid.
EXAMPLE III
Test glass strips are cleaned, scored and opened as in Example I except that the cutting fluid comprises 75 percent by volume 1,1,1-trichloroethane and 25 percent by volume of a paraffin solvent available from Sun Oil Company under the designation Sun T Mineral Spirits (aliphatic hydrocarbon). The edge strengths of the cut edges are measured by beam load testing as in Example I and average 12,350 pounds per square inch, an increase of 27 percent over the edge strength of 9700 pounds per square inch for the cut edges of glass scored with no fluid.
EXAMPLE IV
To determine the effect of cutting fluids of the present invention on the working ranges of cutting wheels, scores are made through a fluid comprising 75 percent by volume 1,1,1-trichloroethane and 25 percent by volume naphtha as in Example I but under wheel loads varying from 3 to 26 pounds using cutting wheels having 134°, 145° and 150° cutting angles. Using a 7/32 inch (6 millimeter) tungsten carbide cutting wheel with a 134° cutting angle, acceptable scores are made under wheel loads ranging from 4 to 14 pounds compared with a working range of 4 to 10 pounds when no fluid is employed. Using the 145° cutting wheel, the working range with the cutting fluid of the present invention is from 5 to 16 pounds compared with a working range of from 5 to 12 pounds with no fluid. The working range for the 150° cutting wheel is from 8 to 16 pounds when no fluid is used and is extended to a range of from 7 to 20 pounds when the cutting fluid of the present invention is employed.
The test strips scored at wheel loads within the working ranges of the cutting wheels are opened and the edge strengths of the cut edges measured as in Example I. FIG. 3 is a comparison of the cut edge strength versus wheel load between dry scoring and scoring with the cutting fluid of this example.
Cutting fluids and a method for performing a glass cutting operation using such fluids have been disclosed herein. Numerous variations and modifications of the cutting fluid compositions and method will become obvious to those skilled in the art. Such variations and modifications fall within the spirit and scope of the present invention and are intended to be within the scope of the appended claims.
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A cutting fluid is disclosed comprising one or more halogenated hydrocarbons dissolved in one or more paraffin, naphtha, or aromatic solvents. Use of the cutting fluid produces a glass edge with increased edge strength compared with a cut edge produced by dry scoring. The cutting fluid is completely evaporative, leaving no residue, thus eliminating the need for washing. Further, use of the cutting fluid extends the useful life of the cutting tool. Blends are formulated to meet specific evaporation rates required by variations in wareroom equipment and practices.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of my copending U.S. provisional application Serial No. 60/160,894, filed Oct. 21, 1999.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to novel sterol esters of conjugated linoleic acids and a process for the production of the same by esterification of sterols and stanols with a conjugated linoleic acid.
2. Background
It is known that the addition of plant sterol (phytosterol) to diets will reduce serum cholesterol levels. Such additives effect the reduction of serum cholesterol through the disruption of intestinal absorption of dietary cholesterol by displacing it from bile and micelli. Free sterols or stanols, though, are not optimum candidates for use in typical pharmaceutical or dietary dosage forms as cholesterol reducing agents due to their very high melting points 130 C. and low solubility in aqueous and oil media. As a result such compounds are preferred to be converted into their fatty esters for food applications, which reduce their melting points and solubility in oil. However, the fatty acids attached to sterol in the current commercial products are from vegetable oil such as sunflower, canola, or soybean oil. Those fatty acids provide no pharmaceutical or nutraceutical functions except increasing the total calories of the products.
Conjugated fatty acids are known to have many health benefits such as reducing body fat, inhibiting tumor growth and reducing atherosclerosis. Such conjugated fatty acids are naturally found in beef and dairy fats in trace amounts (0.2-30 mg/g food). One such conjugated fatty acid is conjugated linoleic acid (octadecadienoic acid), hereinafter referred to as CLA. Cattle convert the linoleic acid in grass into CLA by their special digestive processes. However, since humans cannot produce such conjugated fatty acids, such additives to the human system must be through the diet. Thus the providing of CLA in a form to permit its use in dietetic foods would serve as a significant contribution to the field of dietetic foods since it would enable the recipient to receive a valuable additive since it is known that CLA is effective in increasing body protein or preventing the loss of body protein in a human, increasing food efficiency in humans and assists in reducing body fat.
It is thus an object of the present invention to provide a novel ester composition consisting essentially of phytosterols including plant sterols/stanols and conjugated linoleic acids.
Another object of this invention is to prepare sterol and stanol esters of CLA for their utilization in food and dietary supplement products.
Another object of the present invention is to provide a process for the production of sterol esters of conjugated linoleic acids through transesterification and/or esterification.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, I have discovered that through the esterification of a sterol or stanol with a conjugated fatty acid, such as CLA, there is provided a compound which provides the advantages of both the conjugated fatty acid and the sterol or stanol. CLA is a liquid fatty acid with two conjugated double bonds, therefore, it can reduce the melting point of sterols and stanols dramatically. Indeed, the beta-sitosterol ester of CLA is liquid at ambient temperature while the current commercial products made of the fatty acids derived from vegetable oils are solid or semisolid. The sterol ester of CLA also provides a product having lower total calories than the blended product that provides the same doses of sterol and CLA. Such new products thus offer the combined benefits of sterols/stanols as a cholesterol control agent and CLA as an anticarcinogen and fat reducing agent. Such esters can be used as a supplement or ingredient in foods.
In accordance with another embodiment of the present, sterol esters can be readily prepared through esterification of sterol or stanol with the conjugated fatty acid or by transesterification of sterol or stanol with of the conjugated fatty acid methyl ester. Transesterification is the preferred method to those skilled in the art.
A better understanding of the present invention, its several aspects, and its advantages will become apparent to those skilled in the art from the following detailed description, wherein there is shown and described the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated for carrying out the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein the term “sterol ester” includes both the plant sterol ester per se as well as the hydrogenated sterol products which are referred to as stanol and campestanol. Such compounds have the following general formula:
Ac—CO—O—ST
wherein Ac—CO is an acyl group from a conjugated fatty acid and O—ST is a steryl group derived from a sterol/stanol.
The term “conjugated fatty acid” is intended to refer to conjugated linoleic acid (CLA) which in turn refers to a group of geometrical and positional isomers of linoleic acids including but not limited to 9,11-octadecadienoic acid, and 10-12 octadecadienoic acid. The cis-9, trans-11 isomer is the most dominant isomer of CLA in dairy products and is also the most biologically active form as known at present.
The term “sterol” or “sterol/stanol” as used herein is intended to mean the sterol compound per se or its hydrogenated form including stanol and campestanol.
The present invention is based upon my discovery that through the use of the conjugated fatty acid—CLA—in the esterification of a sterol there is obtained a product which is liquid at ambient temperature and which product has lower total calories and which product provides the combined benefits of cholesterol control agent and an anticarcinogen and fat reducing agent.
The present invention provides a process for esterfying stanols or/and sterols with CLA. This esterification reaction may be accomplished either through the reaction of the sterol with CLA using a esterification catalyst such as sulphonic acids and tin chloride or though the reaction of the sterol with CLA methyl ester using a transesterification catalyst such as sodium methoxide and hydroxide. The results of those esterification reactions is a sterol ester of CLA or a stanol ester of CLA.
While any stanol or sterol that is functionalized with a hydroxy group is suitable for transesterification and esterification by the processes as described herein, in one presently preferred embodiment of the present invention there is utilized a sterol/stanol selected form the group consisting of beta-sitosterol, campesterol, stigmasterol and sitostanol. Other suitable sterols include but not limited to brassicasterol, avenasterol, alpha-spinasterol and ergosterol. It is understood that those sterols/stanols for esterifying may be used in pure form or mixed in certain ratios.
Likewise while any isomer of a conjugated linoleic acid is suitable for esterification by the process as described herein, in one presently preferred embodiment of the present invention there is utilized a conjugated linoleic acid selected from the group consisting of cis-9, trans-11-conjugated linoleic acid and trans-10, cis 12-conjugated linoleic acid.
The acid-catalyzed esterification reaction of sterol with CLA and base-catalyzed transesterification reaction of sterol with CLA methyl ester, respectively, are depicted below demonstrating the formation of a sterol ester of CLA per the present invention. As shown in the reaction mechanism on the left sterol is reacted with CLA in the presence of an acid catalyst to produce sterol ester of CLA. In the reaction mechanism on the right (which represents the preferred mechanism), sterol is reacted with CLA methyl ester to produce sterol ester of CLA in the presence of a base catalyst.
R is defined as following alkyl or alkenyl groups:
beta-Sitosterol: —CH(CH3)CH2CH2CH(C2H5)CH(CH3)2
Stigmasterol: —CH(CH3)CH═CHCH(C2H5)CH(CH3)2
Campesterol: —CH(CH3)CH═CHCH(CH3)CH(CH3)2 (no double bond at 5, 6)
Brassicasterol: —CH(CH3)CH═CHCH2CH(CH3)2
Avenasterol: —CH(CH3)CH2CH2C(═CH—CH3)CH(CH3)2 (double bond at 5, 6 or 7, 8 only)
alpha-Spinasterol: —CH(CH3)CH═CHCH2C(C2H5)CH(CH3)2(double bond at 7, 8)
Ergosterol: —CH(CH3)CH═CHCH(CH3)CH(CH3)2 (double bonds at 5, 6 and 7, 8)
A similar reaction system is carried out when the hydrogenated sterol such as stanol is the reactant.
The molar ratios of the starting materials for the transesterification and esterification reactions are provided in stoichiometric levels. It is preferred that the CLA be present in at least 5-10% excess so as to react with all of the sterol or stanol. Any excess unreacted CLA is easily removed in the product work-up.
The usage of esterification catalyst varies with the catalyst used and their uses are reviewed in Bailey's Industrial Oil and Fat Products, 4th edition, edited by Daniel Swern, Volume 2, PP 113-127. Since esterification involves high reaction temperature and low reaction rate, sterol ester of CLA are preferred to be prepared via transesterification.
In carrying out the process of the present invention solvents such as ethers and short chain alkanes may be added to the reaction mixture to promote reaction.
The reaction rate of transesterification increases at an elevated temperature. The typical reaction temperature ranges from 40 C. to about 250 C. The reaction period may vary widely, but as a general practice a reaction time in the range of about 4 to about 20 hours can be utilized. The reaction is normally carried out for a time which will permit the reaction to go to completion so that the sterol or stanol present is completly esterified. Normally the ester product is obtained in yields of greater than 95%.
Following completing of the reactions, the resulting ester product can be isolated with or without organic solvent extraction after removing the catalyst such as by water washing. Typical solvents are low boiling point organic compounds including but not limited to diethyl or petroleum ethers, hexane, dichloromethance, chloroform, and toluene.
The following examples are intended to be illustrative of the present invention and to teach one of ordinary skill in the art to make and use the invention. These examples are not intended to limit the invention in any way.
EXAMPLE 1
To Prepare Sterol Esters from Conjugated Linoleic Acid Methyl Ester
A commercial CLA methyl ester product was used in the synthesis, which contains 41% of cis 9, trans 11, 44% of trans 10, cis 12, and 10% of cis 10, cis 12 conjugated linoleic acids. 60 grams of plant sterols containing 40% beta-sitosterol, 20-30% campesterol and 10-30% dihydrobrassicasterol was mixed with 100 grams of CLA methyl ester. The mixture is solid at room temperature. After dried at 90-105 C. under about 20 mm Hg vacuum for about an hour, the mixture was cooled down to about 70 C., and 1.3 grams of 25% NaOCH3-Methanol solution was added. A vacuum of up to 20 mm Hg was applied slowly to remove the methanol produced. When no vigorous bubbles came out, the reaction was continued under a high vacuum up to 0.01 mm Hg and the temperature was raised gradually to 110 C. The reaction continued until no methanol was bubbling, then the mixture was cooled down to about 60 C. before breaking the vacuum with N 2 . 6 grams of warm water (40-50 C.) was added to destroy the catalyst. The mixture was stirred for about 1 minute until appearing homogenous and then centrifuged at 5000 G for 5 minutes. The top layer containing sterol esters was collected and washed with 12 g warm water. The mixture was then centrifuged to recover the top sterol ester layer. The sterol ester was then purified by vacuum distillation to remove moisture and residual methyl esters. The product is liquid at ambient temperature and has three melting peaks at 15, 37, and 58 C. as measured by DSC.
EXAMPLE 2
To Prepare Sterol Esters from Conjugated Linoleic Acid
CLA One™, a commercial CLA product available from Pharmanutrients, Inc. and which contains 75% of free fatty acid, was used in this synthesis. CLA One™ typically contains with 35% cis 9, trans 11 and 36% trans 10, cis 12-linoleic acids. 150 g of CLA One™ was mixed with 600 mL methanol and 12 mL concentrated sulfuric acid. The mixture was refluxed for 30 minutes to prepare the methyl esters of fatty acids. The product was washed twice with 100 mL 5% sodium chloride and with 2% potassium bicarbonate until nutral pH in the aqueous phase. The methyl esters of fatty acids were dried by heating at 90-105 C. under up to 20 mm Hg vacuum. One hundred grams of methyl ester produced as above was mixed with 60 g plant sterols that contains 40% beta-sitosterol, 20-30% campesterol and 10-30% dihydrobrassicasterol. The mixture was dried at 90-105 C. under up to 20 mm Hg vacuum for about an hour. After cooling the mixture down below 70 C., 0.5 grams of NaOCH3 powder was added to the reactant mixture as transesterification catalyst. Vacuum was applied slowly to remove the methanol produced so the reaction proceeded to the direction forming sterol esters. When vigorous bubbling ceased, the reaction was continued under a high vacuum up to 0.01 mm Hg and the temperature was raised gradually to 110 C. The reaction continued until no methanol was bubbling out. The mixture was cooled down to about 60 C. and nitrogen was introduced to break the vacuum. 6 grams of 50% citric acid aqueous solution was added to neutralize the transesterification catalyst. The mixture was stirred for about 6 minutes or until appearing homogenous and then centrifuged at 4000 G for 5-30 minutes. The top layer containing sterol esters was collected and washed twice with 12 g warm water. The mixture was then centrifuged at 4000 G for 5 minutes to recover the top sterol ester layer. The sterol ester was then purified by vacuum distillation to remove moisture and residual methyl esters.
The specific examples herein disclosed are to be considered as being primarily illustrative. Various changes beyond those described will not doubt occur to those skilled in the art and such changes are to be understood as forming a part of this invention insofar as they fall within the spirit and scope of the appended claims.
The inventive compositions are usable as a component in any number of food products or as a dietary supplement whereby the compositions may be delivered in a convenient form and the advantages thereof may be easily obtained.
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Novel sterol/stanol esters of a conjugated fatty acid are provided through the esterification or transesterification of a sterol such as beta-sitosterol or a hydrogenated form thereof (stanol). Such novel esters exhibit the combined properties normally possess by the sterol/stanol compound and the conjugated fatty acid and as such are excellent additives for dietetic foods and supplements.
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BACKGROUND OF THE INVENTION
The present invention relates to ultraviolet radiation absorbing contact lenses and to a method for their preparation. More particularly, the invention relates to hydrophilic or "soft" contact lenses having a reactive ultraviolet radiation absorbing agent covalently bonded to polymeric material.
Ultraviolet radiation is ever present in our environment, and consists of wave lengths between 200-400 nm. Exposure to ultraviolet radiation has been found to be the cause of several ocular pathologies. The damaging effect of ultraviolet radiation on the corneal epithelium has been known for a long time. For instance, studies have demonstrated the damaging effect of 290 nm radiation on the rabbit corneal epithelium (Cullen, A. P. (1980): Ultraviolet Induced Lysosome Activity in Corneal Epithelium, Graefes Arch Clin Exp. Ophthalmol 214:107-118), as well as changes in the stroma and endothelium of primary corneal layers (epithelium, stroma and endothelium) subsequent to exposure to a commercially available UV suntan lamp which emits radiation across the full spectrum from 280 nm (Ringvold, A., et al. (1985): Changes in the Rabbit Corneal Stroma Caused by UV-Radiation. Acta Ophthalmol. (Copenh) 63:601-606). Compounding the damage is the fact that ultraviolet radiation damage to the eye is known to be cumulative and obeys the law of reciprocity. These findings reinforce the importance of adequate ocular protection against ultraviolet radiation. Such protection is particularly recommended for people who are prone to UV exposure, patients who have had cataract surgery and patients on photo-sensitizing drugs.
Recently, contact lenses have been developed which serve to absorb ultraviolet radiation. For example, U.S. Pat. No. 4,390,676 discloses an ultraviolet absorbing contact lens formed by copolymerizing a monomer suitable for making lenses and an ultraviolet absorber for absorbing radiation having wavelengths of 340 to 450 nm. The UV absorbing compound, 2-hydroxy-4-methacryloxy-benzophenone or mixtures thereof, is incorporated into the lens' polymeric material at the molecular level. Also, U.S. Pat. No. 4,528,311 discloses ultraviolet light absorbing contact lenses made of a polymeric composition comprising copolymers of 2-hydroxy-5-acrylyloxyphenyl-2H-benzotriazole with one or more other monomers copolymerizable therewith.
The above compounds have been found to copolymerize and give protection to the material. However, the copolymerization efficiency of the compounds has proved to be inadequate. Typically, no more than 15% of the alkenyloxy-benzophenones actually become part of the polymeric chain. The remainder of the material is easily leached out by solvent extraction. Furthermore, while the hydroxy benzophenones copolymerizable with acrylate monomers are effective UV absorbers and form chemically stable copolymers, relatively large amounts, i.e. 3 to 10% by weight, must be incorporated in the polymer to obtain 85% UV absorption at 400 nm and 1 mm thickness. Also, the compounds exhibit very broad absorption bands which extend into the visible spectrum, and lenses incorporating these ingredients tend to be unacceptably yellow in color.
There exists a need, therefore, for an improved ultraviolet radiation absorbing contact lens.
There exists a more particular need for a lens which incorporates a relatively small amount of absorbing agent, which exhibits relatively little yellowing, and from which the absorbing agent does not leach out.
SUMMARY OF THE INVENTION
The present invention relates to ultraviolet radiation absorbing lenses, and a method for their production, comprising a UV absorbing agent covalently bonded to a polymeric lens material. The lens exhibits very little yellowing, and can be produced using a relatively small amount of the absorbing agent. Also, because of the covalent bonding, the absorbing agent does not leach from the lens.
The absorbing agent has the formula: ##STR2## where X=Cl or F;
A=an ultraviolet radiation absorbing component; and
B=an aqueous soluble moiety.
The ultraviolet radiation absorbing component is preferably selected from the group consisting of: ##STR3## where R 1 -R 3 are selected from the group consisting of H, alkyl chains varying from C 1 to C 18 , alkoxy, halogen, nitro, hydroxy, carboxy, sulfonic acid, and sulfonic acid salt substituents. It is also preferred that the aqueous soluble moiety have the formula: ##STR4## where Y is an amine salt or an alkali salt; and R 1 -R 2 are selected from the group consisting of hydrogen, alkyl chains varying from C 1 to C 18 , alkoxy, halogen, nitro, hydroxy, carboxy, sulfonic acid, or sulfonic acid salt substituents.
An ammonium quaternary salt may be used as a catalyst in the process of bonding the absorbing agent to the lens material.
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is applicable to intraocular lenses and lenses used in spectacles, it will be described in connection with contact lenses.
The present invention relates to polymeric lens materials in which exoskeletal covalent bonds are formed between the monomer units of the polymer backbone and a reactive ultraviolet absorbing agent.
The composition of the polymeric lens material may vary so long as there is present in the monomer mixture a component which will provide the polymer with the required exoskeletal functional groups. Examples of such functional groups include hydroxyl, amino, amide and mercapto groups. Suitable monomers include hydroxyalkyl esters of polymerizable unsaturated acids, such as acrylic, methacrylic, fumaric and maleic acids. In addition to hydroxyalkyl esters of unsaturated acids, the following monomeric materials may serve as typical examples of co-monomers which can be used in conjunction with monomers providing the required functional groups: acrylic and methacrylic acids; alkyl and cycloalkyl acrylates and methacrylates; N-(1, 1-dimethyl-3-oxobutyl) acrylamide and heterocyclic N-vinyl compounds containing a carbonyl functionality adjacent to the nitrogen in the ring, such as N-vinyl pyrrolidone. A cross-linking agent, such as ethylene glycol dimethacrylate or diethylene glycol bis-allyl carbonate, may be used to provide the polymeric material. A preferred lens material is hydroxyethyl methacrylate (HEMA), as disclosed in U.S. Pat. No. 2,976,576 and U.S. Pat. Re. No. 27,401. An example of a "hard" contact lens material having an acceptable functional group is cellulose acetate butyrate.
The present invention employs a reactive ultraviolet absorbing agent of the following formula: ##STR5## where X=Cl or F;
A=an ultraviolet radiation absorbing component; and
B=an aqueous soluble moiety.
The ultraviolet radiation absorbing component (A) is preferably selected from the group including: ##STR6## where R 1 -R 3 are selected from the group consisting of H, alkyl chains varying from C 1 to C 18 , alkoxy, halogen, nitro, hydroxy, carboxy, sulfonic acid, and sulfonic acid salt substituents.
It is also preferred that the aqueous soluble moiety have the formula: ##STR7## where Y is an amine salt or an alkali salt; and R 1 -R 2 are selected from the group consisting of hydrogen, alkyl chains varying from C 1 to C 18 , alkoxy, halogen, nitro, hydroxy, carboxy, sulfonic acid, or sulfonic acid salt substituents.
The ultraviolet radiation absorbing components represented by NH 2 A which are required to obtain the mono-halo-s-triazine of Formula I belong to known classes of compounds and readily obtained by conventional procedure well known in the art, such as the ones described in U.S. Pat. Nos. 3,159,646 and 3,041,330.
The following examples illustrate the production of ultraviolet absorbing agents according to the present invention:
EXAMPLE I
Cyanuric chloride, 18.4 g, was dissolved in 150 ml of warm acetone and the solution was poured into a stirred mixture of 200 g of ice and 200 ml of water. To this cyanuric chloride suspension was added simultaneously an aqueous solution made by dissolving 15.3 g of 4-amino salicyclic acid in 120 ml of water containing 5.4 g of sodium carbonate and a dilute sodium carbonate solution (5.4 g in 50 ml of H 2 O). After addition, the mixture was stirred at 5°-10° C. for one and a half hour. The final pH of the mixture was 6.0. The solid was collected by filtration, washed with water and air dried to obtain 30.6 g of 2,4-dichloro-6-[(3-hydroxy-4-carboxy)phenylamino]-s-triazine.
EXAMPLE II
To a mixture of 150 ml of acetone, 100 ml of water, 1 g of sodium carbonate and 6.5 g of dichloro-s-triazine, prepared as described in Example I above, was added an aqueous solution (100 ml) of 7-amino-1,3-naphthalene disulfonic acid, monopotassium salt (8.0 g) containing one gram of sodium carbonate. The resulting mixture was refluxed for two hours. Most of acetone was then distilled off until the pot temperature reached 80° C. The reaction mixture was cooled to about 10° C. The solid which formed was collected by filtration and dried to obtain 1.55 g of 2-chloro-4-[7-(1,3-disulfo)naphthylamino]-6-[(3-hydroxy-4-carboxy)phenylamino]-s-triazine and its sodium salts. More product (9.3 g) was obtained by adjusting the filtrate to pH=3.0 and collecting the precipitate.
EXAMPLE III
Proceeding in a manner similar to that described in Example II above, 9.0 g of 2,4-dichloro-6-[(3-hydroxy-4-carboxy)phenylamino]-s-triazine, 10.5 g of 3-amino-2,7-naphthalene disulfonic acid, monosodium salt, trihydrate and 3.0 g of sodium carbonate were interacted in water-acetone mixture to obtain 11.04 g of 2-chloro-4-[3-(2,7-disulfo)naphthylamino]-6-[(3-hydroxy-4-carboxy)phenylamino]-s-triazine and its sodium salts.
EXAMPLE IV
Following the procedure described in Example I above, 55.2 g of cyanuric chloride was interacted with 120 g of 7-amino-1,3-naphthalene disulfonic acid, monopotassium salt in water-acetone mixture to obtain 81.6 g of 2,4-dichloro-6-[7-(1,3-disulfo)naphthylamino]-s-triazine.
EXAMPLE V
Proceeding in a manner similar to that described in Example II above, 4.9 g of 2,4-dichloro-6-[7-(1,3-disulfo)naphthylamino]-s-triazine, 2.26 g of 2-(4-amino-2-hydroxyphenyl)benzotriazole and 2.1 g of sodium carbonate were interacted in water-acetone mixture to obtain 2-chloro-4-[(3-hydroxy-4-benzotriazo-2-yl)phenylamino]-6-[7-(1,3disulfo)naphthylamino]-s-triazine and its sodium salts.
EXAMPLE VI
Proceeding in a manner similar to that described in Example II above, 47.4 g of 4-amino-2-hydroxy-4-methoxybenzophenone, 25.5 g of 2,4-dichloro-6-[7-(1,3-disulfo)naphthylamino]-s-triazine, and 10.5 g of sodium carbonate were interacted in water-acetone mixture to obtain 71.2 g of 2-chloro-4-[4-(2-hydroxy-4-methoxybenzoyl)phenylamino]-6-[7-(1,3-disulfo)naphthylamino]-s-triazine and its sodium salts.
The standard process for incorporating the reactive ultraviolet absorbing agent into the lens involves contacting the agent to the lens material, preferably under mild reaction conditions. In one method, for example, the lens is rinsed with deionized water and placed in a dry vial. Two milliliters each of a solution containing a reactive UV absorbing agent and diluted sodium carbonate solution are then added to the vial. The vial containing the solutions and the lens is placed in a vial rack in a shaker bath at a set temperature and speed. After a set predetermined period of time has elapsed, the lens is removed from the vial, rinsed with deionized water, and extracted with a 10% glycerine (aq) solution at 80° C. for two hours. The lens is then rinsed with water and stored in a 0.9% saline solution for 30 minutes. The transmission and/or absorbance spectrum of the lens can then be determined using a UV spectrophotometer.
It has also been found that the bonding of the ultraviolet absorbing agent and lens material may be enhanced by including an ammonium quaternary salt catalyst in the agent incorporating process. Examples of such ammonium quaternary salts include triethylbenzylammonium chloride, tetrabutylammonium hydrogen sulfate, phenyltrimethylammonium chloride, benzyltributylammonium chloride, tetrabutylammonium bromide, and tetramethylammonium chloride.
The following Example VII will illustrate the effect of different catalysts on the incorporation of reactive UV absorbing agents in contact lenses:
EXAMPLE VII
A series of corneal contact lenses was prepared and UV transmittance spectra were taken as set forth in the above-described standard process, except that 0.1 ml of an aqueous solution holding a catalyst was added to the vial containing the lens, a tri-sodium phosphate solution for maintaining a high pH and the aqueous solution having a UV blocking agent. The temperature of the bath was maintained at 45° C., the shaker bath speed was at 100 strokes per minute and the time the lenses remained in the shaker bath was two hours. A 1% aqueous solution of the compound of Example VI was employed as the reactive UV blocking agent solution.
Transmittance data from UV absorbing lenses prepared as above using various catalyst solutions were compared to transmittance data from lenses identically prepared except that no catalyst was employed. A sharp decrease in the transmittance curve for lenses prepared without a catalyst was found to occur around 360 nm, and transmittance spectra for these lenses exhibit a shoulder in the region from 275 to 360 nm with a small peak occurring around 290 nm. As is shown in Table I, the quaternary ammonium salt catalysts substantially improved the UV absorbing characteristics of the lenses.
TABLE I______________________________________ Transmittance characteristics in the 275-360Catalyst % T at 290 nm nm range.______________________________________1. no catalyst 2.3% shoulder2. 10% Tyloxapol (aq) 6.9% pronounced shoulder3. 10% Varsulf 4.6% distinct SBFA-30 (aq) shoulder4. 10% Pluronic F-127 (aq) 2.3% similar to no catalyst5. 5% triethylbenzyl- <1% no shoulder ammonium chloride (aq)6. 5% cetylpyridinium 9.2% very prominent chloride (ag) shoulder7. 5% tetrabutylammonium <1% no shoulder hydrogen sulfate (aq)8. 5% p-dimethylamino- 2.3% similar to no pyridine catalyst______________________________________
The following Example VIII further illustrates the effectiveness of different quaternary ammonium salts on the incorporation of absorbing agents in contact lenses:
EXAMPLE VIII
A series of corneal contact lenses was prepared and UV transmittance and absorbance spectra were taken as set forth in Example VII, except that 0.2 ml of a 5% aqueous solution of a quaternary ammonium salt was added to the vial containing the lens, the tri-sodium phosphate solution, and the solution containing a UV blocking agent. The temperature of the bath was maintained at 45° C., the shaker bath speed was 110 strokes per minute, and the time the lenses remained in the shaker bath was two hours. A 1% aqueous solution of the compound of Example VI was employed as the reactive UV blocking agent solution. Five percent (5%) aqueous solutions of (1) tetrabutylammonium hydrogen sulfate, (2) phenyltrimethyammonium chloride, (3) benzyltributylammonium chloride, (4) tetrabutylammonium bromide, (5) tetramethylammonium chloride and (6) a polyquat solution were tested in this example.
Transmittance data from UV absorbing lenses prepared utilizing (1), (2), (3), and (4) showed the superior UV absorbing characteristics of these lenses compared to lenses prepared without any catalyst. The transmittance peak at around 290 nm that appeared in a lens prepared without any catalyst and the shoulder in the 275 to 360 nm region was not present in lenses prepared in the presence of (1), (2), (3) or (4). Absorbance of UV radiation in the 290 nm to 400 nm region was greatest for lenses prepared using (3) followed by those prepared using (4), (1) and (2) respectively. The use of (5) as a catalyst produced lenses with UV absorbing characteristics only slightly better than lenses prepared in the absence of a catalyst. However, the use of (6) as a catalyst retarded the incorporation of the UV absorbing agent in the lens, and lenses prepared in the presence of (6) showed poor UV absorption in the 260 to 400 nm region.
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An ultraviolet radiation absorbing contact lens and method of making the same, comprising a copolymeric hydrogel material to which is covalently bonded at least one halotriazine reactive ultraviolet radiation absorbing agent of the formula: ##STR1## where X=Cl or F;
A=an ultraviolet radiation absorbing component; and
B=an aqueous soluble moiety.
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This is a division of Ser. No. 07/316,090, filed Feb. 27, 1989, now U.S. Pat. No. 5,018,905, which is a continuation-in-part of Ser. No. 06/807,840, filed Dec. 11, 1985, now abandoned, and a continuation-in-part of Ser. No. 06/762,800, filed Aug. 2, 1985, now abandoned, which is a continuation of Ser. No. 06/464,973, filed Feb. 8, 1983, now abandoned.
TECHNICAL FIELD
The invention pertains to a method and apparatus for shoring a building foundation and more particularly to a method and apparatus which uses a piling in a bore drilled in the earth adjacent the building foundation.
BACKGROUND OF THE INVENTION
Heretofore piers have been forced into the ground by jacks or by hammering for shoring a building foundation. Piles or piers have been driven into the ground until the pier could not be driven further with the driving equipment available at the job site. When the pier could not be driven further into the ground, it was assumed that the pier had been driven to bed rock and was sufficiently supported. However, it has been found that driven piers often are not supported by bed rock and that the foundation settles as a result of contraction and expansion of the soil formation in which the piling has been driven.
Further, changes in moisture content results in expansion of the soil which imposes forces longitudinally of the driven pier exerting uplift force through piers. Non-uniform uplift forces applied to portions of a slab or foundation often crack or damage the structure.
Rotary drilling equipment has been used heretofore for drilling wells for production of water, oil and gas. In well drilling operations core samples and chips are inspected by geologists to determine the general nature of the formation in which the well is being drilled. After the well is completed, the casing and tubing are supported by hangers at the well head.
There are several known methods and apparatus for shoring a building foundation in which a piling received within a bore adjacent the foundation provides support for the foundation. One such method and apparatus, disclosed in applicant's co-pending application Ser. No. 762,800, discloses a method and apparatus for shoring a building foundation in which a bore hole is drilled adjacent the foundation. Thereafter, a casing or pipe is lowered into the bore and a fitting, adapted for sliding along the pipe, is received thereover. The fitting is urged against a downwardly-directed portion of the foundation by a hydraulic ram until the foundation is lifted a selected amount. The fitting is secured to the pipe which is cut off below ground level and the fitting and upper portion of the pipe are covered with earth.
The disclosure in the co-pending application provides a method and apparatus for shoring a building foundation which usually includes a very stable support for the shored foundation. The piling is received in the bore which is drilled until bedrock is reached thereby permitting shoring of heavy loads on each piling and assuring that once shored, there will not be additional shifting of the foundation. Moreover, the method and apparatus disclosed in the copending application does not involve pouring concrete and is relatively inexpensive.
Although the above-described method and apparatus represents a substantial improvement over the prior art, the method and apparatus disclosed in the copending application suffers from several disadvantages. In some instances it may be necessary to drill as deep as 40-50 feet or deeper to reach a rock formation which is sufficiently stable to support the lower end of a piling after the weight of the foundation is transferred to the piling. Obtaining and transporting pipe of such length is awkward and costly. In addition, removal of the drill bit and pipe string used to drill the bore and insertion of the casing pipe therein requires more time than if the pipe string having the drill bit mounted thereon could be left in the bore and used as the piling. However, due to the expense of the commercially available bits used to drill the bore, such is not practical. Another disadvantage associated with the past method and apparatus is the wear sustained by the drill bit after a period of use.
Geographical formations vary widely throughout the United States. For example, in certain areas in central Oklahoma, the bed rock is relatively flat. When it has been determined by inspection of chips circulated to the surface of the drilled bore hole that the shaft has reached bed rock, it can be assumed that other piers supporting the same foundation will require drilling to approximately the same depth. However, in certain areas in north Texas the layer of bed rock is not flat or of uniform thickness and the depth of bore holes for piers supporting a single foundation may vary significantly.
It is a more specific object of the instant invention to provide such a method and apparatus in which the drill bit and pipe string used to drill the bore adjacent the foundation may be used as a piling for shoring the foundation.
SUMMARY OF THE INVENTION
The novel invention contemplates a novel method and means for shoring a building foundation which has been particularly designed and constructed for overcoming the foregoing disadvantages. The novel method comprises the initial step of positioning suitable core drilling equipment in the proximity of the building foundation whereby at least one, and usually a plurality of spaced bores may be drilled into the earth in the proximity of the building foundation. It may be preferably to dig a hole in the proximity of the foundation at the desired site for the bore drilling operation prior to the positioning of the drilling equipment. A bore hole is then drilled through the earth to the bedrock formation, this drilling operation being accomplished by a core drilling method wherein core samples are taken at various stages of the drilling operation in order to ascertain the exact formation through which the core drill is moving. When the core samples reveal that the core drill has reached the actual bedrock formation, the drilling operation may be ceased, and the drilling apparatus may be removed from the bore hole. A well casing may then be set in the bore hole in any well known manner with the lower end of the casing being disposed on or embedded within the actual bedrock formation. The well casing then becomes the piling means for support of the foundation, and suitable connecting means is utilized for securing the foundation to the outer periphery of the well casing. Of course, the core drilling may be repeated as many times around the outer peripheral areas of the foundation as required for an effective shoring of the foundation. The novel method and means is simple and efficient in operation and economical and durable in construction.
By load testing each individual pier to a safety factor in a range between two and four times the load which the pier is expected to support, it can be assured that each pier is supported by bed rock or a load supporting formation which is not susceptible to expansion or contraction regardless of the configuration of the layer of bed rock.
BRIEF DESCRIPTION OF THE DRAWINGS
Drawings of a preferred embodiment of the invention are annexed hereto so that the invention can be clearly understood:
FIG. 1 is a side elevational view of a drilling apparatus embodying the invention and as utilized for facilitating the shoring of a building foundation.
FIG. 2 is a view taken on line 2--2 of FIG. 1.
FIG. 3 is an enlarged sectional elevational view of the driving means for a drilling apparatus embodying the invention, with portions shown in elevation for purposes of illustration.
FIGS. 4 through 10 are sectional elevational views illustrating a method of shoring a foundation and which embodies the invention.
FIG. 11 is an enlarged sectional elevational view of a supporting and jacking means for a building foundation and which embodies the invention, with portions shown in elevation for purposes of illustration.
FIG. 12 is a view taken on line 12--12 of FIG. 11.
FIG. 13 is a view taken on line 13--13 of FIG. 12.
FIG. 14 is a view taken on line 14--14 of FIG. 12.
FIG. 15 is a plan view of a manifold utilized in combination with a jacking means embodying the invention, and is taken on line 15--15 of FIG. 16.
FIG. 16 is a view taken on line 16--16 of FIG. 15.
FIG. 17 is an elevational view of a drill bit, shown partly in cross-section, constructed in accordance with the instant invention.
FIG. 18 is a bottom plan view of the drill bit of FIG. 1.
FIG. 19 is an elevational view of a building foundation having a hole excavated in the earth adjacent thereto.
FIGS. 20-23 are views similar to FIG. 19 showing the installation of the apparatus of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, and particularly FIGS. 1, 2 and 3, reference numerals 10 generally indicates a core drilling apparatus comprising a mobile vehicle 12 having a drill assembly 14 provided at the forward end thereof. Whereas the vehicle 12 may be of any suitable type, as shown herein the vehicle comprises a frame or bed portion 16 suitable suspended from a pair of spaced forward wheels 18 and a pair of spaced rear wheels 20. The wheels 18 and 20 are preferably disposed in substantial longitudinal alignment, as is well known, for supporting the vehicle 12 during a drilling operation and for facilitating transporting of the vehicle from one site to another, as is well known. A suitable operator's bench or seat 22 may be mounted on the bed portion, preferably in the proximity of the wheels 20, but not limited thereto. A steering wheel assembly 24 is operable connected with the wheels 218 and/or 20--in a manner as will be hereinafter set forth, whereby the maneuvering of the vehicle may be controlled by the operator disposed in the seat 22.
A suitable power plant 26, such as a gasoline engine or the like, is mounted on the frame or bed portion 16 and is operably connected with a hydraulic pump means 28 through a drive shaft 30 and coupling means 32, is well known. The pump means 28 is operable connected with a plurality of fluid control valves 34 in any suitable manner (not shown) for controlling the circulation of fluid thereto from a fluid reservoir 36 mounted on the bed portion 16. A hydraulic motor 38 is mounted on the bed portion 16 and is in communication with the fluid supply reservoir 36 in any suitable manner (not shown). A sprocket or pulley means 40 is keyed or otherwise secured to the drive shaft 42 of the motor 38 for rotation thereby. A complementary sprocket or pulley member 44 is keyed or otherwise secured around the outer periphery of the axle 46 extending between the wheels 28, and a chain or belt means 48 extends around and between the sprockets 40 and 44 for transmitting rotation therebetween. In addition, a suitable fluid control valve means 50 is mounted on the bed portion 16 in the proximity of the operator's seat 22 and operably connected with the motor 38 for controlling the supply of fluid thereto for operation thereof as will be hereinafter set forth. When the sprocket 44 is rotated by the actuation of the motor 38 and sprocket 40, the axle 46 is rotated about its own longitudinal axis for transmitting rotation to the wheels 18 for a purpose as will be hereinafter set forth.
A second hydraulic motor 52 is mounted on the bed portion 16 and operably connected with the fluid reservoir 36 in any well known manner (not shown) for receiving fluid therefrom through at least one of the valves 34. The drive shaft 54 of the motor 52 is operably connected with a belt and pulley assembly 56 for transmitting rotary motion to a sprocket or pulley 58 through a suitable gear train assembly 60. The assembly 60 is mounted on an A-frame support structure 62, and the sprocket 58 may be supported on the A-frame 62 by suitable bearing means 64. The sprocket 28 is connected with a complementary sprocket pulley 66 through a chain or endless belt 68 for transmitting rotation therebetween as is well known. The sprocket 66 is preferably keyed or otherwise secured to a rotatable shaft 70 having the opposite ends thereof suitably journaled in a pair of spaced brackets or flanges 72, only one of which is shown in FIG. 1. Each bracket 72 is rigidly secured to the bed portion 16 by means of a support structure 74.
Each bracket 72 is rigidly secured to an upstanding elongated I-beam member 76 and 78, respectively. The I-beam members 76 and 78 function as tracks or rails during the reciprocation of a rotary drive table means generally indicated at 80, as will be hereinafter set forth. A first axle or pivot shaft 82 is secured to the lower ends of the tracks 76 and 78 in any well known manner, and spans the distance therebetween as particularly shown in FIG. 2. A second axle or pivot shaft 84 is similarly secured between the upper ends of the tracks 76 and 78 and disposed in substantially parallel relationship with respect to the shaft 82. A first sprocket or gear member 86 is secured on the shaft 82 and substantially centrally disposed between the tracks 76 and 78 in substantial planar alignment with the sprocket 66. A second sprocket or gear member 88 is similarly secured on the shaft 84 and disposed in substantial planar alignment therewith. An endless chain 90 extends around and between the sprockets 86 and 88 and is in engagement with the outer periphery of the sprocket 66 whereby rotation of the sprocket 66 moves the chain 90 linearally between and around the sprockets 86 and 88 for a purpose as will be hereinafter set forth.
The drive assembly 80 comprises a pair of spaced substantially identical T-shaped brackets 92 and 94 loosely secured to the tracks or rails 76 and 78, respectively, by back plates 96 (only one of which is shown in FIG. 1). A cross member 98 is secured between the outer ends of the brackets 92 and 94 and disposed in spaced relation with respect to the outer edges of the rails 76 and 78. A hydraulic motor 100 is secured to the cross member 98 wand in engagement with the chain 90 in any suitable manner (not shown) and operably connected with the hydraulic fluid system in any suitable manner (not shown) for a purpose as will be hereinafter set forth. In addition, a pair of substantially mutually parallel outwardly extending plates or flanges 102 and 104 are welded or otherwise secured to the outer surface of the cross member 98 for receiving and supporting a rotary sealing assembly 106 therebetween.
The rotary sealing assembly 106 comprises a pair of substantially identical oppositely disposed cylindrical housing members 108 and 110 having complementary outwardly extending circumferential flanges 112 and 114, respectively, removably secured together by a plurality of circumferentially spaced bolts 115, as is well known. Each housing 108 and 110 is substantially cup-shaped and the closed ends thereof are provided with bores or apertures 116 and 117, respectively, for receiving a sleeve member 118 therethrough. An outwardly extending circumferential flange 120 is provided around the outer periphery of the sleeve 118 and is disposed within the interior of the coupled housing 108 and 110, as particularly shown in FIG. 3, providing oppositely disposed annular shoulders 122 and 124. A bearing member 126 is disposed around the sleeve 118 within the housing 110 and has the inner race thereof supported on the shoulder 122 and the outer race thereof disposed against the inner periphery of the housing 110 and held in position by the inner surface of the closed end thereof. A second similar bearing 128 is disposed around the sleeve 118 in the housing 108 and has the inner race thereof disposed against the shoulder 124 and the outer race thereof disposed against the inner periphery of the housing 108 and supported by the inner surface of the closed end thereof. In this manner, the sleeve 118 may be freely rotated about its own longitudinal axis independently of any movement of the housing members 108 and 110.
The sleeve 118 is provided with a centrally disposed fluid passageway 130 extending longitudinally therethrough and is preferably provided with a reduced diameter neck portion 132 at the lower end thereof as viewed in the drawings for receiving a suitable coupling member 134 for securing a length of drill pipe 136 thereto. A suitable core drill 138 is secured to the lower end of the drill pipe 136 in the usual manner and for a purpose as will be hereinafter set forth. The upper end of the bore 130 is threaded as shown at 140 for receiving a suitable rotating water coupling member 142 therein. The coupling 142 is carried by or secured to a flexible conduit 144 for directing a suitable fluid into and through the passageway 130 during operation of the apparatus 10, as will be hereinafter set forth. In addition, a sprocket member 146 is rigidly secured to the upper end of the sleeve 118 in any well known manner, such as by a plurality of bolts 148. The sprocket 146 is disposed in substantially planar alignment with a drive sprocket (not shown) secured to the drive shaft 150 of the motor 100, and a chain 152 extends around and between the planar sprockets whereby rotation is transmitted to the sprocket 146 during actuation of the motor 100, thus transmitting rotation to the sleeve 118.
To provide stability for the rails 76 and 78, it is desirable to secure the lower portions thereof to the bed portion 16 by suitable connecting linkages 154 (FIG. 1). In addition, a suitable guide sleeve 156 may be secured in substantial axial alignment with the sleeve 118 for receiving the drill pipe 136 therethrough during a drilling operation. The sleeve or guide 156 may be secured to the rails 76 and 78 by means of a suitable A-frame support means 158 (omitted in FIG. 2 for purposes of illustration).
When the apparatus 10 is utilized for a core drilling operation, the vehicle 12 may be maneuvered into the desired location for positioning of the drill pipe 136 in substantial axial alignment with the location of the bore hole to be drilled. This may be accomplished by the normal operation of the fluid control valve means 50 by the operator (not shown) of the vehicle whereby the motor 38 is activated for transmitting rotation to the front drive wheels 18 through the sprockets 40 and 44 and chain or belt 48. Of course, the vehicle may be steered through the use of the steering wheel means 24 in the usual manner, all as is well known.
When the vehicle 12 has been properly located, the locomotion of the vehicle may be ceased, and the operator may leave the area of the seat 22 and steering wheel means 24, and move to the proximity of the valving mechanism 34 of the usual or normal operation thereof. The motor 52 may be activated by the proper manipulation of the valves 34 whereby the sprockets 58 and 66 are rotated for driving the chain 90 as hereinbefore set forth. Simultaneously the motor 100 may be activated for rotating the sprocket 146 and associated sleeve 118 whereby the drill pipe 136 will be rotated for activation of the core drill 138 to perform a core drilling operation. Of course, a suitable drilling fluid, such as water, is admitted into the interior of the drill pipe through the conduit 144 and passageway 130 for facilitating the drilling operation, as is well known and as will be hereinafter more fully set forth.
As the chain 90 moves in a direction toward the sprocket 86, the assembly 80 moves simultaneously therewith due to the connection of the motor 100 with the chain. The flanges 92 and 94 and complementary back plates 96 slide longitudinally along the rails 76 and 78 for facilitating the guiding of the downward movement of the apparatus or assembly 80. When the assembly 80 approaches the guide sleeve 156 the movement of the chain 90 in the direction toward the sprocket 86 may be ceased, and the direction of movement thereof reversed whereby the assembly 80, being disconnected from the drill pipe 136, may be elevated in order that an additional section of drill pipe may be added to the upper end of the pipe 136 for increasing the overall length thereof. The chain 90 may then again be moved in the direction toward the sprocket 86 for continuing the well bore drilling operation until the bore hole is excavated in any well known manner in the proximity of the foundation 160 for exposing at least a portion thereof as shown in FIG. 4. The vehicle 12 may then be maneuvered in such a manner as to position the drill pipe 136 and core drill 138 in spaced relation with respect to the foundation 160, and in alignment with the hole 162. The operation of the drill pipe and core drill may be initiated in the usual manner for a well bore drilling operation, and the guide sleeve 156 guides the drill pipe 136 as the drilling operation continues at the location of the hole 162. As the core drill 138 penetrates the earth, as particularly shown in FIGS. 5 and 6, water or other suitable drilling fluid is directed longitudinally downwardly through the drill pipe 136 as indicated by the arrow 168. The down flowing water stream emerges from the core drill 138 at the bottom thereof and flows upwardly through the annulus 170 between the drill pipe and inner periphery of the bore hole 172, as indicated by the arrow 174. The water moving upwardly through the annulus 170 washes the cuttings of the core drill from the bottom of the bore 172 to the surface 166 of the earth, as is well known in core drilling operations. The cuttings may be recovered at the surface 166 and may be periodically sampled in order to make a definite determination of the formation through which the core drill 138 is moving during the drilling operation.
When the bore hole 172 has been drilled to a sufficiently great depth that the core drill 138 reaches the actual bedrock formation 176 and penetrates the formation 176, the cuttings from the formation 176 will be washed to the surface 166. As these cuttings reach the surface 166, they may be properly analyzed for ascertaining that the core drill 138 has, indeed, penetrated the actual bedrock formation, whereupon the drilling operation may be ceased and it may be desirable to retrieve the core sample for visual inspection and analysis. It is to be understood that geological information is readily available in substantially every portion of the United States providing information as to the identity of the bedrock formation for the area, thus the sampling of the cuttings from the core drilling operation will provide a positive determination of the penetration of the bedrock formation of the area.
At this time, the drill pipe 136 and core drill 138 may be removed from the bore 172 in the usual manner. A suitable casing 164 may then be installed in the hole 162 in substantial alignment with the bore 162, as particularly shown in FIG. 7. The casing 164 is positioned in such a manner that the upper end thereof is disposed lower than the surface 166 for a purpose as will be hereinafter set forth. In addition, a foundation support apparatus 182 (more particularly shown in FIGS. 11 and 12) is secured to the outer periphery of the casing 164 and is movable longitudinally thereof for engagement with the lower portion 180 of the foundation 160.
When the drill pipe 136 and core drill 138 have been removed from the bore hole 172 a pipe or piling member 178 may then be installed in the bore 172, with the lowermost end of the piling 178 (which may be in the form a well casing member) ultimately resting on or embedded within the actual bedrock formation 176, as shown in FIGS. 9, 10, 11 and 12. Of course, the piling or casing 178 may be set in the bore 172 prior to the installation of the casing 164 therearound, or the piling 178 may be inserted through the casing 164 whereby the casing 164 functions as a guide for the installation of the piling as shown in FIGS. 8 and 9, as desired. In any event, the casing 164 is secured around the outer periphery of the piling or casing 178 in any suitable manner, such as by a plurality of bolts 186 which not only secures the casing 164 to the piling 178, but also secures the foundation support apparatus 182 to the casing 164.
As hereinbefore set forth, the foundation support apparatus 182 is movable longitudinally simultaneously with the casing 164 for positioning thereof in such a manner that the under surface 180 of the foundation 160 is engaged thereby. It is preferable that the apparatus 182 be spaced slightly from the outer surface 184 of the foundation 160, but not limited thereto. The foundation support apparatus 182 may be of any suitable construction, and as shown herein comprises a plate 188 welded or otherwise rigidly secured to the upper end of the casing 164 and integral with or secured to a substantially L-shaped bracket member 190. One leg of the L-shaped bracket member 190 preferably engages the outer periphery of the casing 164 and may be welded or otherwise secured thereto, and the other leg of the bracket 190 extends substantially perpendicularly outwardly therefrom for engagement with the under surface 180 of the foundation 160. A suitable gusset 192 is welded or otherwise secured between the outwardly extending leg of the bracket 190 and the outer periphery of the casing 164. It is preferable to provide a plurality of outwardly projecting prong members 194 on the upper surface of the outwardly extending leg of the bracket 190. The prong members 194 being provided for a slight embedding in the under surface 180 of the footing or foundation 160 for facilitating the engagement of the bracket 190 therewith. It will be apparent that the engagement of the bracket member 190 with the foundation 160 will support the foundation 160 from the actual bedrock formation 176 by virtue of the connection between the foundation support 182, casing 164 and piling 178.
It may be desirable or necessary to "jack up" the foundation 160 somewhat prior to a final step of backfilling the hole 162. In that event, a suitable hydraulic jack apparatus generally indicated at 196 may be suitably secured to the upper end of the casing or piling 178 by means of a support plate 198 removably secured to the upper end of the casing 178. A boss or pipe 199 of an outer diameter smaller than the inner diameter of the piling 178 is secured to the outer face of the plate 198 for insertion within the piling 178 for facilitating securing of the jack 196 to the piling. A pair of spaced flanges 200 and 202 extend upwardly from the inner surface of the plate 198 for receiving a flange 204 of the jack 196 therebetween and the flange 204 may be welded or otherwise secured to the flanges 200 and 204 for securing the jack apparatus 196 to the upper end of the piling 178. The piston rod 208 of the jack 196 is suitably secured to a cross member 210 for reciprocal movement thereof. The cross member 210 is secured to the plate 188 by a pair of spaced elongated rods 212 and 214 as particularly shown in FIGS. 11 and 12. The opposite ends of the rods 212 and 214 are threaded for engagement with the plate 188 and cross member 210. Suitable lock nuts 216 are secured to the rods 212 and 214 against the underside of the plate 188, and similar lock nuts 218 are secured to the rods 212 and 214 against the outer surface of the cross member 210, thus securing the rods to and between the plate 118 and cross member 210.
Suitable fluid lines or conduits 220 and 222 are in communication with the cylinder 224 of the jack 196 for directing actuating fluid to and from the opposite ends of the cylinder for reciprocation of the piston rod 208, as is well known. The conduits 220 and 222 are in communication with a fluid source through a manifold 224 (FIGS. 15 and 16) which may be installed on the vehicle 10, or may be completely independent, as desired.
The manifold 224 preferably comprises a pair of spaced fluid banks 226 and 228, with the fluid bank 226 being in communication with a fluid source through a conduit 230 and the fluid bank 228 being in communication with a fluid source through a conduit 232. Of course, the fluid sources may be a common source, or independent sources. The fluid bank 226 is preferably provided with a plurality of spaced fluid ports 234 and the fluid bank 228 is preferably provided with a plurality of spaced fluid ports 236. In this manner, the manifold 224 may be utilized for providing fluid to and withdrawing fluid from a plurality of jack assemblies 196 for a purpose as will be hereinafter set forth. The conduits 220 of the jack assembly 196 is in operable connection with one of the fluid banks, such as the bank 226, and the conduit 222 is similar in operable connection with the other fluid bank 228. In addition, a suitable on-off valve 238 is interposed in the conduit 220 between the fluid bank 226 and the jack 196, and a similar on-off valve 240 is interposed in the conduit 222 between the fluid bank 228 and the jack 196 in order that either or both of the conduits 220 and 222 may be isolated from the fluid source if desired.
In the event it is necessary or desirable to slightly elevate or lift the foundation 160 at the location of the engagement thereof with the foundation support apparatus 182, a suitable fluid may be admitted into the jack assembly 196 through the conduit 220 for applying a lifting force against the piston rod 208 and simultaneously fluid is withdrawn from the jack or cylinder through the conduit 222. As the piston rod 208 is extended due to the force of the pressure entering the jack through the conduit 220, the cross member 210 is moved upwardly with respect to the piling 178. The upward movement of the cross member 210 is transmitted to the foundation engaging apparatus 182 through the rods 212 and 214 whereby the bracket 190 exerts an upward force on the under surface 180 of the foundation 160.
To load test individual piers, all of the valves 238 are closed except the valve in line 220 connected to the pier which is being tested. When pressure in line 220 to the pier being tested reaches a predetermined limit, for example, 4,000 psi if the final support pressure is to be 1,000 psi, the valve is closed. Each pier is similarly tested. After each pier has been individually load tested, individual valves 238 are actuated for controllably elevating portions of the foundation until each portion of the foundation is raised to a predetermined elevation.
All of the valves 238 are then opened causing the plurality of cylinders 196 to be connected in parallel through supply conduits 220 so that the force on each pier 178 supporting a portion 160 of the foundation will each exert substantially the same uplift force since pressure in all of the cylinders is allowed to equalize.
When the foundation 160 has been elevated through the desired distance, the supply of fluid to the jack through the conduit 220 may be ceased, and the casing 164 may be secured in position on the casing or piling 178 by the bolts 186 or by welding pier 178 to bracket casing 164. The jack apparatus 196 may then be removed from connection with the piling 178 and foundation engaging apparatus 182, whereupon the bore or hole 162 may be filled in the usual or well known manner for completely encasing the foundation, piling 178 and casing 164 and restoring the surface 166 of the earth to its original condition.
It is to be noted that a plurality of drilling operations as hereinbefore set forth may take place in the proximity of the foundation 160 as required for restoring the entire foundation to its original elevation. Subsequent to setting a plurality of the foundation supporting structures 182 in engagement with the under surface 180 of the foundation 160, each of the respective piling members 178 may be operably connected with a jack apparatus 196 and each of the jacks 196 may be operably secured to the manifold 224 in the manner as hereinbefore set forth. All of the jacks 196 may be activated simultaneously to easily and slightly elevate the foundation 160 in a manner for reducing any excess strain at a single position on the foundation. In addition, any of the positions which do not require any additional elevation may be isolated from the fluid source through the manifold by closing of the respective on-off valves 238 and 240. Of course, the operation may be repeated around the outer periphery of the foundation 160 as required for an adequate shoring thereof.
SECOND EMBODIMENT
Detailed Description of Preferred Embodiments
Indicated generally at 310 in FIG. 17 is a drill bit constructed in accordance with a second embodiment of the instant invention. A pipe 312 includes a set of internal threads 314 cut therein at the upper end of the pipe. The lower end of the pipe includes a washer 316, having the usual hole 318 centered therein, welded across the inner diameter of the pipe at the lower end thereof. The washer is welded via a weld 320 at its outer circumference to the radially inner surface of the pipe.
A plate or bit member 322 includes a pair of substantially parallel legs 324, 326 and a pair of cutting element supports 328, 330. The edges of legs 324, 326 and of cutting element supports 328, 330 which are directed toward pipe 312 define a substantially U-shaped notch 332. Bit member 322 includes a raised central portion 334 and a pair of lower outer portions 336, 338. These central and outer portions are formed on the lower edge of the bit member. The bit member is welded to the radially outer surface of pipe 312 via welds 340, 342, 344, 346. Tungsten carbide 348 is welded on the lower edge of bit member 322 with a brass and nickel compound. Tungsten carbide covers the entire lower edge of bit member 322 and presents a downwardly facing roughened surface which, as will later be described, cuts into earth and rock during drilling.
Additional bit members 350, 352, similar to bit member 322, are mounted on pipe 312 and drill bit member 322. Bit member 352 is welded via welds 354, 356 to one side of bit member 322 and by welds 358, 360 to the radially outer surface of pipe 312. Bit member 350 is welded in a similar fashion to the radially outer surface of the pipe and to the other side of bit member 322, via welds as shown. Each bit member 350, 352 includes a lower outer portion, like lower outer portion 364 on bit member 350, which is at substantially the same level as lower portions 336, 338 on bit member 322. The lower edge of each bit member 350, 52 is coated with tungsten carbide in the same fashion that bit member 322 is coated.
Turning now to FIG. 19, a conventional concrete building foundation 366 is partially buried in earth 368 as shown. Foundation 366 supports a building 370 which has settled downwardly thus stressing and forming cracks in the building. A hole 372 is excavated adjacent foundation 366 at a location at which shoring up of the foundation is needed.
Turning now to FIG. 20, indicated generally at 374 is a fitting. The fitting includes a tubular portion 376 which in the view of FIG. 20 has pipe 312 received therethrough. A bracket 378 is welded to tubular portion 376 via welds, like weld 380, as shown. The bracket includes a lateral portion 382 which extends outwardly at a substantially ninety-degree angle from the axis of tubular portion 376. Fitting 374 is more fully described in applicant's copending application Ser. No. 762,800. A pipe 384 includes a set of threads 385 formed on the radially outer surface at the lower end thereof. The upper end of the pipe includes a set of threads (not visible) formed on the radially inner surface thereof, like threads 314 are formed on the inner surface of pipe 312 in FIG. 17.
In using the apparatus of the instant invention, a hole, like hole 372, is first excavated adjacent foundation 366 at a location at which the foundation needs to be raised and supported at a selected higher level. Thereafter, drill bit 310 is slid within tubular portion 376 of fitting 374 and is position in hole 372 as shown in FIG. 20. Next, pipe 384 is threadedly engaged with pipe 312 via threads 385, 314. A conventional portable drilling apparatus is connected to pipe 384 in the usual manner to apply downward pressure and to rotate bit 310, thus drilling a bore 388 in FIG. 21.
During drilling, a source of compressed air is connected to the top of pipe 384 to provide pressurized air into bit 310 and through hole 318 into the bore. Such serves as a circulating fluid which blows cuttings away from the bottom of the bit during drilling and upwardly in the annulus between pipe 310 and bore 388 to the surface of the bore.
As drilling progresses, the upper end of pipe 384 approaches earth 368. At approximately the position shown in FIG. 21, the drilling apparatus is disconnected from pipe 384. Next an additional pipe 390 which includes a set of threads formed on the radially outer surface at the lower end thereof is threadably engaged with the threads (not visible at the upper end of pipe 384.
Thereafter, the drilling apparatus is connected to pipe 390. Rotary motion and downward force is applied to pipe 390, compressed air is circulated therethrough, and drilling proceeds as shown in FIG. 22. As drilling progresses, additional threaded pipes may be connected to the uppermost pipe extending from the ground thereby enabling drilling until a suitable rock formation is reached. The cuttings which are blown to the surface of bore 388 by the circulating fluid may be examined to determine when bit 310 has bored into a suitable rock formation, like rock formation 392. When such occurs, drilling is stopped and the drilling apparatus is disconnected from the uppermost pipe.
If the foundation to be raised up and the load supported thereby is particularly heavy, it may be desirable at this stage to inject grout into the uppermost pipe, like pipe 390 in FIG. 22. When pipes 312, 384, 390 are filled with hardened grout, the pipe can support a greater load than if no grout were added. The grout reinforces the pipe at each threaded connection, the point at which failure is likely when the pipe string is compressed under a heavy load. It should be appreciated that most shoring operations will not require the addition of grout in the pipe string.
When drill bit 310 is in the position shown in FIG. 22 and drilling is stopped, lateral portion 382 of fitting 374 is positioned as shown in FIG. 22 with the lateral portion being beneath foundation 366. Thereafter, fitting 374 is urged upwardly relative to pipe 390. In the instant embodiment of the invention such urging is under action of a hydraulic ram (not shown) mounted on the top of pipe 390 and connected to bracket 374 as disclosed in co-pending application Ser. No. 762,800. When fitting 374 is raised to reposition the foundation by a suitable amount, the fitting is fixedly attached to pipe 390. In the instant embodiment of the invention the fitting is welded to the pipe via a weld 392. After the fitting is so secured, the hydraulic ram is removed and pipe 390 is cut off just above fitting 374. Hole 372 is then filled in so that the apparatus assumes the configuration shown in FIG. 23.
In making drill bit 310, washer 316 is welded to the inner surface of pipe 312 at one end thereof as shown in FIGS. 17 and 18. Bit member 322 is stamped from a substantially planar sheet of metal and is welded via welds 340, 342, 344, 346 to the outer surface of pipe 312 as shown in FIGS. 17 and 18. Bit members 350, 352 are each likewise stamped from a planar piece of metal having substantially the same thickness as the metal from which bit member 322 is cut. Bit member 352 is welded to the outer surface of pipe 312 via welds 358, 360 and to one side of bit member 322 via welds 354, 356. Bit member 350 is welded, opposite bit member 352, to the other side of bit member 322 and to the outer surface of pipe 312 in the same fashion. Thereafter, tungsten carbide is applied to the lower edges of each of the bit members as shown in FIGS. 17 and 18.
Because of the ever changing soil formations from one location to another, load testing the pier into a non-expansive and non-contractive formation has solved the existing problem of achieving the load bearing capability required.
From the foregoing it will be apparent that the present invention provides a novel method and means for shoring a building foundation or footing which assures that the foundation will be supported from the actual bedrock. At least one bore hole is provided in the proximity of the foundation for receiving a piling member therein. The bore hole is drilled by means of a core drilling operation wherein the core samples are reviewed in order to assure that the bore hole is drilled into the actual bedrock formation prior to the setting of the piling member. A support bracket is rigidly secured between the piling and the bottom of the building foundation for efficiently supporting the foundation from the bedrock formation. In addition, in instances wherein it is desirable to actually elevate the foundation at least slightly, fluid jack devices are provided for applying an elevating force simultaneously or independently to selected positions of the foundation for urging the foundation upwardly in a manner substantially precluding damage to the foundation.
While the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.
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Apparatus for shoring a building foundation including spaced pilings extending into drilled bore holes such that the lower ends of the pilings rest on and are supported by a sub-stratum believed capable of supporting a portion of the weight of the foundation. Each of a plurality of pressure actuated jacks is connectable between a support bracket and one of the spaced pilings. The jacks are used to individually load test each of the pilings by application of force exceeding the portion of the weight of the foundation which will be supported by each individual piling. Load equalizing manifolds are connected to the fluid inlets and to the fluid outlets of the jacks to distribute a portion of the weight of the foundation over the pilings.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates in general to a liquid nebulizer. More particularly, the present invention relates to an ultrasonic liquid nebulizer.
[0003] 2. Description of the Related Art
[0004] Medical nebulizers that nebulize a fluid into a fine spray or aerosol for inhalation by a patient are well-known devices commonly used for the treatment of certain conditions and diseases. Persons requiring treatment of certain kinds of respiratory conditions frequently need to have medications delivered directly to the lungs. Since the lungs are close to the heart and the blood circulatory system of the body, drug administration by inhalation provides an effective delivery system to all organs of the body. Further, medical nebulizers have applications for conscious, spontaneously-breathing patients and for controlled, ventilated patients.
[0005] Effective and economical nebulizer therapy includes the ability to quickly generate a large amount of aerosol within a predetermined range of particle size. There are several other considerations that relate to the effectiveness of nebulization therapies. For example, it has been suggested that nebulization therapy is more effective when the generation of aerosol particles is relatively uniform.
[0006] With reference to FIG. 6 , a liquid nebulizing element of a conventional ultrasonic liquid nebulizer comprises a medication cup ( 100 ), a sonic vibrator ( 105 ), a mesh plate ( 110 ) and a vibrating element ( 115 ). The medication cup ( 100 ) is used to storage liquid. The sonic vibrator ( 105 ) longitudinally comprises a proximal end ( 105 a ), a circular vibrating unit ( 105 c , 105 d ), a tube ( 105 e ) and a distal end ( 105 b ). The tube ( 105 e ) comprises a through channel ( 105 f ) and attached with the liquid received in the medication cup ( 100 ) through the proximal end ( 105 a ) and mounted with the mesh plate ( 110 ) through the distal end ( 105 b ). The circular vibrating unit ( 105 c , 105 d ) formed around a portion of the tube ( 105 e ). In application, the vibrating element ( 115 ) provides a voltage with high frequency to let the circular vibrating unit ( 105 c , 105 d ) vibrates and induce the tube ( 105 e ) vibrates up and down. According to the foregoing description, the liquid received in the medication cup ( 100 ) is passed through the proximal end ( 105 a ), the through channel ( 105 f ) of the tube ( 105 e ) and flowing out from the distal end ( 105 b ) to the mesh plate ( 110 ) into a fine spray.
[0007] However, the thin tube of conventional ultrasonic nebulizer is difficult to manufacture and the manufacturing cost is expensive. Furthermore, it is not easy to wash the tube and the through channel of the tube may be blocked easily. Thus, a need exists for improved nebulizer.
SUMMARY OF THE INVENTION
[0008] In order to solve the above noted conventional problems, one aspect of the present invention is to provide a liquid nebulizer that is manufactured easily and cost inexpensively.
[0009] One aspect of the present invention is to provide a liquid nebulizer comprising:
[0010] a sonic vibrator for generating sonic vibrating;
[0011] a channel forming element mounted around the sonic vibrator to form a channel between the channel forming element and the sonic vibrator;
[0012] a medication cup mounted around the channel forming element for receiving liquid that is communication with the channel;
[0013] a mesh plate mounted on the sonic vibrator and in the channel forming element; and
[0014] a sealing element mounted in the channel forming element and between the mesh plate and the channel forming element; wherein
[0015] the liquid received in the medication cup will pass through the channel to the mesh plate for nebulization when the sonic vibrator vibrates.
[0016] In a preferred embodiment of the present invention, the nebulizer is an ultrasonic liquid nebulizer.
[0017] The channel forming element employed in the present invention preferably comprises a hollow tube for mounting a portion of the sonic vibrator to form the channel between the tube and the sonic vibrator. More preferably, the channel forming element further comprises an element proximal end formed on the hollow tube for mounting the sealing element.
[0018] In another preferred embodiment of the present invention, the channel forming element comprises a plate for mounting with the sealing element, and furthermore, the plate may have a notch for mounting the sealing element.
[0019] Preferably, the medication cup further comprises a side wall to form the channel forming element. In addition, the channel forming element may be a tube mounted around the partial sonic vibrator.
[0020] In a preferred embodiment of the present invention, the sealing element further comprises a circular sealing unit mounted around the mesh plate and the circular sealing unit can be composed of an elastic and waterproof material. More preferably, the sealing element further comprises a fastened unit mounted on and around the mesh plate and the mesh plate is more preferably located between the fastened unit and the circular sealing unit.
[0021] Preferably, the medication cap employed in the present invention further comprises a cup proximal end and a cup distal end and wherein
[0022] the cup proximal end is connected with the channel forming element, and
[0023] the cup distal end is connected with the sonic vibrator.
[0024] More preferably, the sonic vibrator comprises a main body and a connector formed on the main body and wherein
[0025] the main body is a mainly ultrasonic vibrating generation unit which is connected with the cup distal end of the medication cup.
[0026] More preferably, the connector is attached with the liquid received in the medication cap and the channel forming element is mounted around the connector of the sonic vibrator and connected with the cup proximal end of the medication cup.
[0027] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a side view of an ultrasonic liquid nebulizer in accordance with the present invention;
[0029] FIG. 2 is a partial cross-sectional view of a preferred embodiment showing A-A line of FIG. 1 ;
[0030] FIG. 3 is a partial cross-sectional view of another preferred embodiment showing A-A line of FIG. 1 ;
[0031] FIG. 4 is a partial cross-sectional view of a further preferred embodiment showing A-A line of FIG. 1 ;
[0032] FIGS. 5A , 5 B, 5 C, 5 D are cross-sectional views respectively showing a location of a channel, a channel forming element and a connector of the nebulizer in accordance with the present invention; and
[0033] FIG. 6 is a perspective view of a liquid nebulizing element of a conventional ultrasonic liquid nebulizer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] With reference to FIG. 1 , it is a side view showing a preferred embodiment of an ultrasonic liquid nebulizer ( 5 ) in accordance with the present invention. The ultrasonic liquid nebulizer ( 5 ) can be like, but is not limited to, a circular column.
[0035] With reference to FIG. 2 , it is a partial cross-sectional view of a preferred embodiment showing A-A line of FIG. 1 . The ultrasonic liquid nebulizer ( 5 ) comprises a medication cup ( 10 ), a sonic vibrator ( 15 ), a mesh plate ( 13 ), a channel forming element ( 17 ) and a sealing element ( 19 ).
[0036] The medication cap ( 10 ) is used for receiving liquid and comprises a cup proximal end ( 10 a ) and a cup distal end ( 10 b ). The sonic vibrator ( 15 ) is mounted in the medication cup ( 10 ) and connected with the cup distal end ( 10 b ) of the medication cup ( 10 ) and comprises longitudinally a main body ( 15 a ) and a connector ( 15 b ) formed on the main body ( 15 a ). In a preferred embodiment, the main body ( 15 a ) such as a vibrator is a mainly ultrasonic vibrating generation unit which is connected with the cup distal end ( 10 b ) of the medication cup ( 10 ) and the connector ( 15 b ) vibrates up and down with the main body ( 15 a ). Further, the connector ( 15 b ) is attached with the liquid received in the medication cap ( 10 ) and the channel forming element ( 17 ) is mounted around the connector ( 15 b ) of the sonic vibrator ( 15 ) and connected with the cup proximal end ( 10 a ) of the medication cup ( 10 ).
[0037] In a preferred embodiment of the present invention, the channel forming element ( 17 ) is a hollow tube and comprises a body ( 17 a ), an element proximal end ( 17 b ) formed on the body ( 17 a ) and an inner wall, thereby the connector ( 15 b ) can be mounted in the hollow tube and leave a thin channel ( 21 ) between the inner wall of the channel forming element ( 17 ) and the connector ( 15 b ) for letting the liquid received in the medication cup ( 10 ) passed from the medication cup ( 10 ) to the channel ( 21 ). Preferably, the liquid received in the medication cup ( 10 ) can climb toward to a top of the connector ( 15 b ) by the action of the ultrasonic vibrating when the sonic vibrator ( 15 ) produces ultrasonic vibrating. Preferably, the channel ( 21 ) just provides the space for the liquid to climb up so the channel ( 21 ) only needs an enough thin path as fine and do not need to couple the shape with the body ( 17 a ) of the channel forming element ( 17 ) and the connector ( 15 b ). Of course, the channel ( 21 ) has an equal diameter is preferred but is not limited to.
[0038] Preferably, the element proximal end ( 17 b ) of the channel forming element ( 17 ) is used for setting the sealing element ( 19 ) and the mesh plate ( 13 ). Further, the connector ( 15 b ) of the sonic vibrator ( 15 ) is extended higher than the element proximal end ( 17 b ) of the channel forming element ( 17 ). In a preferred embodiment, the element proximal end ( 17 b ) of the channel forming element ( 17 ) comprises a plate extended perpendicularly from the element proximal end ( 17 b ) for receiving the sealing element ( 19 ). The sealing element ( 19 ) is preferably formed by a waterproof material and/or silica gel and formed a circular sealing unit ( 19 a ) to prevent the liquid from leaking out through the around of the element proximal end ( 17 b ) of the channel forming element ( 17 ). In addition, the circular sealing unit ( 19 a ) can change shape appropriately when the connector ( 15 b ) vibrates up and down, for example, the circular sealing unit ( 19 a ) is composed of an elastic material. Preferably, the body ( 17 a ) of the channel forming element ( 17 ) further comprises an extending unit (not shown) extended from the element proximal end ( 17 b ) for forming a notch for mounting the circular sealing unit ( 19 a ) and is not limited to the foregoing plate shape.
[0039] The mesh plate ( 13 ) is mounted on the circular sealing unit ( 19 a ) and coupled with the element proximal end ( 17 b ) of the channel forming element ( 17 ). In a preferred embodiment, the liquid climbed through the channel ( 21 ) is guided by the circular sealing unit ( 19 a ) to the mesh plate ( 13 ) for nebulization outside. Preferably, the sealing element ( 19 ) further comprises a fastened unit ( 19 b ) mounted on and around the mesh plate ( 13 ) to fasten the mesh plate ( 13 ) and enhance the sealing function. The shape and the composed material of the fastened unit ( 19 b ) can be, but is not limited to, the same with the circular sealing unit ( 19 a ).
[0040] According to the foregoing description, the mesh plate ( 13 ), the sealing element ( 19 ) and the channel forming element ( 17 ) in accordance with the present invention have simple structure and are mounted easily, washed conveniently and cost cheaply.
[0041] With further reference to FIG. 3 , it is another preferred embodiment showing a new structure of a medication cup ( 30 ) that has a side wall coupled with the connector ( 15 b ) to form the channel ( 21 ). Preferably, the side wall of the medication cup ( 30 ) has a plurality of openings or holes for the liquid to pass through.
[0042] With further reference to FIG. 4 , it is another preferred embodiment showing another structure to form the channel ( 21 ). The nebulizer further comprises an independent tube ( 35 ) mounted around the connector ( 15 b ) of the sonic vibrator ( 15 ) to form the channel ( 21 ) between the independent tube ( 35 ) and the connector ( 15 b ).
[0043] With reference to FIGS. 5A to 5D , they are showing different location between the channel ( 21 ), the connector ( 15 b ) and the channel forming unit ( 17 ). According to the spirit of the present invention, the shape of the channel forming element ( 17 ) and the connector ( 15 b ) has no limit for its shape, such as circle, semi-circle, circular column or square column thus the channel ( 21 ) also has no limit for its shape.
[0044] Other embodiments of the invention will appear to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples to be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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A liquid nebulizer utilizes a channel forming element to position a portion of a sonic vibrator and form a channel passing to a medication cup. When the sonic vibrator vibrates up and down, the liquid from the medication cup passes the channel toward a mesh plate for nebulizing the liquid. The liquid nebulizer provides an easily manufactured channel forming element and has a simple structure. Furthermore, the manufacturing cost of the liquid nebulizer is inexpensive.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 09/871,227, filed May 31, 2001, now U.S. Pat. No. 6,806,262, which in turn is based on and claims priority from Provisional Patent Application Ser. No. 60/208,199 filed May 31, 2000.
BACKGROUND OF THE INVENTION
This invention relates to vitamin D compounds, and more particularly to vitamin D derivatives substituted at the carbon 2 position.
The natural hormone, 1α,25-dihydroxyvitamin D 3 and its analog in ergosterol series, i.e. 1α,25-dihydroxyvitamin D 2 are known to be highly potent regulators of calcium homeostasis in animals and humans, and more recently their activity in cellular differentiation has been established, Ostrem et al., Proc. Natl. Acad. Sci. USA, 84, 2610 (1987). Many structural analogs of these metabolites have been prepared and tested, including 1α-hydroxyvitamin D 3 , 1α-hydroxyvitamin D 2 , various side chain homologated vitamins and fluorinated analogs. Some of these compounds exhibit an interesting separation of activities in cell differentiation and calcium regulation. This difference in activity may be useful in the treatment of a variety of diseases.
Recently, a new class of vitamin D analogs has been discovered, i.e. the so called 19-nor-vitamin D compounds, which are characterized by the replacement of the A-ring exocyclic methylene group (carbon 19), typical of the vitamin D system, by two hydrogen atoms. Biological testing of such 19-nor-analogs (e.g., 1α,25-dihydroxy-19-nor-vitamin D 3 ) revealed a selective activity profile with high potency in inducing cellular differentiation, and very low calcium mobilizing activity. Thus, these compounds are potentially useful as therapeutic agents for the treatment of malignancies, or the treatment of various skin disorders. Two different methods of synthesis of such 19-nor-vitamin D analogs have been described (Perlman et al., Tetrahedron Lett. 31, 1823 (1990); Perlman et al., Tetrahedron Lett. 32, 7663 (1991), and DeLuca et al., U.S. Pat. No. 5,086,191).
In U.S. Pat. No. 4,666,634, 2β-hydroxy and alkoxy (e.g., ED-71) analogs of 1α,25-dihydroxyvitamin D 3 have been described and examined by Chugai group as potential drugs for osteoporosis and as antitumor agents. See also Okano et al., Biochem. Biophys. Res. Commun. 163, 1444 (1989). Other 2-substituted (with hydroxyalkyl, e.g., ED-120, and fluoroalkyl groups) A-ring analogs of 1α,25-dihydroxyvitamin D 3 have also been prepared and tested (Miyamoto et al., Chem. Pharm. Bull. 41, 1111 (1993); Nishii et al., Osteoporosis Int. Suppl. 1, 190 (1993); Posner et al., J. Org. Chem. 59, 7855 (1994), and J. Org. Chem. 60, 4617 (1995)).
Recently, 2-substituted analogs of 1α,25-dihydroxy-19-norvitamin D 3 have also been synthesized, i.e. compounds substituted at 2-position with hydroxy or alkoxy groups (DeLuca et al., U.S. Pat. No. 5,536,713), which exhibit interesting and selective activity profiles. All these studies indicate that binding sites in vitamin D receptors can accommodate different substituents at C-2 in the synthesized vitamin D analogs.
SUMMARY OF THE INVENTION
The discovery of the hormonally active form of vitamin D 3 , 1α,25-dihydroxyvitamin D 3 (1α,25-(OH) 2 D 3 , calcitriol, 1; FIG. 1 ), has greatly stimulated research into its physiology and chemistry. As previously noted, it has been established that 1 not only regulates the mineral metabolism in animals and humans, but also exerts potent effects upon cell proliferation and cellular differentiation. Therefore, the chemistry of vitamin D has been recently focused on the design and synthesis of analogs that can exert selective biological actions.
In a previous investigation of the structure-activity relationship of the vitamin D molecule, an analog of the natural hormone 1, 1α,25-dihydroxy-2-methylene-19-norvitamin D 3 (2), was prepared in which the exocyclic methylene group is transposed, in comparison with 1, from C-10 to C-2. Also, 2α-methyl analog 3 was obtained by selective hydrogenation of 2. Both analogs were characterized by significant biological potency, enhanced especially in their isomers in the 20S-series.
In a continuing search for biologically active vitamin D compounds novel 19-nor analogs of 1, substituted at C-2 with ethylidene (4a,b and 5a,b) and ethyl (6a,b and 7a,b) groups, have now been synthesized and tested. Structurally the novel 2-ethylidene analogs belong to a class of 19-nor vitamin D compounds characterized by the general formula I shown below:
where Y 1 and Y 2 , which may be the same or different, are each selected from the group consisting of hydrogen and a hydroxy-protecting group, and where the group R represents any of the typical side chains known for vitamin D type compounds.
Structurally the novel 2-ethyl analogs belong to a class of 19-nor vitamin D compounds characterized by the general formula II shown below:
where Y 1 and Y 2 , which may be the same or different, are each selected from the group consisting of hydrogen and a hydroxy-protecting group, and where the group R represents any of the typical side chains known for vitamin D type compounds.
More specifically R can represent a saturated or unsaturated hydrocarbon radical of 1 to 35 carbons, that may be straight-chain, branched or cyclic and that may contain one or more additional substituents, such as hydroxy- or protected-hydroxy groups, fluoro, carbonyl, ester, epoxy, amino or other heteroatomic groups. Preferred side chains of this type are represented by the structure below:
where the stereochemical center (corresponding to C-20 in steroid numbering) may have the R or S configuration, (i.e. either the natural configuration about carbon 20 or the 20-epi configuration), and where Z is selected from Y, —OY, —CH 2 OY, —C≡CY, —CH═CHY, and —CH 2 CH 2 CH═CR 3 R 4 , where the double bond may have the cis or trans geometry, and where Y is selected from hydrogen, methyl, —COR 5 and a radical of the structure:
where m and n, independently, represent the integers from 0 to 5, where R 1 is selected from hydrogen, deuterium, hydroxy, protected hydroxy, fluoro, trifluoromethyl, and C 1-5 -alkyl, which may be straight chain or branched and, optionally, bear a hydroxy or protected-hydroxy substituent, and where each of R 2 , R 3 , and R 4 , independently, is selected from deuterium, deuteroalkyl, hydrogen, fluoro, trifluoromethyl and C 1-5 alkyl, which may be straight-chain or branched, and optionally, bear a hydroxy or protected-hydroxy substituent, and where R 1 and R 2 , taken together, represent an oxo group, or an alkylidene group, ═CR 2 R 3 , or the group —(CH 2 ) p —, where p is an integer from 2 to 5, and where R 3 and R 4 , taken together, represent an oxo group, or the group —(CH 2 ) q —, where q is an integer from 2 to 5, and where R 5 represents hydrogen, hydroxy, protected hydroxy, C 1-5 alkyl or —OR 7 where R 7 represents C 1-5 alkyl, and wherein any of the CH-groups at positions 20, 22, or 23 in the side chain may be replaced by a nitrogen atom, or where any of the groups —CH(CH 3 )—, —CH(R 3 )—, or —CH(R 2 )— at positions 20, 22, and 23, respectively, may be replaced by an oxygen or sulfur atom.
The wavy lines, e.g. to the substituents at C-2 and at C-20 indicate that those substituents may have either the R or S configuration.
Specific important examples of side chains with natural 20R-configuration are the structures represented by formulas (a), b), (c), (d) and (e) below. i.e. the side chain as it occurs in 25-hydroxyvitamin D 3 (a); vitamin D 3 (b); 25-hydroxyvitamin D 2 (c); vitamin D 2 (d); and the C-24 epimer of 25-hydroxyvitamin D 2 (e):
Specific important examples of side chains with the unnatural 20S (also referred to as the 20-epi) configuration are the structures presented by formulas (f), (g), (h), (i) and (j) below:
The above novel compounds exhibit a desired, and highly advantageous, pattern of biological activity. The synthesized vitamins were tested for their ability to bind the porcine intestinal vitamin D receptor. The presented results ( FIG. 5 ) indicate that 2-ethylidene-19-norvitamins, possessing methyl group from ethylidene moiety directed toward C-3, i.e., trans in relation to C(6)–C(7) bond (isomers E), are more active than 1α,25-(OH) 2 D 3 in binding to VDR, whereas their counterparts with cis relationship between ethylidene methyl substituent and C(7)-H group (isomers Z) exhibit significantly reduced affinity for the receptor. The competitive binding analysis showed also that 2α-ethyl-19-norvitamins bind to the receptor better than their isomers with 2β-ethyl substituents ( FIG. 6 ). In the next assay, the cellular activity of the synthesized compounds was established by studying their ability to induce differentiation of human promyelocyte HL-60 cells into monocytes. E isomer of (20S)-2-ethylidene-19-norvitamin D 3 ( FIG. 7 ) and both 2α-ethyl-19-norvitamins ( FIG. 8 ) are more potent than 1α,25-(OH) 2 D 3 in this assay, whereas the remaining tested compounds are almost equivalent to the hormone 1. Both E isomers of 2-ethylidene-19-norvitamins, when tested in vivo in rats (Table 1) exhibited very high calcemic activity, the (20S)-compound being especially potent. On the contrary, isomeric Z compounds are significantly less active. 2-Ethyl-19-norvitamins have some ability to mobilize calcium from bone but not to the extent of the hormone 1, while being inactive in intestine. The only exception is the 2α-ethyl isomer from the 20S-series which shows strong calcium mobilization response and marked intestinal activity.
These compounds are thus highly specific in their calcemic activity. Their preferential activity on mobilizing calcium from bone and either high or normal intestinal calcium transport activity allows the in vivo administration of these compounds for the treatment of metabolic bone diseases where bone loss is a major concern. Because of their preferential calcemic activity on bone, these compounds would be preferred therapeutic agents for the treatment of diseases where bone formation is desired, such as osteoporosis, especially low bone turnover osteoporosis, steroid induced osteoporosis, senile osteoporosis or postmenopausal osteoporosis, as well as osteomalacia and renal osteodystrophy. The treatment may be transdermal, oral or parenteral. The compounds may be present in a composition in an amount from about 0.1 μg/gm to about 50 μg/gm of the composition, and may be administered in dosages of from about 0.01 μg/day to about 50 μg/day.
The compounds of the invention are also especially suited for treatment and prophylaxis of human disorders which are characterized by an imbalance in the immune system, e.g. in autoimmune diseases, including multiple sclerosis, diabetes mellitus, host versus graft reaction, lupus, atherosclerosis, and rejection of transplants; and additionally for the treatment of inflammatory diseases, such as inflammatory bowel disease, rheumatoid arthritis and asthma, as well as the improvement of bone fracture healing and improved bone grafts. Acne, alopecia especially chemically induced alopecia (e.g. resulting from chemotherapy), skin conditions such as dermatitis, eczema, keratosis, dry skin (lack of dermal hydration), undue skin slackness (insufficient skin firmness), insufficient sebum secretion and wrinkles, as well as hypocalcernia, hypoparathyroidism and hypertension are other conditions which may be treated with the compounds of the invention.
The above compounds are also characterized by high cell differentiation activity. Thus, these compounds also provide therapeutic agents for the treatment of psoriasis, or as an anti-cancer agent, especially against leukemia, colon cancer, breast cancer and prostate cancer. The compounds may be present in a composition to treat psoriasis, cancer, and/or the above list of diseases in an amount from about 0.01 μg/gm to about 100 μg/gm of the composition, and may be administered topically, transdermally, orally or parenterally in dosages of from about 0.01 μg/day to about 100 μg/day.
This invention also provides novel intermediate compounds formed during the synthesis of the end products.
This invention also provides a novel synthesis for the production of the end products of structures I and II. Two different synthetic paths were devised, both based on Lythgoe type Wittig-Horner coupling of the A-ring fragments, the corresponding phosphine oxides prepared from quinic acid, with the protected 25-hydroxy Grundmann's ketone. In the first method, the allylic phosphine oxides were substituted at C-4′ with the ethylidene group whereas in the alternative approach the introduction of ethylidene moiety was performed in the final step of the synthesis, by Wittig reaction of the intermediate 2-oxo-vitamin D analog. The selective catalytic hydrogenation of 2-ethylidene analogs of 1α,25-dihydroxy-19-norvitamin D 3 provided the corresponding 2α- and 2β-ethyl compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the general structural formulae for 1α,25-dihydroxyvitamin D 3 , 1α,25-dihydroxy-2-methylene-19-norvitamin D 3 , and 1α,25-dihydroxy-2α-methyl-19-norvitamin D 3 , and further illustrates the general structural formulae for the four 2-ethylidene-19-nor-vitamins and the four 2-ethyl-19-nor-vitamins of the present invention synthesized and tested herein;
FIG. 2 illustrates the configurations and preferred conformations of the 4′-ethylidene intermediates 16 and 17 used in the synthesis disclosed herein;
FIG. 3 a illustrates the α- and β-forms of the A-ring chair conformers for vitamin D compounds in solutions;
FIG. 3 b illustrates that the presence of bulky 2-alkyl substituents, characterized by large conformational free energy A values, shifts the A-ring conformational equilibrium of the synthesized 2-ethyl-19-nor-vitamins toward the conformers with the equatorial C(2)-substituents;
FIG. 3 c illustrates that a strong interaction (designated as A (1,3) -strain) exists between the methyl group from the ethylidene moiety and equatorial hydroxyls at C-1 or C-3, and results in a strong bias toward conformers with an axial orientation of this hydroxy group to which the methyl from ethylidene fragment is directed; and
FIG. 4 illustrates the conformational equilibrium in ring A of 2-methylene-19-norvitamin 2 (a) and the preferred, energy minimized (PC MODEL 6.0, Serena Software) A-ring conformations of the synthesized analogs: 4a,b (b), 5a,b (c), 6a,b (d) and 7a,b (e).
FIG. 5 a is a graph illustrating the relative activity of a 2-ethylidene-19-nor-vitamins (isomers E and Z) and 1α,25-dihydroxyvitamin D 3 to compete for binding of [ 3 H]-1,25-(OH) 2 -D 3 to the pig intestinal nuclear vitamin D receptor;
FIG. 5 b is a graph similar to FIG. 5 a except illustrating the relative activity of individual compounds 2α and 2β-ethyl-19-nor-vitamins and 1α,25-dihydroxyvitamin D 3 to compete for binding of [ 3 H]-1,25-(OH) 2 -D 3 to the vitamin D pig intestinal nuclear receptor;
FIG. 6 a is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of the 2-ethylidene-19-nor-vitamins as compared to 1α,25-dihydroxyvitamin D 3 ; and
FIG. 6 b is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of the 2α and 2β-ethyl-19-nor-vitamins as compared to 1α,25-dihydroxyvitamin D 3 .
DETAILED DESCRIPTION OF THE INVENTION
As used in the description and in the claims, the term “hydroxy-protecting group” signifies any group commonly used for the temporary protection of hydroxy functions, such as for example, alkoxycarbonyl, acyl, alkylsilyl or alkylarylsilyl groups (hereinafter referred to simply as “silyl” groups), and alkoxyalkyl groups. Alkoxycarbonyl protecting groups are alkyl-O—CO— groupings such as methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, isobutoxycarbonyl, tert-butoxycarbonyl, benzyloxycarbonyl or allyloxycarbonyl. The term “acyl” signifies an alkanoyl group of 1 to 6 carbons, in all of its isomeric forms, or a carboxyalkanoyl group of 1 to 6 carbons, such as an oxalyl, malonyl, succinyl, glutaryl group, or an aromatic acyl group such as benzoyl, or a halo, nitro or alkyl substituted benzoyl group. The word “alkyl” as used in the description or the claims, denotes a straight-chain or branched alkyl radical of 1 to 10 carbons, in all its isomeric forms. Alkoxyalkyl protecting groups are groupings such as methoxymethyl, ethoxymethyl, methoxyethoxymethyl, or tetrahydrofuranyl and tetrahydropyranyl. Preferred silyl-protecting groups are trimethylsilyl, triethylsilyl, t-butyldimethylsilyl, dibutylmethylsilyl, diphenylmethylsilyl, phenyldimethylsilyl, diphenyl-t-butylsilyl and analogous alkylated silyl radicals. The term “aryl” specifies a phenyl-, or an alkyl-, nitro- or halo-substituted phenyl group.
A “protected hydroxy” group is a hydroxy group derivatised or protected by any of the above groups commonly used for the temporary or permanent protection of hydroxy functions, e.g. the silyl, alkoxyalkyl, acyl or alkoxycarbonyl groups, as previously defined. The terms “hydroxyalkyl”, “deuteroalkyl” and “fluoroalkyl” refer to an alkyl radical substituted by one or more hydroxy, deuterium or fluoro groups respectively.
It should be noted in this description that the term “24-homo” refers to the addition of one methylene group and the term “24-dihomo” refers to the addition of two methylene groups at the carbon 24 position in the side chain. -Likewise, the term “trihomo” refers to the addition of three methylene groups. Also, the term “26,27-dimethyl” refers to the addition of a methyl group at the carbon 26 and 27 positions so that for example R 3 and R 4 are ethyl groups. Likewise, the term “26,27-diethyl” refers to the addition of an ethyl group at the 26 and 27 positions so that R 3 and R 4 are propyl groups.
In the following lists of compounds, the particular isometric form of the ethylidene substituent attached at the carbon 2 position should be added to the nomenclature. For example, if the methyl group of the ethylidene substituent is in its (E) configuration, then the term “2(E)” should be included in each of the named compounds. If the methyl group of the ethylidene substituent is in its (Z) configuration, then the term “2(Z)” should be included in each of the named compounds. In addition, if the methyl group attached at the carbon 20 position is in its epi or unnatural configuration, the term “20(S)” or “20-epi” should be included in each of the following named compounds. Also, if the side chain contains an oxygen atom substituted at any of positions 20, 22 or 23, the term “20-oxa”, “22-oxa” or “23-oxa”, respectively, should be added to the named compound. The named compounds could also be of the vitamin D 2 or D 4 type if desired.
Specific and preferred examples of the 2-ethylidene-compounds of structure I when the side chain is unsaturated are:
2-ethylidene-19-nor-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-dipropoyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethylidene-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; and
2-ethylidene-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 .
With respect to the above unsaturated compounds, it should be noted that the double bond located between the 22 and 23 carbon atoms in the side chain may be in either the (E) or (Z) configuration. Accordingly, depending upon the configuration, the term “22,23(E)” or “22,23(Z)” should be included in each of the above named compounds. Also, it is common to designate the double bond located between the 22 and 23 carbon atoms with the designation “Δ 22 ”. Thus, for example, the first named compound above could also be written as 2-ethylidene-19-nor-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 where the double bond is in the (E) configuration. Similarly, if the methyl group attached at carbon 20 is in the unnatural configuration, this compound could be written as 2-ethylidene-19-nor-20(S)-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 .
Specific and preferred examples of the 2-ethylidene-compounds of structure I when the side chain is saturated are:
2-ethylidene-19-nor-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-dipropyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethylidene-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; and
2-ethylidene-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxyvitamin D 3 .
As noted previously, the above saturated side chain compounds should have the appropriate 2(E) or 2(Z) configuration and/or carbon 20 configuration added to the nomenclature. For example, particularly preferred compounds are:
19-nor-2(E)-ethylidene-1α,25-dihydroxyvitamin D 3 ;
19-nor-2(Z)-ethylidene-1α,25-dihydroxyvitamin D 3 ;
19-nor-2(E)-ethylidene-20(S)-1α,25-dihydroxyvitamin D 3 ; and
19-nor-2(Z)-ethylidene-20(S)-1α,25-dihydroxyvitamin D 3 .
In the following lists of compounds, the particular isometric form of the ethyl substituent attached at the carbon 2 position should be added to the nomenclature. For example, if the ethyl group is in the alpha configuration, the term “2α-methyl” should be included in each of the named compounds. If the ethyl group is in the beta configuration, the term “2β-ethyl” should be included in each of the named compounds. In addition, if the methyl group attached at the carbon 20 position is in its epi or unnatural configuration, the term “20(S)” or “20-epi” should be included in each of the following named compounds. Also, if the side chain contains an oxygen atom substituted at any of positions 20, 22 or 23, the term “20-oxa,” “22-oxa” or “23-oxa,” respectively, should be added to the named compound. The named compounds could also be of the vitamin D 2 or D 4 type if desired.
Specific and preferred examples of the 2-ethyl-compounds of structure II when the side chain is unsaturated are:
2-ethyl-19-nor-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-dipropoyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ;
2-ethyl-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; and
2-ethyl-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 .
With respect to the above unsaturated compounds, it should be noted that the double bond located between the 22 and 23 carbon atoms in the side chain may be in either the (E) or (Z) configuration. Accordingly, depending upon the configuration, the term “22,23(E)” or “22,23(Z)” should be included in each of the above named compounds. Also, it is common to designate the double bond located between the 22 and 23 carbon atoms with the designation “Δ 22 ”. Thus, for example, the first named compound above could also be written as 2-ethyl-19-nor-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 where the double bond is in the (E) configuration. Similarly, if the methyl group attached at carbon 20 is in the unnatural configuration, this compound could be written as 2-ethyl-19-nor-20(S)-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 .
Specific and preferred examples of the 2-ethyl-compounds of structure II when the side chain is saturated are:
2-ethyl-19-nor-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-dipropyl-24-homo-1,25-dihydroxyvitamin D 3 ;
2-ethyl-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; and
2-ethyl-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxyvitamin D 3 .
As noted previously, the above saturated side chain compounds should have the appropriate 2α- or 2β-configuration and/or carbon 20 configuration added to the nomenclature. For example, particularly preferred compounds are:
19-nor-2α-ethyl-1α,25-dihydroxyvitamin D 3 ;
19-nor-2β-ethyl-1α,25-dihydroxyvitamin D 3 ;
19-nor-20(S)-2α-ethyl-1α,25-dihydroxyvitamin D 3 ; and
19-nor-20(S)-2β-ethyl-1α,25-dihydroxyvitamin D 3 .
The preparation of 2-ethylidene-19-nor-vitamin D compounds, and the 2-ethyl-19-nor-vitamin D compounds, having the basic structure I and II can be accomplished by a common general method, i.e. the condensation of a bicyclic Windaus-Grundmann type ketone III with the allylic phosphine oxide IVa or IVb to the corresponding 2-ethylidene-19-nor-vitamin D analogs Va or Vb, respectively followed by a selective reduction of the ethylidene group at C-2 to the corresponding 2-ethyl compounds.
In the structures III, IV, and V groups Y 1 and Y 2 and R represent groups defined above; Y 1 and Y 2 are preferably hydroxy-protecting groups, it being also understood that any functionalities in R that might be sensitive, or that interfere with the condensation reaction, be suitable protected as is well-known in the art. The process shown above represents an application of the convergent synthesis concept, which has been applied effectively for the preparation of vitamin D compounds [e.g. Lythgoe et al., J. Chem. Soc. Perkin Trans. I, 590 (1978); Lythgoe, Chem. Soc. Rev. 9, 449 (1983); Toh et al., J. Org. Chem. 48, 1414 (1983); Baggiolini et al., J. Org. Chem. 51, 3098 (1986); Sardina et al., J. Org. Chem. 51, 1264 (1986); J. Org. Chem. 51, 1269 (1986); DeLuca et al., U.S. Pat. No. 5,086,191; DeLuca et al., U.S. Pat. No. 5,536,713].
Hydrindanones of the general structure III are known, or can be prepared by known methods. Specific important examples of such known bicyclic ketones are the structures with the side chains (a), (b), (c) and (d) described above, i.e. 25-hydroxy Grundmann's ketone (f) [Baggiolini et al., J. Org. Chem, 51, 3098 (1986)]; Grundmann's ketone (g) [Inhoffen et al., Chem. Ber. 90, 664 (1957)]; 25-hydroxy Windaus ketone (h) [Baggiolini et al., J. Org. Chem., 51, 3098 (1986)] and Windaus ketone (i) [Windaus et al., Ann., 524, 297 (1936)]:
For the preparation of the required phosphine oxides of general structure IV, a new synthetic route has been developed starting from methyl quinicate derivative 9, easily obtained from commercial (1R,3R,4S,5R)-(−)-quinic acid 8 as described by Perlman et al., Tetrahedron Lett. 32, 7663 (1991) and DeLuca et al., U.S. Pat. No. 5,086,191. The overall process of transformation of the starting methyl ester 9 into the desired A-ring synthons, is summarized by the Scheme I. Reduction of the ester 9 with diisobutylaluminum hydride (DIBALH) or other suitable reducing agent (e.g. lithium aluminum hydride) provided the diol 10 which was subsequently oxidized by sodium periodate to the cyclohexanone ketone derivative 11. Then, the secondary 4-hydroxyl group of 11 was oxidized with RuO 4 (a catalytic method with RuCl 3 and NaIO 4 as co-oxidant). Use of such a strong oxidant was necessary for an effective oxidation process of this very hindered hydroxyl. However, other more commonly used oxidants can also be applied (e.g. pyridinium dichromate), although the reactions usually require much longer time for completion. The next step of the process comprises the Peterson reaction of the ketone 12 with methyl(trimethylsilyl)acetate to form ester 13.
Referring now to Scheme 2, the next step of the synthesis comprises the Wittig reaction of the sterically hindered 4-keto compound 13 with ylide prepared from ethyltriphenylphosphonium bromide and n-butyllithium leading to ethylidene compounds 14 and 15. Ethylidene compounds 14 and 15 in turn were treated with diisobutylaluminum hydride and the formed alcohols 16 and 17 were in turn transformed to the desired A-ring phosphine oxides 18 and 19. Conversion of 16 and 17, to 18 and 19, respectively involved 3 steps, namely, in situ tosylation with n-butyllithium and p-toluenesulfonyl chloride, followed by reaction with diphenylphosphine lithium salt and oxidation with hydrogen peroxide.
Several 2-ethylidene-19-nor-vitamin D compounds of the general structure V may be synthesized using the A-ring synthons 18 and 19 and the appropriate Windaus-Grundmann ketone III having the desired side chain structure. Thus, for example, Scheme 3 illustrates that Wittig-Horner coupling of the phosphinoxy 18 with the protected 25-hydroxy Grundmann's ketone 20 prepared according to published procedure [Sicinski et al., J. Med. Chem. 37, 3730 (1994)] gave the expected protected vitamin compound 21. This, after deprotection afforded 1α,25-dihydroxy-2(E)-ethylidene-19-nor-vitamin D 3 (4a). Similarly, Scheme 3 illustrates the synthesis of 1α,25-dihydroxy-2(Z)-ethylidene-19-nor-vitamin D 3 (5a) from phosphinoxy 19 and Grundmann's ketone 20.
Referring now to Scheme 6, the final step of the process was the selective homogeneous catalytic hydrogenation of the ethylidene unit at carbon 2 in the vitamins 4a and Sa performed efficiently in the presence of tris(triphenylphosphine)rhodium(I) chloride [Wilkinson's catalyst, (Ph 3 P) 3 RhCl]. Such reduction conditions allowed to reduce only C(2)=CH 2 unit leaving C(5)–C(8) butadiene moiety unaffected. The isolated material is an epimeric mixture (ca. 1:1) of 2-ethyl-19-nor-vitamins 6a and 7a differing in configuration at C-2. The mixture can be used without separation or, if desired, the individual 2α- and 2β-isomers can be separated by an efficient HPLC system.
The C-20 epimerization may be accomplished by the analogous coupling of the phosphine oxides 18 and 19 with protected 20(S)-25-hydroxy Grundmann's ketone 26 (Scheme 5) which after hydrolysis of the hydroxy-protecting groups gave 20(S)-1α,25-dihydroxy-2-ethylidene-19-nor-vitamin D 3 compounds 4b and 5b. Hydrogenation of 4b and 5b provided the expected mixture of the 2-ethyl-19-nor-vitamin D analogs 6b and 7b.
As noted above, other 2-ethylidene and 2-ethyl-19-nor-vitamin D analogs may be synthesized by the method disclosed herein. For example, 1α-hydroxy-2-ethylidene-19-nor-vitamin D 3 can be obtained by providing the Grundmann's ketone (g). Subsequent reduction of the A-ring ethylidene group in the formed compound can also give the corresponding epimeric mixture of 1α-hydroxy-2-ethyl-19-nor-vitamin D 3 compounds.
A number of oxa-analogs of vitamin D 3 and their synthesis are also known. For example, 20-oxa analogs are described in N. Kubodera at al, Chem. Pharm. Bull., 34, 2286 (1986), and Abe et al, FEBS Lett. 222, 58, 1987. Several 22-oxa analogs are described in E. Murayama et al, Chem. Pharm. Bull., 34, 4410 (1986), Abe et al, FEBS Lett., 226, 58 (1987), PCT International Application No. WO 90/09991 and European Patent Application, publication number 184 112, and a 23-oxa analog is described in European Patent Application, publication number 78704, as well as U.S. Pat. No. 4,772,433.
This invention is described by the following illustrative examples. In these examples specific products identified by Arabic numerals (e.g. 1, 2, 3, etc) refer to the specific structures so identified in the preceding description and in the Schemes.
EXAMPLE 1
Chemistry
The strategy of the synthesis of 2-substituted 19-norvitamins was based on Lythgoe-type Wittig-Horner coupling. Since the corresponding C,D-ring ketones were available, attention was focused on the synthesis of the phosphine oxide A-ring synthons (Scheme 1 and 2). Configurations of the ethylidene unit at C′-4 in the isomeric compounds 16, 17 ( FIG. 2 ) and 17, 18, as well as their preferred conformations, were determined by analysis of 1 H NMR spectra, NOE measurements and spin decoupling experiments.
The Wittig-Horner reaction of the conjugate base of 20 with the protected 25-hydroxy Grundmann's ketone 20 produced 19-norvitamin D compound 21 in a very high yield, i.e. 91% (Scheme 3), but the yield of an analogous coupling of the isomeric phosphine oxide 19 was very low, i.e. 13%. The obtained condensation products 21 and 22, following deprotection, gave 2-ethylidene-19-norvitamins 4a and 5a. Considering the low yield of the Wittig reaction of the cyclohexanone 13, leading to ethylidene compounds 14 and 15 (Scheme 2), an alternative synthetic approach was sought.
Thus, the carbonyl group in 13 was protected as O-trimethylsilyl hemimethylthioketal and the corresponding phosphine oxides 25 were efficiently synthesized (Scheme 4). Coupling of their anions with the hydrindanone 26 (Scheme 5) afforded the protected 19-norvitamin D compound 27 in a high yield. This, after deprotection of 2-oxo group, Wittig reaction and subsequent hydrolysis was converted to (20S)-2-ethylidene-19-norvitamins 4b and 5b. The selective catalytic hydrogenation of 2-ethylidene analogs 4a, b and 5a, b (Scheme 6) provided the corresponding 2-ethyl-19-norvitamins 6a, b and 7a, b, which were easily separated by HPLC.
Stereochemistry at C-2 in the synthesized vitamin D compounds was tentatively assigned on the basis of conformational analysis, molecular modeling studies, and 500 MHz 1 H NMR spectroscopy.
EXAMPLE 2
Conformational Analysis
It has been established that vitamin D compounds in solutions exist as a mixture of two rapidly equilibrating A-ring chair conformers abbreviated as α- and β-forms ( FIG. 3 a ). Presence of bulky 2-alkyl substituents, characterized by large conformational free energy A values ( FIG. 3 b ), shifts the A-ring conformational equilibrium of the synthesized 2-ethyl-19-norvitamins toward the conformers with the equatorial C(2)-substituents. In the obtained 2-ethylidene-19-norvitamin D compounds, an additional strong interaction (designated as A (1,3) -strain, FIG. 3 c ) is involved, existing between the methyl group from the ethylidene moiety and equatorial hydroxyls at C-1 or C-3. It results in the strong bias toward conformers with an axial orientation of this hydroxy group to which the methyl from ethylidene fragment is directed.
Conformational equilibrium in ring A of 2-methylene-19-norvitamin 2 (a) and the preferred, energy minimized (PC MODEL 6.0, Serena Software) A-ring conformations of the synthesized analogs: 4a, b (b), 5a, b (c), 6a, b (d) and 7a, b (e) are shown in FIG. 4 . The steric energy differences between the preferred conformers and their partners with the inverted chair forms (calculated for model compounds lacking side chain) are given. The corresponding percentage populations (in parentheses) of conformers are given for room temperature (25° C.).
EXAMPLE 3
Biological Evaluation
The synthesized vitamins were tested for their ability to bind the porcine intestinal vitamin D receptor. The presented results ( FIG. 5 a ) indicate that 2-ethylidene-19-norvitamins, possessing methyl group from ethylidene moiety directed toward C-3, i.e. trans in relation to C(6)–C(7) bond (isomers E), are more active than 1α,25-(OH) 2 D 3 in binding to VDR, whereas their counterparts with cis relationship between ethylidene methyl substituent and C(7)-H group (isomers Z) exhibit significantly reduced affinity for the receptor. The competitive binding analysis showed also that 2α-ethyl-19-norvitamins bind the receptor better than their isomers with 2β-ethyl substituents ( FIG. 5 b ). In the next assay, the cellular activity of the synthesized compounds was established by studying their ability to induce differentiation of human promyelocyte HL-60 cells into monocytes. E isomer of (20S)-2-ethylidene-19-norvitamin D 3 ( FIG. 6 a ) and both 2α-ethyl-19-norvitamins ( FIG. 6 b ) are more potent than 1α,25-(OH) 2 D 3 in this assay, whereas the remaining tested compounds are almost equivalent to the hormone.
Both E isomers of 2-ethylidene-19-norvitamins, when tested in vivo in rats (Table 1) exhibited very high calcemic activity, the (20S)-compound being especially potent. On the contrary, isomeric Z compounds are significantly less active. 2-ethyl-19-norvitamins have some ability to mobilize calcium from bone but not to the extent of the hormone 1, while being inactive in intestine. The only exception is 2α-ethyl isomer from 20S-series that shows strong calcium mobilization response and marked intestinal activity.
TABLE 1
Support of Intestinal Calcium Transport and Bone Calcium Mobilization
By 2-Substituted Analogs of 1α,25-Dihydroxy-19-norvitamin D 3
In Vitamin D-Deficient Rats on a Low-Calcium Diet a
Ca
compd.
amount
transport S/M
Serum Ca
compound
no.
(pmol)
(mean ± SEM)
(mean ± SEM)
none (control)
0
3.0 ± 0.7
4.3 ± 0.1
1α,25-(OH) 2 D 3
1
130
5.5 ± 0.5
5.1 ± 0.3
260
5.9 ± 0.4
5.8 ± 0.3
2-ethylidene-19-nor-
4a
65
5.0 ± 0.4
4.5 ± 0.1
1α,25-(OH) 2 D 3
130
6.8 ± 0.4
5.2 ± 0.2
(E-isomer)
2-ethylidene-19-nor-
5a
65
4.4 ± 0.4
4.4 ± 0.2
1α,25-(OH) 2 D 3
130
5.7 ± 0.9
4.2 ± 0.0
(Z-isomer)
none (control)
0
4.4 ± 0.2
4.1 ± 0.2
1α,25-(OH) 2 D 3
1
130
4.9 ± 0.7
5.2 ± 0.2
260
6.0 ± 0.9
6.4 ± 0.4
2-ethylidene-19-nor-
4b
65
9.0 ± 0.3
8.2 ± 0.3
(20S)-1α,25-
130
5.8 ± 0.8
12.1 ± 0.6
(OH) 2 D 3 (E-isomer)
2-ethylidene-19-nor-
5b
65
4.3 ± 0.7
4.0 ± 0.3
(20S)-1α,25-
130
3.8 ± 0.3
4.0 ± 0.1
(OH) 2 D 3 (Z-isomer)
none (control)
0
3.8 ± 0.4
3.9 ± 0.1
1α,25-(OH) 2 D 3
1
260
6.5 ± 0.9
5.8 ± 0.1
2α-ethyl-19-nor-
6a
260
4.0 ± 0.4
5.1 ± 0.1
1α,25-(OH) 2 D 3
2β-ethyl-19-nor-
7a
260
3.7 ± 0.3
5.0 ± 0.1
1α,25-(OH) 2 D 3
2α-ethyl-19-nor-
6b
260
5.0 ± 0.4
7.0 ± 0.1
(20S)-1α,25-
(OH) 2 D 3
2β-ethyl-19-nor-
7b
260
4.1 ± 0.3
5.6 ± 0.1
(20S)-1α,25-
(OH) 2 D 3
a Weanling male rats were maintained on a 0.47% Ca diet for one week and then switched to a low-calcium diet containing 0.02% Ca for an additional three weeks. During the last week, they were dosed daily with the appropriate vitamin D compound for seven consecutive days. All doses were administered intraperitoneally in 0.1 mL propylene glycol/ethanol (95:5). Controls received the vehicle. Determinations were made 24 hours after the last dose. There were at least six rats per group.
For treatment purposes, the novel compounds of this invention defined by formula I and/or II may be formulated for pharmaceutical applications as a solution in innocuous solvents, or as an emulsion, suspension or dispersion in suitable solvents or carriers, or as pills, tablets or capsules, together with solid carriers, according to conventional methods known in the art. Any such formulations may also contain other pharmaceutically-acceptable and non-toxic excipients such as stabilizers, anti-oxidants, binders, coloring agents or emulsifying or taste-modifying agents.
The compounds may be administered orally, topically, parenterally, sublingually, intranasally, or transdermally. The compounds are advantageously administered by injection or by intravenous infusion or suitable sterile solutions, or in the form of liquid or solid doses via the alimentary canal, or in the form of creams, ointments, patches, or similar vehicles suitable for transdermal applications. Doses of from about 0.01 μg to about 100 μg per day, preferably from 0.1 μg to 50 μg per day of the compounds are appropriate for treatment purposes, such doses being adjusted according to the disease to be treated, its severity and the response of the subject as is well understood in the art. Since the new compounds exhibit specificity of action, each may be suitably administered alone, or together with graded doses of another active vitamin D compound—e.g. 1α-hydroxyvitamin D 2 or D 3 , or 1α,25-dihydroxyvitamin D 3 —in situations where different degrees of bone mineral mobilization and calcium transport stimulation is found to be advantageous.
Compositions for use in the above-mentioned treatment of psoriasis and other malignancies comprise an effective amount of one or more 2-substituted-19-nor-vitamin D compound as defined by the above formula I and/or II as the active ingredient, and a suitable carrier. An effective amount of such compounds for use in accordance with this invention is from about 0.01 μg to about 100 μg per gm of composition, and may be administered topically, transdermally, orally, sublingually, intranasally, or parenterally in dosages of from about 0.1 μg/day to about 100 μg/day.
The compounds may be formulated as creams, lotions, ointments, topical patches, pills, capsules or tablets, or in liquid form as solutions, emulsions, dispersions, or suspensions in pharmaceutically innocuous and acceptable solvent or oils, and such preparations may contain in addition other pharmaceutically innocuous or beneficial components, such as stabilizers, antioxidants, emulsifiers, coloring agents, binders or taste-modifying agents.
The compounds are advantageously administered in amounts sufficient to effect the differentiation of promyelocytes to normal macrophages. Dosages as described above are suitable, it being understood that the amounts given are to be adjusted in accordance with the severity of the disease, and the condition and response of the subject as is well understood in the art.
The formulations of the present invention comprise an active ingredient in association with a pharmaceutically acceptable carrier therefore and optionally other therapeutic ingredients. The carrier must be “acceptable” in the sense of being compatible with the other ingredients of the formulations and not deleterious to the recipient thereof.
Formulations of the present invention suitable for oral administration may be in the form of discrete units as capsules, sachets, tablets or lozenges, each containing a predetermined amount of the active ingredient; in the form of a powder or granules; in the form of a solution or a suspension in an aqueous liquid or non-aqueous liquid; or in the form of an oil-in-water emulsion or a water-in-oil emulsion.
Formulations for rectal administration may be in the form of a suppository incorporating the active ingredient and carrier such as cocoa butter, or in the form of an enema.
Formulations suitable for parenteral administration conveniently comprise a sterile oily or aqueous preparation of the active ingredient which is preferably isotonic with the blood of the recipient.
Formulations suitable for topical administration include liquid or semi-liquid preparations such as liniments, lotions, applicants, oil-in-water or water-in-oil emulsions such as creams, ointments or pastes; or solutions or suspensions such as drops; or as sprays.
For asthma treatment, inhalation of powder, self-propelling or spray formulations, dispensed with a spray can, a nebulizer or an atomizer can be used. The formulations, when dispensed, preferably have a particle size in the range of 10 to 100μ.
The formulations may conveniently be presented in dosage unit form and may be prepared by any of the methods well known in the art of pharmacy. By the term “dosage unit” is meant a unitary, i.e. a single dose which is capable of being administered to a patient as a physically and chemically stable unit dose comprising either the active ingredient as such or a mixture of it with solid or liquid pharmaceutical diluents or carriers.
In its broadest application, the present invention relates to any 19-nor-analog of vitamin D which have the vitamin D nucleus. By vitamin D nucleus, it is meant a central part consisting of a substituted chain of five carbon atoms which correspond to positions 8, 14, 13, 17 and 20 of vitamin D, and at the ends of which are connected at position 20 a structural moiety representing any of the typical side chains known for vitamin D type compounds (such as R as previously defined herein), and at position 8 the 5,7-diene moiety connected to the A-ring of an active 1α-hydroxy vitamin D analog (as illustrated by formula I herein). Thus, various known modifications to the six-membered C-ring and the five-membered D-ring typically present in vitamin D, such as the lack of one or the other or both, are also embraced by the present invention.
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Biologically active 19-nor vitamin D analogs substituted at C-2 in the A-ring with an ethylidene or an ethyl group. These compounds have preferential activity on mobilizing calcium from bone and either high or normal intestinal calcium transport activity which allows their in vivo administration for the treatment of metabolic bone diseases where bone loss is a major concern. These compounds are also characterized by high cell differentiation activity.
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FIELD OF THE INVENTION
The present invention relates to diaminopyridine-based azo dyes for cellulose-containing fibers. More particularly, it relates to reactive azo dyes for use in dyeing of cellulose-containing fibers, particularly cellulose fibers and mixed fibers of polyester fibers and cellulose fibers in from orange to blue having excellent fastness to light, etc.
SUMMARY OF THE INVENTION
The present invention is to provide diaminopyridine-based azo dyes for cellulose-containing fibers, represented by the general formula (I): ##STR2## and the other is a hydrogen atom, a phenyl group, a benzyl group, an allyl group, or an alkyl group which may be substituted by a hydroxyl group or a lower alkoxy group
(wherein)
A is a methylene group, an ethylene group, a propylene group, or a 1,3-butylene group;
n is 0 or 1;
Y 1 and Y 2 are each a hydrogen atom, or an alkyl group, an alkenyl group, a cyclohexyl group, an aryl group, or an aralkyl group which may all be substituted by a cyano group, a hydroxy group, a lower alkoxy group, or a dialkylamino group, and they may combine together in combination with nitrogen to form a 5- or 6-membered nitrogen-containing heterocylic ring (NY 1 Y 2 ), the total number of carbon atoms of Y 1 and Y 2 being 18 or less;
R 1 is a nitro group, a cyano group, a methylsulfonyl group, a phenylsulfonyl group, a mono-lower alkylaminosulfonyl group, a di-lower alkylaminosulfonyl group, an acetyl group, or a benzoyl group;
R 2 and R 3 are each a hydrogen atom, a trifluoromethyl group, a halogen atom, or a cyano group;
R 4 is a hydrogen atom, a lower alkyl group, a mono- or di-lower alkylaminosulfonyl group, a mono- or di-lower alkylcarbamoyl group, or an acetylamino group;
R 5 and R 6 are each a hydrogen atom, a halogen atom, or a lower alkyl group;
R 7 is a lower alkyl group;
R 8 is a trifluoromethyl group, or a halogen atom; and
R 9 is a hydrogen atom, or a halogen atom).
DETAILED DESCRIPTION OF THE INVENTION
The dyes represented by the general formula (I) can be easily prepared, for example, by reacting compounds represented by the general formula (IV): ##STR3## and the other is a hydrogen atom, a phenyl group, a benzyl group, an allyl group, or an alkyl group which may be substituted by a hydroxyl group or a lower alkoxy group, and A and n are the same as described hereinbefore) with compounds represented by the general formula (V): ##STR4## (wherein Y 1 and Y 2 are the same as described hereinbefore) in a solvent, e.g., N-methyl-2-pyrrolidone.
Halogen atoms as indicated by R 2 , R 3 , R 5 , R 6 , R 8 and R 9 in the general formulae (I) and (IV) include a fluorine atom, a chlorine atom, and a bromine atom. Lower alkyl groups as indicated by R 4 and R 5 include a methyl group, an ethyl group, and a straight or branched alkyl group containing from 3 to 4 carbon atoms.
Alkyl groups as indicated by X 1 , X 2 , Z 1 and Z 2 include a methyl group, an ethyl group, and a straight alkyl group containing from 3 to 6 carbon atoms. Examples of alkyl groups substituted by a hydroxyl group include a 2-hydroxyethyl group, a 3-hydroxypropyl group, a 2-hydroxypropyl group, a 2-hydroxybutyl group, a 4-hydroxybutyl group, a 1,1-dimethyl-2-hydroxyethyl group, a 5-hydroxypentyl group, a 6-hydroxyhexyl group, a (β-hydroxy)ethoxyethyl group, a (γ-hydroxy)propoxypropyl group, and a (β-hydroxy)ethoxyethoxyethyl group. Examples of alkyl groups substituted by a lower alkoxy group include a 2-methoxyethyl group, a 2-ethoxyethyl group, a 3-methoxypropyl group, a 3-isopropoxypropyl group, a methoxyethoxyethyl group, an ethoxyethoxypropyl group, a methoxyisopropoxyethyl group, and a methoxyethoxyethoxyethyl group.
Alkyl groups as indicated by Y 1 and Y 2 in the general formulae (I) and (V) include a methyl group, an ethyl group, and a straight or branched alkyl group containing from 3 to 18 carbon atoms. Examples of substituted alkyl groups include cyano group-, hydroxyl group-, lower alkoxy group-, or dialkylamino group-substituted alkyl groups, such as a cyanomethyl group, a 2-cyanoethyl group, a 3-cyanopropyl group, a 2-hydroxyethyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a 4-hydroxybutyl group, a 2-(2-hydroxyethoxy)ethyl group, a tris(hydroxymethyl)methyl group, a 2-ethoxyethyl group, a 3-isopropoxypropyl group, a 3-(2-methoxyethoxy)propyl group, a 2,2-diethoxyethyl group, a 2-(N,N-diethylamino)ethyl group, a 2-(N,N-dimethylamino)ethyl group, and a 3-(N,N-dimethylamino)propyl group.
Alkenyl groups include an allyl group, a 2-methylallyl group, a 3-methylallyl group, and a straight or branched alkenyl group containing from 4 to 18 carbon atoms. Substituted alkenyl groups include cyano group-, hydroxy group-, or lower alkoxy group-substituted alkenyl groups, such as a 3-cyanoallyl group, a 2-hydroxyallyl group, a 3-methoxyethoxyallyl group, and a 1-methyl-3-(N,N-diethylamino)allyl group.
Aryl groups include a phenyl group, a naphthyl group, an o-tolyl group, and a p-butylphenyl group. Examples of aryl groups substituted by a cyano group, a hydroxy group, a lower alkoxy group, or a dialkylamino group include an m-cyanophenyl group, a p-hydroxyphenyl group, a p-methoxyphenyl group, a p-(2-methoxyethoxy)phenyl group, a 2,5-dimethoxyphenyl group, and a p-(N,N-dimethylamino)phenyl group.
Aralkyl groups include a benzyl group, a phenetyl group, an m-methylbenzyl group, and a p-methylphenetyl group. Examples of substituted aralkyl groups include an m-cyanobenzyl group, a p-hydroxybenzyl group, a p-hydroxyphenetyl group, and an o-anisyl group.
Nitrogen-containing heterocyclic groups as represented by NY 1 Y 2 include a 1-pyrrolidinyl group, a 3-methyl-1-pyrrolidinyl group, a 2-hydroxyethyl-1-pyrrolidinyl group, a 2,5-dimethyl-1-pyrrolidinyl group, a 3-thiazolidinyl group, a 1-pyrrolyl group, a 1-pyrazolyl group, a 1-imidazolyl group, a morpholino group, a piperidino group, a 2,6-dimethylpiperidino group, a 1-piperadinyl group, and a 4-methyl-1-piperazinyl group.
Of the compounds represented by NY 1 Y 2 , di-substituted amino groups having a total number of carbon atoms of from 6 to 12 are particularly preferred.
When n is 0, in particular, light fastness is excellent.
In preparing the disazo dyes of the general formula (I), disazo compounds represented by the general formula (II) are added to from 1 to 1.2 moles of difluorotriazines represented by the general formula (III), per mole of the disazo compound, and they are heated at a temperature of from 40° to 90° C. for a period of from 0.5 to 5 hours in an organic solvent, such as acetone, methyl ethyl ketone, toluene, nitrobenzene, dioxane, N,N-dimethylformaldehyde, N-methyl-2-pyrrolidone, or dimethylsulfoxide, in the presence of from 1 to 2 moles per mole of the disazo compound of an acid coupler, such as tertiary amine, e.g., triethylamine, tributylamine, or N,N-diethylaniline, and inorganic base, e.g., potassium carbonate, or potassium hydrogencarbonate. The reaction solution is then cooled and poured into, for example, water to form a precipitate. By separating the precipitate by techniques such as filtration and centrifugal separation, there can be almost quantitatively obtained the disazo dyes represented by the general formula (I).
Cellulose-containing fibers which are to be dyed with the dyes represented by the general formula (I) include fibers such as natural fibers, e.g., cotton and flax, semi-synthetic fibers, e.g., viscose rayon and copper ammonia rayon, and modified cellulose fibers, e.g., partially aminated or partially acylated cellulose fibers, and their fabrics, unwoven fabrics, and so forth. In addition, mixed fibers of cellulose fibers and other fibers, such as polyester fibers, cation dyeable polyester fibers, anion dyeable polyester fibers, polyamide fibers, wool, acryl fibers, urethane fibers, diacetate fibers, and triacetate fibers, and their fabrics can be used. Of the above-described fibers and fabrics, cellulose fibers, mixed fibers of cellulose fibers and polyester fibers, and their fabrics are particularly suitable for dyeing with the dyes of the general formula (I).
In the practice of dyeing, it is desirable that the dye of the general formula (I) is finely dispersed in a medium so that the grain size is from about 0.5 to 2 microns.
Various techniques can be employed for such fine dispersion, including a method in which a nonionic or Pluronic surface active agent, an anionic dispersant, such as sodium ligninsulfonate, or a water-soluble dispersant, such as a sodium salt of a naphthalene-sulfonic acid-formalin condensate, is employed, and the dye is finely dispersed in water by the use of a grinder such as a sand grinder and a mill; a method in which a water sparingly soluble or water-insoluble dispersant, such as a compound prepared by adding a low molecular amount of ethylene oxide to sulfosuccinic acid ester, nonylphenol, or the like, is employed, and the dye is finely dispersed in a solvent other than water, such as alcohols, e.g., ethyl alcohol, isopropyl alcohol, and polyethylene glycol, ketones, e.g., acetone and methyl ethyl ketone, hydrocarbons, e.g., n-hexane, toluene, xylene, and mineral turpentine, halogenated hydrocarbons, e.g., tetrachloroethylene, esters, e.g., ethyl acetate and butyl acetate, ethers, e.g., dioxane, and tetraethylene glycol dimethyl ether, and their mixed solvents, and a method in which the dye is finely dispersed in a mixture of water and a solvent compatible with water in any proportion, selected from the above-described solvents.
In addition, a polymeric compound soluble in each dispersant, a surface active agent having mainly a function other than the dispersion action, etc., may be added in the course of the fine dispersion.
The finely dispersed dye solution can be used as such as a padding bath for use in a padding dyeing method, or as a printing color paste for use in a printing method. It is usual, however, that the finely dispersed dye solution is diluted with water, a mixture of water and a solvent compatible with water in any proportion, an o/w emulsion in which the oil phase is petroleum hydrocarbon such as mineral turpentine or halogenated hydrocarbon such as tetrachloroethylene, or a w/o emulsion in which the oil phase is the same as above to a level determined depending on the desired dyeing concentration and, thereafter, is used as a padding bath or a printing color paste.
In the preparation of such padding baths and printing color pastes, a cellulose fiber-swelling agent can be added for advantageously effecting dyeing, or alkali metal compounds, organic epoxy compounds, organic vinyl compounds, etc., can be added as acid couplers for the purpose of accelerating the reaction between the dye and cellulose fibers. Alkali metal compounds which can be used include alkali metal carbonic acid salts, alkali metal hydrocarbonic acid salts, alkali metal phosphoric acid salts, alkali metal boric acid salts, alkali metal silicic acid salts, alkali metal hydroxides, alkali metal aliphatic acid salts, e.g., alkali metal acetic acid salts, and alkali metal precursors which generate alkalis when heated in the presence of water, such as sodium trichloroacetate and sodium acetoacetate. The amount of the alkali metal compound being used is usually sufficient to be such that the pH of the padding bath or printing color paste is from 7.5 to 8.5. Organic epoxy compounds which can be used include ethylene glycol diglycidyl ether and polyethylene glycol diglycidyl ether having an average molecular weight of from 150 to 400. Organic vinyl compounds include ethylene glycol diacrylate and diacrylate or dimethacrylate of polyethylene glycol having an average molecular weight of from 150 to 400. The amount of the organic epoxy compound or organic vinyl compound being used is from about 3 to 6% by weight based on the padding bath or printing color paste.
In order to prevent dry migration during padding dyeing, or to regulate the color paste viscosity to the optimum level in various printing methods, a tackifier such as a water-soluble polymer, e.g., sodium alginate, may be added.
The preparation of padding bath or printing color paste is not limited to the above-described methods. It is not always necessary for the cellulose swelling agent and acid coupler to be present in the padding bath or printing color paste, and they may be added in advance to cellulose fibers. Any cellulose fiber-swelling agents can be used as long as they have a boiling point of at least 150° C. and have the effect of swelling cellulose fibers. Examples are ureas, such as N,N,N',N'-tetramethylurea, polyhydric alcohols, such as polyethylene glycol and polypropylene glycol, and their derivatives. In particular, polyhydric alcohol derivatives which are prepared by dimethylating or diacetylating both terminal hydroxy groups of polyethylene glycol, polypropylene glycol, or the like having an average molecular weight of from about 200 to 500 and which do not react with the reactive groups of the dye are preferred as cellulose fiber swelling agents.
The amount of the cellulose fiber-swelling agent used is appropriately from 5 to 25% by weight, preferably from 8 to 15% by weight, based on the padding bath or printing color paste.
The above-described cellulose-containing fibers are dyed with the dyes represented by the general formula (I) by the usual method. For example, a cellulose-containing fiber material is impregnated or printed with a padding bath or printing color pastes as prepared by the above-described method, heat-treated with hot air or super heated steam maintained at 160° to 220° C. for 0.5 to 10 minutes, or treated in high pressure saturated steam maintained at 120° to 150° C. for 3 to 30 minutes and, thereafter, washed with heated water containing a surface active agent, an o/w or w/o emulsion cleaning bath in which the oil phase is halogenated hydrocarbon such as tetrachloroethylene, or by the usual dry cleaning method.
In accordance with the above-described method, there can be obtained a dyed product which is sharp and uniformly dyed in a color having good light fastness and moisture fastness.
The following examples are given to illustrate the invention in greater detail although the invention is not limited thereto. All parts are by weight.
EXAMPLE 1
A dye composition consisting of 15 parts of a disazo dye represented by the formula: ##STR5## 15 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 70 parts of water was finely dispersed by the use of a paint shaker as a finely dispersing apparatus to prepare a dye dispersion. The thus-prepared dye dispersion was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 6.55% Aqueous sodium alginate solution 55Polyethylene glycol dimethyl ethyl 9having an average molecular weightof 400Water 29.5Total 100 (pH: 8.0)______________________________________
A polyester/cotton mixed cloth (mixing ratio: 65/35) was printed with the above-prepared printing color paste by the use of a screen printing machine, which was then subjected to intermediate drying at 80° C. for 3 minutes and fixed by dry heating at 215° C. for 90 seconds. The cloth was washed with water and, thereafter, was subjected to soaping using a cleaning liquid containing 2 g/l of a nonionic surface active agent (Scorerol #900 (trade name) produced by Kao Sekken Co., Ltd.) at 80° C. for 20 minutes at a bath ratio of 1:30. There was thus obtained a product dyed in red having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows. 3',4'-Dichloro-4-aminoazobenzene was diazotized by the usual method and coupled with 2-(m-hydroxy)anilinio-3-cyano-4-methyl-6-(γ-methoxypropylamino)pyridine to obtain a dye. A mixture of 5.76 g of the above-obtained dye, 2.1 g of 2,4-difluoror-6-(diethyl)aminotriazine, 1.0 g of triethylamine, and 1.0 g of anhydrous potassium carbonate was added to 100 ml of acetone and heated at reflux for 3 hours to achieve a condensation reaction. The reaction solution was then added dropwise to 1,000 ml of water to form a precipitate. The precipitate was separated by filtration, washed with water, and dried at room temperature to obtain 7.1 g of red powder of the dye represented by the above-described formula (yield: 95%). For this dye, λmax (acetone) was 505 nm.
EXAMPLE 2
A dye composition consisting of 15 parts of a disazo dye represented by the formula: ##STR6## 10 parts of a Pluronic surface active agent (Pluronic L64 (trade name) produced by Asahi Denka Kogyo Co., Ltd.), and 75 parts of water was finely dispersed by the use of a sand grinder as a finely dispersing apparatus to prepare a dye dispersion. This dye dispersion was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 75% Aqueous sodium alginate solution 55Diacetate of polypropylene glycol 10having an average molecular weightof 300Polyethylene glycol diglycidyl ether 3having an average molecular weightof 200Water 25Total 100 (pH: 6.5)______________________________________
A cotton broad (cotton yarn number: 40) which had been subjected to silket processing was printed with the above-prepared printing color paste by the use of a screen printing machine, was subjected to intermediate drying at 80° C. for 3 minutes, and then, was treated with super heated steam at 185° C. for 7 minutes. Thereafter, washing processing was performed in the same manner as in Example 1, and there was thus obtained a product dyed in red having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows. 2'-Trifluoromethyl-4'-chloro-4-aminoazobenzene was diazotized by the usual method and coupled with 2-(p-hydroxy)anilino-3-cyano-4-methyl-6-(β-hydroxyethylamino)pyridine to prepare a dye. The dye thus obtained was reacted with 2,4-difluoro-6-[di(n-propyl)amino]triazine in N-methyl-2-pyrrolidone by the use of triethylamine as an acid-removing agent to obtain the dye represented by the above-described formula. For this dye, λmax (acetone) was 506 nm.
EXAMPLE 3
A dye composition consisting of 10 parts of a disazo dye represented by the formula: ##STR7## 2 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 8.9), and 88 parts of diethylene glycol diacetate was ground by the use of a paint conditioner as a finely dispersing apparatus to prepare a dye ink.
A mixture of 10 parts of the dye ink as prepared above and 55 parts of mineral turpentine was gradually poured into 35 parts of an aqueous solution having the composition as described hereinafter while stirring by a homomixer at 5,000 to 7,000 rpm, and the resulting mixture was then stirred until it became uniform to prepare a viscous o/w emulsion type color paste.
______________________________________Composition of Aqueous Solution parts______________________________________Water 31Repitol G (trade name, special 3.8nonionic surface active agent,produced by Dai-ichi Kogyo SeiyakuCo., Ltd.)Sodium trichloroacetate 0.1Total 34.9______________________________________
Using the above-prepared color paste, a polyester/cotton mixed cloth (mixing ratio: 65/35) was printed by the use of a screen printing machine, which was then dried at 100° C. for 2 minutes and treated with super heated steam at 175° C. for 7 minutes. Thereafter, when the cloth was washed with a hot tetrachloroethylene bath containing a small amount of water and dried, there was obtained a product dyed in red having excellent light fastness and wet color fastness and free from contamination in the white background.
The dye used in this example was prepared as follows. 3',5'-Dichloro-3-methyl-4-aminoazobenzene was diazotized by the usual method and coupled with 2-ethoxyethylamino-3-cyano-4-methyl-6-(p-hydroxyphenylethylamino)pyridine to prepare a dye. The dye thus prepared was then reacted with 2,4-difluoro-6-piperidinotriazine in the same manner as in Example 1 to obtain the desired dye. For this dye, λmax (acetone) was 506 nm.
EXAMPLE 4
A dye composition consisting of 16 parts of a disazo dye represented by the formula: ##STR8## 7 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 13.3), 3 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 74 parts of water was finely dispersed by the use of a sand grinder to prepare a dye dispersion. This dye dispersion was used to prepare a padding bath having the following composition:
______________________________________ parts______________________________________Dye dispersion 6Tetraethylene glycol dimethyl ether 15Water 79Total 100 (pH: 8.0)______________________________________
A polyester/cotton mixed cloth (mixing ratio: 65/35) was impregnated with the above-prepared padding bath, squeezed at a squeezing ratio of 45%, dried at 100° C. for 2 minutes, and fixed by dry heating at 200° C. for 1 minute. By washing the cloth with a hot ethanol bath, there was obtained a product dyed in red having excellent light fastness and wet color fastness.
The dye used in this example was prepared in the same manner as in Example 1. For this dye, λmax (acetone) was 506 nm.
EXAMPLE 5
Printing was performed in the same manner as in Example 1 except that a nylon/rayon mixed cloth (mixing ratio: 50/50) was used, and the dry heating fixing temperature was 185° C. There was obtained a product dyed in red having good wet color fastness and light fastness.
EXAMPLE 6
Using a series of disazo dyes as shown in Tables 1 to 15, printing was performed in the same manner as in Example 1. All dyed products had good light fastness and wet color fastness. The hue of each dyed cloth and λmax (acetone) of dye are shown in Tables 1 to 15.
TABLE 1__________________________________________________________________________ ##STR9## No. ##STR10## ##STR11## X Z Hue of Dyed λmax (acetone) (nm)__________________________________________________________________________ ##STR12## ##STR13## H N(C.sub.3 H.sub.6 CN).sub.2 red 505 2 ##STR14## " CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.3 ##STR15## " 504 3 ##STR16## " " N[C.sub.3 H.sub.7 (n)].sub.2 " 505 4 ##STR17## " " ##STR18## " " 5 " ##STR19## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 N(CH.sub.2CHCH.sub.2).sub.2 " 506 6 " ##STR20## " NH.sub.2 deep red 510 7 ##STR21## ##STR22## " ##STR23## red 506 8 ##STR24## ##STR25## ##STR26## ##STR27## " 505 9 " ##STR28## " N(CH.sub.2 CH.sub.2 CH.sub.2 OH).sub.2 " 508 10 ##STR29## ##STR30## " ##STR31## " 504 11 " " ##STR32## N[C.sub.5 H.sub.11 (n)].sub.2 " "12 " ##STR33## " ##STR34## " 506 13 ##STR35## ##STR36## CH.sub.2 CH.sub.2 CH.sub.2 OCH.sub.3 ##STR37## deep red 510 14 " " " ##STR38## " " 15 " ##STR39## C.sub.3 H.sub.7 (i) N[C.sub.3 H.sub.6 N(CH.sub.3).sub.2 "sub.2 512 16 ##STR40## ##STR41## " N[C.sub.9 H.sub.19 (n)].sub.2 " 510 17 " " " NHC.sub.7 H.sub.15 (n) " " 18 " ##STR42## CH.sub.2 CH.sub.2 CH.sub.2 OH ##STR43## " 513__________________________________________________________________________
TABLE 2__________________________________________________________________________ ##STR44## No. ##STR45## ##STR46## X Z Dyed ClothHue (nm)(acetone)λmax__________________________________________________________________________19 ##STR47## ##STR48## C.sub.4 H.sub.9 (i) ##STR49## red 506 20 ##STR50## " CH.sub.3 ##STR51## " " 21 " ##STR52## C.sub.2 H.sub.4 OCH.sub.3 ##STR53## deep red 510 22 ##STR54## ##STR55## " ##STR56## red 506 23 ##STR57## " " ##STR58## " " 24 ##STR59## ##STR60## ##STR61## NH.sub.2 " 508 25 " ##STR62## CH.sub.2CHCH.sub.2 N[C.sub.3 H.sub.7 (i)].sub.2 " 506 26 ##STR63## " C.sub.2 H.sub.4 OCH.sub.3 NHC.sub.3 H.sub.7 (i) deep red 509 27 ##STR64## " " N(C.sub.2 H.sub.4 CN).sub.2 red 506 28 ##STR65## " H N(CH.sub.2CHCH.sub.2).sub.2 " " 29 " ##STR66## CH.sub.2 CH.sub.2 OCH.sub.3 ##STR67## deep red 509 30 " ##STR68## ##STR69## N[C.sub.3 H.sub.7 (i)].sub.2 " 508 31 ##STR70## ##STR71## C.sub.5 H.sub.11 (n) ##STR72## red 506 32 " " " N(C.sub.2 H.sub.5).sub.2 " " 33 " ##STR73## CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OH N(C.sub.2 H.sub.4 CN).sub.2 red-brown 512 34 ##STR74## ##STR75## " N[C.sub.6 H.sub.13 (sec)].sub.2 deep red 509 35 " ##STR76## CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.2 H.sub.5 N(C.sub.2 H.sub.4 OH).sub.2 " 510 36 " ##STR77## C.sub.3 H.sub.7 (n) N(C.sub.2 H.sub.5).sub.2 " "__________________________________________________________________________
TABLE 3__________________________________________________________________________ ##STR78## No. ##STR79## ##STR80## X Z Dyed ClothHue (nm)(acetone).la mbda.max__________________________________________________________________________37 ##STR81## ##STR82## (CH.sub.2).sub.3 O(C.sub.2 H.sub.4 O).sub.2 CH.sub.3 ##STR83## red 505 38 ##STR84## ##STR85## C.sub.4 H.sub.9 (i) NHCH.sub.3 " 507 39 ##STR86## ##STR87## ##STR88## ##STR89## deep red 511 40 ##STR90## ##STR91## ##STR92## N[C.sub.3 H.sub.7 (n)].sub.2 red 505 41 ##STR93## " C.sub.3 H.sub.6 OCH.sub.3 NH(CH.sub.2).sub.8 CHCH(CH.sub.2).sub.7 CH.sub.3 " 504__________________________________________________________________________
TABLE 4__________________________________________________________________________ ##STR94## No. ##STR95## ##STR96## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________42 ##STR97## ##STR98## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 N[C.sub.9 H.sub.19 (n)].sub.2 red 506 43 ##STR99## " " ##STR100## " " 44 ##STR101## ##STR102## " N[C.sub.3 H.sub.7 (i)].sub.2 deep red 510 45 ##STR103## ##STR104## " N[C.sub.4 H.sub.9 (n)].sub.2 red 507 46 ##STR105## ##STR106## C.sub.6 H.sub.13 (n) N[C.sub.4 H.sub.9 (sec)].sub.2 red 506 47 ##STR107## ##STR108## (CH.sub.2).sub.3 O(CH.sub.2).sub.2 OH ##STR109## deep red 512__________________________________________________________________________
TABLE 5__________________________________________________________________________ ##STR110## No. ##STR111## ##STR112## X Z Dyed ClothHue (nm)(acetone)λmax__________________________________________________________________________48 ##STR113## ##STR114## ##STR115## ##STR116## red 506 49 ##STR117## ##STR118## " ##STR119## deep red 510 50 ##STR120## ##STR121## CH.sub.2 CH.sub.2 OC.sub.3 H.sub.7 (i) ##STR122## " 511 51 ##STR123## " " ##STR124## red 505__________________________________________________________________________
TABLE 6__________________________________________________________________________ ##STR125## No. ##STR126## ##STR127## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________52 ##STR128## ##STR129## (CH.sub.2).sub.5 OH NHC.sub.3 H.sub.6 OH red 50653 ##STR130## " " N(C.sub.2 H.sub.4 OC.sub.2 H.sub.5).sub.2 " " 54 ##STR131## " " ##STR132## deep red 511 55 ##STR133## ##STR134## C.sub.4 H.sub.9 (sec) ##STR135## red 506__________________________________________________________________________
TABLE 7__________________________________________________________________________ ##STR136## No. ##STR137## ##STR138## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________56 ##STR139## ##STR140## ##STR141## ##STR142## red 506 57 ##STR143## ##STR144## CH.sub.2CHCH.sub.2 ##STR145## deep red 511 58 ##STR146## ##STR147## C.sub.3 H.sub.6 OCH.sub.3 ##STR148## " 509 59 ##STR149## " " N(C.sub.2 H.sub.4 CN).sub.2 red 504__________________________________________________________________________
TABLE 8__________________________________________________________________________ ##STR150## No. ##STR151## ##STR152## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________60 ##STR153## ##STR154## ##STR155## N(C.sub.2 H.sub.5).sub.2 red 505 61 ##STR156## " CH.sub.3 NHC.sub.6 H.sub.13 (sec) " " 62 ##STR157## ##STR158## " N[C.sub.3 H.sub.7 (n)].sub.2 deep red 507 63 ##STR159## ##STR160## C.sub.3 H.sub.7 (i) N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 red 507 64 ##STR161## " C.sub.2 H.sub.4 OH ##STR162## deep red 511__________________________________________________________________________
TABLE 8__________________________________________________________________________ ##STR163## No. ##STR164## ##STR165## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________65 ##STR166## ##STR167## C.sub.3 H.sub.6 OCH.sub.3 NHC.sub.3 H.sub.6 OH red 507 66 ##STR168## ##STR169## " N[C.sub.3 H.sub.7 (i)].sub.2 red-brown 514 67 ##STR170## ##STR171## " NHC.sub.2 H.sub.4 OH deep red 511 68 ##STR172## ##STR173## C.sub.3 H.sub.6 OCH.sub.3 N(C.sub.2 H.sub.5).sub.2 red 506 69 ##STR174## " CH.sub.3 ##STR175## deep red 511__________________________________________________________________________
TABLE 10__________________________________________________________________________ ##STR176## No. ##STR177## ##STR178## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________70 ##STR179## ##STR180## C.sub.2 H.sub.4 OH N[C.sub.7 H.sub.15 (n)].sub. 2 deep red 513 71 ##STR181## ##STR182## (CH.sub.2).sub.6 OH ##STR183## red 505 72 ##STR184## " " ##STR185## " " 73 ##STR186## " (CH.sub.2).sub.2 OH ##STR187## " 503 74 ##STR188## " C.sub.6 H.sub.13 (n) N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 " 506__________________________________________________________________________
TABLE 11__________________________________________________________________________ ##STR189## No. ##STR190## ##STR191## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________75 ##STR192## ##STR193## (CH.sub.2).sub.3 OH ##STR194## red 505 76 " ##STR195## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OH N(C.sub.3 H.sub.6 CN).sub.2 deep red 509 77 ##STR196## ##STR197## ##STR198## N(C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OCH.sub.3).s ub.2 red 504 78 ##STR199## ##STR200## H ##STR201## " 506 79 ##STR202## ##STR203## C.sub.3 H.sub.7 (i) N(CH.sub.3).sub.2 " 504__________________________________________________________________________
TABLE 12__________________________________________________________________________ ##STR204## No. ##STR205## ##STR206## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________80 ##STR207## ##STR208## CH.sub.2CHCH.sub.2 ##STR209## red 507 81 " ##STR210## (CH.sub.2).sub.4 OH NHC.sub.7 H.sub.15 (n) " 505 82 ##STR211## " C.sub.3 H.sub.6 OC.sub.3 H.sub.7 (i) NHC.sub.3 H.sub.7 (i) " "83 ##STR212## ##STR213## C.sub.4 H.sub.9 (i) N[C.sub.4 H.sub.9 (i)].sub.2 deep red 513__________________________________________________________________________
TABLE 13__________________________________________________________________________ ##STR214## No. ##STR215## ##STR216## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________84 ##STR217## ##STR218## (CH.sub.2).sub.5 OH NHCH.sub.3 deep red 51185 ##STR219## ##STR220## C.sub.3 H.sub.6 OC.sub.2 H.sub.4 OCH.sub.3 N[C.sub.4 H.sub.9 (n)].sub.2 " 509 86 ##STR221## ##STR222## " ##STR223## red 507 87 ##STR224## ##STR225## H NH.sub.2 " 506__________________________________________________________________________
TABLE 14__________________________________________________________________________ ##STR226## No. ##STR227## ##STR228## X Z Dyed ClothHue of (nm)(acetone)λmax__________________________________________________________________________88 ##STR229## ##STR230## ##STR231## N[C.sub.3 H.sub.7 (n)].sub.2 red 505 89 ##STR232## ##STR233## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 ##STR234## deep red 511 90 ##STR235## ##STR236## C.sub.3 H.sub.6 OH(n) N(C.sub.2 H.sub.5).sub.2 red 505__________________________________________________________________________
TABLE 15__________________________________________________________________________ ##STR237## No.D m Z ##STR238## (T/C mixed cloth)Hue of Dye Cloth (acetone) (nm)λmax__________________________________________________________________________91##STR239## 2 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 ##STR240## red-brown 483 92##STR241## " OCH.sub.3 ##STR242## red 485 93 " 3 OC.sub.2 H.sub.5 ##STR243## " 487 94##STR244## 2 ##STR245## ##STR246## bluish red 512 95 " " OCH.sub.3 ##STR247## " " 96##STR248## " OC.sub.3 H.sub.7 (n) ##STR249## orange 470 97 " 3 " ##STR250## " 472 98##STR251## 2 OC.sub.2 H.sub.4 OCH.sub.3 ##STR252## gold 469 99##STR253## " OC.sub.3 H.sub.6 OC.sub.2 H.sub.5 " " 461 100##STR254## " OC.sub.2 H.sub.5 ##STR255## yellowish red 489 101 " 3 OC.sub.4 H.sub.9 (t) ##STR256## " " 102##STR257## 2 OCH.sub.3 ##STR258## " 499 103##STR259## " " ##STR260## red 501 104##STR261## " OC.sub.2 H.sub.5 ##STR262## " 503 105 " 3 ##STR263## " " 505 106 " 2 OCH.sub.3 ##STR264## " 501 107##STR265## " OC.sub.3 H.sub.7 (n) ##STR266## " 503 108 " " OC.sub.2 H.sub.4 OCH.sub.3 ##STR267## " 501 109##STR268## " OCH.sub.3 ##STR269## deep red 505 110##STR270## " ##STR271## " " " 111 " " OC.sub.4 H.sub.9 (sec) ##STR272## " 503 112##STR273## " OC.sub.3 H.sub.7 (i) ##STR274## " 507 113 " 3 OCH.sub.3 " " 508 114##STR275## 2 OC.sub.2 H.sub.5 " " 505 115 " 3 OC.sub.2 H.sub.4 OCH.sub.3 ##STR276## " 506 116##STR277## 2 OC.sub.5 H.sub.11 (n) ##STR278## " 507 117##STR279## " OC.sub.4 H.sub.9 (t) ##STR280## " " 118 " " ##STR281## " " " 119 " 3 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 ##STR282## " 508 120##STR283## 2 OC.sub.3 H.sub.6 OCH.sub.3 ##STR284## " 506 121##STR285## 3 OCH.sub.3 ##STR286## " 509 122##STR287## 2 OC.sub.2 H.sub.5 ##STR288## orange 468 123##STR289## " OC.sub.3 H.sub.7 ##STR290## " " 124##STR291## " OC.sub.2 H.sub.5 ##STR292## red 494 125 " " " ##STR293## " 492 126##STR294## " OC.sub.5 H.sub.11 (sec) ##STR295## reddish blue 594 127 " 3 OC.sub.2 H.sub.5 " " 595 128 " 2 OC.sub.3 H.sub.7 (i) ##STR296## " 592 129 " 3 OC.sub.4 H.sub.9 (sec) ##STR297## " 593__________________________________________________________________________
EXAMPLE 7
A dye composition consisting of 15 parts of a disazo dye represented by the formula: ##STR298## 15 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 70 parts of water was finely dispersed by the use of a paint shaker as a finely dispersing apparatus to prepare a dye dispersion. This dye dispersion was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 6.55% Aqueous sodium alginate solution 55Polyethylene glycol dimethyl ether 9having an average molecular weightof 400Water 29.5Total 100 (pH 8.0)______________________________________
The thus-prepared printing color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printer, was subjected to intermediate drying at 80° C. for 3 minutes, and was fixed by dry heating at 215° C. for 90 seconds. The cloth was then washed with water and was subjected to soaping using a cleaning liquid containing 2 g/l of a nonionic surface active agent (Scorerol #900 (trade name), produced by Kao Sekken Co., Ltd.) at 80° C. for 20 minutes at a bath ratio of 1:30. There was thus obtained a product dyed in yellowish red having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows.
In accordance with the usual method, 4-aminoazobenzene was diazotized and coupled with 2(m-hydroxy)anilino-3-cyano-4-methyl-6-(Υ-methoxypropylamino)pyridine to prepare a dye. A mixture of 5.07 g of the above-prepared dye, 2.1 g of 2,4-difluoro-6-(diethyl)aminotriazine, and 1.0 g of anhydrous potassium carbonate was added to 100 ml of acetone and heated at reflux to achieve a condensation reaction. The resulting reaction solution was added dropwise to 1,000 ml of water. The precipitate thus obtained was separated by filtration, washed with water, and dried at room temperature to obtain 6.5 g of red powder of the dye represented by the above-described formula. For this dye, λmax (acetone was 490 nm.
EXAMPLE 8
A dye composition consisting of 15 parts of a disazo dye represented by the formula: ##STR299## 10 parts of a Pluronic surface active agent, Pluronic L64 (trade name, produced by Asahi Denka Kogyo Co., Ltd.), and 7.5 parts of water was finely dispersed by the use of a sand grinder as a finely dispersing apparatus to prepare a dye. This dye was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 75% Aqueous sodium alginate solution 55Diacetate of polypropylene glycol 10having an average molecular weightof 300Polyethylene glycol diglycidyl ether 3having an average molecular weightof 200Water 25Total 100 (pH: 6.5)______________________________________
The above-prepared printing color paste was printed on a cotton broad (cotton yarn number: 40) which had been subjected to silket processing, by the use of a screen printing machine, was subjected to intermediate drying at 80° C. for 3 minutes, and was treated with super heated steam at 185° C. for 7 minutes. Thereafter, a cleaning processing was performed in the same manner as in Example 7, and there was thus obtained a product dyed in reddish brown having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows.
In accordance with the usual method, 1-aminoanthraquinone was diazotized and coupled with 2-(p-hydroxy)anilino-3-cyano-4-methyl-6-(β-hydroxyethylamino)pyridine to prepare a dye. The dye thus formed was then reacted with 2,4-difluoro-6-[di(n-propyl)amino]triazine in N-methyl-2-pyrrolidone by the use of triethylamine as an acid-removing agent to obtain the desired dye. For this dye, λmax (acetone) was 483 nm.
EXAMPLE 9
A dye composition consisting of 10 parts of a monoazo dye represented by the formula: ##STR300## 2 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 8.9), and 88 parts of diethylene glycol diacetate was finely dispersed by the use of a paint conditioner as a finely dispersing apparatus to prepare a dye ink.
A mixture of 10 parts of the above-prepared dye ink and 55 parts of mineral turpentine was gradually poured into 35 parts of an aqueous solution having the composition as described hereinafter while stirring by a homomixer at 5,000 to 7,000 rpm, and the resulting mixture was stirred until it became uniform to prepare a viscous o/w emulsion type color paste.
______________________________________Composition of Aqueous Solution parts______________________________________Water 31Repitol G (trade name, special 3.8nonionic surface active agent,produced by Dai-ichi Kogyo SeiyakuCo., Ltd.)Sodium trichloroacetate 0.1Total 34.9______________________________________
This color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printing machine, dried at 100° C. for 2 minutes, and treated with super heated steam at 175° C. for 7 minutes. Thereafter, the cloth was washed with a hot tetrachloroethylene bath containing a small amount of water and dried, and there was thus obtained a golden dyed product having excellent light fastness and wet color fastness, and free from contamination in the white background.
The dye used in this example was prepared as follows.
In accordance with the usual method, 2-chloro-4-methylsulfonylaniline was diazotized and coupled with 2-(p-hydroxyphenylethylamino)-3-cyano-4-methyl-6-ethoxyethylaminopyridine to form a dye. The dye thus formed was reacted with 2,4-difluoro-6-piperidinotriazine in the same manner as in Example 7 to obtain the desired dye. For this dye, λmax (acetone) was 469 nm.
EXAMPLE 10
A dye composition consisting of 16 parts of a disazo dye represented by the formula: ##STR301## 7 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 13.3), 3 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 74 parts of water was finely dispersed by the use of a sand grinder to prepare a dye dispersion. This dye dispersion was used to prepare a padding bath having the following composition:
______________________________________ parts______________________________________Dye dispersion 6Tetraethylene glycol dimethyl ether 15Water 79Total 100 (pH: 8.0)______________________________________
A polyester/cotton mixed cloth (mixing ratio: 65/35) was impregnated with the above-prepared padding bath, squeezed at a squeezing ratio of 45%, dried at 100° C. for 2 minutes, and fixed by dry heating at 200° C. for 1 minute. By washing the cloth with a hot ethanol bath, there was obtained a product dyed in red having excellent light fastness and wet color fastness.
The dye used in this example was prepared in the same manner as in Example 7. For this dye, λmax (acetone) was 503 nm.
EXAMPLE 11
Printing was performed in the same manner as in Example 1 except that a nylon/rayon mixed cloth (mixing ratio: 50/50) was used and the dry heating fixing temperature was 185° C. There was thus obtained a product dyed in red having good light fastness and wet color fastness.
EXAMPLE 12
Using a series of azo dyes as shown in Tables 16 to 22, printing was performed in the same manner as in Example 7.
All dyed clothes had good light fastness and wet color fastness. The hue of each dyed cloth and λmax (acetone) of each dye are shown in Tables 16 to 22.
TABLE 16__________________________________________________________________________ ##STR302## λmax Hue (acetone)No. D Z W Dyed (nm)h__________________________________________________________________________ ##STR303## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 N[CH.sub.2 CH.sub.2 N(CH.sub.3).su b.2 ].sub.2 red-orange 472 2 " H ##STR304## " 468 3 ##STR305## ##STR306## N(CH.sub.2 CH.sub.2 CH.sub.2 OH).sub.2 deep 513 4 " CH.sub.2 CH.sub.2 CH.sub.2 OCH.sub.3 ##STR307## " " 5 ##STR308## C.sub.5 H.sub.11 (n) ##STR309## red-orange 476 6 ##STR310## (CH.sub.2).sub.3 O(CH.sub.2).sub.2 OH ##STR311## reddish yellow 469 7 ##STR312## CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.3 H.sub.7 ##STR313## reddish yellow 470 8 ##STR314## C.sub.4 H.sub. 9 (sec) NH.sub.2 red 503 9 ##STR315## (CH.sub.2).sub.5 OH NHC.sub.3 H.sub.7 (i) " " 10 " CH.sub.2 CH.sub.2 OH N[C.sub.4 H.sub.9 (sec)].sub.2 " 512 11 " (CH.sub.2).sub.3 O(C.sub.2 H.sub.4 O).sub.2 CH.sub.3 ##STR316## " 513 12 ##STR317## ##STR318## ##STR319## orange 469 13 ##STR320## C.sub.4 H.sub.9 (i) ##STR321## " " 14 " C.sub.5 H.sub.11 (sec) ##STR322## red 493 15 " (CH.sub.2).sub.2 O(CH.sub.2).sub.2 OH NHC.sub.5 H.sub.11 (i) " " 16 ##STR323## CH.sub.2 CH.sub.2 CH.sub.2 OH ##STR324## reddish blue 593 17 " ##STR325## N(C.sub.2 H.sub.5).sub.2 reddish blue "__________________________________________________________________________
TABLE 17__________________________________________________________________________ ##STR326## λmax Hue (acetone)No. D Z W Dyed (nm)h__________________________________________________________________________18 ##STR327## CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.2 H.sub.5 ##STR328## reddish yellow 471 19 " C.sub.2 H.sub.5 ##STR329## reddish yellow " 20 ##STR330## (CH.sub.2).sub.3 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 N(CH.sub.2 CH.sub.2 OCH.sub.3).sub.2 bluish 513 21 " ##STR331## ##STR332## " 514 22 ##STR333## C.sub.3 H.sub.7 (i) N(CH.sub.3).sub.2 yellowish red 487 23 " CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.2 H.sub.5 NH.sub.2 yellowish 486 red 24 ##STR334## C.sub.5 H.sub.11 (sec) ##STR335## red 492 25 ##STR336## CH.sub.2 CH.sub.2 OH ##STR337## " 501 26 ##STR338## CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OH N[C.sub.3 H.sub.7 (i)].sub.2 " 502 27 ##STR339## CH.sub.2 CH.sub.2 CH.sub.2 OH ##STR340## reddish yellow 470 28 ##STR341## H ##STR342## reddish orange 478 29 ##STR343## ##STR344## N(C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OCH.sub.3).sub.2 red 502 30 ##STR345## CH.sub.2 CH.sub.2 OCH.sub.3 ##STR346## yellowish red 494 31 ##STR347## (CH.sub.2).sub.3 O(CH.sub.2).sub.4 OH ##STR348## red 503 32 ##STR349## ##STR350## N[C.sub.4 H.sub.9 (sec)].sub.2 " 500 33 ##STR351## C.sub.5 H.sub.11 (n) N(CH.sub.2CHCH.sub.2).sub.2 orange 473 34 ##STR352## C.sub.2 H.sub.4 OH N[C.sub.3 H.sub.7 (i)].sub.2 red 492__________________________________________________________________________
TABLE 18__________________________________________________________________________ ##STR353## λmax Hue (acetone)No. D Z W Dyed (nm)h__________________________________________________________________________35 ##STR354## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OCH.sub.3 NHC.sub.2 H.sub.4 OH yellow 461 36 ##STR355## ##STR356## NHC.sub.5 H.sub.11 (n) bluish red 513 37 ##STR357## C.sub.4 H.sub.9 (i) N[C.sub.6 H.sub.13 (n)].sub.2 bluish red 514 38 ##STR358## C.sub.2 H.sub.4 OH NH(CH.sub.2).sub.8 CHCH(CH.sub.2).sub.7 CH.sub.3 bluish red 512 39 ##STR359## CH.sub.3 N[C.sub.9 H.sub.19 (n)].sub.2 orange 469 40 ##STR360## C.sub.2 H.sub.4 OCH.sub.3 N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 red-brown 486 41 ##STR361## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 N[C.sub.3 H.sub.7 (n)].sub.2 reddish blue 592__________________________________________________________________________
TABLE 19__________________________________________________________________________ ##STR362## λmax Hue of (acetone)No. D- Z W Dyed Cloth (nm)__________________________________________________________________________42 ##STR363## CH.sub.2 CH.sub.2 CH.sub.2 OH ##STR364## yellowish red 495 43 ##STR365## " ##STR366## orange 465 44 ##STR367## " N(C.sub.2 H.sub.4 CN).sub.2 bluish red 513 45 ##STR368## CH.sub.2 CH.sub.2 OC.sub.2 H.sub.5 N[C.sub.5 H.sub.11 (i)].sub.2 yellowish red 491 46 ##STR369## " ##STR370## red 510 47 ##STR371## CH.sub.2 CH.sub.2 OC.sub.2 H.sub.5 NH.sub.2 bluish red 523 48 ##STR372## C.sub.4 H.sub.9 (n) NHC.sub.18 H.sub.37 (n) orange 472__________________________________________________________________________
TABLE 20__________________________________________________________________________ ##STR373## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________49 ##STR374## ##STR375## N[C.sub.3 H.sub.7 (i)].sub.2 yellowish red 489 50 ##STR376## " N[C.sub.4 H.sub.9 (n)].sub.2 red-brown 487 51 ##STR377## " NHC.sub.7 H.sub.15 (sec) orange 465 52 ##STR378## CH.sub.2 CH.sub.2 CH.sub.2 OCH.sub.3 ##STR379## red-orange 479 53 ##STR380## " N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 yellowish red 491 54 ##STR381## C.sub.3 H.sub.7 (i) N(C.sub.2 H.sub.4 OH).sub.2 red 505 55 ##STR382## C.sub.2 H.sub.4 OH ##STR383## deep red 511__________________________________________________________________________
TABLE 21__________________________________________________________________________ ##STR384## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________56 ##STR385## ##STR386## ##STR387## bluish red 514 57 ##STR388## " NHC.sub.14 H.sub.29 (sec) reddish yellow 469 58 ##STR389## CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.3 H.sub.7 (i) ##STR390## orange 471 59 ##STR391## " ##STR392## red 492 60 ##STR393## CH.sub.2 CH.sub.2 CH.sub.2 OC.sub.3 H.sub.7 (i) N(CH.sub.2CHCH.sub.2).sub.2 " 501 61 ##STR394## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 NHC.sub.2 H.sub.5 " " 62 ##STR395## " N[C.sub.3 H.sub.7 (i)].sub.2 " 504__________________________________________________________________________
TABLE 22__________________________________________________________________________ ##STR396## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________63 ##STR397## ##STR398## ##STR399## red 505 64 ##STR400## " ##STR401## reddish orange 479 65 ##STR402## C.sub.6 H.sub.13 (i) N[C.sub.3 H.sub.7 (n)].sub.2 yellowish red 491 66 ##STR403## " N[C.sub.7 H.sub.15 (n)].sub.2 bluish red 518 67 ##STR404## CH.sub.2 CH.sub.2 OC.sub.2 H.sub.4 OH ##STR405## orange 466 68 ##STR406## " ##STR407## red 493__________________________________________________________________________
EXAMPLE 13
A dye composition consisting of 15 parts of a disazo dye represented by the formula: ##STR408## 15 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 70 parts of water was finely dispersed by the use of a paint shaker as finely dispersing apparatus to prepare a dye dispersion. This dye dispersion was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 6.55% Aqueous sodium alginate solution 55Polyethylene glycol dimethyl ether 9having an average molecular weightof 400Water 29.5Total 100 (pH 8.0)______________________________________
The thus prepared printing color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printing machine, was subjected to intermediate drying at 80° C. for 3 minutes, and was fixed by dry heating at 125° C. for 90 seconds. The cloth was then washed with water, and was subjected to soaping using a cleaning liquid containing 2 g/l of a nonionic surface active agent (Scorerol #900 (trade name), produced by Kao Sekken Co., Ltd.) at 80° C. for 20 minutes at a bath ratio of 1:30. There was thus obtained a product dyed in yellowish red having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows.
In accordance with the usual method, 4-aminoazobenzene was diazotized and coupled with 2-(γ-methoxypropylamino)-3-cyano-4-methyl-6-(m-hydroxyanilino)pyridine to form a dye. A mixture of 5.07 g of the above prepared dye, 2.1 g of 2,4-difluoro-6-(diethyl)aminotriazine, 1.0 g of triethylamine, and 1.0 g of anhydrous potassium carbonate was added to 100 ml of acetone and heated at reflux for 3 hours to achieve a condensation reaction. The reaction solution was then added dropwise to 1,000 ml of water, and the precipitate thus formed was separated by filtration, washed with water, and dried at room temperature to obtain 6.4 g of red powder of the dye represented by the above described formula. For this dye, λmax (acetone) was 490 nm.
EXAMPLE 14
A dye composition consisting of 15 parts of a monoazo dye represented by the formula: ##STR409## 10 parts of a Pluronic surface active agent, Pluronic L64 (trade name, produced by Asahi Denka Kogyo Co., (Ltd.), and 75 parts of water was finely dispersed by the use of a sand grinder as a finely dispersing apparatus to prepare a dye dispersion. This dye dispersion was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 75% Aqueous sodium alginate solution 55Diacetate of polypropylene glycol 10having an average molecular weightof 300Polyethylene glycol diglycidyl ether 3having an average molecular weightof 200Water 25Total 100 (pH: 6.5)______________________________________
The thus prepared printing color paste was printed on a cotton broad (cotton yarn number: 40) which had been subjected to silket processing, by the use of a screen printing machine, was subjected to intermediate drying at 80° C. for 3 minutes, and was treated using super heated steam at 185° C. for 7 minutes.
Thereafter, a washing processing was performed in the same manner as in Example 13, and there was thus obtained a product dyed in reddish brown having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows.
In accordance with the usual method, 1-aminoanthraquinone was diazotized and coupled with 2-anilino-3-cyano-4-methyl-6-(4-hydroxybenzylamino)pyridine to form a dye. The dye thus formed was reacted with 2,4-difluoro-6-(N,N-diisopropylamino)triazine in N-methyl-2-pyrrolidone by the use of triethylamine as an acid-removing agent to obtain the desired dye. For this dye, λmax (acetone) was 484 nm.
EXAMPLE 15
A dye composition consisting of 10 parts of a monoazo dye represented by the formula: ##STR410## 2 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 8.9), and 88 parts of diethylene glycol diacetate was ground by the use of a paint conditioner as a finely dispersing apparatus to prepare a dye ink.
A mixture of 10 parts of the above prepared dye ink and 55 parts of mineral turpentine was gradually poured into 35 parts of an aqueous solution having the composition as described hereinafter while stirring by a homomixer at 5,000 to 7,000 rpm, and the resulting mixture was then stirred until it became uniform to obtain a viscous o/w emulsion color paste.
______________________________________Composition of Aqueous Solution parts______________________________________Water 31Repitol G (trade name, special 3.8nonionic surface active agent,produced by Dai-ichi Kogyo SeiyakuCo., Ltd.)Sodium trichloroacetate 0.1Total 34.9______________________________________
The thus prepared color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printing machine, dried at 100° C. for 2 minutes, and treated with super heated steam at 175° C. for 7 minutes. The cloth was washed with a hot tetrachloroethylene bath containing a small amount of water and dried, and there was thus obtained a golden dyed product having excellent light fastness and wet color fastness, and free from contamination in the white background.
The dye used in this example was prepared as follows.
In accordance with the usual method, 2-chloro-4-methylsulfonylaniline was diazotized and coupled with 2-amino-3-cyano-4-methyl-6-(p-hydroxyanilino)pyridine to form a dye. The dye thus formed was reacted at reflux with 2,4-dichloro-6-(n)-hexylaminotriazine in dioxane in the presence of tri-n-butylamine as an acid-removing agent for 3 hours. At the end of the time, the reaction solution was cooled, and crystals separated were collected by filtration to obtain the desired dye. For this dye, λmax (acetone) was 467 nm.
EXAMPLE 16
A dye composition consisting of 16 parts of a disazo dye represented by the formula: ##STR411## 7 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 13.3), 3 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 74 parts of water was finely dispersed by the use of a sand grinder to prepare a dye dispersion. This dye was used to prepare a padding bath having the following composition:
______________________________________ parts______________________________________Dye dispersion 6Tetraethylene glycol dimethyl ether 15Water 79Total 100 (pH: 8.0)______________________________________
A polyester/cotton mixed cloth (mixing ratio: 65/35) was impregnated with the above prepared padding bath, squeezed at a squeezing ratio of 45%, dried at 100° C. for 2 minutes, and fixed by dry heating at 200° C. for 1 minute. The cloth was washed with a hot ethanol bath, and there was thus obtained a product dyed in red having excellent light fastness and wet color fastness.
The dye used in this example was prepared according to the method as described in Example 13. For this dye, λmax (acetone) was 503 nm.
EXAMPLE 17
Printing was performed in the same manner as in Example 13 except that a nylon/rayon mixed cloth (mixing ratio: 50/50) was employed and the dry heating fixing temperature was 185° C. There was obtained a product dyed in red having good light fastness and wet color fastness.
EXAMPLE 18
Using a series of azo dyes as shown in Tables 23 to 30, printing was performed in the same manner as in Example 13.
All dyed clothes had good light fastness and wet color fastness. The hue of each dyed cloth and λmax (acetone) of each dye are shown in Tables 23 to 30.
TABLE 23__________________________________________________________________________ ##STR412## λmax (ace- Hue tone)No. D Z W Dyed (nm)h__________________________________________________________________________ 1 ##STR413## H N(C.sub.2 H.sub.5).sub.2 red 473nge 2 " ##STR414## NHC.sub.2 H.sub.4 OH " 474 3 " C.sub.2 H.sub.4 OCH.sub.3 ##STR415## " " 4 ##STR416## CH.sub.2CHCH.sub.2 ##STR417## deep 514 5 " ##STR418## N[C.sub.3 H.sub.7 (i)].sub.2 " " 6 ##STR419## C.sub.3 H.sub.7 (n) ##STR420## deep 514 7 ##STR421## C.sub.3 H.sub.6 OCH.sub.3 ##STR422## orange 477 8 " C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OCH.sub.3 N(C.sub.2 H.sub.4 OCH.sub.3).sub. 2 " " 9 ##STR423## C.sub.3 H.sub.6 OC.sub.2 H.sub.4 ##STR424## reddish yellow 470 10 ##STR425## C.sub.4 H.sub.9 (n) N(CH.sub.2CHCH.sub.2).sub.2 gold 471 11 ##STR426## C.sub.3 H.sub.6 OC.sub.3 H.sub.7 (i) ##STR427## red 504 12 ##STR428## C.sub.2 H.sub.4 OH N(C.sub.2 H.sub.4 CN).sub.2 red 504 13 ##STR429## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OH ##STR430## " 503 14 ##STR431## " NHC.sub.3 H.sub.7 (i) deep 519 15 ##STR432## C.sub.3 H.sub.6 OH N(n-C.sub.3 H.sub.7).sub.2 orange 471 16 " ##STR433## N(i-C.sub.3 H.sub.7).sub.2 " " 17 ##STR434## C.sub.4 H.sub.9 (i) NHC.sub.6 H.sub.13 (sec) red 495 18 ##STR435## ##STR436## NH.sub.2 reddish blue 595 19 " C.sub.4 H.sub.8 OH N(C.sub.2 H.sub.5).sub.2 " "__________________________________________________________________________
TABLE 24__________________________________________________________________________ ##STR437## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________20 ##STR438## C.sub.2 H.sub.4 OH ##STR439## red orange 473 21 ##STR440## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 N(C.sub.2 H.sub.4 CN).sub.2 yellowish red 489 22 " H ##STR441## yellowish red " 23 ##STR442## ##STR443## ##STR444## reddish yellow 472 24 ##STR445## C.sub.6 H.sub.13 (n) ##STR446## red-brown 490 25 ##STR447## ##STR448## ##STR449## bluish 517 26 ##STR450## C.sub.5 H.sub.11 (n) ##STR451## red 502 27 ##STR452## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OH N(CH.sub.3).sub.2 yellow 464 28 ##STR453## ##STR454## ##STR455## red 509 29 ##STR456## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 N[C.sub.4 H.sub.9 (sec)].sub.2 yellowish red 495 30 ##STR457## " ##STR458## yellowish red 494 31 ##STR459## C.sub.2 H.sub.5 " deep red 503 32 " C.sub.3 H.sub.6 OC.sub.3 H.sub.7 ##STR460## deep red " 33 ##STR461## C.sub.3 H.sub.6 OH NHC.sub.7 H.sub.15 (n) deep red 510 34 ##STR462## C.sub.4 H.sub.8 OH N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 deep red 510 35 ##STR463## H N(C.sub.9 H.sub.19).sub.2 orange 475 36 ##STR464## CH.sub.2CHCH.sub.2 N(CH.sub.2CHCH.sub.2).sub.2 red-brown 488__________________________________________________________________________
TABLE 25__________________________________________________________________________ ##STR465## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________37 ##STR466## C.sub.2 H.sub.4 OH N[C.sub.3 H.sub.6 N(CH.sub.3).sub.2 ].sub.2 orange 473 38 ##STR467## " ##STR468## yellow 463 39 ##STR469## " ##STR470## red-brown 491 40 ##STR471## C.sub.2 H.sub.4 OC.sub.2 H.sub.5 N(CH.sub.2CHCH.sub.2).sub.2 red 503 41 ##STR472## CH.sub.3 ##STR473## " 506 42 ##STR474## C.sub.3 H.sub.6 OH ##STR475## " 494 43 ##STR476## C.sub.3 H.sub.7 (i) ##STR477## reddish blue 595__________________________________________________________________________
TABLE 26__________________________________________________________________________ ##STR478## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________44 ##STR479## C.sub.4 H.sub.9 (i) ##STR480## yellowish red 488 45 ##STR481## H ##STR482## orange 478 46 ##STR483## C.sub.2 H.sub.4 OCH.sub.3 N(C.sub.2 H.sub.5).sub.2 red 504 47 ##STR484## CH.sub.2CHCH.sub.2 N[C.sub.3 H.sub.7 (i)].sub.2 red 508 48 ##STR485## C.sub.3 H.sub.6 OCH.sub.3 N[C.sub.5 H.sub.11 (n)].sub.2 red 510 49 ##STR486## ##STR487## ##STR488## bluish red 524 50 ##STR489## C.sub.2 H.sub.4 OC.sub.3 H.sub.7 (i) ##STR490## orange 471__________________________________________________________________________
TABLE 27__________________________________________________________________________ ##STR491## λmax Hue of (acetone)No. D Z W Dyed (nm)h__________________________________________________________________________51 ##STR492## C.sub.2 H.sub.4 OC.sub.3 H.sub.7 N[C.sub.9 H.sub.19 (n)].sub.2 deep 514 52 ##STR493## ##STR494## N(CH.sub.2 CH.sub.2 CH.sub.2 OH).sub.2 red-brown 488 53 ##STR495## ##STR496## NH(CH.sub.2).sub.8 CHCH(CH.sub.2).sub.7 CH.sub.3 yellow 462 54 ##STR497## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OH ##STR498## red 507 55 ##STR499## CH.sub.2CHCH.sub.2 N[C.sub.3 H.sub.7 (n)].sub.2 red 508 56 ##STR500## ##STR501## ##STR502## red 493 57 ##STR503## C.sub.3 H.sub.6 OH N[C.sub.4 H.sub.9 (n)].sub.2 red 508 58 ##STR504## C.sub.3 H.sub.6 OH NH.sub.2 deep 510__________________________________________________________________________
TABLE 28__________________________________________________________________________ ##STR505## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________59 ##STR506## C.sub.6 H.sub.13 (n) ##STR507## red 502 60 ##STR508## C.sub.2 H.sub. 4 OH N(CH.sub.2CHCH.sub.2).sub.2 " 505 61 ##STR509## ##STR510## N(C.sub.2 H.sub.5).sub.2 reddish yellow 470 62 ##STR511## C.sub.3 H.sub.6 OH ##STR512## orange 472 63 ##STR513## C.sub.4 H.sub.8 OH N(C.sub.2 H.sub.4 OH).sub.2 reddish blue 595__________________________________________________________________________
TABLE 29__________________________________________________________________________ ##STR514## λmax Hue of (acetone)No. D Z W Dyed Cloth (nm)__________________________________________________________________________64 ##STR515## ##STR516## N[C.sub.3 H.sub.7 (n)].sub.2 deep red 514 65 ##STR517## C.sub.2 H.sub.4 OC.sub.2 H.sub.4 OCH.sub.3 N[C.sub.6 H.sub. 13 (sec)].sub.2 yellowish red 492 66 ##STR518## C.sub.3 H.sub.7 (i) ##STR519## red-brown 510 67 ##STR520## CH.sub.3 N(C.sub.2 H.sub.4 CN).sub.2 orange 471 68 ##STR521## C.sub.2 H.sub.4 OH N(C.sub.3 H.sub.6 CN).sub.2 red 496__________________________________________________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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Diaminopyridine-based azo dyes for cellulose-containing fibers, represented by the following formula: ##STR1## and the other is hydrogen, phenyl, benzyl, allyl, or alkyl which are unsubstituted or substituted by hydroxyl or lower alkoxy
(wherein
A is methylene, ethylene, propylene, or 1,3-butylene;
n is 0 or 1;
Y 1 and Y 2 , which are the same or different, are hydrogen, alkyl, alkenyl, cyclohexyl, aryl, or aralkyl which are unsubstituted or substituted by cyano, hydroxy, lower alkoxy, or dialkylamino, or Y 1 and Y 2 together form a 5- or 6-membered heterocyclic ring (NY 1 Y 2 ) containing one nitrogen, the total number of carbon atoms of Y 1 and Y 2 being 18 or less;
R 1 is nitro, cyano, methylsulfonyl, phenylsulfonyl, mono-lower alkylaminosulfonyl, di-lower alkylaminosulfonyl, acetyl, or benzoyl;
R 2 and R 3 , which are the same or different, are hydrogen, trifluoromethyl, halogen, or cyano;
R 4 is hydrogen, lower alkyl, mono- or di-lower alkylaminosulfonyl, mono/or di-lower alkylcarbamoyl, or acetylamino;
R 5 and R 6 , which are the same or different, are hydrogen, halogen, or lower alkyl;
R 7 is lower alkyl;
R 8 is trifluoromethyl, or halogen; and
R 9 is hydrogen, or halogen).
The dyes are useful for dyeing cellulose-containing fibers, particularly cellulose fibers and mixed fibers of polyester fibers and cellulose fibers in from orange to blue.
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FIELD OF THE INVENTION
This invention pertains to the field of foot coverings. More particularly, this invention relates to foot coverings and protective gear for large, solid-hoofed quadrupeds of the Equus Caballus or horse family.
BACKGROUND OF THE INVENTION
Horses' hooves are hard boney masses that become sharp along the bottom edge from constant treading. The normal gait of a horse does not generally allow contact between the hoof and one or more of the horses' legs. However, during extraordinary movements or actions, such as hard or sharp turns in a "barrel" race, or dance steps or calf roping, all actions generally encountered in horse shows, rodeos and the like, there is such a propensity for the horse to kick itself that special safety precautions must be taken.
The coronet is the lowest part of the pastern of a horse; the pastern being the short boney part of the foot above the hoof and below the fetlock just below the shank or lower part of the leg. The rear of the coronet contains ligaments and tendons as well as arteries, veins and nerve endings, and is covered and protected only by skin and hair, as opposed to other parts of the horse that are additionally protected by bone and muscle tissue. The coronet is very susceptible to injury from a blow from the hoof of the opposite leg of the horse during these rather violent, non-standard movements such as in certain show events. It is therefore important to protect the coronet, especially the coronet of the front legs where most of the side-to-side movements originate. Protective coronet boots have been thus developed to be worn by the horse during show events.
The coronet boot of the prior art is a bell-shaped molded rubber skirt called a "bell-boot" containing an upper edge, for fitting around the pastern, the skirt extending therefrom sharply bulging outward and then vertically downward to a bottom edge for a loose fit around the outside bottom edge of the hoof, and opposed vertical edges for abutment, to enclose the coronet and whole hoof by the use of external straps, ties and the like. This style of boot has been found to last a very short time, as little as one day of a horse show, and becomes tattered and destroyed by the constant blows from the horses' hooves. Part of the problem appears to stem from the high frictional rubber surface of the boot, any grazing by another hoof causes the boot to deform excessively and stretch the skirt. Another problem appears to come from the actual bell shape itself; an annular air space is created around the upper part of the hoof between the hoof surface and the bell-shaped skirt thus allowing an incoming blow from a hoof to "grab" the rubber skirt causing a fold in the rubber that seems to hold or attach itself to the striking hoof and put more stretch on the skirt as the striking hoof goes by. Two other problems occasion the prior art coronet boot; one is that the molded bell shape of the skirt will not permit the boot to lay flat thus packaging, storing and shipping are done with boxes, a significant cost item. The other problem is that the boots only come in one color, black, and are not amenable to color coordination with today's highly decorative and colorful riding outfits and tack.
SUMMARY OF THE INVENTION
This invention overcomes all of the aforementioned problems of the prior art. It comprises a flat sheet of foam elastomer cut in the shape of a right circular trapezoid sandwiched between outer layers of high strength, low surface friction cloth and bounded on the upper and lower edges by concentric arcs and on the opposed ends by straight edges with internal fasteners so that when applied to the horses' hoof and coronet, said sheet forms a full truncated cone configuration that is tight to the pastern and hoof with no annular spaces therebetween and no unsightly outer connectors.
The low friction surface allows incoming blows from a hoof to easily skid by; the lack of an air space between the hoof, pastern and skirt allows the incoming hoof to slide by without grabbing the skirt and tearing the material. This construction has resulted in a coronet boot that will outwear the prior art boot by weeks and months. This inventive boot may be made by inexpensive cutting and sewing operations, as opposed to the more costly molding operation of the present boot, and the finished product may be packaged, stored and shipped in flat packaging thus reducing costs considerably. Finally, the outer layer of cloth presents a right circular truncated cone that may be fully colored from a wide range of colors, as opposed to the characteristic black color of molded rubber, thus permitting color coordination between the coronet boots and the rider's costume.
Accordingly, the main object of this invention is a new and longer wearing coronet boot for horses. Other objects of this invention include a boot that will last longer while providing the same or more protection than the present coronet boot, a boot that is less expensive to make, cheaper to store, package and ship and a boot that is amenable to various colors to fit into color coordinations of the rider.
These and other objects of the invention will become more readily apparent by reading the following Description of the Preferred Embodiment taken in conjunction with the drawings appended hereto. The scope of protection sought by the inventor herein may be obtained from a fair reading of the claims that conclude this specification.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom plan view of the coronet boot of this invention in its flattened configuration showing the internal fastening means.
FIG. 2 is a sectional view of the coronet boot of this invention taken along lines 2--2 in FIG. 1.
FIG. 3 is a perspective view of the coronet boot of this invention in its application to the rear of the horse's pastern and hoof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows boot 1 of this invention in its open, flattened configuration in the shape of a circular trapezoid, preferably a right circular trapezoid 3 defined by an upper arcuate side or edge 5, a lower arcuate side or edge 7 and a pair of opposed first and second ends 9 and 11 respectively. It is preferred, albeit not necessary, that upper and lower edges 5 and 7 be concentric from a common center A and that ends 9 and 11 be straight and lay along radii from said center A. Upper edge 5 should be the typical circumference of the horse's pastern while lower edge 7 should be the typical circumference of the lower edge of the horse's hoof.
When circular trapezoid 3 is rolled up to form a truncated cone, preferably a right circular truncated cone, and placed around a horse's hoof (see FIG. 3), ends 9 and 11 meet in mutual abutment and are held together by internal attachment means 13. While said means 13 may take the form of laces or snaps or clasps and the like, it is preferred that it take the shape of a pair of strips or patches of flexible material 15, fastened to boot 1 near second end 9 such as by sewing along lines 17 and adapted to extend beyond end 9 and containing a large plurality of loop elements 19* thereof in conjunction with a similar pair of strips 23 sewn fully to boot 1 and containing an upwardly facing large plurality of similar loop elements 25. At the other first end 11 of boot 1 means 13 comprises a pair of strips or patches of flexible material 27, fastened to boot 1 near boot end 11, such as by sewing along lines 29, and adapted to extend beyond end 11, and containing a plurality of hook elements 31 on both upper and lower surfaces thereof.
Loop elements 19 and 25 and hook elements 31 are resilient and deformable and when pressed together become removeably entangled, securing strips 15, 21 and 27 and thus securing boot ends 9 and 11 in joined abutment. Strips 15, 23 and 27 can be released from entangled engagement by positively pulling hook elements 31 away from loop elements 19 and 25 or vice versa. The loop and hook fabric elements 15, 23 and 27 are available under the trademark "Velcro", more specific details of which may be had from U.S. Pat. No. 2,717,437 entitled VELVET TYPE FABRIC AND METHOD OF PRODUCING SAME issued Sept. 13, 1955 to George de Mestral and U.S. Pat. No. 3,114,951 entitled DEVICE FOR JOINING TWO FLEXIBLE ELEMENTS issued Dec. 24, 1963 to George de Mestral. The material is hereinafter referred to as "Velcro" loop material and "Velcro" hook material, a product of American Velcro, Inc.
FIG. 2 shows in cross-section the makeup of boot 1 to comprise opposed top outer layer 33 and bottom outer layer 35 of strong, flexible low friction material such as woven nylon cloth of which a good example is 400 Denier nylon Pack® cloth. Sandwiched therebetween is a layer of flexible elastomeric foam 37 either with or without a fabric surface. A good example of such a material is nylon coated (one side) nitrogen-blown, 1/8 inch thick neoprene foam rubber of the type used in making underwater driving suits. Surrounding upper and lower edges 5 and 7 and ends 9 and 11 is a strip 39 of strong tape, such as 3/4 inch wide woven nylon tape that is sewn to the layers 33 and 35 and foam layer 37 along lines 41 and in conjunction with reinforcing sew lines 43 to form a tight, strong, cohesive composite.
As shown in FIG. 3, boot 1 is wrapped about the horse's pattern 45 above the hoof 47 and ends 9 and 11 abutted and "Velcro" loop strips 15 and 23 and hook strips 27 pressed together to fasten boot 1 about the horse's foot in a close-fitting truncated cone configuration.
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A boot for a horse's hoof to protect the coronet comprising a layer of flexible elastomeric foam sandwiched between opposed layers of strong, flexible low-friction cloth like woven nylon, cut in a flat right circular trapezoid shape and bound around the edge with cloth tape and cross-sewn to form a tight sandwich for wrapping around the hoof and fix with Velcro® strips.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of logic design, and more particularly, to a logic design and method for reducing leakage current in logic circuits using field-effect transistors.
2. Background
Referring to FIG. 1, an SRAM memory array is shown. The memory array 10 includes a plurality of memory cells 12 arranged in (n) rows and (m) columns, a row decoder 14, a plurality of word lines 16(l) through 16(n) corresponding to each of the (n) rows in the array, a column decoder 18, and (m) differential bit line pairs BL and BL corresponding to each of the (m) columns. Each pair of differential bit lines BL and BL includes a precharge circuit 20(l) through 20(m) and a write driver circuit 22(l) through 22(m) respectively. Each write enable circuit 22(l) through 22(m) receives a write enable input signal 26(l) through 26(m) from the column decoder 18 respectively.
During a write operation, the precharge circuits 20 precharge the differential bit lines BL and BL for each of the (m) columns of the memory array 10. The row decoder 14 then selects a row in response to a row select address and the column decoder 18 selects a column in response to a column select address. The output of the column decoder 18 activates the write driver circuit 22 corresponding to the selected column. Consequently, the write driver circuit 22 causes the corresponding differential bit lines BL and BL to move in accordance with the data input signal provided at the data signal input 24 of the corresponding write driver circuit 22. For example in a memory array where the precharge is high, if the data input signal received at the data input 24 is high, the bit line BL discharges low and BL remains at the precharge voltage. If the data input signal is low, the bit line BL remains at the precharge level and BL discharges low. The memory cell 12 at the intersection of the selected row and column then stores the data on the moved differential bit lines BL and BL. When the word line 16 is deactivated signalling the end of the write operation, the memory cell 12 stores the data indefinitely until another access operation of the memory cell 12 occurs. The above example shows how a binary data value is stored in a single memory cell 12 of a selected row. With different embodiments, the column decoder 18 may activate a plurality of write driver circuits 22 in response to a selected address. In response thereto, a plurality of data input signals 24 may be written into the plurality of memory cells 12 along the selected row.
Referring to FIG. 2, a prior art logic diagram of a write driver circuit 22 is shown. The write driver circuit 22 includes a data input 24 for receiving the data input signal, an enable input 26 for receiving the write enable signal, write line pass transistors 30 and 32, and inverters 34, 36, and 38. The enable input 26 is coupled to the gates of transistors 30 and 32. The source of the transistor 30 is coupled to the output of inverter 34 and the drain is coupled to the bit line BL. The input of inverter 34 is coupled receive the data input signal provided at the data input 24. The source of the transistor 32 is coupled to the output of inverter 38 and the drain is coupled to the bit line BL. The input of inverter 38 is coupled to the output of inverter 36 and the input of inverter 36 is coupled to receive the data input signal provided at the data input 24.
The write driver circuit 22 has two states, inactive and write. During the inactive state, the write enable input 26 is low, causing the transistors 30 and 32 to be off. The voltage level of the differential bit lines BL and BL is therefore independent of the value of the data input signal because they are not coupled to the output of inverters 34 and 38 respectively. Conversely, during the write state, the bit lines BL and BL are first precharged. The write enable signal 26 then transitions high causing the transistors 30 and 32 to turn on, coupling the bit line BL to the output of inverter 34 and the bit line BL to the output of inverter 38. If the signal at the data input 24 is high, the output of inverter 34 is low, causing the bit line BL to be pulled low through the inverter 34. On the other hand, bit line BL remains high because the output of inverter 38 remains high when the signal at the data input 24 is high. The complement of the above applies when the data input signal is low.
Recently, complementary metal oxide semiconductor field-effect transistors (CMOS) logic has seen ever increasing use in digital systems. As MOSFET technology has evolved, individual MOSFET's have become steadily smaller, i.e., with narrower features. This has allowed more and more MOSFET's to be integrated together in one integrated circuit (IC), as well as to allow the requisite power supply voltage (VDD) to become smaller. Benefits of the former include reduced size and weight and increased operating frequencies, while benefits of the latter include reduced power consumption. However, operating MOSFET's at today's low power supply voltages has the undesirable effect of lowering MOSFET current which reduces the maximum operating frequency. Hence, in order to minimize reductions in circuit performance, the MOSFET threshold voltages (V TH ) are reduced so as to minimize reductions in the MOSFET current. (Further discussion of the relationship(s) between power supply voltage, threshold voltage, and operating performances for MOSFET's can be found in commonly assigned, copending U.S. patent application Ser. No. 08/292,513, filed Aug. 18, 1994, and entitled "Low Power, High Performance Junction Transistor"; the disclosures of which are hereby incorporated by reference.) However, this in turn has the effect of increasing MOSFET leakage current, i.e., MOSFET current flowing when the device is off.
The Applicant believes that if the write driver circuit of FIG. 2 was constructed with the low powered, low threshold transistors discussed in the above referenced copending application, leakage current in the write line pass transistors 30 and 32 of a write driver circuit 22 would adversely affect the operation of the circuit by inducing a read operation failure due to corruption of the bit line voltage levels.
SUMMARY OF THE INVENTION
The present invention relates to a circuit for reducing current leakage in a logic circuit such as a write driver circuit in a memory array. The current leakage reducing circuit includes a data line configured to be set to a predetermined voltage, a data drive circuit, and an enable circuit. The enable circuit is coupled to the data fine and the data drive circuit, and is configured to enable the data line to accept a data value from the data drive circuit. The invention also includes current leakage prevention circuit, coupled to the enable circuit, and configured to substantially reduce leakage from the data line through the enable circuit when the enable circuit is not enabled.
DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the system of the present invention will be apparent from the following description in which:
FIG. 1 illustrates a prior art SRAM memory array.
FIG. 2 illustrates a prior art logic diagram of a write driver circuit.
FIG. 3 illustrates a logic diagram of write driver circuit according to one embodiment of the invention.
FIG. 4 illustrates a logic diagram of a write driver circuit configured with NAND gates according to one embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3, a logic diagram of a write driver circuit 22a according to one embodiment of the invention is shown. The write driver circuit 22a includes an enable input 26 for receiving the write enable signal; four n-channel write line pass transistors 40, 42, 44, and 46, two p-channel pull up transistors 48 and 50, a reference voltage 52, three inverters 54, 56 and 58, and a data input 24 for receiving the data input signal. The enable input 26 is coupled to the gates of transistors 40, 42, 44, and 46 and to the gates of transistors 48 and 50. The source of transistor 40 is coupled to the drain of transistor 42 and the drain of transistor 40 is coupled to the bit line BL. The source of transistor 42 is coupled to the output of inverter 54. The input of inverter 54 is coupled to receive the data input signal provided at the data input 24. The source of transistor 48 is coupled to the drain of transistor 42 and the drain of transistor 48 is coupled to the reference voltage 52. The source of transistor 44 is coupled to the drain of transistor 46 and the drain of transistor 44 is coupled to the bit line BL. The source of transistor 46 is coupled to the output of inverter 58. The input of inverter 58 is coupled to the output of inverter 56. The input of inverter 56 is coupled to receive the data input signal provided at the data input 24. The source of transistor 50 is coupled to the drain of transistor 46 and the drain of transistor 50 is coupled to the reference voltage 52.
The write driver circuit 22a has two states, inactive and write. During the inactive state, the write enable signal 26 is low. As a result, low potential is applied to the gates of transistors 40, 42, 44, and 46, causing them to be off. Transistors 48 and 50, however, are turned on, coupling the drains of transistors 42 and 46 to the reference voltage 52. In one embodiment, the reference voltage 52 is set at Vdd. Thus, the sources of transistors 40 and 44 are pulled to the reference voltage 52. As a result, transistors 40 and 44 are reversed biased off, minimizing the amount of leakage current through these transistors. Furthermore, since the bit lines BL and BL are also precharged high, the transistors 40 and 44 are also reversed biased off on the drain side of these transistors. Note that there may be an increase in current leakage through transistors 42 and 46 because the pull up operation causes an increased source to drain voltage of one of these transistors. However, this current leakage is of minor consequence because lost charge will be replenished by current passing through transistors 48 and 50 from reference voltage 52.
During a write operation, the bit fines BL and BL are precharged. The write enable signal then transitions high causing the transistors 40, 42, 44, and 46 to turn on. The bit lines BL and BL are therefore coupled to the output of inverter 54 and 58 respectively. In addition, the transistors 48 and 50 turn off. The bit lines BL and BL can therefore be moved, depending on the state of the data input. If the data input signal received at the data input 24 is high, the output of inverter 54 is low, causing the bit line BL to be pulled low through the inverter 54. On the other hand, the output of inverter 58 is high when the data input signal is high, causing the bit line BL to remain high. The complement of the above applies when the data input signal received at the data input 24 is low.
Referring to FIG. 4, a logic diagram of a write driver circuit 22b configured with NAND gates according to another embodiment of the invention is shown. The write driver circuit 22b includes an enable input 26 for receiving the write enable signal, two n-channel write line pass transistors 60 and 62, two NAND gates 64 and 66, an inverter 68, and a data input 24 for receiving the data input signal. The enable input 26 is coupled to the gates of transistors 60 and 62. The source of the transistor 60 is coupled to the output of NAND gate 64 and the drain is coupled to the bit line BL. One of the inputs of NAND gate 64 is coupled to the data input 24 to receive the data input signal and the other input is coupled to the enable input 26 to receive the write enable signal. The source of transistor 62 is coupled to the output of NAND gate 66 and the drain is coupled to the bit line BL. One of the inputs of NAND gate 66 is coupled to the output of inverter 68 and the other input is coupled to the enable input 26 to receive the write enable signal. The input of inverter 68 is coupled to the data input 24 to receive the data input signal.
During the inactive state, the write enable signal is low which causes transistors 60 and 62 to be off and causes a low signal to be provided at the write input of each of the NAND gates 64 and 66. This causes the output of NAND gates 64 and 66 to be high since the output of a NAND gate will always be high unless both of its inputs are high. A negative gate to source voltage is therefore applied to transistors 60 and 62, reverse biasing both transistors 60 and 62 off. As a result, leakage current through transistors 60 and 62 is substantially reduced. Also, if the bit lines BL and BL are precharged high, the transistors 60 and 62 are also reversed biased off on the drain side of these transistors.
During a write operation, the bit lines BL and BL are precharged. The write enable signal then transitions high, causing the transistors 60 and 62 to turn on, coupling the bit lines BL and to the output of NAND gates 64 and 66 respectively. The high write enable signal causes one input at each NAND gate 64 and 66 to transition high. Accordingly, when the data input signal from data input 24 arrives, the second input to one of either NAND gates 64 or 66 transitions high, depending of the value of the data input signal. For example, if the data input signal is high, the second input into NAND gate 64 is also high. The NAND gate 64 therefore produces a low output because both of its inputs are high and the bit line BL discharges low. On the other hand, when the data input signal is high the input of inverter 68 is high, causing the second input into NAND gate 66 to be low. As a result, the output of NAND gate 66 remains high. Thus, the bit line BL remains high. The complement of the above applies when the data input signal received at the data input 24 is low.
The present invention may also be used in DRAM devices. In DRAMs, the only one bit in per column is typically used. Consequently, a complementary circuits is not required to reverse-bias the write line pass transistor coupled to the bit line BL.
Although the present invention has been described in the context of a memory array, it should be noted that the present invention may be used to reduce current leakage from any logic circuit having a data line that is preset to a predetermined voltage during an inactive state of the logic circuit.
While the invention has been described in relation to the preferred embodiments shown in the accompanying figures, other alternatives, embodiments and modifications will be apparent to those skilled in the art. It is intended that the specification be only exemplary, and that the true scope and spirit of the invention be indicated by the following claims.
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A circuit for reducing current leakage in a logic circuit such as a write driver circuit in a memory array is disclosed. The current leakage reducing circuit includes a data line configured to be set to a predetermined voltage, a data drive circuit, and an enable circuit. The enable circuit is coupled to the data line and the data drive circuit, and is configured to enable the data line to accept a data value from the data drive circuit. The invention also includes a current leakage prevention circuit, coupled to the enable circuit, and configured to substantially reduce leakage from the data line through the enable circuit when the enable circuit is not enabled.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of my application Ser. No. 334,660, filed Dec. 28, 1981, now abandoned and is a continuation-in-part of my companion pending patent applications Ser. No. 112,332, filed Jan. 15, 1980 for DUST TRAP WITH EQUALIZING VALVE, now U.S. Pat. No. 4,308,894 issued Jan. 5, 1982, and Ser. No. 112,333, filed Jan. 15, 1980 for DUST TRAP WITH REMOVABLE SEAT, now U.S. Pat. No. 4,307,747, issued Dec. 29, 1981.
BACKGROUND OF THE INVENTION
The present invention relates to a dust trap and valve for controlling flow through the dust trap, and more particularly to an eccentric mounting of an operating lever or arm with respect to the valve flap to facilitate opening of the valve flap with relatively lower effort and torque.
Dust traps of the type herein referred to have been used for years in collection systems such as bag houses wherein a valve seat and matching valve flap closes a dust collecting zone, as beneath a series of vacuum bags, and the valve flap is opened from time to time to dump the contents collected above the flap. In the usual operation of such devices and as set forth in the above noted companion applications, the disclosures of which are incorporated herein by reference and also in my previously issued U.S. Pat. No. 3,257,054 entitled DUST TRAP AND VALVE THEREFOR, there is a substantial pressure differential across the valve flap when closed which can call for the use of substantial force to break the vacuum and pull the valve flap away from its seat.
It is the purpose of this invention to so position the flap actuating lever with respect to the flap in an eccentric or off-center manner so as to initially lift only one edge of the valve flap plate while the other remote edge therefrom serves as a fulcrum, thereby to initially break the vacuum prior to full opening and swing removal of the valve plate.
As a consequence, the torque required on the operating shaft for opening the valve is reduced and the accompanying power requirements for the operating motor or manual actuator are substantially lessened.
DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will become apparent upon reference to the following specification taken with the accompanying drawings in which:
FIG. 1 is a side elevation partially in section showing a valve body including a valve seat and a matching valve flap in the closed position;
FIG. 2 is a view similar to FIG. 1 but wherein the valve is shown in its initially cracked open position prior to full opening thereof; and,
FIG. 3 is a sectional view illustrating the connection between the operating lever and the valve flap.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a valve body 2 of usual form is provided having a flange 4 which is secured by bolts 6 into a vacuum system thereabove in conventional manner. The valve body defines a central flow path therethrough indicated by passageway 8 and a rectangular hollow valve seat 10 is suitably mounted in the valve body and defines an angled and polished seating face 11 in usual manner. The valve seat may be of the readily removable type as shown in my companion application Ser. No. 112,333, above noted.
The valve seat 10 is closed by a valve flap 12 which is supported for movement into and out of engagement with the valve seat, and includes preferably polished surfaces mating with seating face 11 to minimize air leakage. More particularly, the valve flap or plate 12 is supported and moved by a drive arrangement shown generally at 14 which includes a lever or operating arm 16 having an integral collar 18 which is suitably affixed as by bolt 20 to a shaft 22. The shaft 22 extends outwardly through the valve body 2 and is mounted for power rotational movement externally of the valve body as by hydraulic, mechanical, or manual force whereby upon rotation of shaft 22, arm 16 will pivot with the shaft.
The distal end of lever 16 is connected to flap 12 to move the same into or out of engagement with the valve seat 10. To this end it will be seen that the valve flap or plate 12 includes a pair of upstanding ears 24, 26 which are provided with elongated aligned slots 28. The arm 16 extends from its pivot connection to shaft 22 to lie between the upstanding ears 24, 26 as seen in FIG. 3 and is provided with a transverse pin 30 frictionally fitted or otherwise held on the arm 16, the pin 30 extending respectively into the slots 28 of each ear.
To facilitate the connection between the operating arm 16 and the valve plate ears 24, 26, a compression spring 32 is preferably provided at the distal end of the arm which is conveniently retained in confronting shallow recesses formed in the valve plate 12 and the arm 16 so as to normally provide a separating force between the arm and the plate at that point tending to rock the plate about the pivot pin, whereby the valve plate will not have a totally free or unrestrained loose connection to the operating arm through the elongated slots 28. By the same token, the spring 32 also provides a yieldable accommodation to manufacturing tolerances and in bringing the extended end of the valve flap 12 into contact with the arm 16 adjacent the pivot mounting means 14 as a result of spring 32, the chance of dust accumulation from the grain or other material passing vertically through the valve opening is far less likely to accumulate at and render ineffective the pivot mounting means.
Accordingly, it will be seen that when shaft 22 is rotated in a clockwise direction as seen in FIG. 1, the pin 30 will bear against the ends of the slot 28 remote from the valve flap to pull the flap away from the seat 10 and conversely, counterclockwise rotation of shaft 22 will swing the flap plate toward the seat 10 as pin 30 bears against the other ends of the slots 28. The arm 16 when exerting opening force on the flap is preferably slightly spaced from the adjacent flap surface.
Importantly, the pin or other connection between the arm 16 and the valve flap 12 is eccentric or offset to the relative center of the valve plate, and is appreciably nearer the edge thereof near shaft 22 as clearly seen in the drawings. As a consequence, upon application of valve opening force against a relative vacuum in the passageway 8, greater force will be exerted along the proximate left-hand edge of the valve plate at the seating face 11, whereby the valve plate will initially break loose from the seat at the left-hand edge as shown in FIG. 2, the right-hand edge of the valve plate remaining in contact with the valve seat thereat and initially pivoting with respect thereto and as urged by spring 32.
It will be seen, then, that opening force is relatively concentrated along the left-hand edge to initially crack the plate open to relieve any vacuum present after which the plate will swing open readily. This contrasts sharply with the forces required when the connection to the valve flap plate is located substantially centrally thereof which requires that the entire valve plate break away substantially simultaneously about its entire periphery from the valve seat. Such simultaneous plate separation may require two to three times the power required for the tilt-open technique of my invention.
While elongated or elliptical slots 28 have been shown with respect to the connection to the operating arm 16, the connection may be a simple pivoted connection rather than a lost motion arrangement as shown. In such case the arm 16 would also be in slightly spaced relation to the adjacent face of the valve flap so as to permit the slight relative pivoting motion in opening the near side of the valve flap in the initial separation of the valve flap from its polished seating surface 11.
While I have shown a preferred form of my invention, it is to be understood that the same is capable of variations and modifications while still embracing the concept and scope thereof as defined by the accompanying claims.
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A dust trap having an annular valve seat and a pivoted valve flap closing the same including an off-center connection between the actuating means for said pivoted flap and said flap thereby to lessen the force required to open the valve passageway against the force of vacuum.
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FIELD OF THE INVENTION
The present invention pertains to a fleece folding machine with a plurality of carriages movable in relation to one another and a plurality of laying belts between which the nap is taken up and guided at least in some areas, wherein the fleece folding machine has a belt intake of the laying belts on the intake side for taking up the nap, and wherein the belt intake has an obliquely downwardly sloped intake section with two belt sections running adjacent to one another.
BACKGROUND OF THE INVENTION
Such a fleece folding machine has been known from FR-2 553 102. The fleece folding machine, designed as a so-called belt layer, has two main carriages movable relative to one another and two endless and rotatingly driven laying belts, which are guided in loops. The laying belts run in parallel at least in the section between the main carriages, and they take up and guide the nap between them. On the intake side, the fleece folding machine has a so-called belt intake of the laying belts for taking up the nap. The laying belts, moved on from two sides, meet here and form an intake section with an opening angle of the laying belts of at least 20°. The intake slot at the inlet of the intake section is very large as a result and is substantially wider than the nap thickness. The nap fed in on one of the laying belts is deflected obliquely downward against the horizontal at an acute angle in the belt intake. The nap lies open in the intake section due to the large opening angle and the wide intake slot and is clamped and guided on both sides between the laying belts only at the lower end between the two adjacent deflecting rollers. The nap may be lifted off from the lower laying belt in the intake section at high speeds. This may lead to disturbances, especially in sensitive naps. The feed speed is limited in this arrangement.
The nap fed on the laying belt is deflected downwards in the belt intake. In the belt intake, the two laying belts have two belt sections that run in parallel next to each other and in a straight line and form the said intake slot. These belt sections extend downwards at right angles in the state of the art, as a result of which the nap fed in horizontally is deflected by 90° at the belt intake. It was found in practice that such a belt intake can be used for limited nap feed speeds and work speeds of the fleece folding machine only. If the feed speeds become too high, tearing off may occur in the very light and highly sensitive fiber nap.
FR-2 553 102 shows another fleece folding machine. In the belt intake, the two laying belts have two straight belt sections running in parallel next to each other, which extend vertically downward, as a result of which the nap fed in horizontally is deflected by 90° at the belt intake. It was found in practice that such a belt intake can likewise be used for limited feed speeds of the nap and limited working speeds of the fleece folding machine only. If the feed speeds become too high, tearing off may occur in the very light and highly sensitive fiber nap.
Developments, e.g., according to EP-A-0 517 568, tend to provide a very broad and wide open intake hopper before the belt intake. The laying belt feeding in the nap has an obliquely falling belt section, on which nap is conveyed, however, open. The second laying belt comes in only at the lower end of the belt section, as a result of which the nap enters between the two laying belts at this point only and is taken up and guided bilaterally by the laying belts at the deflection of the belt only. The belt intake is arranged at the upper main carriage and consequently movably in this case as well.
WO 91/156018 shows another variant of the belt intake, in which both laying belts are guided via two large deflecting rollers at the main carriage. A wide intake hopper is also formed as a result for the nap fed in on the one laying belt. The two large deflecting rollers are arranged horizontally next to each other approximately at the same level, as a result of which the nap is taken up and guided on both sides by the laying belts coming close to each other here only approximately at the level of the center of the two rollers. Before and after this, the laying belts move apart due to the roller shape. Even though these above-mentioned two fleece folding machines are designed for higher nap feed speeds and work speeds of the fleece folding machine, speed-limiting problems nevertheless arise due to the fact that the laying belts are brought together in a punctiform or linear manner only and the guide length is correspondingly short.
Furthermore, fleece folding machines with stationarily arranged belt intakes, in which the laying belts are guided via stationarily arranged deflecting rollers, have been known from DE-A 19 27 863 and DE-A 24 29 106. Both fleece folding machines have horizontal belt intakes.
In DE-A 24 29 106, the two laying belts form a horizontal intake slot, which joins the feed belt coming from the card engine. The laying belts are separated from one another at the upper main carriage, the nap is deflected downwards by 90° and is conveyed and guided on the one lower laying belt only. In DE-A 19 27 863, the nap is fed in via a stationary conveyor belt arranged upstream and is brought in free fall onto a subjacent, somewhat obliquely extending laying belt section in front of the belt intake. The second laying belt is arranged only at a certain distance behind this point. The intake slot is formed only very late at the deflection point into the next horizontal intake section of the belt intake. Both embodiments with the stationary belt intake considerably limit the nap feed speed and the speed of the fleece folding machine.
SUMMARY AND OBJECTS OF THE INVENTION
The object of the present invention is to show a fleece folding machine with an improved belt intake.
The present invention accomplishes this object with first and second belts and a carriage receiving the first and second belts to form a belt intake and intake section for accumulating the nap. The belt intake and intake section are formed by two sections of the first and second belts running adjacent to one another and forming an intake slot. The intake section is adapted to a thickness of the nap, and the two belt sections run either substantially parallel to each other or at an acute angle to each other. The two belt sections both guide and cover opposite sides of the nap in the intake section.
The belt intake according to the present invention has an obliquely downwardly sloped intake section, which is formed by two belt sections running close to each other. On entry into the belt intake, the belt sections form a narrow intake slot between their adjacent deflecting rollers, which is adapted to the nap thickness. The two belt sections take up the nap fed in the next intake section and guide and/or cover it on both sides.
The belt sections are directed obliquely downward at an obtuse angle against the feed and intake direction. This offers the advantage that the nap is deflected more softly and the centrifugal forces acting do not become too strong. Due to the oblique position, the upper belt section can act as a cover for the nap at the deflection and prevent the nap from being lifted off by centrifugal forces, wind effects, etc. The belt intake according to the present invention ensures an especially gentle and reliable uptake of the nap. It makes possible substantially higher belt speeds and nap feed speeds, while preserving a high reliability of function and operation.
The belt sections are preferably straight and can run essentially in parallel over a certain section. As an alternative, an intake section tapering in a funnel-shaped manner is also possible. The nap can be optionally guided without compression in the intake section or be gradually compressed or clamped. The fast-moving nap is reliably grasped due to the funnel-shaped intake section and the air contained in it is squeezed out gently over a longer section and longer time period. Abrupt clamping points, rapid air flows and turbulence, which could damage or destroy the nap, are avoided. It is advantageous for the intake section to extend essentially in a straight line.
Due to the oblique intake section, the nap is taken up softly at the upper end and is deflected more sharply at the lower end only. It is advantageous to provide at least one belt loop at the lower deflection point. In an especially preferred embodiment, there are at least two belt loops, the first belt loop being arranged in front of the deflection point and the second belt loop behind it. Disturbing relative speeds of the laying belts and of their belt sections are prevented as a result at the critical deflection points. As a result, the nap can be deflected in an especially reliable and unloaded maimer. The nap is preferably clamped at three or more points in the deflection area by deflecting rollers.
Different possible settings are possible at the belt intake for adjustment to different conditions of use of the fleece folding machine, varying types of nap, etc. In particular, the width and optionally also the slope of the intake section can be varied. The adjustability of the distance between the laying belts makes possible an exact adaptation to the nap thickness and the setting of the frictional conditions necessary for conveying the nap. A preferred possibility of setting is the feeding of the different deflecting rollers or plate-like support means, depending on the design of the belt intake. However, other design variants are possible as well.
The belt intake may be stationary or mobile. It is located in front of or at the upper main carriage in the preferred exemplary embodiments.
The discharge section extending between the upper carriage and the laying carriage may also extend at an angle to the horizontal. This makes it possible to further reduce the deflection angle of the nap in the upper carriage and to reduce the centrifugal forces acting on the nap in the deflection area.
The laying belt that is the lower laying belt in the intake section may extend straight in a lead section in front of the intake. The nap is transferred from a feed belt onto this laying belt. As an alternative, the laying belt that is the lower laying belt in the intake section may also be designed as a feed belt at the same time. The lower laying belt may be deflected twice in this case to form the intake gap in front of the intake. If the lower laying belt is designed as a feed belt at the same time, some rollers and drives are eliminated, which leads to a less expensive design.
A pressing roller, preferably a screen or perforated roller, which is intended to remove air from the nap, may lie on the nap in front of the belt intake.
In an alternative exemplary embodiment, the feed section and the intake section may be located in a common plane. This plane is sloped downward by an angle toward the upper carriage relative to the horizontal. With such an intake zone, the nap is not deflected needlessly and can be fed straight to the upper carriage.
Additional advantageous embodiments of the present invention are described in the subclaims.
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 synoptic view of a fleece folding machine with a moving belt intake at the laying carriage;
FIG. 2 is an enlarged and detailed partial view of the belt intake according to FIG. 1;
FIG. 3 is a synoptic view of a fleece folding machine as a variant to FIG. 1 with a stationary belt intake;
FIG. 4 is a detail of the belt intake from FIG. 3 with a pressing roller arranged in front of it;
FIG. 5 is an alternative exemplary embodiment of the belt intake from FIG. 4, in which the lower laying belt is also the feed belt; and
FIG. 6 is another alternative exemplary embodiment for FIGS. 4 and 5, in which the lower laying belt is also the feed belt.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and in particular to FIGS. 1 and 3, a fleece folding machine 1 is synoptically shown which is designed as a so-called belt layer. In a housing or frame 54, it has an upper main carriage 2 and a lower main carriage 3 and may also have one or more auxiliary carriages or tensioning carriages 32, 34. Two endless laying belts 5, 6 are guided over the carriages 2, 3, 32, 34 by means of suitable rollers. At least the two main carriages 2, 3 are driven by suitable drives, movably to and fro. The two laying belts 5, 6 are also rotatingly driven by means of suitable controllable and adjustable drives.
The fiber nap 7 produced by a nap maker (not shown), e.g., a card engine, enters the fleece folding machine 1 over a feed belt 25. It is guided over a feed section 26 either to, or at, the upper main carriage 2 and enters between the two laying belts 5, 6 at the belt intake 4, 9, which will be described in greater detail later. The laying belts are led in a loop in parallel to one another at least in the area between the two main carriages 2, 3 and they take up the nap 7 between them, convey it and guide it. This loop area is called the discharge section 27. It may extend horizontally or obliquely and connect the main carriages 2, 3 directly or via a deflection means (not shown), which is rigidly connected to the frame. The discharge section 27 advantageously extends in a straight line.
The nap 7 exits downward at the lower main carriage 3, the so-called laying carriage, and is laid down into a fleece 23 on an endless takeoff belt 8 running transversely. The laying carriage 3 moves to and fro over the takeoff belt 8, as a result of which the nap 7 is laid in a plurality of layers one on top of another at right angles and in a zigzag pattern to the delivery direction. The nap 7 is piled up in a scale-like pattern. The laying belts 5, 6 move apart again at the laying carriage 3 and are moved away to the outside in separate loops and then to the belt intake 9.
A great variety of possibilities, as they are known from, e.g., the prior art mentioned in the introduction to the specification, are available for the design embodiment and the function of the fleece folding machine 1. To form a short passage section, the two main carriages 2, 3 may move in the same direction, as in DE-A-19 27 863 or EP-A-0 517 568, or in opposite directions with stationary belt deflection, as in FR-A-2 553 102 or WO 91/156018. To influence the nap laying on the takeoff belt 8, internal stores may be formed by means of the auxiliary or tensioning carriages 32, 34. It is also possible to work with a draft during nap laying to set a defined thickness profile of the fleece 23.
The belt intake 4 is mobile in the fleece folding machine according to FIGS. 1 and 2 and is located at the upper carriage 2. It has a comparatively short intake section 9 of a fixed length. FIGS. 3 through 6 show a variant with a stationary belt intake 4, which is arranged in front of the upper carriage 2. The intake section 9 is larger here and has a variable length.
FIG. 2 illustrates the belt intake 4 of the fleece folding machine 1 according to FIG. 1 in detail. The belt intake 4 is located at the upper main carriage 2 in this embodiment. The two laying belts 5, 6, which are again guided separately behind the laying carriage 3, meet at the belt intake 4, then run close to one another and take up the nap 7 fed in from the outside between them to form a closed belt intake section as shown in FIG. 2. One of the laying belts 5 is also used as a nap feed means 25 in the embodiment shown and is correspondingly led out of the housing 54 of the fleece folding machine 1. The nap 7 lies here open on the laying belt 5 and is conveyed by this to the belt intake 4.
The two laying belts 5, 6 are led together over deflecting rollers 14, 16 at the belt intake 4 to form a narrow intake slot 12. The deflecting rollers 14, 16 are joined by the intake section 9, which is formed by two belt sections 10, 11 of the laying belts 5, 6, which sections extend essentially straight, to another deflection 15. The belt sections 10, 11 take up the nap 7 between them and cover it and guide it on both sides along the intake section 9.
The intake slot 12 has an adjustable width, which can be adjusted to the particular requirements of the nap material. It is preferably somewhat larger than the nap thickness, so that the loose nap 7 can be taken up at first without forcing or compression. However, the width may be the same or smaller than the nap thickness and may optionally lead to a clamping already at the time of the entry of the nap 7 into the belt intake 4.
The belt sections 10, 11 extend essentially in parallel. This may be strictly parallel. However, as an alternative, the distance of the run may also decrease over the direction of run 24. An intake section 9 tapering at an acute angle in a funnel-shaped manner is formed as a result, in which the nap 7 is gradually compressed and clamped before it reaches the lower deflection 15. It may be favorable in this variant to set the width of the intake slot 12 larger than the nap thickness. However, it is also possible to clamp the nap 7 immediately at the time of entry into the belt intake 4 in the case of a small slot width and to further increase the compression over the length of the intake section 9. The selection of the suitable setting depends on the type of the nap material and possibly also on the nap feed speed and/or other parameters.
The intake section 9 and the belt sections 10, 11 forming same are sloped obliquely downward against the horizontal or the feed or intake direction 24 at an obtuse angle β. This obtuse angle β is related in FIG. 1 to the belt deflection of the laying belt 5 at the deflecting roller 14. The preferably horizontal feed section 26 of the laying belt 5 is deflected into the oblique belt section 10. The obtuse angle β between the belt sections is greater than 90° and smaller than 180°. It is preferably about 135°.
At the lower end of the intake section 9, the nap 7 and the laying belts 5, 6 are again deflected into a preferably horizontal direction and reach the laying carriage 3 via the discharge section 27. Thus, the nap 7 and the laying belts 5, 6 are deflected, on the whole, by 180° at the belt intake 4. Due to the oblique direction of the intake section 9, the deflection is smaller at its top end and greater at its lower end. The nap 7 is already fed securely over a rather long, straight section by the belt intake 4 before the lower, greater deflection 15 and is covered, and, as a result, it does not reach the clamping point at the deflection 15 suddenly.
The laying belt 5 is guided via two relatively stationarily arranged deflecting rollers 14, 15, which are preferably arranged at the upper main carriage 2. The deflecting rollers 14, 15 are spaced from one another vertically and horizontally corresponding to the oblique direction of the intake section 9.
The upper deflecting roller 16 of the other laying belt 6 is arranged above the opposite deflecting roller 14. The line connecting the two roller axes extends approximately at right angles to the slope of the intake section 9.
The laying belt 6 has two or more belt loops 13 at the lower end of the intake section 9. One of the belt loops 13 is located in front of the deflection point formed by the deflecting roller 15, and the second belt loop 13 is located behind it. The laying belt 6 located in the belt intake 9 on the top or on the outside is detached from the nap 7 via the belt loops 13 at the critical deflection points.
Different belt speeds are avoided in the area of the deflection due to the detachment, because the two laying belts 5, 6 move, with the nap between them, around the axis of the deflecting roller 15. The upper laying belt 6 would have to have a higher relative speed of travel to be able to guide the nap 7 without tension over the entire deflection area. However, the two laying belts 5, 6 have the same speed of travel. The two belt loops 13 eliminate the problem.
The first belt loop 13 is formed by deflecting rollers 17, 18, 19. The first deflecting roller 17 is seated at the lower end of the belt section 11 and is located above the deflecting roller 15. It is arranged such that the line connecting the axes of the two rollers is directed approximately at right angles to the slope of the intake slot 12. As a result, the laying belt 6 or its upper belt section 11 is separated from the nap 7 at approximately the same point at which the lower belt section 10 reaches the deflecting roller 15. As a result, the nap 7 enters the deflection area at the roller 15 without draft.
Via the deflecting roller 19, which is offset obliquely to the rear, the laying belt 6 is pulled out to the belt loop 13 and is then returned to the deflecting roller 18. The latter is located essentially at the same level as the deflecting roller 15 and has approximately the same diameter. As a result, the two laying belts 5, 6 meet again approximately at the level of the axes of the two rollers 15, 18 and can guide the nap 7 between them. They have essentially the same speed of travel, which is also equal to the speed of the nap.
The second belt loop 13, which is pulled out by a laterally offset deflecting roller 20, is seated behind the deflecting roller 18. Its diameter is selected to be such that the laying belt 6 is subsequently deflected into a horizontal section extending in parallel to the laying belt 5. The two laying belts 5, 6 are again so close to one another in this next section that they guide the nap 7 between them on both sides.
A support means, e.g., a support roller 21 for the laying belt 6, may be arranged under the deflecting roller 15. The support roller 21 influences the distance between the laying belts 5, 6.
The nap 7 is squeezed or clamped by the roller arrangement shown in the area of the lower deflection at the deflecting roller 15 at three points between the laying belts 5, 6 and is as a result guided reliably and at the same belt speeds. At the end of the intake section 9, the guiding between the belt sections 10, 11 is just long enough to reach the lower deflecting roller 15. Bilateral guiding takes place thereafter approximately at the level of the axes of the deflecting rollers 15, 18. The third guiding point is located at the end of the deflection between the deflecting roller 15 and the support roller 21, which is preferably located perpendicularly under it. The laying belt 5 again leaves the deflecting roller 15 at this point.
The belt intake 4 and the intake section 9 are adjustable. For example, the position of the deflecting rollers 16, 17, 18 and the support roller 21 can be changed with suitable feed means 22. The direction of feed is preferably at right angles to the direction of the intake section 9 in the case of the deflecting rollers 16, 17 located in the area of the intake slot 12. The width of the intake slot 12 and optionally also the funnel-shaped narrowing of the intake section 9 can be changed as a result. The laying belts 5, 6 may be permeable to air, so that the nap is compressed due to the increasing tapering of the intake section 9 and the air contained in it is squeezed out in the process.
The deflecting roller 18 is preferably adjustable horizontally and, as a result, it can be brought closer to or moved away from the deflecting roller 15 of the laying belt 5. The second guiding point for the nap 7 in the lower deflection area is influenced by this.
The support roller 21 is vertically adjustable and it can also be brought closer to or moved away from the deflecting roller 15 as a result. The nap guiding is influenced with the support roller 21 at the third guiding point.
The direction of travel of the nap 7 and of the laying belt 5 feeding it in the area of the belt intake 9 is marked by arrows 24.
Modifications of the embodiment shown are possible in various ways. In the exemplary embodiment shown, the two belt sections 10, 11 taking up the nap 7 begin at approximately the same level at the inlet of the intake slot 12. As an alternative, the upper belt section 11 may also be arranged somewhat higher and it may optionally project over the deflection point at the roller 14. This is favorable, e.g., for catching a very fast-moving nap. However, the belt section 11 may also be arranged somewhat lower. The design, number and arrangement of the belt loops 13 at the lower end of the intake section 9 are variable as well. It is possible, e.g., to have only the one, lower belt loop 13. The possibilities of adjusting and feeding the individual deflecting rollers or other belt-guiding parts at the belt intake 4 are also variable. The intake section 9 may also be slightly curved.
In the alternative exemplary embodiment shown in FIG. 3, the fleece folding machine 1 has a separate feed belt 25, via which the nap 7 is fed from a card engine arranged in front of it at a uniform, but variable speed. The fleece folding machine 1 is again equipped with four carriages, namely, with an upper carriage 2, a laying carriage 3 and one tensioning carriage 32, 34 each for each laying belt 5, 6.
The first laying belt 5 takes over the nap 7 from the feed belt 25 in the area of the feed section 26 and guides the nap 7 into a stationary belt intake 4 between the two laying belts 5, 6, which extends to the upper carriage 2 and to the deflection 15 located there. The stationary belt intake 4 is arranged in the vicinity of the end of the path of movement of the upper carriage 2 approximately in the middle of the laying width of the fleece folding machine 1. The laying belt 5 is fed to the belt intake 4 as a lower laying belt, while the upper laying belt 6 is fed in via a deflecting roller 16.
The stationarily mounted deflecting roller 16 has a diameter that is substantially larger than that of the other deflecting rollers, as a result of which an intake hopper is formed at the belt intake 4. The distance between the laying belts 5, 6 at the belt intake 4 is, e.g., greater than the nap thickness. The intake slot 12 thus formed makes possible the intake of the nap 7 on the belt at first without an essential clamping or compression. A height-adjustable support means 21, with which the gap width of the intake slot 12 can be set, is located under the lower laying belt 5.
Between the intake slot 12 and the upper carriage 2 extends the essentially straight intake section 9, in which the belt sections 10, 11 of the laying belts 5, 6 gradually move toward each other, so that the distance between them will be adapted to the nap thickness at the latest at the end of the intake section 9 at the upper carriage 2. This distance may correspond, e.g., to the nap thickness or it may be set at a fixed value, e.g., 15 mm. The nap 7 is gradually guided on both sides and covered in the intake section 9 tapering in a funnel-shaped manner. This may happen without compression. As an alternative, the nap 7 may also be gradually compressed and clamped in the intake section 9. The intake section 9 changes its length with the movement of the upper carriage 2.
As in the above-described exemplary embodiment, the upper laying belt 6 is deflected several times in the upper carriage 2 over a guide roller 17 and over the rollers 18, 19, 20, forming two belt loops 13, so that the nap 7 does not run between the two laying belts 5, 6 in the deflection area of the upper carriage 2. The nap 7 is again guided between the two laying belts 5, 6 only under the deflecting roller 15 for the lower laying belt 5. The laying belts 5, 6 may be supported at the roller 56 of the laying carriage 3.
The discharge section 27 extending between the upper carriage 2 and the laying carriage 3 preferably extends in a straight line, and, after another deflection by 90° in the laying carriage 3, the nap 7 is discharged at a discharge point and is laid by the laying carriage 3 performing alternating movements on the takeoff belt 8. The laying carriage 3 also has a guide roller 56 for the laying belt 5, which is again returned to the belt intake 4 via additional deflecting rollers after being deflected twice over the deflecting rollers 60, 62. The laying belt 6 is deflected over a deflecting roller 58 and is returned to the belt intake 4.
The intake section 9 and/or the discharge section 27 preferably extend obliquely downward at an obtuse angle β to the horizontal in the direction of movement 24 of the laying belts 5, 6. As in the first exemplary embodiment in FIGS. 1 and 2, this angle is between 90° and 180° and equals, e.g., about 170°.
A tensioning carriage 32, which is controlled as a function of the movement of the laying carriage 3, is provided for the laying belt 5. A tensioning carriage 34, which is controlled as a function of the movement of the upper carriage 2 and of the laying carriage 3, is provided for the laying belt 6. The movement of the tensioning carriage 34 is restrictedly guided by means of toothed belts.
The tensioning carriage 34 is arranged behind a stationary deflecting roller 36 and the additional, stationary deflecting roller 16 at the belt intake 4 in the direction of travel of the laying belt 6.
FIG. 4 shows the belt intake 4 on a larger scale, wherein a pressing roller 30 comprising a perforated or screen roller can precompress the nap 7 before the intake slot 12. The pressing roller 30 may be held at a predetermined distance from the lower laying belt 5.
FIG. 5 shows an alternative exemplary embodiment, in which the laying belt 5 that is the lower laying belt in the intake section 9 is also used as a feed belt 25 at the same time. A feed section 26 located in front of the lead section 9 before the belt intake 4 is located in the same plane as the intake section 9 and is sloped downward relative to the horizontal in the direction of movement of the laying belt 5. The nap 7 is no longer deflected in this exemplary embodiment in the feed zone and in the intake section 9 up to the upper carriage 2.
FIG. 6 shows another exemplary embodiment, in which the lower laying belt 5 is also used as a feed belt 25 at the same time. The laying belt 5 is deflected several times over the deflecting rollers 38 through 40, so that the laying belt 5 can be fed to the intake section 9 at a spaced location from the laying belt 6 to form the intake slot 12. Instead of the support means 21, the deflecting roller 39 may be adjustable in height in this case.
The features described in specification, drawings, abstract, and claims, can be used individually and in arbitrary combinations for practicing the present invention.
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.
APPENDIX
List of Reference Numbers
1 Fleece folding machine
2 Main carriage, upper carriage
3 Main carriage, laying carriage
4 Belt intake
5 Laying belt, feed belt
6 Laying belt, opposite belt
7 Nap
8 Takeoff belt
9 Intake section
10 Belt section
11 Belt section
12 Intake slot, intake hopper
13 Belt loop
14 Deflecting roller, feed belt
15 Deflecting roller, feed belt
16 Deflecting roller, opposite belt
17 Deflecting roller, opposite belt
18 Deflecting roller, opposite belt
19 Deflecting roller, belt loop
20 Deflecting roller, belt loop
21 Support means, support roller
22 Feed means
23 Fleece
24 Direction of travel
25 Feed belt
26 Feed section
27 Discharge section
30 Pressing roller
32 Tensioning carriage, auxiliary carriage
34 Tensioning carriage, auxiliary carriage
36 Deflecting roller
38 Deflecting roller
39 Deflecting roller
40 Deflecting roller
42 Deflecting roller
54 Frame
56 Guide roller
58 Deflecting roller
60 Deflecting roller
62 Deflecting roller
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The invention relates to a process for producing a nonwoven fabric and a matting device with several layering belts between which the web is taken up and guided at least in regions. The matting device has a belt inlet on the inlet side for the layering belts with an oblique downwards inclined inlet section with two belt sections running close to one another between which the web is led or covered on both sides. The width of the inlet section can be altered and can narrow like a funnel. The belt inlet can be mounted on the upper carriage so as to be either fixed or mobile.
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This is a division of application Ser. No. 08/132,597 filed Oct. 6, 1993 now U.S. Pat. No. 5,453,399.
FIELD OF THE INVENTION
This invention generally relates to semiconductor-on-insulator structures, and more particularly to semiconductors on fluoride insulators.
BACKGROUND OF THE INVENTION
Heteroepitaxial semiconductor/group-II fluoride/Si structures are potentially useful in a number of semiconductor-on-insulator technologies. As one of the most promising candidates in this area, the CaF 2 /Si couple has attracted considerable attention (see T. Asano and H. Ishiwara, "Epitaxial Growth of Ge Films onto CaF 2 /Si Structures", Jpn. J. Appl. Phys., 21, p. L630, 1982, and R.W. Fathauer, et al., "Heteroepitaxy of semiconductor-on-insulator structures: Si and Ge on CaF 2 /Si( 111)", J. Appl. Phys. 60(11), p.3886, 1986). From a materials preparation point of view, CaF 2 /Si is a relevant choice among the fluorides for deposition on silicon because it fits several important criteria for a good epitaxial system, i.e. small lattice mismatch and similar cubic structure. Previous studies have shown that the chemical and structural properties of the CaF 2 /Si interface vary under different deposition conditions and that these variations can significantly change the electrical characteristics of a system incorporating this interface. Co-assigned patent application 07/704,535 describes a method that allows the growth of films in which the orientation of the CaF 2 /Si film is essentially identical to that of the silicon substrate, a characteristic which is important for good interface properties. Additionally, co-assigned U.S. Pat. No. 5,229,333 discloses a low-temperature growth technique for producing improved CaF 2 /Si interfaces.
A primary concern in obtaining good crystal growth by molecular-beam-epitaxy (MBE) or other related vapor-phase techniques is the growth mode of the film. Both lattice strain and surface free energy help determine whether a film undergoes layer-by-layer growth (Frank-Van der Merwe), islanding (Volmero-Weber), or layer-by-layer growth followed by islanding (Stranski-Krastanov). Deliberate introduction of a surfactant that alters the surface free energy can change the growth mode of a film. Surfactants such as Sb, Ga, As, and Te have been widely studied for improving the epitaxial growth of Ge on Si (See, for example, M. Copel, et al. "Surfactants in Epitaxial Growth", Phys. Rev. Lett. 63(6), p.632, Aug. 1989, or R. Cao, et al. "Microscopic study of the surfactant-assisted Si, Ge epitaxial growth", Appl. Phys. Lett. 61(19), p. 2347, Nov. 1992).
SUMMARY OF THE INVENTION
In one form of the invention, a method is disclosed for fabricating a semiconductor-on-insulator structure comprising the steps of: forming an insulator layer; forming a layer comprising boron (B) on the insulator layer; and forming a semiconductor layer on the layer comprising B.
In another form of the invention, a method is disclosed for fabricating a semiconductor-on-insulator structure comprising the steps of: forming an insulator layer; forming a layer comprising boron (B) on the insulator layer; and forming a semiconductor layer on the layer comprising B.
In another form of the invention, a method is disclosed for fabricating a semiconductor-on-insulator structure comprising the steps of: providing a Si substrate; forming a layer comprising CaF 2 /Si on the substrate; forming a layer comprising B on the layer comprising CaF 2 /Si; and forming a semiconductor layer on the layer comprising B.
In still another form of the invention, a semiconductor-on-insulator structure is disclosed, the structure comprising: an insulator layer; a layer comprising B on the insulator layer; and a semiconductor layer on the layer comprising B.
An advantage of the invention is that it allows the formation of a semiconductor-on-insulator structure without the formation of islands and other defects that have plagued prior art techniques. Another advantage of the invention is that semiconductor films may be grown that predominately have a crystalline orientation identical to that of the insulator layer on which the semiconductor is grown. Films having this property have been shown to be superior to unoriented films.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a cross-sectional view of a first preferred embodiment material structure;
FIG. 2 is a plot of x-ray diffraction data showing the (111) peaks of Ge, CaF 2 and Si for three Ge/CaF 2 /Si(111) samples;
FIGS. 3a and 3b are plots of x-ray diffraction data showing the (224) peaks of Ge, CaF 2 and Si for three Ge/CaF 2 /Si(111) samples at two azimuthal angles;
FIG. 4 is a plot showing the full-width-half-maximum (FWHM) and intensity of Ge(111) peaks for Ge/CaF 2 /Si(111) structures with B predeposited layers of varying thickness;
FIG. 5 is a plot showing the FWHM of Ge(224) peaks for Ge/CaF 2 /Si(111) samples with various surface modification treatments;
FIG. 6 is a plot showing ratios of A-type and B-type Ge on CaF 2 /Si(111) modified by various methods prior to Ge growth;
FIGS. 7a and 7b are SIMS depth profiles of Ge/CaF 2 /Si(111) with (FIG. 7a), and without (FIG. 7b), an approximately 1 nm B predeposit;
FIGS. 8a-8d show the surface morphology of Ge films during nucleation and final stages of growth;
FIGS. 9a and 9b are micrographs of approximately 4 nm thick Si on CaF 2 /Si(111) with (FIG. 9a), and without (FIG. 9b), an approximately 1 nm B predeposit.
Corresponding numerals and symbols in the different figures refer to corresponding parts unless otherwise indicated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While CaF 2 /Si and other fluorides have been used as buffer layers, either to reduce the lattice mismatch and/or stress between a substrate and a top-layer film, or as an insulator for semiconductor-on-insulator (SOI) devices, epitaxial growth of high quality semiconductors on these fluorides is often difficult because the surface free energy of the fluoride is lower than the surface free energy of the semiconductor film. The higher surface energy of the semiconductor results in three dimensional island growth and thus degrades the crystalline quality of the semiconductor films.
Previous studies of Ge epitaxial growth on CaF 2 , SrF 2 , and (Ca,Sr)F 2 have shown that the crystalline quality of Ge on CaF 2 is better than that of Si on CaF 2 , even though the lattice mismatch between Ge and CaF 2 is bigger than the mismatch between Si and CaF 2 at room temperature. Similar to the growth of Si on the fluorides, Ge forms islands and the Ge(111) is typically a mixture of A- and B-type grains on CaF 2 (111)/Si(111). ("A-type" epitaxy denotes the growth of a film with crystalline orientations identical to the underlying material. "B-type" epitaxy refers to the film with crystalline orientations rotated 180° azimuthally with respect to the underlying material.) The crystalline quality of the Ge is reportedly improved when a thin (about 1 nm) amorphous Ge layer is deposited at room temperature before the subsequent growth of Ge at a higher temperature (see S. Kanemaru, et al. "Improvement of the Quality of Ge Films on CaF 2 /Si(111) Structures by Predeposited Thin Ge Layers", Surf. Sci. 174 p. 666, 1986).
Although the function of the predeposited amorphous Ge layer is not completely clear, it can be reasoned that the low-temperature-deposited Ge layer suppresses island formation by decreasing the kinetic energy available for the Ge atoms deposited over the amorphous Ge layer. The predeposited Ge layer may also reduce the interfacial reaction between impinging Ge atoms and the CaF 2 film.
The problem of three-dimensional growth, or "islanding", is also important for other material systems, particularly for Ge on Si. The method discussed above, using "surfactants" such as Sb, Ga, As and Te to suppress island formation, has been widely studied for the epitaxial growth of Ge on Si. While Ge grows on Si(100) by the Stranski-Krastanov mode (layer-by-layer growth followed by island formation), its three dimensional growth can be suppressed when a thin surfactant layer is evaporated on the Si(100) substrate prior to the Ge deposition. The surfactant exchanges sites with Ge and remains on the top during the Ge growth. Since the surface energy of the surfactant is smaller than the energies of the epilayers and the substrate, it promotes layer-by-layer growth. The surfactants have also been found to increase critical thickness and reduce defects in the Ge film.
Applicant has discovered that significantly improved Ge crystalline quality results when a thin boron (B) layer is deposited on CaF 2 (111)/Si(111) or CaF 2 (100)/Si(100) prior to the epitaxial growth of Ge on CaF 2 /Si, or Si on CaF 2 /Si. In contrast to the aforementioned surfactants, which migrate to the growth front, the predeposited B stays at the Ge/CaF 2 interface. Furthermore, the B predeposit suppresses the migration of Ca to the top surface of the Ge films, and prevents interaction between Ge and CaF 2 . Applicant has also found that on CaF 2 (111)/Si(111) substrates, the predeposited B promotes the epitaxial growth of A-type Ge, a result that is important for achieving superior film quality.
In a first preferred embodiment of the invention, shown in FIG. 1, CaF 2 and Ge films are grown on Si(111) and Si(100) wafers by molecular beam epitaxy (MBE). Clean Si surfaces are obtained by annealing a 4-inch Si wafer 20 (wafers in both the (111) and (100) orientations have been used) in an MBE chamber at approximately 950° C. for about 10 minutes, plus another approximately 10 minutes with Si evaporating at a rate of about 0.01 monolayers per second. Reflection high-energy electron diffraction and Auger electron spectroscopy are used to characterize the cleaning process. The CaF 2 22 and B 24 are deposited from effusion cells with growth rates of approximately 4 nm per minute and approximately 0.005 nm per second, respectively. The Ge 26 is deposited by electron beam evaporation at a rate of approximately 6.6 nm per minute. For Ge/CaF 2 /Si(111) samples, the CaF 2 is grown by ramping the substrate temperature from approximately 100° C. to approximately 600° C. over about five minutes to achieve high quality A-type films. The Ge and B are grown at a constant temperature in the range of approximately 400° C. to approximately 700° C., with a preferred temperature of about 600° C. In a second preferred embodiment in which a Ge/CaF 2 /Si(100) material structure is formed, the CaF 2 , Ge, and B layers are all grown at a constant temperature in the range of approximately 400°-700° C., with a preferred temperature of approximately 600° C. The thicknesses of the Ge, CaF 2 , and B layers are approximately 0.2 um, 0.2 um and 1 nm, respectively. The crystalline properties of Ge are typically studied by x-ray diffraction analysis and cross-section transmission electron microscopy (TEM), while the depth profiles of various elements are characterized by secondary ion mass spectroscopy (SIMS). The surface morphology is studied by Nomarski optical microscopy.
FIG. 2 shows the (111) peaks of Ge, CaF 2 and Si for three Ge/CaF 2 /Si(111) samples grown by using: a) an approximately 1 nm B predeposit, b) an approximately 1 nm Ge predeposit grown at room temperature and c) no predeposited layer. The amplitudes of the Ge peaks are 730,430 and 40 counts per second for a), b), and c), respectively. FIGS. 3a and 3b show the Ge(224) peaks of the three samples for two different azimuthal angles. The peaks are well separated from the CaF 2 (224) and Si(224) peaks and are easier to characterize than the Ge(111) peak. The amplitudes of the peaks are 2530, 1350, and 1190 counts per second, for a), b) and c), respectively. These results show that the crystalline quality of Ge with a B predeposit is not only better than the crystalline quality of Ge with no predeposit, but also better than that with a thin Ge predeposit. Similar improvement in Ge crystalline quality was observed from Ge/CaF 2 /Si(100) samples (when a 1 nm B predeposit was used), by analyzing the x-ray rocking curves of the Ge(004) and Ge(224) peaks.
FIG. 4 shows the FWHM and intensity of Ge(111) peaks for Ge/(CaF 2 /Si(111) structures with B predeposited layers of varying thickness. Smaller Ge FWHM and larger intensity indicate better crystalline quality. It is clear from this Figure that a predeposited B layer of approximately 1 nm in thickness provides superior crystalline quality than do B layers of 0.3, 5, and 10 nm.
FIG. 5 shows the FWHM of Ge(224)peaks for Ge/CaF 2 /Si(111) samples with various surface modification treatments. "N/A" in FIGS. 5 and 6 indicates that no predeposited layer was used. "Flash" indicates that the CaF 2 was heated to approximately 950° C. prior to deposition of the Ge layer. "Flash/B" indicates that the CaF 2 was heated to approximately 950° C. prior to deposition of B, followed by the Ge layer. "Sb", "Si", "Ge", and "B" indicate the material used as a predeposit before the deposition of Ge. Smaller Ge FWHM and larger Ge/CaF 2 ratio indicate better crystalline quality. The crystalline quality of Ge is clearly improved when 1 nm thick B is predeposited on CaF 2 before the following Ge growth (as in the first preferred embodiment). Depositing 1 nm Ge, as reported by Kanemaru et al., also improves the Ge quality, but not to the extent of that achieved by the B predeposit. FIG. 5 also shows that some improvement can be obtained when the CaF 2 is heated to 950° C. prior to deposition of the B layer and the following Ge layer growth. Deposition of 1 nm of Sb or Si prior to the Ge layer growth did not show significant improvement in Ge crystalline quality.
The ratios of A-type to B-type Ge on CaF 2 /Si(111) are approximately 4.1, 2.1 and 1.5 for the B-predeposited, Ge-predeposited and Ge/CaF 2 /Si(111) samples with no predeposited layer, respectively. The ratios of A-type to B-type grains are determined by comparing the Ge(224) peaks at opposite azimuthal directions. X-ray diffraction measurements are carried out at room temperature after the films are prepared. The samples are mounted on a four-circle diffractometer equipped with a channel cut Ge crystal as the monochromator. Cu K.sub.α radiation is used. The FWHM of the symmetric (111) reflection curve is used to estimate the crystal quality of these films. For films of the same thickness, a smaller FWHM indicates better crystalline quality. In order to identify the structure type as A-type and/or B-type, the asymmetric reflection from (224) planes of the Ge and CaF 2 films and the Si substrate is measured. The (224) plane makes an angle of approximately 19.5° with respect to the (111) sample surface.
The ratios of A-type to B-type Ge on CaF 2 /Si(111) modified by various methods prior to Ge growth are shown in FIG. 6 (N/A in FIG. 6 indicates that no predeposited layer was used). Since the boundaries between A-type and B-type grains are twin defects, it is desirable to have films with either A-type or B-type orientation, but not grains of mixed orientation. A film with an A/B ratio close to unity tends to have worse crystalline quality than a film with a higher or lower A/B ratio, because of its high concentration of twin boundaries. In FIG. 6, it is clear that a B predeposit before Ge layer growth has the highest A/B ratio of the various methods. Again, this is consistent with a crystalline quality that is superior to that produced with the other methods. From FIG. 6, it is apparent that some improvement can be obtained when the CaF 2 is heated to approximately 950° C. prior to the deposition of subsequent layers.
FIGS. 7a and 7b are the SIMS depth profiles of Ge/CaF 2 /Si(111) with (FIG. 7a), and without (FIG. 7b), an approximately 1 nm B predeposit, respectively. A clear B peak 30 is observed at the Ge/CaF 2 interface when a B predeposit was used. The small B peaks 32 at the CaF 2 /Si interfaces in the two figures are due to autodoping during thermal cleaning of the Si substrates. No B was detected at the Ge surface 34, indicating that B does not migrate to the growth front during Ge deposition. Furthermore, FIG. 7a shows no Ca near the Ge surface (i.e. the Ca concentration is lower at the Ge surface than in the bulk Si). In contrast, the sample with no B predeposit shows a small Ca peak near the Ge surface. This comparison shows that the B (FIG. 7b) predeposit can prevent Ca migration in the Ge films.
The surface morphology of the Ge films during nucleation and final growth stages are shown in FIGS. 8a to 8d. FIGS. 8a and 8b are optical micrographs of 4 nm thick Ge on B-covered CaF 2 (111), and CaF 2 (111) with no predeposited layer, respectively. It is clearly shown that at the nucleation stage, B helps Ge to wet the CaF 2 surface, which in turn suppresses island formation (FIG. 8a). Without the B predeposit, large Ge islands may be clearly seen (FIG. 8b). FIGS. 8c and 8d are micrographs of 0.2 um thick Ge on B-covered CaF 2 (111), and CaF 2 /Si(111) with no predeposited layer, respectively. The surfaces are smoother than those during the nucleation stage. The surface of the sample with the B predeposit (FIG. 8c) is very shiny and shows little texture under an optical microscope, in contrast to the highly textured surface in FIG. 8d. TEM pictures of cross-sections of the samples show that the Ge/CaF 2 interface is sharper and smoother when the B predeposit is used. The major defects in the Ge films are twin boundaries along the (112), (111) and (111) planes. The surface morphology of Ge/CaF 2 /Si(100) samples is also improved when a B predeposit is used, but the difference is not as clear as in FIGS. 8c and 8d.
In addition to Ge/CaF 2 /Si, experiments have also been performed for the Si/CaF 2 /Si material structure. However, since it is more difficult to characterize the crystalline quality of the Si on CaF 2 /Si by x-ray diffraction (because of the very large substrate Si peak that results), the effect of the B predeposit in the Si/CaF 2 /Si material structure was studied by atomic force microscopy. FIGS. 9a and 9b are micrographs of approximately 4 nm thick Si on CaF 2 /Si(111) without (FIG. 9a ), and with (FIG. 9b), an approximately 1 nm B predeposit. It is clearly shown that the B predeposit improves the surface morphology of the film and suppresses island formation. Thus, there is strong evidence that the beneficial effects of a B predeposit described hereinabove for the Ge/CaF 2 /Si material system, also apply to the Si/CaF 2 /Si material system.
It is believed that the B predeposit changes the surface energies of the CaF 2 /Si samples and thus allows the Ge or Si subsequently deposited to wet the new surface more readily. It is likely to form relatively strong bonds with CaF 2 so that Ca atoms do not migrate into the Ge or Si films. The B atoms most likely stay at proper sites on the CaF 2 so that they do not interfere with the epitaxial growth of Ge or Si.
In summary, by modifying the surface energy of CaF 2 with a thin B layer, Applicant has been able to improve the surface morphology and crystalline quality of Ge films on CaF 2 /Si(111) and CaF 2 /Si(100). Similar concepts have been applied to the epitaxial growth of other materials systems, such as Si/CaF 2 /Si, where the substrate surface energy is lower than the epilayer surface energy. The B predeposit also reduces the interactions between Ge and CaF 2 , and enhances the growth of A-type Ge(111).
A few preferred embodiments have been described in detail hereinabove. It is to be understood that the scope of the invention also comprehends embodiments different from those described, yet within the scope of the claims. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. For example, though CaF 2 was the insulator used in the embodiments described herein, it may be appreciated that other fluoride insulators (i.e. CaF 2 , SrF 2 , BaF 2 , or mixtures thereof, for example) may also be used in this invention. In addition, though Si and Ge were the semiconductors used in the embodiments of the invention, it may be appreciated that other semiconductors (i.e. GaAs and InP, for example) may be used in the invention. It is therefore intended that the appended claims encompass any such modifications or embodiments.
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In one form of the invention, a method is disclosed for fabricating a semiconductor-on-insulator structure comprising the steps of: forming an insulator layer 22; forming a layer 24 comprising boron (B) on the insulator layer 22; and forming a semiconductor layer 26 on the layer 24 comprising B.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation under 35 U.S.C. §120 of U.S. application Ser. No. 12/544,320 filed on Aug. 20, 2009, the entire disclosure of which is hereby incorporated by reference herein, which claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. Provisional Application Ser. No. 61/090,606 filed on Aug. 20, 2008, the entire disclosure of which is also hereby incorporated by reference herein.
FIELD OF INVENTION
[0002] The invention relates to the rehabilitation of underground small diameter potable water distribution conduits as well as large diameter watermains.
BACKGROUND OF THE INVENTION
[0003] Trenchless methods are known for the rehabilitation of sewer and potable water conduits. Known methods include cured-in-place-piping (CIPP) and pulled-in-place-piping (PIPP), the major difference between the two applications being internal pressure. CIPP is achieved by producing a composite tube that is inserted or inverted into a host pipe. The composite is cured inside the host pipe to activate a resin system to produce a solid composite lining inside the pipe. An example of CIPP is disclosed in U.S. Pat. No. 5,384,086, this disclosure of which is incorporated by reference herein. Another method is disclosed in Canadian Patent #2 361 960 (US 2002/0058121) entitled “A Tubular Liner and Method of Rehabilitating of Conduits”, this disclosure of which is incorporated by reference herein. There is, however, a need for improved installation devices and methods to increase product quality, installation reliability, and execution efficiency.
SUMMARY OF THE INVENTION
[0004] An embodiment of the invention provides improved installation devices and methods related to the lining of the inner surface of an underground potable water conduit. In accordance with an embodiment of the invention, a non-protruding, polymeric finned plug which is inserted into a protruding, partially protruding, non-protruding, or even in a saddle service. The plug is inserted entirely within the service or hole leaving the face of the service or hole available and without interference to the liner and its polymeric resin so as a leak-tight bond may be formed. The absence of any plug lip or shoulder assures that no foreign matter remains entrapped between the liner/polymeric resin combination and the service or inner wall of the host pipe. This minimizes the possibility of entrapped air around the service face and host pipe which could lead to liner delamination after the service is opened and the water pressure is re-established in the water conduit. This aspect is directed specifically to product quality.
[0005] An embodiment of the invention also covers an improved leak-tightness of the service plugging operation. When the polymeric flexible multileveled finned plug is inserted into a service, the oversized fins flex and deform to conform to and apply a constant external force against the lateral inner wall of the service or hole creating a leak-tight seal of the service. The multiple levels of fins add additional layers of leak-tight protection.
[0006] An embodiment of the invention also addresses the loading and dispensing of the above described polymeric finned plugs. Where long conduits with numerous services entrances are involved, which is often the case on residential and commercial streets, the total time required to plug all services within the entire conduit is comprised of the time to load the plugging device and plug each service plus the time required to move the plugging equipment into position for each service. If the plugging equipment needs to be pulled out of the conduit to load a plug onto the plugging device, this lengthens the total time required to complete plugging of all services in a conduit. The invention addresses pre-loading a large quantity of plugs onto a magazine which is mounted on the plugging device. By pre-loading numerous plugs into the magazine and introducing the plugging equipment and loaded plug magazine avoids the need to pull the plugging device out of the conduit to load a plug onto the plugging device between each service plugging operation. The mounted magazine and dispensing mechanism must be sufficiently small to fit into conduits of small diameter as is often the case in potable water distribution conduits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1A is an elevational view of a polymeric flexible finned plug used to render service entrances leak-tight against polymeric resin from the liner according to an embodiment of the invention. FIG. 1B is a plan view of the plug of FIG. 1A .
[0008] FIG. 2A is a plan view a plug magazine according to an embodiment of the invention with high plug loading capacity with spring-loaded pusher forcing the plugs to advance through the magazine as they are stripped away individually for use. FIG. 2B is an elevational view of the plug magazine of FIG. 1A .
[0009] FIG. 3 is a plan view of the plug magazine plug dispensing system according to an embodiment of the invention showing the spring-loaded retaining fingers used to hold back the series of plugs in the magazine.
[0010] FIG. 4 is an elevational view of a conforming material dispensing system assembly according to an embodiment of the invention.
[0011] FIG. 5 is an enlarged view of the conforming/sealing material pneumatic, remote actuated dispenser according to an embodiment of the invention including the single or multi-part sealing material.
[0012] FIG. 6 is an enlarged elevational view of the compact, right-angle conforming/sealing material dispensing valve according to an embodiment of the invention including a multi-element static mixing nozzle used to mix multi-part material.
[0013] FIG. 7 is an enlarged elevational view of the compact, right-angle conforming/sealing material dispensing valve according to an embodiment of the invention depicting the compact size and appropriate angular configuration between the inlet of the dispensing valve and the outlet of the conforming/sealing material through the static mixing nozzle nested within the plug insertion tool and capable of injecting the material once the plug is installed in the service without having to change equipment or position.
[0014] FIG. 8 shows an assembled view of the polymeric flexible-finned plug positioned within an irregular shaped hole whereby the service is installed in a saddle on the outer face of the pipe.
[0015] FIG. 9 shows an elevational view depicting a plug dispensing magazine according to an embodiment of the invention mounted on commercially available robot.
[0016] FIG. 10 an end view of an embodiment of the invention having mounting multiple plug dispensing magazines onto a commercially available robot.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIGS. 1A and 1B refer to an embodiment of the invention which is a plug 1 made of polymeric material such as polyethylene, polypropylene, polyurethane, polyamide, and synthetic rubbers or other polymeric or rubberized material which is relatively rigid and approved by a recognized authority for use in potable water application. Plug 1 is inserted in a pipe service entrance prior to lining the pipe in order to keep uncured resin from the lining process from infiltrating and thus clogging the service entrance. The plug 1 has a core body 3 and at least one thin flexible fin 2 extending therefrom. The core body 3 may contain radial vent holes 4 and the at least one thin flexible fin 2 may contain longitudinal vent holes 21 for a function to be described in a later embodiment. The fins 2 are of a diameter slightly larger than the nominal diameter of the service entrance at its time of installation. Since the fins 2 are flexible and have memory, during the insertion of the plug 1 into the service entrance, the fins 2 flex and deform as the plug 1 is inserted into the service, however, the fins' 2 material memory will want to return to their original configuration except for some plastic deformation. The oversized flexible fins 2 will apply a constant lateral force against the inner wall of the service entrance thus allowing for sealing the service entrance. In the illustrated embodiment, in order to increase certainty and reliability that the service entrance is leak-tight, fins 2 are multi-layered with at least two layers of fins 2 longitudinally spaced about core 3 . With each fin 2 being flexible and at various heights within the service, various service diameters and surface conditions are accommodated sealed at each fin 2 . This provides for extra levels of leak-tightness within a compact plug design.
[0018] The plug 1 configuration and its features as described in embodiments of the invention will accommodate variations in service entrance diameter and surface finish found at the time of conduit rehabilitation, which can vary greatly from case to case due to reasons such as age, quality of valve construction, quantity and quality of water having passed through the service entrance over its time of use since entry into service, and other such factors. The described features of the oversized, flexible, multi-leveled fins 2 shall serve to maximize the number of cases whereby one plug design will satisfy the largest possible service entrance configurations of a given nominal diameter.
[0019] The plug 1 , which is inserted into the service entrance prior to conduit lining, allows the face of the service entrance be clear of any obstructions so that the polymeric resin and liner may form a clean, strong, and homogeneous bond with the face of the service entrance or inner wall of the conduit in the case where the service entrance is not penetrating beyond the inner wall of the conduit.
[0020] Embodiments of the invention apply not only to services which are protruding through an inner face of a conduit but also to services which are either; a) tapped into a conduit but the face of the plug is even or within the inner wall of the conduit, or b) the service is supported by a saddle or conduit joining union whose inner diameter is nominally equal to the outside diameter of the host pipe(s). In this case, a hole is present in the host pipe approximately in-line with the axis of the service entrance being supported by the saddle or union.
[0021] This plug 1 design allows for it to be inserted entirely within the service and thus not protruding the service within the conduit. The added advantage of this as opposed to a plug design which protrudes within the conduit is that when the liner is installed in a subsequent operation, the liner and its resin have virtually no opportunity to have air bubbles or pockets entrapped at the interface between the liner and the plug 1 .
[0022] FIGS. 2A and 2B refer to another aspect of the invention which is the high loading capacity and distribution magazine 5 for the above described flexible finned polymeric plugs 1 . Water mains to be rehabilitated are typically long and the preparation work to be performed prior to lining, notably the service plugging operation, must be accomplished from within the conduit. Embodiments of the invention reduce operation time, increase efficiency by minimizing the number of times that the equipment sent into the conduit be pulled out to load with plugs. Embodiments of the invention include a preloaded plug distribution magazine 5 with a large number of plugs 1 , ideally enough to cover the number of service entrances in the conduit is required and is the basis for the invention.
[0023] Referring to FIG. 2 , it is shown that a long, spring-loaded magazine 5 or track capable of being loaded with several plugs 1 . The plug dispensing magazine 5 is designed to be able to be retrofitted directly onto commercially available equipment 6 ( FIGS. 4 and 9 ) specific for conduit rehabilitation. Examples of commercially available equipment such as remotely controlled robots are disclosed in U.S. Pat. Nos. 4,648,454; 5,318,395 and 5,368,423, the disclosures of which are incorporated by reference herein. In order for the plug insertion equipment to work properly, the force required to advance a plug 1 into position after one has been removed by the plug insertion tool 7 ( FIG. 7 ) should be constant. In the invention, this is assured by a constant force biasing member or spring 23 activating a plug pusher 9 . As well as applying a constant force, the utilized spring has a very long stroke. This allows for a magazine 5 to be quite long and having a loading capacity of many plugs 1 .
[0024] The cross sectional profile of the magazine 5 or track is shaped in such a manner as to support the plugs 1 in between two levels of fins 2 . This assures that the plug 1 are always presented to the plug strip-off point at the same level.
[0025] At the front end of the magazine 5 is a set of spring-loaded plug retaining fingers 8 ( FIG. 3 ) which have a higher spring force than the plug advancement force. This keeps the plugs from being pushed through. The spring-loaded retaining finger(s) 8 can be singular or dual. They are made from a flexible material such as spring steel, and angled to hold back the plugs 1 in the magazine 5 . The plug insertion tool approaches the plug 1 in position ready to be stripped off from underneath the plug 1 . The plug insertion tool engages the waiting plug 1 and then moves forward, thereby forcing the retaining fingers 8 to spread open and allow the plug 1 to be stripped from the magazine 5 . Concurrently, the constant force plug advancing pusher 9 moves the next plug 1 into position ready for the next cycle. The pusher 9 acts on the trailing plug 10 of the series and thus the entire series of plugs 1 advances.
[0026] Referring again to FIG. 9 , it can be seen that due to the plug dispensing magazine's low profile, it can be mounted directly onto a commercially available robot 6 used for rehabilitating small diameter conduits and still fit.
[0027] FIG. 10 refers to the possibility of mounting multiple plug dispensing magazines 5 onto a commercially available robot 6 . By offsetting the plug dispensing magazines 5 a , 5 b angularly, it is possible to mount more than one magazine on the robot 6 . This allows for the possibility of either multiplying the total number of plugs 1 which can be pre-loaded prior to sending the equipment into the conduit or for having more than one size of plugs such that once the equipment inside the conduit, the operator, who is operating the equipment remotely, can plug service of various sizes without the need to withdraw the equipment from the conduit to change the size of plugs in the magazine 5 . Again the purpose of this is to minimize the time required to plug the services and thus increasing operation efficiency.
[0028] Yet another aspect of the invention is directed at plugging service entrances against resin infiltration during the lining process when service entrances are irregular in shape to the point whereby a usual plug 1 cannot guarantee leak-tightness. FIG. 4 shows a conforming/sealing material dispensing system 11 comprising later described elements 12 , 13 , 14 and 15 mounted on commercially available equipment 6 designed and built for rehabilitation of small diameter potable water conduits. With rigid, semi-rigid, or even multi-level flexible-finned plugs 1 as described earlier, there exists cases where a service entrance, either a service tapped directly into the host pipe or a service entrance made up of a valve in a saddle, is of a shape and/or surface finish which is not round enough or smooth enough in finish allowing for a leak-tight seal by the plug 1 . In these such circumstances, the invention provides for injecting a material which lends itself to injection, fills gaps between the plug 1 and the service entrance wall, approved for contact with potable water, and cures to a hardness allowing for it to be drilled out after the lining process along with the plug itself.
[0029] Embodiments of the invention include a pneumatic remote operated injection device 12 , a cartridge of single or multi-part conforming/sealing material 13 ( FIG. 5 ), a single or plurality of flexible hoses 14 for delivering the conforming/sealing material 13 , a remote operated dispensing valve 15 to control the moment at which the conforming/sealing material 13 is required, a static mixer 16 required for mixing multi-part conforming/sealing material. The sum of the above stated components is mounted on a commercially available robot 6 designed for performing plugging, drilling and inspection within small diameter potable water conduits and the like. The dispensing valve 15 ( FIG. 6 ) is designed and constructed to be able to fit within small diameter potable water conduits. It is pneumatically operated and can be actuated remotely. Its inlet and outlet are angled at 90 degrees for a compact arrangement. A nozzle 17 with if necessary a static mixer 16 is fixed onto the dispensing valve 15 . The static mixer 16 is required in the case where multi-part conforming/sealing materials are used. FIG. 7 shows the dispensing valve 15 mounted onto the plug insertion tool support block 18 along with the plug insertion tool 7 and a plug 1 which would previously have been stripped from the plug dispensing magazine 5 . The conforming/sealing single or multi-part material arriving from the dispenser arrives under pressure via flexible tubes (not shown). At the operator's discretion, the dispensing valve 15 is opened and the single or multi-part conforming/sealing material flows through the dispensing valve 15 and through the nozzle 17 which is equipped with or without a static mixing element 16 required for multi-part sealing materials. The nozzle 17 passes through an opening within the plug insertion tool support block 18 and plug insertion tool 7 . If the service entrance was deemed to be of irregular shape or of unsmooth finish prior to the insertion of the plug 1 , once the plug 1 is inserted into the service entrance, the operator triggers a dosed shot of conforming/sealing material. The conforming/sealing material passes through the central channel of the plug 1 ( FIG. 8 ) then out through radial vent holes 4 in the plug 1 to fill the gaps between the flexible multilevel fins 2 , the inner wall 20 of the service or hole and the outer core of the plug. Longitudinal vent holes 21 through the lower fins 2 allow for air which was trapped between the fins 2 to escape so the conforming/sealing material can fill all the voids and conform to the inner wall 20 of the service entrance regardless of its shape and/or surface finish and adhere to all the walls and seal the service entrance rendering it leak-tight. Longitudinal vent holes 21 in the lowest flexible fin 2 allow for some of the conforming/sealing material to escape providing the operator with evidence, via the camera 22 , that the conforming/sealing material has been injected in sufficient quantity. Should there not have been enough conforming/sealing material injected to fill the gaps and ooze through the longitudinal vent holes 21 of the lowest flexible fin 2 , then the operator can trigger a supplemental shot of material. This is repeated until the operator sees the material ooze out the lowest fin 2 . In order to contain the conforming/sealing material and from keeping it from infiltrating into the inner side of the service entrance, the topmost, or leading flexible fin 2 along with the top portion of the plug 1 are continuous without longitudinal vent holes 21 or openings. This also allows for a front line defense against leaks or at the very least keeps the possible path for resin infiltration to a minimum, thus reducing the size of the possible paths for the resin to travel.
[0030] If not otherwise stated herein, it may be assumed that all components and/or processes described heretofore may, if appropriate, be considered to be interchangeable with similar components and/or processes disclosed elsewhere in the specification, unless an express indication is made to the contrary.
[0031] If not otherwise stated herein, any and all patents, patent publications, articles and other printed publications discussed or mentioned herein are hereby incorporated by reference as if set forth in their entirety herein.
[0032] It should be appreciated that the apparatus and methods of the invention may be configured and conducted as appropriate for any context at hand. The embodiments described above are to be considered in all respects only as illustrative and not restrictive.
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A plug for a tubular service entrance of a conduit, wherein the plug includes a core body having a central hollow channel extending from a first end to second end of the core body; at least one flexible fin extending radially outwardly from the core body and having an outer diameter greater than the inner diameter of the tubular service entrance so that the plug is adapted to fit tightly into the tubular service entrance, and wherein the at least one flexible fin is deformable to adapt to the shape of the service entrance and apply a lateral force against the inner diameter of the service entrance. A plug dispensing magazine for storing and dispensing service entrance plugs to be service entrances of a conduit prior to installation of a liner in the conduit and a method of sealing the service entrances.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a facility for the production and/or assembly of goods. As is known, such facilities are factories or fixed buildings in which there are machines and also transport capacities for producing individual parts of an article and/or putting together a complete article from a number of individual parts, that is to say assembling the article, and then further processing or transporting the article produced in that way.
2. Description of the Related Art
However, for the production and assembly of goods, it is not always worthwhile to just erect an entire factory building. The reasons for this are not only general costs, but can also be that a given project has to be performed at a given location, but subsequently production at that location no longer makes any further economic sense.
EP 0 411 126 A1 discloses an industrial building having various cells, wherein a crane is arranged at the centre of each cell and serves to hold a horizontal platform of a ceiling construction.
JP 04306366 A discloses a roof construction for a crane in order to be able to carry out building works even in bad weather.
DE 44 27 164 A1 discloses a tent which is held by a crane. In that arrangement the crane is disposed with its jib outside the tent so that the crane can access components within the tent only at a location with a corresponding opening in the roof of the tent.
DD 137 131 discloses a large-chamber double silo. A rotary cane is provided within each silo.
DE 102 08 850 A1 discloses an assembly works for the assembly of industrial products. In particular shown therein is an assembly works for motor vehicles. The assembly works substantially comprises a main module with laterally disposed secondary modules.
DE 298 90 471 also discloses an installation for the production of industrial goods.
DE 689 09 169 T2 discloses a method and a modular building arrangement for industrial buildings. A building can be erected by means of a multiplicity of those modules.
BRIEF SUMMARY OF THE INVENTION
According to one embodiment, the present invention provides a simple solution so that the production of goods at a given location is also possible without having to erect expensive factory buildings, for example, by providing a facility as set forth in one or more of the attached claims. Advantageous developments are set forth in the appendant claims.
In accordance with the invention there is proposed a preferably transportable (mobile) and/or re-usable production facility, such as to be quickly and easily erected at virtually any location in this world. The production facility comprises virtually a tent structure, wherein the roof of that facility is held by at least one carrier as the support and also at the same time at least one device for raising or lowering or moving goods or parts thereof, for example crane structures, is provided on the carrier itself. Such a crane structure can be of a widely variable configuration and facilitates in particular the production of goods which are very heavy and which for assembly cannot be lifted or moved by human strength.
The invention includes the idea of using a commercially available rotary crane, in particular a commercially available rotary tower crane, as a main support for a production tent.
According to one alternative, a lightweight construction hall is equipped with a transport or crane capacity and to which modular units, for example in the form of containers, can be docked, so that the hall itself forms the working space while the respective kind of production is defined by way of the connected modular production units. The essential production know-how is therefore made available by the docked modular unit, in which respect that know-how also includes in particular machines and in particular also those items of equipment which are required for the assembly and/or handling and/or production of the goods to be produced.
It will be appreciated that it is also possible to place not just one modular unit but a plurality thereof in the production facility in order thus to allow the most possible complex production of a plurality of different goods.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention is described in greater detail hereinafter by means of an embodiment. In the drawing:
FIG. 1 shows a perspective view in section of a mobile production facility in accordance with a first embodiment by way of example,
FIG. 2 shows a portion of the arrangement of FIG. 1 ,
FIG. 3 shows a plan view of the mobile production hall of FIG. 1 , and
FIG. 4 shows a plan view of a production facility in accordance with a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view in section of a production hall or a production tent 1 according to one embodiment. In this case the production tent 1 preferably comprises two tent units which are connected together. The two tent units are supported by a large crane 2 and a small crane 3 . Both cranes 2 , 3 can be commercial rotary tower cranes (as shown). In order to increase the height of the tent 1 above the crane height, a support element 4 is mounted on the large crane 2 and a support element 5 is mounted on the small crane 3 . Accordingly the two cranes 2 , 3 carry the vertical loads of the tent 1 . Cables 12 , 17 , in particular steel cables, are used for lateral support for the tent 1 . In that case, two tips of the two tent units, respectively, are connected together by a tensioning cable 17 , while further tensioning cables 17 are connected to an outer post 10 a . In order further to improve stability, pillars 10 are disposed at least one edge of the tent 1 , the pillars 10 being connected by means of tensioning cables 12 to a ring 13 through which the support 4 extends. The ring 13 serves for connecting the pillars 10 to each other, not however for transmitting the forces from the support.
A concrete mixing installation 30 with corresponding silos 40 is provided toward at least one edge of the tent 1 . The concrete can be conveyed into containers 32 by way of a chute 31 so that those containers 32 with the concrete can be transported by means of the large crane to appropriate locations in the tent 1 . Provided at predetermined positions in the tent 1 are individual production departments 20 which serve to carry out the various production steps. The concrete can then be poured into a mold or used as a component for a product. After the concrete has cured, the crane 2 can pick up the completed product and place it on a truck or some other transportation vehicle to remove the assembled part from the structure.
A respective ventilation opening 90 can be provided at the tip of each of the large and small cranes 2 , 3 . In addition a trench 200 for water drainage can be provided laterally at the tent 1 .
While FIG. 1 shows a tent 1 comprising two sub-tents, the mobile production unit can also be implemented only with one tent. As an alternative thereto the (mobile) production unit may also be implemented with a plurality of tents.
FIG. 2 shows a portion of the perspective sectional view of FIG. 1 . Here the transition between the crane 2 and the support 4 is shown in greater detail. In this case the crane 2 has a pivot joint socket 2 a at its tip. At its one end which is towards the crane 2 the support 4 has a pivot joint ball 4 a which is fitted into the pivot joint socket 2 a . By virtue of that arrangement of the pivot joint socket 2 a and the pivot joint ball 4 a , the crane can rotate without the support 4 also rotating therewith. This pivot joint socket connection is shown as a general schematic of one acceptable coupling. Many other acceptable couplings can be used which connect the support 4 to the crane 2 , including a closed socket connection, a ball and joint or other connection. A pivot joint ball and a pivot joint socket can also be provided between the small crane 3 and the support 5 .
A ring 13 is also shown. Shown on the ring 13 are the cables 12 , preferably made of steel, extending between the ring 13 and the respective pillars 10 . In this case the cables 12 serve for lateral stabilization of the tent. The arrangement of the ring 13 provides that the forces can be transmitted between the posts or away from the posts without in that case influencing the support 4 .
FIG. 3 shows a plan view of the production unit of FIG. 1 . In this case also the production unit is formed from two tents which are connected together. The two cranes 2 , 3 in this arrangement serve to carry the vertical forces. Arranged at the tent 1 are a plurality of pillars 10 which are connected by means of cables 12 to the ring 13 (not shown) to carry away the forces. The large crane 2 and the small crane 3 are arranged in this case in such a way that their respective radii of action overlap in the portion 100 . Accordingly, a production operation can be effected in the radius of action of the small crane 3 , that is to say in the small tent, in which case the goods produced can then be transported by means of the small crane 3 into the portion 100 where the goods can then be further assembled and/or transported into the large tent by the large crane 2 . Once again a concrete mixing installation 30 with the corresponding silos 40 is shown externally at the large tent. Paths 50 which extend within the tents are provided for transporting or transporting away the goods produced. In this respect those paths 50 are better consolidated than the remaining region of the tent floor which for example can comprise gravel.
A storage area 60 for the goods produced can also be provided outside the tent.
By way of example, pylon segment portions of wind power installations can be produced from concrete and reinforcements, in the production facility. For that purpose, the reinforcement is suitably laced together to produce a cage, in the small tent. The small crane 3 then moves the laced cage into the portion 100 so that the large crane 2 can take over the cage and can set it down at the suitably provided place 20 ( FIG. 1 ) in the large tent. The corresponding concrete casting shuttering is placed around the cage and the concrete produced by the concrete mixing installation 30 is transported to the concrete shuttering for example by means of the containers or buckets 32 and poured into the shuttering. After the concrete has set, the shuttering is removed and a corresponding transport apparatus transports the finished concrete parts to the storage area 60 . That is preferably effected over the consolidated paths 50 .
As an alternative to the above-described transport of the concrete by means of buckets 32 ( FIG. 1 ), the large crane 2 can also be provided with a suitable concrete pump so that the concrete can be pumped from the concrete mixing installation 30 into the corresponding shuttering moulds at the respective working area 20 ( FIG. 1 ).
The above-described production unit can be used in particular for the production of prefabricated concrete elements, such as for example pylon segments for wind power installations or elements for prefabricated house production. In other words: it is possible to achieve series production of elements which are bulky and difficult to transport or which becomes bulky after assembly and wherein the raw materials are to be present on site or are to be easily transported thereto.
In regard to the production of concrete elements, it is important that when setting, the concrete elements are at a predetermined temperature. As a certain time is required until the concrete elements then cool down again, the heat which is produced in that situation can be employed to heat certain regions such as for example a living region (for the workers) in the immediate proximity of the mobile production unit.
Wind turbines are often constructed at remote locations, far from extra-wide or heavy-duty roads and at the tops of mountains or on islands, and also far from buildings, structures or other commercial production facilities. It might be that the cost to build the extra-wide or heavy-duty stable roads necessary to transport completed concrete pylons segments by trucks to the remote location will be impossible or cost prohibitive. According to this invention, the mobile production facilities can be set up at or near the final site for the wind turbine pylon. The raw materials, such as gravel, cement, water and other components can be brought on standard trucks which do not need an extra width or road supports. The wind turbine pylon segments of any size can then be manufactured in the mobile production hall 1 . The mobile hall 1 can be built at a very low cost. When the construction of the wind tower components is completed, the mobile production hall 1 can be disassembled and moved to a new location to build a new wind turbine at a low cost. The impact on the environment is thus much less since heavy or bulky loads do not need to be transported over long distances and the cost is lower for the overall production of the final wind turbine.
The above-described re-buildable production facility can permit substantially autonomous production at many more or less inaccessible locations. In regard to power supply, it is advantageous to provide an autonomous current island network which is supplied with electrical power by means of diesel generators, wind power, solar power, by a flywheel or the like. Particularly at remote locations the power supply for a production facility can entail a not inconsiderable degree of complication and expenditure if for example the diesel for diesel generators has to be transported over great distances. In that respect, an improvement in the autonomous power supply is represented by the use of solar modules on the roof of the tent or solar modules which are integrated into the roof of the tent. For example the illumination for the production facility can be powered or partially powered by means of the solar modules and suitable energy storage devices. The provision of solar modules on the tent roof also has the advantage that the solar modules provide shade. Alternatively or additionally thereto, a wind power installation can be used for the power supply for the production facility. It will be appreciated that in that respect a wind power installation is particularly advantageous, which can be quickly set up and possibly removed again.
To provide hot water, tubes can be run on the tent roof or at the edge of the tent roof, which are filled with water so that that water is heated throughout the day by way of the solar radiation and thereafter can be used as process water for industrial use. This also has the advantage that the tent structure is further weighted down so that stability is increased.
In addition conveyor devices for bulk materials such as for example sand, cement or the like can be arranged in such a way that they lead from the exterior into the tent or the concrete mixing installation in order accordingly to transport the corresponding bulk materials to the required locations.
The floor covering of the tent can comprise gravel, as an alternative thereto the floor can also be surfaced.
Residential containers or residential tents for the workers of the installation can be set up in the proximity of the facility. A water processing installation for a supply of drinking water is preferably also provided. As workers are occupied for a certain period of time at the building site or during production, a mobile medical station including the necessary implements, equipment and the like can also be provided.
At certain portions within the tent, in particular at the inside wall of the tent, it is possible to provide a peripherally extending framework such as for example building scaffolding for the storage of small parts.
The production facility can be provided for rail construction, for the assembly of electricity pylons, for components of prestressed concrete bridges, for components for road construction, for prefabricated houses, for goods packaging, for foodstuffs storage and/or for the processing and loading for example of an oil mill, an oil storage facility, an oil freighting facility, for production/assembly of all parts of a wind power installation or a solar installation.
In accordance with a further embodiment of the invention there is provided a central support on which a ring with spokes can be pulled up. At least one traveling trolley can be provided on that ring with the spokes so that the traveling trolley can be used for raising goods or articles within the tent. Preferably the traveling trolley can also move along the spokes. A plurality of trolleys are also possible. Accordingly there is no need for the ring or the crane units 2 , 3 to rotate as the traveling trolley can move along the outer ring and along the spokes.
FIG. 4 shows a plan view of a production facility in accordance with a further embodiment of the invention. Here a central unit 101 is firstly set up. That unit 101 can be implemented for example by a tent. Commercially available containers 102 can be docked to the outside of a hall 104 of the unit 101 . For example standard workstations can be embodied in the containers 102 so that those workstations can be easily transported to and from between the various production facilities. A crane 103 which can move within the hall 104 is provided for transport of goods along at least two axes 105 , 106 within the hall 104 .
To erect the above-described unit 101 or hall 104 therefore it is only necessary to level the ground so that thereafter a support framework for the hall 104 can be set up, which for example is covered with a tent roof. The appropriately required special workstations are embodied as described hereinbefore in the containers 102 so that they only have to be docked to the hall 104 .
That arrangement has in particular the advantage that halls of that kind can be easily transported and erected in a short time so that corresponding production can be effected at any locations.
The containers 102 just described above can also be docked to the production facilities described with reference to FIGS. 1 to 3 in order to provide specialist workstations such as for example laboratories or the like.
The above-described production facility can also be used to produce steel pylons for example for a wind power installation.
All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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There is proposed a preferably transportable (mobile) and/or re-usable production facility, as is quick and easy to erect virtually at any location in this world. This production facility virtually comprises a tent structure, wherein the roof of the facility is held by at least one carrier (support) and at the same time at least one device for raising or lowering or moving goods or parts thereof, for example crane structures, is also provided on the carrier itself. Such a crane structure can be of a variable configuration and facilitate in particular the production of goods which are heavy and/or which for assembly can no longer be raised or moved by human strength.
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This application is a continuation-in-part of application Ser. No. 062,908 filed Aug. 1, 1979, now abandoned.
FIELD OF THE INVENTION
This invention relates to an acrylic fiber suitable for use in a process for preparing a precursor fiber for production of carbon or graphite fibers.
Conversion of acrylic fibers to carbon or graphite fibers useful as reinforcing materials has been known for many years. In the known process, the acrylic fibers are first heated for one to two hours at 200°-300° C. in an oxidizing atmosphere to provide a cyclized precursor fiber which is then heated at 800°-1500° C. in an inert atmosphere to form carbon fibers or to even higher temperatures to form graphite fibers. This process is costly because of the slowness of the cyclization step.
Heating acrylic fibers in an oxidizing atmosphere causes formation of a cyclic structure consisting of naphthyridine rings and crosslinking. The naphthyridine ring-containing fibers are sufficiently resistant toward melting so that they can be heated at the high temperatures required to convert them to carbon or graphite fibers.
The temperature of the cyclization step is limited by the melting behavior of the fibers being treated. Use of relatively high temperatures in order to provide a higher rate of reaction causes difficulty in that the exothermic cyclization reaction is difficult to control, resulting in loss of fiber properties, fused filaments and nonuniformity in the product. Inclusion of various cross-linking comonomers in the acrylic fibers has been suggested as a way to increase the temperature resistance of the fibers so that the cyclization step can be carried out at a higher temperature.
Japanese Patent Application Publication (JPAP) No. 7531/78 suggests for the preparation of carbon fibers an acrylic fiber containing a cross-linking comonomer along with another comonomer which is the ammonium or amine salt of a sulfonic acid. Carbon fibers from this precursor fiber are alleged to be stronger and to provide greater interlaminar strength in resin composite structures. JPAP No. 7531/78 does not recognize any improvement in the rate of the cyclization reaction. Cross-linkable copolymers are undesirable in fiber-spinning processes in which the polymer solutions are heated as in dry spinning since premature cross-linking can occur resulting in gelation of the solution, causing serious economic penalty or even preventing manufacture.
This invention provides an acrylic fiber suitable for the preparation of carbon or graphite fibers which can be heated rapidly to high temperatures without interfilament fusion or loss of ultimate carbon or graphite fiber strength. Use of higher temperatures permits completion of the cyclization reaction in a much shorter time, thus making the cyclization process more economical.
The fiber of this invention is an acrylic fiber of an acrylic polymer containing 93-99.4 mol percent acrylonitrile units, 0.6-4.0 mol percent ammonia or amine having a pKb of 5 or less incorporated into the polymer as neutralizing cations for sulfate or sulfonate end groups derived from the initiator and activator, if present, and as neutralizing cations for sulfonate groups incorporated into the polymer by copolymerization of one or more copolymerizable, sulfonate containing comonomers selected from the group consisting of styrene sulfonic acid, allyl sulfonic acid, methallyl sulfonic acid, 2-acrylamido-2-methylpropane sulfonic acid and ethylene sulfonic acid and 0-3.0 mol percent of units of one or more neutral comonomers selected from the group consisting of alkyl acrylates having 1-4 carbon atoms in the alkyl group, alkyl methacrylates having 1-4 carbon atoms in the alkyl group, vinyl acetate, vinyl propionate, styrene, vinyl chloride and vinylidene chloride and no more than 0.3 mol percent neutralizing cations other than ammonia or amine having a pK b of 5 or less. Preferably, the fibers contain no more than 0.1 mol percent of cations other than ammonium or amine. Preferably sulfate and sulfonate end groups, when present, are derived from ammonium persulfate initiator and ammonium bisulfite activator.
Preferably the precursor fibers contain 0.8 to 2.0 mol percent sulfonic acid containing comonomer. Preferably the sulfonic acid containing comonomer is 2-acrylamido-2-methylpropanesulfonic acid (AMPS). Most preferably no neutral comonomer is present.
The above fibers are useful in a process for preparing precursor fibers for the preparation of carbon or graphite fibers wherein the fibers of claim 1 are heated for 4-20 minutes in one or more stages in air at a temperature at least 10° C. below the stick temperature of the fibers entering that stage to provide fibers having a density of at least 1.36 g/cm 3 . Preferably the acrylic fibers are heated in air at 250°-360° C. Most preferably the process is continued until the precursor fibers have a density of at least 1.40 g/cm 3 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plot of fiber stick temperature against time for (1) an acrylic fiber containing 98.8 mol percent acrylonitrile and 1.2 mol percent 2-acrylamido-2-methylpropanesulfonic acid ammonium salt, (curve A), (2) an acrylic fiber containing 95.4 mol percent acrylonitrile, 0.8 mol percent itaconic acid and 3.8 mol percent methyl acrylate (curve B) and (3) an acrylic fiber containing 98.8 mol percent acrylonitrile and 1.2 mol percent sodium styrenesulfonate (curve C), all samples being heated in air, fibers (1) and (3) at 280° C. and fiber (2) at 250° C. (highest possible without damaging the fiber).
FIG. 2 is a plot of fiber density against time of heating in air for fiber (1) above heated at 270° C. for 2 minutes, 310° C. for four minutes and 360° C. for 2 minutes (curve D), for fiber (2) above heated at 250° C. (curve E), and for fiber (3) above heated at 250° C. (curve F).
FIG. 3 shows differential thermal analysis curves obtained on heating two fiber samples in air or nitrogen at 50° C./min. Fiber (1) above is heated in air (curve G), and in nitrogen (curve H). Fiber (3) above is heated in air (curve I) and in nitrogen (curve J).
FIG. 4 shows a series of differential thermal analysis curves obtained at 20° C./min. under nitrogen for fibers of a polymer containing 98.8 mol percent acrylonitrile and 1.2 mol percent 2-acrylamido-2-methylpropane sulfonic acid as the ammonium salt (curve K), the sodium salt (curve L), 0.80 mol percent ammonium salt-0.40 mol percent sodium salt (curve M), and 0.64 mol percent ammonium salt-0.56 mol percent sodium salt (curve N).
FIG. 5 shows differential thermal analysis curves obtained at 20° C./min under nitrogen for fiber (1) above (curve O) and fiber (2) above (curve P). Stick temperatures of the fibers are indicated by arrows below the curves.
DETAILED DESCRIPTION OF THE INVENTION
The acrylic fibers of this invention are useful in any process for the preparation of carbon or graphite fibers. They offer substantial advantages in the speed of cyclization, resulting in a significant reduction in the cost of the overall carbonization/graphitization processes. The largest improvement is realized by use of a temperature program during cyclization in which temperature is increased rapidly with the provision that it must never be higher than 10° below the increasing stick temperature of the fiber.
The cyclization reaction is substantially complete when the starting fibers having a density of about 1.18 g./cm. 3 have achieved a density of at least 1.36 g./cm. 3 and preferably at least 1.40 g./cm. 3 . Such fibers are totally insoluble in hot polyacrylonitrile solvents. The cyclized intermediate fibers having a density of at least 1.36 g./cm. 3 may be converted to carbon or graphite fibers by methods known in the art, e.g., heating the intermediate fibers in an inert gas at 800°-1500° C. or higher for a short period of time. Carbon fibers will have a density of about 1.70 g./cm. 3 and graphite fibers ordinarily have a density in the range of 1.85-1.95 g./cm. 3 .
Suitable sulfonic acid containing monomers are styrenesulfonic acid, allylsulfonic acid, methallylsulfonic acid, 2-acrylamido-2-methylpropane sulfonic acid, and ethylenesulfonic acid. The sulfonic acid containing monomers are preferably polymerized as the ammonium or amine salts but alternatively may be polymerized as the free acid or metallic salt and then converted to the ammonium or amine salt by ion exchange.
A fiber containing 1 mol percent alkali metal cation as copolymeric sulfonate will exchange about 0.8 mol percent of the alkali metal cation with ammonium ion on soaking 2 hours at room temperature in 5% aqueous ammonium sulfate.
Amounts of sulfonic acid ammonium or amine salt containing comonomer much greater than about 2 mol percent increase the water sensitivity of the starting fibers without providing much further increase in catalytic activity. For this reason, a maximum of 4 mol percent sulfonic acid containing monomers is specified.
Suitable amines for forming the amine salts are those amines having a pKb of 5 or less such as methyl, ethyl, dimethyl, diethyl, triethyl, ethanol, diethanol amines.
The ammonia or amine groups bound to the acrylic polymer chains via sulfonic acid groups are believed to act as catalysts in the cyclization reaction permitting a rapid increase in the resistance of the fibers to high temperatures. Ammonia or amine salts of sulfonic acid or sulfate end groups, when present, also act as catalysts. In the usual range of molecular weights, 0.2-0.35 mol % of ammonium or amine ion can be associated with end groups.
Acrylic polymers suitable for the preparation of the fibers of the present invention may be prepared by conventional free-radical polymerization procedures, such as systems employing redox catalysts, in suspension, solution or emulsion systems. Preferably, the polymerization is carried out in a system containing no metallic cations or at least a system containing only a low level of metallic cation.
The acrylic fibers may be prepared by conventional solution-spinning processes such as dry spinning, wet spinning or dry-jet wet spinning. Dry spinning is preferred.
The acrylic fibers are preferably drawn 2 to 8×. Drawing is preferably carried out in hot water (e.g. 90° C.) or in steam. The drawn fibers may be dried by conventional procedures but are preferably dried in a way providing precursor fibers having a density of about 1.18 g./cm. 3 . If the acrylic fibers of the invention are to be prepared by ion exchange, this is preferably carried out on fibers which have not been dried and are still water swollen from the extraction and drawing steps of the manufacturing process.
From FIGS. 1 and 2 it can be seen that fibers useful in the process of the present invention are converted to substantially completely cyclized intermediate fibers having a density of at least 1.40 g./cm. 3 . much more rapidly than other acrylic fibers.
From FIG. 3 it can be seen that fibers useful in the process of the present invention undergo an exothermic reaction (cyclization) both in nitrogen and in air at a lower temperature than fibers not useful in the present invention and that a smaller exotherm occurs in a non-oxidizing atmosphere (nitrogen).
From FIG. 4 it can be seen that an increasingly larger portion of the exothermic reaction occurs below 300° C., the initial stick temperature, as the amount of ammonium ion increases.
From FIG. 5 it can be seen that a fiber according to the invention undergoes exothermic reaction below its stick temperature under nitrogen while a carbon fiber precursor of the prior art does not. It will be noted that all of the inert-atmosphere DTA curves for the production of this invention exhibit an exothermic reaction before the stick temperature is reached, which is unique for the composition. The comparison is best seen in FIG. 4 where a composition having no ammonium or amine neutralizing cations is compared with others having various levels of ammonium-ion content. Evidently, the low temperature reaction occurring in the fibers of the invention makes possible a faster conversion without filament fusion because the fiber stick temperature begins increasing at a lower temperature.
TESTS
Differential Thermal Analysis
A discussion of differential thermal analysis (DTA) appears at p. 263, et seq., of Physical Methods in Macromolecular Chemistry, Carroll, Vol. 1, 1969, Marcel Dekker, authored by Feng and Freeman. The method provides a measure of the heat absorbed or generated in a sample as a function of temperature. In the present invention, this method provides a useful comparison of total heat and rate of the exothermic reaction leading to the "cyclized" form of an acrylic fiber which is suitable for rapid carbonization or graphitization at high temperature. The results are essentially identical whether polymer or fiber samples are used.
In this analysis, a 5 mg sample is placed in a sample cup which is in turn placed on one loop of the differential thermocouple in a DTA cell (the "Stone" cell, Traco Model SH-15BR2-Ni, is suitable, among others). An empty cup is placed on the other loop.
The temperature is programmed to rise at 20° C./min. or 50° C./min. from 100° C. to 400° C.
Density
Density determinations are made in calibrated density gradient tubes as known in the art. A container such as a standard 250 ml graduated cylinder contains a fluid prepared to have the desired density gradient and calibrated by the addition of "floats" of selected, known density. The fiber to be tested is knotted, the ends clipped and the knot dropped into the tube. When it has settled to its equilibrium level, its position is read in terms of proximity to calibration floats above and below it. Interpolation between these points gives the sample density.
Fiber Stick Temperature
The measurement of fiber stick temperature is an adaptation of the "Procedure for Melting Point Determination", ASTM D-276-62T. Two changes were made to improve accuracy in the measurement of stick temperature of a nonmelting fiber such as the fiber of this invention:
Temperature is measured with a reliable surface pyrometer rather than a submerged thermometer.
A convexly curved surface is used to heat the bare fibers; no cover glasses are used.
In the actual measurement, a strand of fibers is held against the convex surface for a maximum of 10 seconds. If sticking occurs, the temperature is dropped about 5° C. and the test repeated; if the filaments do not stick, the temperature is raised about 5° C. and the test repeated. A fresh sample is used for each test. Once sticking occurs, the tests are repeated at temperatures near this value until successive trials show incidence of sticking within a 2° C. range.
Polymer Preparation
The acrylonitrile polymers suitable for use in making the acrylic fibers of the present invention are preferably made in the conventional aqueous suspension system as generally taught in the Sampson et al. U.S. Pat. No. 3,308,109 with recipe modifications appropriate to production of the polymer useful in the present invention. This is a continuous, steady-state redox (e.g., bisulfite-activated/persulfate initiated) polymerization in which all ingredients are metered to an agitated, jacketed vessel, a representative portion of the contents overflowing constantly. Polymer and unreacted monomers are recovered from the overflowing slurry. The heat of reaction is removed by water circulating through the jacket.
PREPARATION A
The following ingredients are continuously fed:
______________________________________ Parts, by Weight, per Hour______________________________________Demineralized Water 75Acrylonitrile 23.3AMPS* 1.67 (dissolved in part of the water feed)SO.sub.2 0.2 (dissolved in acryloni- trile)(NH.sub.4).sub.2 S.sub.2 O.sub.8 0.07 (dissolved in part of the water feed)NH.sub.4 HSO.sub.3 0.2 (dissolved in part of the water feed)Fe.sup.++ 4 ppm (on feeds, as ferrous ammonium sulfate)To overflowing slurry: in excess of that needed toSodium-neutralized ethylene complex the irondiamine tetraacetic acid______________________________________ *2-methyl-2-acrylamidopropanesulfonic acid neutralized to pH 2.5 with NH.sub.4 OH
The reactor has a working capacity to the continuous overflow of about 50 parts, resulting in a residence time of 30 minutes. The temperature is controlled at 60°±1° C. The pH of the reacting mass is 2.6. The acrylamidomethylpropanesulfonic acid content of the polymer is 0.7 mol percent. The total ammonium ion content is 1.07 mol percent.
Overall conversion is found to be 78% of a polymer having an intrinsic viscosity of 1.11. The metal ion content is found by analysis to be <10 ppm (<0.002 mol % on polymer).
Two additional polymers are made as above, using feeds as follows:
______________________________________ Parts, by Weight, per Hour B C______________________________________Water 80 80Acrylonitrile 18.0 18.8AMPS 2.0 1.2(NH.sub.4).sub.2 S.sub.2 O.sub.8 0.06 0.06NH.sub.4 HSO.sub.3 0.03 0.06Fe.sup.+ 2 ppm 2 ppmpH 3.0 2.8Conversion 80% --*Intrinsic Viscosity 2.4 2.8AMPS Content** 1.5 mol % 0.74 mol %Total Ammonium 1.8 mol % 0.92 mol %______________________________________ *Not determined; about equivalent to that of B. **By Xray fluorescence to give total sulfur and correction for the end groups calculated from the intrinsic viscosity
It should be noted that the end groups derived from the initiator and activator are a significant proportion of the total ammonium- or amine-binding capacity. A polymer of lower molecular weight, thus requires less comonomeric sulfonate.
EXAMPLE I
Polymers are separately dry spun and wash drawn, as known in the art, to 1500-filament, 1.5 dpf yarns for this experiment. Polymer D is made by the prior art procedure, employing K 2 S 2 O 8 as initiator, sodium bisulfite as activator and sodium styrenesulfonate as the comonomer. Otherwise, the general procedure of the foregoing preparations is followed. Polymer E is prepared, as illustrated under the foregoing preparations. Polymer D contains 1.0 mol % of sodium styrenesulfonate. Polymer E contains 1.0 mol-% AMPS as the ammonium salt.
The yarns are passed continuously at constant length through a tubular furnace at such a rate as to reach a density of 1.4 g/cc in one pass. The yarn from Polymer D required 96 minutes residence at 270° C. and that of Polymer E 6 minutes, at a temperature profile from 270°-350° C.
Twelve-inch lengths of each yarn are placed, untensioned, in a muffle furnace under nitrogen and heated, over the course of 1 hour, to 1100° C. After 30 minutes at that temperature, the furnace is cooled to 200° C. over the course of 3 hours before exposing the carbonized yarns to air. The samples are measured for denier, to determine total cross-sectional area, and embedded in an epoxy resin.
PREPARATION OF EPOXY COMPOSITE FOR TESTING
1. Weigh 100 parts "Epon" 826 (a product of Shell Chemicals) and 14 parts of metaphenylenediamine into a glass container.
2. Dilute with 200 parts acetone. Mix well. This solution must be used within 2 hours after preparation.
3. Pour the solution into a pan of suitable size and into it coil an 18-inch (approximately 50 centimeters) or longer strand of a carbon (or graphite) yarn having a denier of about 1500 (166 tex).
4. Pull the impregnated strand through a glass, fire-polished, eye dropper having a minimum internal diameter of 0.060" (1.5 mm).
5. Clamp the ends of the impregnated, collimated strand between the arms of hinged clamps which have been coated with "Silastic" silicone rubber. The clamps can be made from common 4 inch iron strap hinges by securing two bolts to one side of each to permit convenient fastening with nuts after closing on the impregnated sample.
6. Hang the sample on a horizontal rack by attaching one of the closed clamps to one side of the rack, attaching a 4-pound (1.8 kg) weight to the second clamp and allowing this weighted end to drape across the other side of the rack, leaving about 15 inches (38.1 cm) of strand suspended across the opening. Allow the solvent to escape for 2 to 3 hours at room temperature.
7. Cure, without removing from the rack, at 120° C. for 2 hours and 155° C. for 4 hours in a circulating air oven.
8. Trim the ends of the strand and measure its length accurately; weight it to the nearest 0.1 milligram. From this weight, the known length and the known denier of the strand, establish that the resin content of the composite is about 40-50% before proceeding further.
9. Sandwich about 2 inches (5 cm) of each end of the strand between approximately 1"×2" (2.5×5 cm) pieces of cardboard along with additional epoxy resin; clamp the cardboard tabs together and re-cure as in (7) above. This procedure minimizes breakage of the brittle carbon fibers by the Instron clamp.
10. Test the composite to failure on an Instron in the known manner.
Properties are summarized in the following table.
______________________________________ Tensile Strength Initial ModulusComposite of (× 1000 kg/cm.sup.2) (× 10.sup.6 kg/cm.sup.2)______________________________________Fiber of Polymer DCyclized in air, 96 min. 10.9 1.1Fiber of Polymer ECyclized in air, 6 min. 9.1 0.8______________________________________
EXAMPLE 2
Two additional polymers, F and G, are made by the process as generally described above to have intrinsic viscosities of 1.50 and 1.35, respectively. Polymer F consists essentially of 98.8 mol % acrylonitrile and 1.2 mol % sodium styrene sulfonate and serves as a comparison; polymer G consists essentially of 98.8 mol % acrylonitrile and 1.2 mol % ammonium 2-acrylamido-2-methylpropanesulfonate. Both polymers are dry spun into fibers which are drawn to 580% of their as-spun length to yield 700-filament yarns of 1.4 denier/filament.
Stabilization of these yarns is carried out by passing them continuously through a 36", three-zone tube furnace. Each 12" zone has independent temperature controls. Fibers are processed with equal input and exit speeds to achieve constant fiber length during stabilization. Hold-up time is set by selection of yarn speed. All fibers are stabilized under conditions tabulated below in an air atmosphere and have densities after treatment of 1.38-1.40 gm/cc.
______________________________________ Process Temperature °C. Hold-Up TimeFiber Composition Zone 1 Zone 2 Zone 3 (Minutes)______________________________________Polymer F 255 260 270 90Polymer G-Run 1 250 270 300 60Polymer G-Run 2 250 270 300 30Polymer G-Run 3 250 270 300 24Polymer G-Run 4 250 270 300 17______________________________________
Increase in Zone #2or Zone #3 by 10° C. beyond those tabulated for treatment of the fiber of Polymer F cause filament fusion and breaks. Reduction in overall process time from 90 to 60 minutes for treatment of the fiber of polymer F results in fiber density below 1.36 gm/cc, the minimum density consistent with good carbonization performance.
After stabilization according to the conditions tabulated, each yarn is carbonized by passage through a 36° tube furnace heated to 1100° C. which is continuously flushed with nitrogen. Yarn speed is adjusted to provide 12-minutes exposure. The physical properties tabulated below are obtained after potting the samples at 60% fiber, as described in Example 1 (elongation rate--10%/min).
______________________________________ Elongation InitialComposition Denier Tenacity (%) Modulus______________________________________Polymer F 515gpd AVG 5.72 1.83 360kg/cm.sup.2 9.3 × 10.sup.3 -- 0.58 × 10.sup.6psi 143 × 10.sup.3 -- 7 × 10.sup.6Polymer G-Run 1 516gpd avg 7.21 1.58 487kg/cm.sup.2 11.7 × 10.sup.3 -- 0.79 × 10.sup.6psi 180 × 10.sup.3 -- 12.2 × 10.sup.6Polymer G-Run 2 579gpd avg 5.10 1.42 478kg/cm.sup.2 8.3 × 10.sup.3 -- 0.77 × 10.sup.6psi 128 × 10.sup.3 -- 12.0 × 10.sup.6Polymer G-Run 3 528gpd avg 6.78 1.40 526kg/cm.sup.2 11.0 × 10.sup.3 -- 0.85 × 10.sup.6psi 169.5 × 10.sup.3 -- 13.1 × 10.sup.6Polymer G-Run 4 509gpd avg 8.57 1.72 637kg/cm.sup.2 13.9 × 10.sup.3 -- 1.03 × 10.sup.6psi 214 × 10.sup.3 -- 15.9 × 10.sup.6______________________________________
These data suggest that improved physical properties are obtained with the shortest possible stabilization times. Shorter stabilization times are also desirable for economic reasons.
For a continuous, commercial process, the shortest time of conversion can be selected for a given precursor fiber, as follows:
1. Determine the stick temperature of the acrylic fibers.
2. Heat samples of the fibers in air at a temperature 10° C. below the stick temperature for increasing periods of time such as 0.25, 0.5, 1.0 and 2 minutes using a fresh sample for each test and determine the density and stick-temperature for each sample.
3. From the data obtained in 2., select a new temperature 10° C. below the stick temperature of a sample for a second short-term treatment of that sample at various times at the new temperature.
4. Continuing in this manner, select a temperature for a third and a fourth, etc., incremental treatment, always starting the incremental treatment at about 10° C. below the then-attained fiber stick temperature.
5. Plot fiber stick temperature as a function of total time treatment. Select a rate of temperature change from the plotted data which results in continuous treatment at a temperature as near as possible to 10° C. below the then-attained stick temperature and program the furnace to operate at this rate.
If excessive fused filaments are obtained the rate of temperature increase should be decreased slightly. By optimization of the rate of temperature increase, treatments requiring 15-20 minutes as illustrated in the examples can be accomplished in as little as 6 or even 4 minutes.
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An acrylic fiber useful in the preparation of precursor fibers for the preparation of carbon or graphite fibers contains 93.0-99.4 mol percent acrylonitrile, 0.6-4.0 mol percent of ammonium or amine having a pKb of 5 or less as neutralizing cations for sulfonate and sulfate end groups derived from the initiator and activator and as neutralizing cations for sulfonate groups derived from one or more sulfonic acid containing comonomers and 0-3.0 mol percent of one or more comonomers selected from the group consisting of simple acrylate or methacrylate esters, simply vinyl esters, styrene, vinyl chloride and vinylidene chloride, the fiber containing no more than 0.3 mol percent of cations other than ammonium or amine.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 09/868,753 filed Jun. 21, 2001 which is a nationalization of PCT/US00/29231 filed Oct. 23, 2000, which claims the benefit of U.S. Provisional Application Nos. 60/161,292 filed Oct. 25, 1999 and 60/161,193 filed Oct. 22, 1999, the contents of all of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Infectious disease remains the largest cause of mortality in the world. A significant proportion of infectious disease associated morbidity and mortality results from bacterial pathogens. One widely applied technique used in controlling the spread and severity of bacterial infection is vaccination. Several notable vaccine examples prevent a number of lethal microbial diseases, the DPT vaccine protects against diphtheria, pertusis and tetanus. The BCG or bacillus Calmette-Guerin vaccine is an example of an attenuated strain which is used worldwide to control the spread of tuberculosis (TB). A central issue in the development of safe and effective bacterial vaccines is the identification of protective antigens or attenuated strains of bacteria which can promote the development of an immune response in the host yet in vaccine composition fail to cause morbidity or martality in the host. A variety of methods can be employed to identify vaccine compositions including the production of attenuated or killed vaccine strains. Often these strains are in single genes which have been shown to play a role in virulence of the organism. Vaccine compositions can include a live or fixed bacterial preparation of the mutant strain, the fixed protein, a fusion protein made of the virulence gene product and a suitable carrier and more recently the DNA encoding the protein.
[0003] Attenuated strains offer the potential of presenting a nearly intact complement of pathogen associated antigens to immune system. Furthermore, these antigens are likely to be presented in a bacterial context that mirrors that seen during early stages of infection by a virulent strain. This is evidenced by the ongoing practice of using live attenuated strains in the extensive vaccination of both human and livestock. e.g., BCG for tuberculosis and strain 19 against bovine brucellosis and Sterne's spore vaccine against anthrax in cattle.
[0004] The use of live vaccines can present developmental obstacles including the retention of unacceptable levels of virulence, the risk of reversion to virulence during culture or in vivo and lack of efficacy. The ability to create more effective live or attenuated vaccines is in part dependent upon the ability to control and restrict the expression of virulence determinants so as to create vaccine strains that are protective and safe.
[0005] Bacteria respond to nutritional stress by the coordinated expression of different genes. This facilitates their survival in different environments. Among these differentially regulated genes are the genes responsible for the expression of virulence determinants. The selective expression of these genes in a sensitive or susceptible host allows for the establishment and maintenance of infection or disease. Virulence include genes which encode toxins, colonization factors and genes required for siderophores production or other factors that promote this process.
[0006] The expression of virulence genes in bacteria therefore enable the organism to invade, colonize and initiate an infection in humans and/or animals, however, these genes are not necessarily expressed constantly (constitutively). That is, the bacterium is not always orchestrating gene expression patterns to maximize “infectious” potential. In many circumstances, the expression of virulence genes is controlled by regulatory circuitry which include repressor proteins and a corresponding operon or operator. One class of repressors which is activated upon binding to or forming a complex with a transition metal ion such as iron, zinc or mangenese is thought to control the expression of a subset of genes in a number of Gram positive organisms. When such repressors are activated and associated with virulence gene expression in pathogens, they bind the operator sites thereby preventing production of virulence determinants.
[0007] Virulence determinants are most often expressed when the bacterial pathogen is exposed to environmental stress such nutritional restriction. An iron-poor environment is an example of such a condition. In many eucaryotes such an environment is the norm—insufficient iron is present to maintain the repressor in its active state. In the inactive form, the repressor cannot bind to target operators. As a result, virulence genes are de-repressed and the bacterium is able to initiate, establish, promote or maintain infection.
[0008] The expression of these virulence determinants is in many bacterial species co-regulated by metal ions. In most instances the metal co-factor that is involved in vivo is iron [but can include zinc, nickel, mangenese, cobalts]. In the presence of iron, the repressor is activated and virulence gene expression is halted.
[0009] This pattern of gene regulation is illustrated by the following example. The bacterium that causes diphtheria produces one of the most potent toxins known to man. The toxin is only produced under conditions of iron deprivation. In the presence of iron, the bacterial repressor (which in this species is known as diphtheria toxin repressor protein, abbreviated “DtxR”) binds iron and undergoes conformational changes that activate it and allow it to dimerize and bind a specific DNA sequence called the tox operator. The tox operator is a specific DNA sequence found upstream of the gene that produces the diphtheria toxin, thereby preventing its expression. Typically, during infection of a human host the diphtheria bacillus (or other pathogenic/opportunistic bacteria) grows in an environment that rapidly becomes restricted in several key nutrients. Paramount among these essential nutrients is iron, and when iron becomes limiting the diphtheria bacillus begins to produce the toxin. Moreover, the constellation of virulence genes that DtxR controls becomes de-repressed and the diphtheria bacillus becomes better adapted to cause an infection. In the case of diphtheria, the toxin kills host cells thereby releasing required nutrients including iron.
SUMMARY OF THE INVENTION
[0010] A first aspect of the present invention is directed to a composition containing a virulent or opportunistic prokaryote in which metal ion-dependent gene regulation confers a growth or an infectious advantage. The prokaryote contains a recombinant DNA molecule comprising a promoter in operable association with a sequence encoding a dominant, metal ion-independent repressor protein or a partially metal ion independent repressor protein, and a carrier. In preferred embodiments, a promoter is constitutive in nature. In other preferred embodiments, the DNA molecule contains a sequence encoding a metal ion-independent DtxR protein or a partially metal ion-independent DtxR protein. In yet other preferred embodiments, the bacterium is a member of the genus Mycobacterium, Staphylococcus or Streptococcus.
[0011] The second aspect of the present invention is directed to a method of enhancing protective immunity against infection or disease caused by an opportunistic or virulent prokaryote pathogen in which metal or metal ion-dependent gene regulation confers a growth or an infectious advantage. The method entails administering the compositions to the animal. In preferred embodiments, the animal is a human. In other preferred embodiments, the compositions are administered prophylactically e.g. prior to the onset of the infection or disease. In yet other preferred embodiments, the prokaryote contained in the compositions is in a live or killed form.
[0012] A related aspect is directed to a method of attenuating or reducing the severity of an infection or a disease caused by an opportunistic or virulent prokaryotic pathogen in which metal or metal ion-dependent gene regulation confers a drug or an infectious advantage. The method also entails administering the compositions to the animal, preferably prior to the onset of the infection or disease condition.
[0013] Yet another aspect of the present invention is directed to isolated and purified DNA molecules consisting essentially of a sequence encoding a metal or metal ion-independent or a partially metal or metal ion-independent DtxR or homologue thereof. Preferred homologues are IdeR and SirR. In other preferred embodiments, the molecule is placed in an expression cassette or a vector (e.g., a plasmid) so as to be in operable association with a promoter element, especially a constitutive promoter. Vectors containing the DNA molecules and prokaryotes transformed with DNA molecules (including cultures thereof) are also provided.
[0014] A further aspect of the present invention is directed to a method for preparing the compositions. The method entails obtaining a DNA molecule encoding a metal ion-independent repressor protein or a partially metal ion-independent repressor protein. The wild-type protein, in its native state, is a metal ion-dependent gene regulator and confers upon a virulent or opportunistic prokaryote a growth or an infectious advantage. The DNA molecule is linked to a promoter, preferably a constitutive promoter, and then introduced into such a virulent or opportunist prokaryote. The DNA is expressed in the prokaryote and inhibits metal ion-dependent gene regulation.
[0015] The present invention entails the incorporation of an exogenous DNA encoding a dominant, metal ion (hereinafter “metal”) independent or partially metal ion independent mutant repressor into an otherwise virulent or opportunistic prokaryote in which metal ion-dependent gene regulation confers a growth or an infectious advantage. Such prokaryotes include gram-positive and gram-negative bacteria. Without intending to be bound by theory, Applicants believe that the dominance of the metal-independent mutant repressor subverts the normal patterns of gene regulation (under the control of the native, metal-dependent repressor), thereby creating a recombinant prokaryote that is attenuated or avirulent relative to the wild-type prokaryote. That is, the exogenous mutant repressor renders inoperable or significantly inoperable the normal metal-dependent genetic circuitry that occurs in vivo and causes in whole or in part the prokaryote carrying such a recombinant genetic compliment to become less infectious or non-pathogenic. This property renders the recombinant prokaryote suitable for use as an immunogen to be formulated into a vaccine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 aligns the amino acid sequences of DtxR, IdeR and SirR.
[0017] FIG. 2 aligns amino acid sequences of various IdeR/SirR homologues found in various species of mycobacterium.
[0018] FIG. 3 aligns and compares the amino acid sequence of various homologues of various DtxR type repressors, including DtxR from Brevibacterium lactofermentum (Bl), DtxR from Corynebacterium diphtheriae (Cd), IdeR from Mycobacterium tuberculosis (Mt), M. leprae [P], M. smegmatis [P]; DesR from Streptomyces lividans (Sl), M.tuberculosis SirR, Staphylococcus aureus (Sa) SirR, S. epidermidis SirR, Enterococcus fecalis DtxR homologue [P], and the DtxR homologues from the Streptococcus gordonii, S. mutans, S. pneumoniae and S. pyogenes . The consensus amino acid sequences between these members of the DtxR family of iron-dependent repressors is indicated. *, metal ion coordination residues in the Primary site; #, metal ion coordination residues in the Ancillary site; @, the single amino acid residue that interacts with a base in the binding of DtxR dimers to the tox operator.
[0019] FIG. 4 is a Western blot of cell lysates incubated with polyclonal antibody against DtxR. Lane 1 shows purified DtxR (25.3 kDa). Lanes 3 and 5 show lysates from wild-type M.smegmatis and M.tuberculosis , respectively, expressing native IdeR (25.2 kDa.). Lane 4 shows lysate from the M.smegmatis heterodiploid harboring pNBV1/SAD expressing both DtxR(E175K) and IdeR. The molecular weight masses, determined by size standards, are shown on the left.
[0020] FIGS. 5A and B are bar graphs showing virulence comparison of wild-type M.tuberculosis and M.tuberculosis DtxR(E175K) mutant. FIG. 5A shows the log CFU of the homogenized spleens of mice sacrificed at 4 week intervals. FIG. 5B shows the log CFU of homogenized lungs at 4 week intervals. Each point represents the mean log CFU of 5-6 mice ±1 standard deviation (error bars). Asterisks denote statistically significant differences between groups at a given time point.
[0021] FIG. 6 is a photograph of a 10 week-old representative colony of wild-type M.tuberculosis (strain CDC1551) on 7H10 agar, and FIG. 6B is a photograph of a 10 week-old representative colony of M.tuberculosis DtxR(E175K) on 7H10 agar.
[0022] FIG. 7 is an alignment of the “iron box” consensus sequence, known DtxR binding sites, and putative M.tuberculosis DtxR/IdeR binding sites identified by an in silico genome search. The “consensus sequence” at the top of the figure represents the compilation of the 9 aligned sequences in the figure. The “published consensus” is drawn from the literature. Gene homologues of the downstream ORFs are shown on the right.
[0023] FIG. 8 shows autoradiographs of gel binding assays between DtxR and putative M.tuberculosis DtxR/IdeR binding sites, wherein 100 bp 32 P-end-labeled DNA fragments containing toxO (lanes 1 & 2), IB-1 (lanes 3 & 4), IB-2 (lanes 5 & 6), IB-3 (lanes 7 & 8), IB-4 (lanes 9 & 10), IB-5 (lanes 11 & 12) were separated in a non-denaturing 6% polyacrylamide gel. Odd numbered lanes contain DNA only (“unbound”), and even numbered lanes contain DNA pre-incubated with purified DtxR (“bound”).
[0024] FIGS. 9A and B are graphs showing that virulence of S. aureus is altered in a mouse skin lesion model following 8 days of in vivo incubation. 8.0 log CFU of the parent strain MA2181 [RN6390 carrying emtpy shuttle vector pSPT181] and 7.8 log CFU of the complemented MA2004 strain carrying DtxR E175K were injected sub-cutaneously on day 1. Abscess size[mm] was measured each day over 8 days and on the last day the abscess was removed and the number of CFU were determined. CFU [a.] and abscess size [b.] were compared between groups.
DETAILED DESCRIPTION
[0025] To prepare the compositions of the present invention, a determination is made as to whether or not the species of interest regulates virulence determinant expression as a function of available metal ion concentrations. This can be done, for example, by screening protein from the bacteria of interest with an antibody for DtxR or other DtxR like proteins to ascertain if a homologous repressor exists in the species. This can also be accomplished using specialized techniques like gel mobility shift assays or the method disclosed in Sun, et al., PNAS 95:14985-14990 (1998), or more common gene expression monitoring methods such northern analysis and PCR. If the species of interest employs a DtxR type repressor than the expression of this repressor can be elucidated by one of the aforementioned methods and the techniques described here can be employed to build a recombinant attenuated strain for vaccine purposes.
[0026] Preferred prokaryotes are Gram positive bacterial species, and particularly those listed below. These species contain DtxR like metal dependent repressors. Specific examples include:
S. pneumoniae S. agalactia S. equisimillis S. meningitis S. bovis S. anginosus S. pyogenes S. salivarius S. sanguis S. suis S. mutans Enterococcus faecalis Staphylococcus species S. aureus S. epidermitis Mycobacteria species M. tuberculosis M. avium complex M. kansasii M. leprae M. scrofulaceum M. fortuitum M. ulcerans M. marinum M. bovis M. microtii M. africanum M. paratuberculosis Actinomyces species A. pyogenes A. israelii A. bovis A. viscosus A. hordeovulneris A. gerencseriae A. naeslundii A. odontolyticus and others Listeria monocytogenes Proprionibacterium acnes Erysipelothrix rhusiopathiea
[0027] The repressor which typifies the class of genetic regulators in the above listed bacteria is the diphtheria toxin repressor DtxR in C. dihptheriae , the causitive agent of diphtheria. DtxR is a metal dependent repressor which under limiting concentrations of metal ions becomes inactivated permitting the derepression of a number of virulence genes including diphtheria toxin. This pattern of gene expression is common to both Gram-positive and Gram-negative bacteria. In Gram-positive bacteria, DtxR or DtxR homologues appear to be important metal dependent regulators whereas in Gram-negative bacteria, Fur is the significant metal dependent regulator. Some species of pathogen appear to contain both DtxR and Fur like metal dependent repressors. In each case, the presence of repressor bound metal ion is critical for appropriate activity of the repressor which coordinates the repression of gene expression in vivo.
[0028] The prokaryotes of the present invention having a dominant, metal ion independent or partially metal ion independent mutant of the repressor (such as the diphtheria toxin repressor gene DtxR or a DtxR-homolog e.g., IdeR, SirR) will render the pathogen unable to effectively establish a full infection. (Hill, et al., Infection and Immunity 66: 4123-4129 (1998); and Dussurget, ., Molecular Microbiology 22:536-544 (1996); and Pohl, et al., J. Molecular Biology 285:1145-1156 (1999)). Apart from the targeting vector sequences or plasmid DNA used to generate the attenuated strains and the mutant repressor gene, the recombinant prokaryote is in all other aspects identical genetically to the wild-type organism. The presence of the dominant iron-independent repressor results in a phenotypic change in the organisms' virulence.
[0029] In preferred embodiments, the exogenous DNA comprises a sequence encoding a dominant, metal-independent DtxR or a functional fragment, variant or homologue thereof (collectively referred to as “a DtxR protein”). DtxR is a metal iron-dpendent DNA-binding protein having a deduced molecular weight of 25,316 and which functions as a global regulatory element for a variety of genes on the C. diphtheriae chromosome. See Tao et al., Proc. Natl. Acad. Sci. USA 89:5897-5901 (1992); Schmitt et al., Infect. Immun. 59:1899-1904 (1994). For example, DtxR regulates the expression of the diphtheria toxin structural gene (tox) in a family of closely related Corynebacteriophages. The repressor has also been shown to regulate a number of other iron-dependent genes. The gene for DtxR and a number of DtxR homologues have been cloned and sequenced. A number of detailed structural and functional studies have be performed to analyse DtxR. See Boyd et al., Proc. Natl. Acad. Sci. USA 87:5968-5972 (1990); Schmitt et al., supra. DtxR is activated by divalent transition metal ions (e.g., iron). Once activated, it specifically binds the diphtheria tox operator and other related palindromic DNA targets. See Ding et al., Nature Struct. Biol. 3(4):382-387 (1996); Schiering et al. Proc. Natl. Acad. Sci. USA 92:9843-9850 (1995); White et al., Nature 394:502-506 (1998). DNA sequences encoding DtxR from various C. diphtheria strains are defined by accession numbers M80336, M80337, M80338, and M34239.
[0030] Functional fragments or variants of DtxR, when activated, retain their binding activity to the tox operator (or a functional fragment thereof) and/or the DtxR consensus binding sequence. DtxR fragments and variants can be identified by standard techniques such as mutagenesis. Tao et al., Proc. Natl. Acad. Sci. USA 90:8524-8528 (1993) identified important residues for DtxR function and analysis. Other variants are disclosed in Tao et al., Mol. Microb. 14(2):191-197 (1994). Tao discloses that some DtxR alleles have different amino acid sequences, e.g., the DtxR allele from strain 1030(−) of C. diphtheriae was found to carry six amino acid substitutions in the C-terminal region, none of which affected the iron-dependent regulatory activity of DtxR (1030) (Tao II). See also Boyd et al., J. Bacteriol. 174:1268-1272 (1992) and Schmitt et al., Infect. Immun. 59:3903-3908 (1991). Thus, DtxR fragments and variants may be mutagenized to an iron-independent phenotype.
[0031] Many other bacterial species employ regulatory circuits and repressor proteins that exhibit high degrees of sequence similarity to DtxR. (Posey, et al., Proc Natl Acad Sci 96:10887-10892 (1999), Que, et al., Molecular Microbiology :1454-1468 (2000), Kitten, et al., Infect and Immun 68:4441-4451 (2000), Manabe, Proc Natl Acad Sci 96:12844-12848 (1999). Thus, dominant, metal-independent DtxR homologues may also be employed in the methods of the present invention. Iron-dependent regulator (IdeR), isolated from Mycobacterium tuberculosis , has been found to share 60% amino acid homology with DtxR. See Schmitt et al., Infect Immun. 63(11):4284-4289 (1995). See also Doukhan et al., Gene 165(1):67-70 (1995), which reports and references DtxR homologs in Mycobacterium smegmatis and Mycobacterium leprae . DtxR homologues have been cloned in other gram-positive organisms including Brevibacterium lactofermentum and Streptomyces lividans . See Oguiza et al., J. Bacteriol. 177(2):465-467 (1995); Gunter et al., J. Bacteriol. 175:3295-3302 (1993); and Schmitt et al., Infect. Immun. 63:4284-4289 (1995). Staphylococcal iron regulated repressor (SirR), native to Staphylococcus epidermitis , is another known DtxR homologue. These proteins bear a common feature they share a remarkably high sequence similarity in the respective N-terminal 139 amino acid regions, especially those amino acids involved in DNA recognition and transition metal ion coordination.
[0032] A collection of accession numbers for sequences that are either homologous to DtxR or contain a consensus tox O/P is presented in Table 1. See http://www.ncbi.nlm.nih.gov/BLAST and http://www.ncbi.nlm.nih.gov/unfinishedgenomes.html. See also, Altschul, et al., J. Mol. Biol. 215:403-410 (1990); Gish, et al., Nature Genet. 3:266-272 (1993); Madden, et al., Meth. Enzymol. 266:131-141 (1996); Altschul, et al., Nucleic Acids Res. 25:3389-3402 (1997); and Zhang, et al., Genome Res. 7:649-656 (1997). This high degree of sequence similarity and homology is indicative of a widely conserved metal ion dependent regulatory pathway employing DtxR-family repressors. It is noteworthy that many important human and animal pathogens are present in this collection of bacteria. Dominant metal independent repressors can be generated and introduced inot a prokaryote. Such mutants alter virulent phenotype in vivo and may be used as vaccines.
TABLE 1 DtxR Homologs and Species with DtxR Binding Sites Pathogenic Human/Veterinary Applications Other CAA67572 S. epidermitis L35906 C. glutamicum Gi 1777937 T. pallidum Z50048 S. pilosus CAA15583 M. tuberculosis Z50049 S. lividans U14191 M. tuberculosis L78826 M. leprae M80336 C. diphtheriae M80337 C. diphtheriae M34239 C. diphtheriae M80338 C. diphtheriae AAD18491 C. pneumoniae Gi 3328463 C. trachomatis TIGR 1280 S. aureus OUACGT S. pyogenes Sanger 518 B. bronchoseptica Sanger 1765 M. bovis Sanger 520 B. pertusis WUGSC K. pneumoniea TIGR 1351 E. faecalis AE000783 B. burgdorferi TIGR 1313 S. pneumoniea Snager 632 Y. pestis AE001439 H. pylori TIGR 1752 V. cholera TIGR1O97 C. tepidum U14190 M. smegmatis Gi 2621260 M. thermoautotrophicum Gi 2622034 M. thermoautotrophicum M50379 M. jannaschi Q57988 M. jannaschi O33812 S. xylosus Gi 264870 A fulgidus Gi 2648555 A fulgidu Gi 2650396 A fulgidus Gi 2650706 A fulgidus BAA79503 A. pernix CAB49983.1 P. abyssi BAA30263 P. horikoshi AL109974 S. coelicolor L35906 B. lactofermentum Stanford 382 S. meliloti TIGR 76 C. crescentus TIGR 24 S. putrificacieus AE000657 A. aeolius TIGR 920 T. ferrooxidans
[0033] Preferred gram positive pathogenic bacteria include Mycobacterium bovis, Mycobacterium leprae, Mycobacterium paratuberculosis, Mycobacterium tuberculosis, Mycobacterium avium, Staphylococccus aureus, Staphylococcus epidermitis, Streptoccus mutans and Streptococcus pneumoniae . The preferred dominant DtxR (or homologue) repressors are metal independent and contain a single amino acid change to convert the native, metal-dependent repressor to metal independent regulation.
[0034] A preferred metal independent repressor is the mutant E175K DtxR. This same substitution can be made in DtxR fragments and variants. In addition, DtxR homologues that exist in other bacterial species may be mutated at the corresponding position. FIG. 1 displays the degree of amino acid homology between DtxR and the homologous proteins, IdeR from Mycobacterium tuberculosis and SirR from Staphylococcus epidermitis . As shown in FIG. 1 , the single amino acid at residue E175K in DtxR, the glutamic acid is conserved in IdeR, hence a 177K mutation of IdeR would most likely have the analogous functional implications. Dussurget, et al., Molecular Microbiology 22:536-544 (1996) and Pohl et al.,J. Molecular Biology 285:1145-1156 (1999)).
[0035] FIG. 2 presents a comparison of IdeR/SirR homologues found in other mycobacterium that cause significant disease including M. tuberculosis, M. smegmatis and M. leprae and a SirR clones from M. tuberculosis . Shown in bold is the conserved glutamic acid in the C-terminal region of these repressors that can potentially be mutated to yield an iron-independent version of each of these repressors. Thus, corresponding mutations would be expected to result in a metal-independent genotype. FIG. 3 illustrates the amino acid sequence homology of a number of homologous DtxR type repressors. These repressors differ slightly in their sequence length and the ClustalW program used to carry out a logical alignment adjusts for these differences. See NCBI [www.ncbi.nlm.nih.gov] web site and Baylor College of Medicine Search Launcher[http/.gc.bcm.tmc.edy] for details. Indicated by Bold ‘E’ is the highly conserved glutamic acid residue in the C-terminus of these repressors which is a possible target for generating metal ion independent versions of each of these represssors.
[0036] A combination of standard techniques may be used to make other dominant, metal-independent DtxR proteins, namely mutagenesis followed by tests to determine if a given mutant binds the corresponding operator. A number of theoretical mutations can be incorporated which will convert the repressor to become metal-independent. To generate repressor DNA clones with a random distribution of mutated bases, any of several saturation mutagenesis techniques can be utilized. DNA, plasmid preparation, and DNA sequence analysis are performed according to standard methods. The saturation of random mutations throughout the length of repressor DNA of interest introduces random changes in amino acid sequence throughout the encoded protein that potentially can confer a metal independent phenotype on the mutant repressor.
[0037] Several approaches can be pursued to generate effective vaccines relying upon DtxR. In preferred embodiments, DtxR homologues are identified in a species of interest. This can be achieved by performing PCR on genomic DNA from the species of interest using primer sets compatible to conserved domains within the DtxR family. Specific sequences may be composed of degenerate primers flanking the iron binding domain, or the helix-turn-helix domain. Cloning may also be performed from phage libraries using DtxR conserved regions as probes, utilizing the PSTD system or by in silico searches and de novo in vitro synthesis.
[0038] The DtxR has a domain structure which is composed of a helix-turn-helix domain, and N-terminal iron binding domain. There are a number of additional highly conserved sequences including a proline rich region which lies between the HLH and C-terminal domain. The polymerase chain reaction allows the amplification of any DNA target from a population of DNA molecules if compatible oligonucleotide primers can be identified. While a number of software programs are available to assist in the design of effective primers, optimal primer sets often require empirical determination.
[0039] Cloning of DtxR homologues from any given species can be achieved by mixing primers with genomic DNA isolated from the species of interest in the appropriate ratios in the presence of free oligonucleotides, optimized buffer conditions and the TAQ polymerase (or a suitable version of a thermostable polymerase) and cycling the reaction conditions with the aid of an automated thermocycler. The PCR reaction generates a series of products that represent target DNA sequences that are bounded by sequences homologous to the selected 5′ and 3′ primers. Thus, the selection of primers which lie within conserved regions of DtxR will likely bind under the appropriate conditions to homologous DNA that will likely represent a gene or domain similar to that of DtxR.
[0040] DtxR homologues may further be identified by screening genetic libraries of a given species created in E. coli . Pathogen libraries can then be screened by radio-labeled probes generated from dtxR clones, oligonucleotides from the dtxR sequence, or protein assays using antibodies directed against DtxR.
[0041] Sun, et al. have developed a screen can be used as a positive selection assay for DtxR homologues. See Sun, et al., PNAS 95:14985-14590 (1998). This screen requires only the generation of a gDNA library from the species of interest be transformed into the appropriate background host. Colonies which appear upon selection by chloramphenicol can only arise if a functional DtxR like protein is being expressed from the cloned GDNA fragment. Once a clone has been identified, sequencing and sequence analysis will reveal a gene which has at least partial sequence homology to DtxR and functional equivalence based on the PSDT screen developed by Sun et al.
[0042] Once identified, these clones become the substrates from which a vaccine strain is assembled. Two approaches are preferred. The first approach is a knock-in approach which is coupled with in vitro mutagenesis or PCR mutagenesis. The knock-in approach is focused on generating strains having dominant activated repressors. These strains contain a defective or altered copy of DtxR or a DtxR homologue that containing at least one but up to several mutations resulting in a repressor that recognizes and binds the toxAPO or suitable cognate binding sites in both the presence and absence of iron (or the appropriate metal ion). These metal-ion independent mutants are cloned into suitable vectors (e.g., targeting vectors having a selectable marker and restriction sites) to develop strains expressing dominant activated DtxR constitutively. These plasmids are used to generate knock-in vaccine strains, essentially altered forms of the wild-type virulent strain differing in only the presence of a dominant activated DtxR or DtxR-homologous repressor. The constructs can also be used in gene replacement strategies in which the mutant metal independent repressor gene replaces the endogenous wild-type gene. (Howard, et al., Gene 166:181-182 (1995), Jacobs, et al., Mthds in Enz 204:537-555 (1991), Rubin, et al., Proc Natl Acad Sci 1644-1650 (1999)), Caparon, et al., Mthds in Enz 204:556-586 (1991), Norgren, et al., Infect and Immun 57:3846-3850 (1989), Biswas, et al., J Bact. 175:3625-3635 (1993). Such a strain is effectively avirulent since its ability to up-regulate iron-dependent virulence genes has been crippled.
[0043] Metal ion-independent clones can be sequenced to identify the specific amino acid changes that confer the iron-independent phenotype. Again, a preferred mutant is characterized by a change from glutamic acid to lysine at position 175 in native DtxR. In general, however, multiple mutations are also embraced by the present invention. Multiple mutations are advantageous because they greatly decrease the likelihood of reversion to wild-type function. This likelihood becomes statistically more akin to that of a strain which has all of its iron regulated genes knocked out. Multiple mutations either clustered or distributed through out the repressor can result in the same phenotype. For example, a double mutant DtxR with the replacement of asparagine at position 130 with glycine and the glutamine at position 181 with arginine was also identified with a metal independent phenotype. In addition a mutant with an intermediate phenotype was also identified having a total of six mutations [valine 5 to isoleucine, aspartic acid 110 to glutamic acid, valine 112 to phenylalanine, isoleucine 153 to threonine, aspartic acid 197 to glutamic acid, threonine 220 to alanine]. These mutations produced a partially metal dependent phenotype. Thus, the present invention also embraces the use of partially metal ion-independent repressors. It is believed that expression of these repressors allows the partial colonization of the host which promotes the development of a robust protective immune response. The metal dependent phenotype can be readily revealed by linking a readily assayed reporter gene to the tox O/P in E. coli and assessing reporter function under metal and metal conditions as described by Sun, et al.
[0044] More generally, however, the DtxR mutants of the present invention are not limited to those characterized by single or multiple amino acid substitutions. Insertion and deletion mutants are also contemplated. These mutants may be identified using the instantly disclosed techniques as well.
[0045] Strains and putative mutants can be tested for metal independent phenotype by several approaches including the PSTD screen described in Sun et al. Additional methods of determining if conversion to iron-independent phenotype include computer modeling, structural analysis, dimerization analysis by gel electrophoresis, DNA binding by electrophoretic mobility shift assay, transcriptional profiling, tissue culture and in vivo virulence assays. Ultimately, in vivo screening will be required to determine if the iron-independent phenotype is stable in a host environment and to determine if virulence is attenuated. Attenuated virulence can be defined by biochemical, physiological and immunological markers but will minimally include an assessment of ED 50 or LD 50 in wild-type, knock-in, replacement and recombinant strains.
[0046] A second rational mutagenesis strategy can be utilized to generate metal-independent mutants. This strategy relies upon the conserved domain structure of the DtxR family of repressors. Several DtxR iron-independent mutants have been identified and published. These mutants define two classes of iron-independent mutations which are likely to alter iron-dependent regulation in DtxR homologues. Site directed mutagenesis of the analogous amino acid residues in DtxR homologues may have the same iron-independent phenotype. In addition, as the data from structural studies grow it will likely be possible to construct mutants that replace amino acids involved in the coordination of iron binding or dimerization that result in an iron-independent phenotype.
[0047] Mutagenesis is then carried out to generate a library of the desired mutants of this DtxR homologue of interest. Identification of iron-independent mutants from this population is achieved by using the PSTD system. Using the cloned and mutant homologue genes, one can select for the growth of colonies in the PSTD strains in the presence of dipyridyl (DP). Dipyridyl chelates iron from the media and therefore leads to the disassociation of DtxR homologues from the regulatory regions of the genetic elements in the PSTD screen. As a result, all iron-dependent repressors will not be able to survive chloramphenicol selection. In contrast, iron-independent mutants will grow.
[0048] Mutants of DtxR are generated in accordance with standard techniques. Polymerase chain reaction (PCR) mutagenesis of the dtxR gene is described in Vartanian et al. [Vartanian, J.-P., Henry, S., & Wain-Hobson, S. (1996) Hypermutagenic PCR involving all four transitions and a sizeable proportion of transversions. Nucleic Acid Res., 24, 2627-2631.]. Briefly, BglII-tagged primers 1515 (5′-ACCAGATCTGCCGAAAAACTTCGA-3′) and 1516 (5′-ACCAGATCTCCGCCTTTAGTATTTA-3′) were used to PCR amplify dtxR from plasmid pRDA which carries the wild-type dtxR operon. The products of the amplification were then digested with BglII and ligated either into BglII-linearized pSC6M1 and transformed into E. coli TOP10/λRS65T, or ligated into BamHI digested pBR322 and transformed into E. coli TOP10/λRS65T/pSC6. Iron-independent mutants of DtxR were then selected on LB agar plates supplemented with Cm and DP in accordance with the procedure described in Sun, et al.
[0049] Broadly speaking, these mutations should conserve the structural integrity and maintain the ability of the repressor to bind and repress gene expression through the consensus or near consensus tox P/O sites. Bacterial clones containing mutagenized dtxR can be analysed by DNA sequencing and used in functional biochemical assays such as electrophoeretic mobility shift assay, native gel analysis and gluteraldehyde crosslinking studies to reveal the activated state of the repressor in question under metal limiting conditions. This can be determined through gel shift analysis or by functional assays, but it is preferably made using the one-step method described by Frigg, et al. [Sun, L., vanderSpek, J. & Murphy, J. R. Proc. Natl. Acad. Sci. USA, 95:14985-14990 (1998)]. For gel shift analysis the native tox operator (i.e., 5′-ATAATTAGGATAGCTTTACCTAATTAT-3′) is a 27 base pair interrupted palindromic sequence upstream of the diphtheria tox structural gene can be used as a probe. This sequence features a 9-base pair inverted repeat sequence that is separated by 9 base pairs. See Kaczorek et al., Science 221:855-858 (1983); Greenfield et al., Proc. Natl. Acad. Sci. USA 80:6853-6857 (1983); Ratti et al., Nucleic Acids Res. 11:6589-6595 (1983); and Fourel et al., Infect. Immunol. 57:3221-3225 (1989). It overlaps both the −10 region of the tox promoter and the transcriptional start sites at −45, −40 and −39 upstream of the diphtheria toxin structural gene. See Boyd et al., J. Bacteriol. 170:5940-5952 (1988). The minimal essential DNA target site, i.e., 5′-GTAGGTTAGGCTAACCTAT-3′, is a 19 base pair sequence that forms a perfect palindrome around a central C or G,and is described in Tao and Murphy, Proc. Natl. Acad. Sci. USA 91:9646-9650 (1994). Additional probes are variants of ToxO based on the DtxR consensus-binding sequence (5′-ANANTTAGGNTAGNCTANNCTNNNN-3′). Variants are defined by the following sequence: 5′-TWAGGTTAGSCTAACCTWA-3′. Thus the function of the repressor and mutant can be defined by recognition and binding or regulation of gene expression via the sequences or variants described above.
[0050] Once a dominant, metal-independent DtxR DNA clone is identified, it can be produced and manipulated in accordance with techniques known in the art. For example, they may be generated using standard chemical synthesis techniques. See, e.g., Merrifield, Science 233:341-347 (1986) and Atherton et al., Solid Phase Synthesis, A Practical Approach, IRL Press, Oxford (1989). Preferably, they are obtained by recombinant techniques. Standard recombinant procedures are described in Sambrook et al., 1989, Molecular Cloning, A Laboratory Manual, Second ed., Cold Spring Harbor, N.Y., and Ausubel et al., (eds.) Current Protocols in Molecular Biology, Green/Wiley, N.Y. (1987 and periodic supplements). The appropriate sequences can be obtained from either genomic or cDNA libraries using standard techniques. DNA constructs encoding the DNA gene segments may also be prepared synthetically by established methods, e.g., in an automatic DNA synthesizer, and then purified, annealed, ligated and cloned into suitable vectors. Atherton et al., supra. Polymerase chain reaction (PCR) techniques can also be used. See e.g., PCR Protocols: A Guide to Methods and Applications, 1990, Innis et al. (ed.), Academic Press, New York.
[0051] The DNA encoding the mutant metal-independent repressor is operably linked to a promoter element. Preferred promoters include the endogenous DtxR promoter or the promoter of the DtxR homologue in question or any suitable constitutive promoter functional in the species of interest. The constructs may further contain an associated selectable marker gene to follow maintenance of the mutant construct. For example, in Mycobacterial species, a hygromycin resistance gene in an E. coli shuttle vector provides great utility for cloning and expression of a mutant IdeR or another dominant metal ion independent repressor [DtxR E175K]. See, Bishai et al., Gene 166:181-182 (1995). In other embodiments, the vectors also contain a copy of a gene lethal to the bacterium under the control of the metal dependent regulator. Examples of such genes include antibiotic genes, restriction enzymes, proteolytic enzymes, lethal phage genes or any gene whose product once expressed would kill the bacterium. The presence of this “suicide cassette” further ensures that vaccines containing the prokaryote in live form do not revert to any significant degree and cause disease in vivo.
[0052] Suitable cloning and expression vectors are readily available from a number of sources. In preferred embodiments, the construct is introduced into the prokaryote by way of a vector, in which case the construct may be formed prior to or upon introduction of the DNA into the vector. A vector for a given species must contain an origin of replication, a selectable marker and a functional promoter by which the mutant metal-ion independent repressor can be expressed in the strain of interest. (Howard et al., Gene 166:181-182 (1995), Jacobs et al., Mthds in Enz 204:537-555 (1991), Rubin et al., Proc Natl Acad Sci 1644-1650 (1999)), Caparon et al., Mthds in Enz 204:556-586 (1991), Norgren, et al., Infect and Immun 57:3846-3850 (1989), Biswas et al., J Bact. 175:3625-3635 (1993).
[0053] The vectors are introduced into the cells in accordance with standard techniques such as transformation, co-transformation, direct transfection (e.g., mediated by calcium phosphate or DEAE-dextran) biolistics and electroporation. The recombinant cells are then cultured via standard techniques. Conditions may vary depending upon the prokaryote (e.g., bacterial species) being used. In general, culturing is continued from about 24 to 48 hours at a temperature between about 30 and about 39° C., preferably 37° C. The recombinant cells are cultured in an appropriate complete medium containing a selectable marker to assure a pure population. The strains can also be counter engineered as described below so that if significant levels of the metal independent repressor is not produced, a suicide gene will be de-repressed resulting in the death of the vaccine strain in situ. Iron is an essential element for both the bacterial pathogen and its animal host; thus, successful competition for this element is an essential component of the infectious process. The concentration of free iron in the mammalian host available to an invading bacterial pathogen is also extremely limited. As a result, the expression of virulence determinants (e.g., colonization factors, siderophores, hemolysins and toxins) by bacterial pathogens is regulated by iron. Accordingly, the vaccine cultures must be propageted in a complete medium containing iron and other divalent metal cations to facilitate their proliferation.
[0054] The vaccines of the present invention may be used in a wide variety of vertebrates, particularly man and domestic animals such as bovine, ovine, porcine, equine, caprine, domestic fowl, Leporidate, or other animals that may be held in captivity or may be a vector for a disease affecting a domestic vertebrate.
[0055] Pathogens of interest include any specie of microorganism which causes disease and relies entirely or partially upon a repressor mediated regulation of metal-dependent virulence. The present invention relates to methods of vaccinating a host with live recombinant bacteria to elicit protective immunity in the host. The recombinant vaccine can be used to produce humoral antibody immunity, cellular immunity (including helper and cytotoxic immunity) and/or mucosal or secretory immunity.
[0056] The manner of application of a vaccine strain may be varied widely, any of the conventional methods for administering an attenuated vaccine being applicable. These include aerosol applications, oral applications, in drinking water, on a solid physiologically acceptable base, or in a physiologically acceptable dispersion, parenterally (e.g., subcutaneously, intramuscularly, intravascularly or intraperitoneally), by injection, by in ovo inoculation or the like. The dosage of the vaccine (e.g., number of prokaryotic cells, number of administrations, period of administration, etc.) will vary according to the vaccine strain used and the species, age, and size of host to be protected. Persons skilled in the art will be able to determine the doseage to be administered so as to provide a sufficient immune response. The recombinant prokaryotes in the composition may be “live” or in “killed” form, as these terms are commonly used in the vaccine art.
[0057] The formulation of vaccine strain compositions may also vary widely. Pharmaceutically acceptable vehicles such as water are expected to be useful for oral administration. Other such vehicles including normal saline may be used for parenteral, cloacal or other routes of administration. The vaccine compositions may also be admixed with food for some applications.
[0058] The following example is not intended to limit the scope of the invention in any manner.
EXAMPLE 1
[heading-0059] Attenuation of Virulence in Mycobacterium tuberculosis Expressing a Constitutively Active Iron Repressor
[0060] This example describes the construction of a candidate strain which is severely attenuated with respect to the parent wild-type strain yet which persists long enough to allow the host to mount an immune response.
[heading-0061] Summary
[0062] With over one-third of the world's population latently infected with Mycobacterium tuberculosis , the global burden of tuberculosis is staggering. The emergence of multi-drug resistant strains and the increased susceptibility of the HIV-infected further highlights the need for elucidation of the molecular pathogenesis of M.tuberculosis and its virulence genes.
[0063] Iron plays a critical role in the regulation of virulence of many bacterial pathogens (1). In tuberculosis, there is indirect clinical and in vitro evidence that iron regulation is important to the virulence of this microbial pathogen (2-5). Iron is an essential nutrient for the survival of most organisms and has played a central role in the virulence of many infectious disease pathogens. Mycobacterial IdeR is an iron-dependent repressor that shows 80% identity in the functional domains with its corynebacterial homologue, DtxR. In a novel approach to attenuation, Mycobacterium tuberculosis has been transformed with a vector expressing an iron-independent, positive dominant, corynebacterial DtxR hyperrepressor, DtxR(E175K). Western blots of whole cell lysates of M. tuberculosis expressing the dtxR(E175K) gene revealed the stable expression of the mutant protein in mycobacteria. BALB/c mice were infected by tail vein injection with 2×10 5 organisms of wild-type or M.tuberculosis transformed with the dtxR mutant. At 16 weeks, there was a 1.2 log reduction in bacterial survivors in both spleen (p=0.0002) and lungs (p=0.006) with M. tuberculosis DtxR(E175K). A phenotypic difference in colonial morphology between the two strains was also noted. A computerized search of the M. tuberculosis genome for the palindromic consensus sequence to which DtxR and IdeR bind, revealed six putative “iron boxes” within 200 base pairs of an open reading frame. Using a gel shift assay, it was shown that purified DtxR binds to the operator region of five of these. Attenuation of Mycobacterium tuberculosis can be achieved by the insertion of a plasmid containing a constitutively active, iron-insensitive repressor, DtxR(E175K), which is a homologue of IdeR. The results demonstrate that IdeR controls genes essential for virulence in M.tuberculosis.
[0064] In a phylogenetically related organism, Corynebacterium diphtheriae , iron depletion results in the derepression of virulence genes such as the diphtheria toxin (tox) gene by DtxR (diphtheria toxin repressor). The corynebacterial DtxR has a homologue in M. tuberculosis , IdeR (iron-dependent repressor). In the amino terminal 140 amino acids that contain the Fe 2+ and DNA-binding domains of DtxR, IdeR shares 80% identity with DtxR (6). In 1995, ideR was first described by Doukhan et al. in conjunction with the sigA sigB cluster of genes (7). Subsequently, the ability of mycobacterial IdeR to bind to the corynebacterial tox operator region in a metal ion-dependent manner was demonstrated by gel shift assay (8). Mutation of ideR in M.smegmatis resulted in derepressed siderophore production in high iron conditions (9). These findings parallel those described in corynebacterial dtxR and suggest that the homology between these two genes may allow for cross-genus functional complementation.
[0065] Using a positive genetic selection system to clone dtxR alleles, Sun et al. isolated and characterized a series of DtxR mutants created by PCR mutagenesis (10). One of the mutants which bound to the tox operator (toxO) and constitutively repressed reporter gene expression in an iron-independent manner was characterized and found to have a single amino acid substitution of lysine for glutamic acid at position 175 (DtxR(E175K)). In merodiploid strains harboring both wild-type dtxR and mutant dtxR(E175K) genes, Sun et al. found the mutant to be dominant over the wild-type allele.
[heading-0066] Methods
[0067] Strains, Plasmids, and Cultures The bacterial strains and plasmids used in this study are listed in Table 2, set forth at the conclusion of this example (10-14). Escherichia coli cultures were grown in Luria broth or Luria agar supplemented with ampicillin (100 g/ml) or hygromycin (200 g/ml). M. tuberculosis CDC 1551 and M. smegmatis cultures were grown in standard Middlebrook 7H9 broth (Difco), supplemented with albumin dextrose complex (ADC), 0.1% glycerol, and 0.05% Tween 80 at 37° C. in roller bottles (15).
[0068] Construction of dtxR (E175K) Shuttle Vector Plasmid A 1.5 kb BamHI-HindIII fragment of DNA from pSDM2 was cloned into pNBV1. The resulting recombinant plasmid, pNBV1/SAD was cloned in E.coli DH5 and purified using the Qiagen system (Qiagen, Chatsworth, Calif.) (16). Purified plasmids were then electroporated into M. tuberculosis CDC1551 by standard protocols (15).
[0069] Western Blot Analysis Recombinant E.coli and mycobacteria were lysed in 3M urea, 0.5% Triton X-100, 3.25M DTT, 2% Pharmalyte (Pharmacia Biotech, Piscataway, N.J.), PMSF (100 g/ml) and leupeptin (2 g/ml). Using 0.1 mm glass beads, the samples were homogenized twice in a Mini-bead-beater (Biospec Products, Bartlesville, Okla.) at maximum speed for 1 minute. Samples were centrifuged to remove cellular debris and unlysed cells. After separation by 12% SDS polyacrylamide gel electrophoresis, proteins were transferred to nitrocellulose membranes (Hybond, Amersham, Buckinghamshire, UK) by semi-dry technique (Transblot S.Dak., Hercules, Calif.) and blocked with 5% non-fat milk in PBS with 0.1% Tween 20 (PBS-T) for 1 hour. Membranes were then incubated overnight in PBS-T with rabbit anti-DtxR polyclonal antibodies at the appropriate concentration at 4° C. (17). After washing, membranes were incubated with horseradish peroxidase-conjugated anti-rabbit antibody diluted in PBS-T for 2 hours. The Supersignal Chemiluminescent Substrate (Pierce, Rockford, Ill.) was used for autoradiograph development.
[0070] Murine Tuberculosis Infection Model 6-8 week-old BALB/c mice were infected by tail vein injection with 2×10 5 organisms of wild-type or M.tuberculosis DtxR(E175K). Bacterial infection was monitored over a 119-day period. Colony forming units (CFU) in spleen and lungs were assessed at 4 week intervals by serial dilutions of organ homogenates plated on 7H10 Middlebrook agar containing cycloheximide (50 g/ml), carbenicillin (50 g/ml), trimethoprim (20 g/ml), and polymyxin (200 units/ml) (18).
[0071] DNA Gel Shift Binding Assay The DNA migration retardation assay was performed as previously described (19). Purified DtxR protein was isolated by methods as described (20). Radiolabeled DNA iron box fragments were generated by PCR using 100 ng of 32 P-end-labeled primer mixed with 150 ng of unlabeled primer and template DNA from gel-purified 100 bp cold fragments containing the iron box of interest. Binding reactions were carried out in 10mM Tris-OAc (pH7.4), 1 mM EDTA, 50 mM KCl, 1 mM DTT, 5% glycerol, 50 g/ml calf thymus DNA. Binding reactions were equilibrated for 30 minutes and then loaded onto a non-denaturing 6% acrylamide gel (21).
[heading-0072] Results
[heading-0073] Expression of the Corynebacterial dtxR Gene in Mycobacteria
[0074] The 1.5 kb corynebacterial DNA fragment cloned in pNBV1/SAD contained 500 bp of 5′ non-coding sequences as well as the entire dtxR(E175K) open-reading frame. To determine if the corynebacterial mutant dtxR(E175K) gene was expressed in mycobacteria, we transformed M. smegmatis , a fast growing strain of mycobacteria, with pNBV1/SAD. Whole cell lysates prepared from M. smegmatis cultures were separated by 12% SDS PAGE. FIG. 4 shows a Western blot developed with polyclonal anti-DtxR antibodies. As illustrated, these antibodies recognize both DtxR and IdeR because of their significant antigenic similarity. Although the deduced molecular mass of IdeR (25.2 kDa) differs by only 0.1 kDa from DtxR (25.3 kDa) we have repeatedly observed anomalous accelerated migration of IdeR in our SDS-PAGE gels in which it runs at 23 kDa in spite of its mass of 25 kDa. This phenomenon has also been noted by Schmitt et al. (8) In preparations from M.smegmatis harboring pNBV1/SAD ( FIG. 4 , lane 4), two distinct bands appear. Because dtxR(E175K) is expressed from a multicopy plasmid, significantly more DtxR(E175K) protein is made than the chromosomally expressed IdeR. Similar results in M.tuberculosis transformed with pNBV1/SAD were also found (results not shown). The in vitro growth rate of wild-type M. tuberculosis was indistinguishable from that of M. tuberculosis DtxR(E175K) by the BACTEC radiometric growth monitoring system.
[0075] Attenuation of Virulence in M. tuberculosis Expressing the Constitutively Active DtxR Hyperrepressor After confirming that the corynebacterial mutant dtxR was expressed in transformed mycobacteria, we turned to an in vivo animal model to test the effect of the hyperrepressor on virulence. Forty-eight BALB/c mice were inoculated with 2×10 5 CFU of CDC1551 M. tuberculosis or M. tuberculosis DtxR(E175K) by tail-vein injection. Both animal weights and the tissue burden of surviving bacteria were monitored over time. Mice infected with wild-type M.tuberculosis began to lose weight beginning at 13 weeks while the M. tuberculosis DtxR(E175K)-infected animals initially gained weight, then maintained stable weights for the duration of the experiment. At 17 weeks, there was a statistically significant difference of 1.7 gms (p=0.006 by two-tailed t-test) between the wild-type and DtxR(E175K) groups.
[0076] FIGS. 5A and 5B show the survival of the two M. tuberculosis strains in lungs and spleens of mice over time. At 17 weeks, there was a 1.2 log attenuation in virulence of the DtxR(E175K) expressing strain compared with wild-type which was statistically significant in both spleen (p=0.0002) and lungs (p=0.006). Analysis of the colonies from the mouse tissues at 12 weeks showed that 99% of the colonies were hygromycin-resistant indicating maintenance of the pNBV1/SAD plasmid. Histopathologic inspection of spleen and lungs of wild-type and DtxR(E175K) expressing strains corroborated our CFU data with fewer visible acid fast bacilli at 17 weeks in histologic sections of mouse organs from animals infected with the M. tuberculosis DtxR(E175K) than with the wild-type.
[0077] Differences in Colonial Morphology Between Strains Colonies of M. tuberculosis DtxR(E175K) grown from frozen stocks on 7H10 Middlebrook agar showed no difference in growth rate in vitro as compared to wild-type CDC1551, but were noted to have a distinct colonial morphology (see FIGS. 6A and 6B ). The recombinant strain colonies were rougher and drier-appearing and were more raised and wrinkled than wild-type colonies. In addition, yellow pigmentation was also noted in the DtxR(E175K) expressor. Both strains exhibited a spreading phenotype and were crenelated at the periphery.
[0078] Identification of Iron Boxes An imperfect palindromic consensus sequence of the “iron box” for DtxR/IdeR has been established by in vivo and in vitro methods (8, 22, 23). This consensus sequence is listed at the top of FIG. 7 . To identify genes that may be regulated by IdeR, we searched the M. tuberculosis genome for iron boxes that were in untranslated regions within 200 bp of an open reading frame. We chose two half-site sequences with allowance for a variable number of intervening base pairs for our search. In the 4.41 MB of the M. tuberculosis genome (24), 58 sequences with acceptable homology to the consensus sequence were identified. Six of these were in untranslated regions and had corresponding downstream open reading frames.
[0079] A DNA gel binding assay was used to assess the ability of DtxR to bind to these putative iron-regulated operator regions drawn from the M.tuberculosis genome. FIG. 8 shows the results of gel binding assays using 32 P-end-labeled 100 bp DNA fragments containing five of the putative iron boxes (IB1-5). Binding of DtxR to the tox operator could be abolished with the addition of unlabeled tox DNA, but not with nonspecific DNA. All five of these putative iron boxes were bound by DtxR to a similar degree as that observed with the tox operator. The iron box upstream of the narG homologue, IB6, did not bind to DtxR (data not shown).
[0080] Table 3 identifies the open reading frames (ORF) downstream of these six iron boxes. BLAST searches reveal that these genes encode a PhoP homologue (a transmembrane sensor of a two-component sensor-regulator pair), a homologue of the HtrA serine protease, 16S ribosomal RNA, an alcohol dehydrogenase AdhB, and a homologue of the M. tuberculosis 19kDa antigen (a protein shown to be involved in the human immune response to tuberculosis) (25). IB6, which was not shifted by DtxR in vitro, appears upstream of a nitrate reductase subunit gene, narG.
[0081] The concentration of free ferrous iron (Fe 2+ ) is extremely limited in vivo. For this reason, many pathogenic prokaryotes such as Vibrio cholerae, E.coli, Neisseria gonorrheae , and Corynebacterium diphtheriae co-regulate virulence gene expression with iron sensing and scavenging systems (26-28). In C.diphtheriae , one such mechanism of iron regulation relies on a repressor, DtxR, which binds to a specific palindromic sequence in the operator regions of the genes that it controls (29). In low iron states, the metal-ion triggered conformational change that allows it to bind to the DNA is disrupted, the repressor loses affinity for the operator site, and gene expression occurs. Recently, a positive dominant DtxR(E175K) mutant unresponsive to iron was generated by random PCR mutagenesis using a genetic selection system (10).
[0082] Significant amino acid identity between corynebacterial DtxR and mycobacterial IdeR has been described. In the amino terminal 140 amino acids there is a DNA binding helix-turn-helix motif, a primary metal ion binding site and a protein-protein interaction domain. Corynebacterial DtxR and mycobacterial IdeR share 80% amino acid identity in this portion of both proteins. Evidence of functional homology between IdeR and DtxR has been shown previously by Schmitt et al. (8).
[0083] The results show that the positive dominant DtxR(E175K) iron-independent repressor is expressed in the phylogenetically related mycobacteria. Furthermore, we have shown that it is dominant and constitutively attenuates M. tuberculosis in a murine model of infection. Rational attenuation of M. tuberculosis provides the opportunity to define specific virulence factors of the organism and the development of live vaccines superior to BCG. However, gene replacement has proven difficult in M. tuberulcosis due to high rates of illegitimate recombination. Addition of a dominant mutant gene is technically simpler than gene replacement in M. tuberculosis and permits comparison of a defined merodiploid strain with an isogenic wild-type strain. There are reports of E. coli genes introduced into other bacteria to regulate the expression of endogenous genes. In a paper by de Henestrosa et al., a mutant E. coli recA gene produced aberrancies in SOS gene induction when expressed in heterologous gram-negative systems (30). Although a M. tuberculosis strain containing empty plasmid was not compared with wild-type M. tuberculosis , the in vitro Bactec comparison showed no differences in the rate of growth of the mutant strain as compared to wild-type. In addition, studies of deletion mutants have shown that plasmid complementation fully restores virulence suggesting that there is little cost to the organism to maintain the plasmid (31, 32). This strain is the first example of the use of a dominant positive gene from another pathogenic prokaryote to attenuate the virulence of M. tuberculosis.
[0084] Animal models have shown that inactivation and clearance of virulent M. tuberculosis in liver and spleen are effectively accomplished, but that the same cell-mediated immune mechanisms appear relatively ineffective in lungs. These data point to a difference in the intracellular microenvironment of the lung granuloma (33). It has been postulated from BCG and H37Ra data that avirulent or attenuated strains lack the genes required for effective growth within lung phagocytes (34). The data suggest that IdeR may regulate genes important for M. tuberculosis survival late in lung infection as attenuation seems to increase dramatically at 12 weeks after infection. This may correlate with the onset of granuloma formation in mouse lungs and the need for M. tuberculosis to scavenge iron from extracellular rather than intracellular sources (35).
[0085] The ideR gene has been found in M. tuberculosis, M. bovis , and M. smegmatis . In M. smegmatis , an ideR mutant showed defective regulation of siderophore biosynthesis. (9) Potential IdeR binding sites upstream of exochelin biosynthesis genes such as fbA have recently been confirmed (36, 37). In addition, several IdeR recognition sequences have been identified using computer searches of the M. tuberculosis genome (38). We have similarly identified 6 potential IdeR-binding sites in M. tuberculosis, 5 of which demonstrated significant binding with DtxR in a gel shift assay. We postulate that the sixth sequence was unable to bind in our in vitro assay because of incorrect spacing between the two relatively well-conserved half-sites. We used DtxR rather than IdeR in this gel-shift assay because we specifically sought to identify genes responsible for the attenuated phenotype of M. tuberculosis DtxR(E175K). The predicted ORF downstream of IB-1 encodes a homologue of phoP, a phosphotransfer response regulator. A number of two-component pairs have been shown to regulate virulence pathways in bacterial pathogens. These include BvgA/BvgS in Bordatella pertussis , VanR/VanS in Enterococcus faecium , PhoP-PhoQ in Salmonella typhimurium , and OmpT/EnvZ in Shigella flexneri (39, 40). In M. tuberculosis , a two-component pair, mtrA-mtrB, has been previously described and appears to play an intracellular role as expression of mtrA increases upon entry into macrophages (41). Furthermore, phoP- mutants in Salmonella are unable to synthesize many of the proteins expressed on interaction with macrophages (42). Downstream of IB-2 is adhB, an alcohol dehydrogenase. In Salmonella typhimurium , it has been postulated that alcohol dehydrogenase genes such as eutG may confer a protective role from reactive aldehyde intermediates associated with inflammatory cell activation (43).
[0086] IB-3 lies upstream of an ORF homologous to a HtrA-like serine protease which, in E.coli are thought to be required for growth of the organism at high temperature, and may play a role in degrading abnormal proteins within the periplasm (44, 45). It is a known virulence factor in several organisms including Salmonella typhimurium, Yersinia enterocolitica, Brucella abortus , and Brucella melitensis (46-49). In an animal protection model, a Salmonella typhimurium htrA mutant is attenuated and a safe and immunogenic live vaccine strain in mice (50). Both Mycobacterium avium subsp. paratuberculosis and M. tuberculosis have putative serine proteases with significant homology to HtrA (24, 51).
[0087] IB-4 lies upstream of rrnA, a 16S rRNA gene which has been shown to be part of a group of rDNA operons in both slow and fast-growing mycobacteria with hypervariable multiple promoter regions (HMPR). The M.tuberculosis rrnA operon has 2 promoters one of which is conditionally induced suggesting complex regulation of this esential gene (52).
[0088] Our results indicate that a dominant positive corynebacterial dtxR allele attenuates the virulence of M.tuberculosis in a murine model. These data implicate the M.tuberculosis IdeR repressor as a regulator of genes essential for full virulence.
TABLE 2 Strain/Plasmid Genotype/Description Source/Reference Plasmids PNBV1 E. coli -mycobacterial shuttle vector (12) Ap R , Hy R pSDM2 pSC101-derivative containing the (10) dtxR(E175 K) gene, Km R pNBV1/SAD pNBV1 containing the dtxR(E175 K) this paper gene, Ap R , Hy R Strains E. coli DH5 F − recA1, hsdR17, thi-1, gyrA96, (14) supE44, endA1, relA1, recA1, deoR, (lacZYA-argF) U169 (80 lacZ M15) M. smegmatis transformable variant of mc 2 6 (13) mc 2 6 1-2C M. tuberculosis virulent recent clinical isolate (11) CDC1551 M. tuberculosis pNBV1/SAD this paper DtxR(E175K) Hy hygromycin, Ap ampicillin, Km kanamycin
[0089]
TABLE 3
Iron Boxes (IB)
Downstream
Accession
Name
ORF
Number
Description
IB-1
PhoP
Rv0761c
Two-component
homologue
phosphotransferase
regulatory protein
IB-2
AdhB
Rv0757
Alcohol dehydrogenase
IB-3
HtrA
Rv0983
Serine protease, HtrA-antigen
homologue
family
IB-4
RrnA
MTB00368
16S ribosomal RNA protein
IB-5
Hypothetical
Rv3764c
Predicted ORF with 26% similarity
protein
to M. tuberculosis 19 kDa antigen
beginning at base 4,210,314
EXAMPLE 2
[heading-0090] Attenuation of Staphylococcus Infection in a Murine Model
[0091] In Example 1 Applicants demonstrated the ability of an in vitro constructed and tested metal ion-independent mutant gene of a normally metal ion dependent transcriptional repressor to attenuate virulence in a pathogenic bacterium of a different species. The metal ion dependent repressor was from C. diphtheriae and the pathogenic species was M. tuberculosis . The sequence homology of DtxR and the endogenous mycobacterial DtxR-like repressor IdeR is approximately 60% [approaching 90% in the N-terminal half of the repressors]. In this example two, applicants have expanded this observation to demonstrate that a dominant metal ion independent repressor such a the mutant E175K DtxR is capable of attenuating virulence across wider species differences in a bacterial strain which co-regulates virulence with iron concentrations and in which there is a Fur or Fur-like repressor. (Heidrich et al., FEMS 140:253-259 (1996); Trivier et al., FEMS 141:117-127 (1996)).
[0092] Briefly and as described above in Example 1, partial diploid analysis in reporter host strains of Escherichia coli was performed revealing dtxR(E175K) is dominant in strains which carry dtxR/dtxR(E175K). A recombinant partial diploid [dtxR(E175K)/SirR ] of Staphylococcus aureus was constructed carrying the iron-independent E175K mutant DtxR. When this strain was used in a series of mouse challenge experiments, it was found to attenuate virulence in a mouse model of staphylococcal infection See FIGS. 9A and 9B . When this strain was compared to the parent strain in a mouse skin lesion model, there was a significant decrease in CFU isolated from the lesion after 8 days associated with a significant decrease in lesion size compared to wt at each time point throughout the study. See FIGS. 9A and 9B . These data further demonstrate that activated E175K DtxR or E175K DtxR/DtxR-like (IdeR or SirR) heterodimeric repressors decrease the virulence of pathogenic microorganisms.
[0093] It is noteworthy that a dominant metal ion independent repressor from C. diphtheriae suppresses virulence in S. aureus , especially since the homology of the two repressors is at the amino acid level approaches only 30% as compared to the nearly 60% identity between IdeR from M. tuberculosis and DtxR. This means that dominant metal ion independent repressors can be employed across species barriers to selectively control gene expression to produce desired phenotypical changes.
[0094] All publications cited in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All these publications are herein incorporated by reference to the same extent as if each individual publication were specifically and individually indicated to be incorporated by reference. In addition, U.S. Provisional Application Nos. 60/161,193, filed Oct. 22, 1999, and 60/161,292, filed Oct. 25, 1999, are hereby incorporated by reference.
[0095] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
[heading-0096] References
[none]
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34. Pascopella, L., Collins, F. M., Margin, J. M., Jacobs, W. R. J. & Bloom, B. R., Infect. Agents dis. 2: 282-284(1993).
35. Long, E. R. in The chemistry and chemotherapy of tuberculosis, ed. Long, E. R. (Williams & Wilkins, Baltimore), pp. 163-182 (1958).
36. Fiss, E. H., Yu, S. & Jacobs, W. R. J., Mol. Microbiol. 14:557-569 (1994).
37. Dussurget, O., Timm, J., Gomez, M., Gold, B., Yu, S., Sabol, S. Z., Holmes, R. K., Jacobs, W. R. & Smith, I., J. Bacteriol. 181:3402-3408 (1999).
38. Dussurget, O. & Smith, I., Trends Microbiol. 6:354-8 (1998).
39. Groisman, E. A. & F., H., in Two-component signal transduction, eds. Hoch, J. A. & Silhavy, T. J. (ASM Press, Washington, D.C.), pp. p319-332 (1995).
40. Dziejman, M. & Mekalanos, J. J., in Two-Component Signal Transduction, eds. Hoch, J. A. & Silhavy, T. J. (ASM Press, Washington, D.C.), pp. 305-317(1995).
41. Via, L. E., Curcic, R., Mudd, M. H., Dhandayuthapani, S., Uhner, R. J. & Deretic, V., J. Bacteriol. 178:3314-3321 (1996).
42. Buchmeier, N. A. & Heffron, F., Science 248:730-732 (1990).
43. Stojiljkovic, I., Baumler, A. J. & Heffron, F., J. Bacteriol. 177:1357-1366 (1995).
44. Lipinska, B., Fayet, O., Baird, L. & Georgopoulos, C., J. Bacteriol. 171:1574-1584 (1989).
45. Strauch, K. L. & Beckwith, J., Proc. Natl. Acad. Sci. USA 85:1576-1580 (1988).
46. Johnson, K., Charles, I., Dougan, G., Pickard, K., O'Gaora, P., Costa, G., Ali, T., Miller, I. & Hormaeche, C., Mol. Microbiol. 5:401-407 (1991).
47. Yamamoto, T., Hanawa, T., Ogata, S. & Kamiya, S., Infect. Immun. 64: 2980-2987 (1996).
48. Robertson, G. T., Elzer, P. H. & II, R. M. R., Vet. Microbiol. 49:197-207 (1996).
49. Phillips, R. W., Elzer, P. H. & II, R. M. R., Microb. Pathog. 19:227-284 (1995).
50. Chatfield, S., Strahan, K., Pickard, D., I., C., Hormaeche, C. E. & Dougan, G., Microb. Pathog. 12145-151 (1992).
51. Cameron, R. M., Stevenson, K., Inglis, N. F., Klausen, J. & Sharp, J. M., Microbiol. 140:1977-1982 (1994).
52. Gonzalez-Y-Merchand, J. A., Garcia, M. J., Gonzalez-Rico, S., Colston, M. J. & Cox, R. A., J. Bacteriol. 179:6949-6958 (1997).
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Disclosed are virulent or opportunistic prokaryotes in which metal ion-dependent gene regulation confers a growth or an infectious advantage. The prokaryote contains a DNA molecule containing a sequence encoding a dominant, metal ion-independent repressor protein or a partially metal-ion independent repressor protein. The prokaryotes are formulated into vaccine compositions and administered to a human or other animal to enhance protective immunity against infectious and diseases caused by prokaryotes in which metal ion-dependent gene regulation confers a growth or an infectious advantage.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 482,231, filed June 24, 1974.
BACKGROUND OF THE INVENTION
Systems for protecting premises or areas against improper intrusion have become widely used, particularly those which more or less continually monitor the premises or area from a remote location. The latter typically includes a police or central station which is tied to the monitored premises or area, a bank, for instance, by means of electrical cables such as a pair of telephone lines. Signals are sent from the central station to "interrogate" the premises or area which in turn sends back an appropriate signal to indicate its status. In the event trouble arises somewhere in the system or any tampering or improper intrusion should occur at the protected premises or area, a failure or change of the return signal to the central station activates a trouble indicator or an alarm.
To be fully adequate, the system must not only monitor the premises or area but itself as well. This is because, besides warning of trouble or failure of the system, it must also guard against attempts to subvert it by inducing false signals that all is well when in fact it is not. Subversion can be accomplished, for instance, by monitoring the connecting lines to note and record the nature of the response of the premises or area when interrogated and no trouble or alarm situation exists. A false signal of well being can then be insinuated into the lines in response to each interrogation and the connecting lines cut or the system at the premises or area otherwise disabled. Various methods to secure such systems against subversion are well known. Some include sending a mixture of signals to the premises or area, only some of which actually provide the interrogation while the remainder are decoys, the former being hidden amid the welter of the latter. Others interrogate only at random intervals, thus making it difficult if not impossible to provide a false return signal at the necessary times. Still others provide line security only as a manually instituted adjunct to the main system rather than as an innate, automatic part of it. The nature of the interrogation and response signals also varies, pulses being used in some cases and tones in others, though the former seem to predominate. Trouble and alarm conditions are often indicated by voltage or impedance changes on the connecting lines or by reversal of their polarity in the case of a DC line system. Many systems tend to be rather if not inordinately complex, particularly those in which signals to and from several premises at different locations are issued and monitored from a common complex of apparatus at the central station rather than by a separate or discrete installation for each location.
It is the primary object of the present invention, therefore, to provide a system of the nature and for the purposes described which is simpler and more reliable than many while at the same time providing complete security both for the premises or area to be protected as well as for the lines interconnecting the latter with the central station.
SUMMARY OF THE INVENTION
The system of the present invention relies essentially upon the transmission of audio tones back and forth over the connecting lines. At the central station, a timer produces a succession of pulses P1 at random time intervals, but at least one every 11/2 minutes, which activate a transmitter T1 to provide a succession of audio tones of frequency F1 over the connecting or telephone lines. At the protected premises, the tones F1 enter a receiver R1 which produces a succession of pulses P2. The latter activate a second transmitter T2 at the protected premises which in turn sends a succession of audio tones of frequency F2 over the telephone lines to a receiver R2 at the central station. The latter receiver R2 produces a succession of pulses P3 which together with pulses P1 are applied to a logic complex. All the pulses P2 and P3 and the tones F1 and F2 have substantially the same intervals between them and are of the same durations as the pulses P1. Hence, if both pulses P1 and P3 are received at the logic complex all is well, but if pulses P1 and not pulses P3 are received or some other out of phase condition should occur, then a signal lamp and an audio alert is activated at the central premises to indicate trouble somewhere in the system, such as failure of some part or portion, or breakage or cutting of the telephone lines.
An alarm condition at the protected premises activates a transmitter T3 there which sends a constant audio tone of frequency F3 to a receiver R3 at the central station, the latter in turn energizing an alarm signal lamp and an audio alert. A test switch is also incorporated at the protected premises to check operation of the entire system. When closed, the test switch causes the system to interrogate the protected premises, the interrogation registering visually on a meter at the latter, in addition to normal interrogation from the timer at the central station.
Several features reside in the foregoing. First, the use of audio frequencies only over the telephone lines, instead of pulses, more readily fits the characteristics of those lines and their supporting equipment since, of course, they are designed for audio frequencies rather than pulses. Tones are also relied upon to provide trouble and alarm signals rather than changes in impedance or reversals of polarity on the telephone line. Second, not only does interrogation occur at wholly random intervals, thus innately producing line protection, but when interrogation occurs is determined wholly at the central station uninfluenced by any events at the protected premises. Hence, most of the time there is no signal of any kind on the telephone lines at all, making it extremely difficult for a potential intruder to pick out of a bundle of telephone lines those which in fact monitor the premises concerned. Third, an individual installation is employed at the central station for each protected premises, rather than a common complex into which all premises are tied. This both increases reliability as well as reduces cost and intricacy. In the same vein, owing to the reliance upon randomness, each installation is therefore necessarily unique and its various audio frequencies can be readily altered to differentiate it from other installations simply by adjusting the respective transmitters and receivers. The tolerances of the components are not critical and indeed contribute to the randomness and uniqueness of each installation. Thus there is no need to worry about integrating one system with others at the central station. Fourth, the ability to test operation of the system from the protected premises adds to the assurance and peace of mind of those who rely upon it. Furthermore, it is not necessary to warn the central station in advance that the system is being tested since that can be done without setting off a trouble or alarm alert at the central station (unless of course one of those conditions should actually exist at the moment of the test). Other and further features of the present invention will become apparent from the more detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram indicating the relationship and logic of the components of the system of the present invention at both the central station and the protected premises.
FIGS. 2A and 2B are schematic diagrams of the circuitry at the central station.
FIG. 3 is a schematic diagram of the circuitry at the protected premises.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As indicated, FIGS. 2A and 2B schematically illustrate the electronic circuitry located at the police or central station for each protected premises or area to be monitored. FIG. 3, on the other hand, schematically illustrates the electronic circuitry at the protected premises or area itself, the two being connected by telephone lines or equivalent means. Beginning first with FIGS. 2A and 2B, the randomness of the system is generated by a random timer RT in which a Zener diode ZD, biased for the "white noise" region, provides an AC signal of random amplitudes which is passed through an amplifier AM1 and "clipped" by an amplifier AM2 biased to produce a succession of discrete peaks or signals at random intervals. The latter are conditioned by a "single shot" multi-vibrator MV1 to produce a succession of uniform pulses of 30 millisecond duration each at the preceding random intervals which are accumulated in a capacitor C1 until sufficient to fire a uni-junction transistor QU whose output is led through a line 10 to the interrogation timer IT. Within the latter the random succession of pulses from the random timer RT are applied to an OR gate OG together with a succession of fixed pulses of 11/2 minutes duration each from a fixed timer FT. The output of gate OG is sent to another "single shot" multi-vibrator MV2, which, regardless of the occasion of either set of pulses from the gate OG, provides a resulting succession of pulses of 5 second duration each, at random time intervals, which are conditioned by the driver D having two outputs. The first output, which is otherwise LO, provides a set of random HI interrogation pulses P1 while the second, which is otherwise HI, provides a corresponding set of LO interrogation pulses P'1. The fixed timer FT assures that there are a pair of interrogation pulses P1, P'1 of 5 second duration at least every 11/2 minutes regardless of the interval between the random succession of pulses supplied through the line 10 from the random timer RT.
The pulses P1 are applied to a line 12 to activate a transmitter T1 at the central station whose output provides an AC signal or tone of frequency F1, which is within audio range, at the line 14 and thence over the telephone lines 16 to the protected premises where they are led through a line 18 to a receiver R1. The latter includes a phase lock loop L1, responsive only to the signals F1, to produce an output in the form of pulses P2 which are applied through a line 20 to the premises logic PL. Within the latter a relay K1 is energized through line 22 and suitable alarm contacts, for example, a switch (not shown), located at whatever is to be protected at the premises, a door, for instance. The relay K1 includes two sets of contacts KK1a and KK1b which are shown in their positions when the relay K1 is energized. The line 20 applies the pulses P2 to a meter M, in order to provide visual indication at the protected premises that the system is being interrogated, and through the closed contacts KK1a and a line 24 to a transmitter T2 which produces a different audio AC signal or tone of frequency F2. The tone F2 is applied through a line 26 to the telephone lines 16 and thence through a line 28 to a receiver R2 at the central station. The receiver R2 includes two outputs from a second phase lock loop L2. The first, which is otherwise LO, provides HI pulses P3 on a line 30 to the output logic OL for purposes to be described. At the same time the second output, which is otherwise HI, provides LO pulses P'3 through a line 32 to the first of two inputs to an exclusive OR gate EG in the interrogation logic IL whose output is LO if its two inputs are either both HI or both LO. The second input to the gate EG, as will be observed, is normally HI, and hence in the absence of pulses P'3 both inputs to the gate IG are HI so that its output is LO. However, the second input to the gate EG is influenced by an AND gate AG to which the pulses P'1 from the interrogation timer IT are applied through a line 34. Since both the pulses P'1 and P'3 are LO, both inputs to the gate EG also change from HI to LO so that the output of the gate EG continues LO. But if the pulses P'1 should be present at the gate EG but not the pulses P'3, the latter input would remain HI while the other input to the gate EG would change from HI to LO owing to the pulses P'1, whence the output of the gate EG would change from LO to HI to activate a signal indicating trouble somewhere in the system, for instance, the telephone lines 16 have been cut or are broken or something else is amiss elsewhere, etc., all as will now be described.
As long as the output of the gate EG is LO, the transistor Q1 in the interrogation logic IL is OFF and hence, as will be observed, a line 36 to a diode D1 in the output logic OL is HI. Meanwhile, as long as the line 36 is HI, a transistor Q2 in the interrogation logic IL is ON so that the output from a latch circuit LC controlled by the transistor Q2 is HI and applied through a line 38 to a diode D2 in the output logic OL. As will also be observed, as long as both lines 36 and 38 are HI, the output of a diode D3 remains HI and through a line 40 keeps a transistor Q3 ON. The latter completes a circuit through a line 42 to a trouble relay K2 in the trouble circuit TR to hold its two contacts KK2 in the position shown in FIG. 2B. Now, in the event the output of the gate EG in the interrogation logic IL should change from LO to HI owing to the absence of pulses P'3 and thus a trouble condition somewhere in the system, the transistor Q1 will be turned ON and so the line 36 changed from HI to LO. At the same time, the transistor Q2 will be turned OFF to change the output of the latch circuit LC in the line 38 also from HI to LO. Accordingly, both diodes D1 and D2 in the output logic OL will be LO and thus also the output of diode D3 in the line 40, turning OFF the transistor Q3 and opening the circuit to the trouble relay K2. Its contacts KK2 open the trouble circuit TR through the lines 44 to turn on an appropriate signal light and sound an alert (not shown). Since each pulse P'1 and P'3 is of relatively short duration, the output of the gate EG would return to LO once the interrogation was completed, since both inputs to the gate EG would return to HI until the next interrogation was attempted, whence the transistor Q1 would be turned ON again to restore power to the trouble relay K2 and turn off the trouble signal light and alert were it not for the latch circuit LC. In the event of trouble the output of the latter remains LO so that the line 38 and thus the output of diode D3 stay LO to keep the transistor Q3 OFF. Meanwhile, pulses from the interrogation timer IT corresponding to pulses P1 and P'1 are applied through a line 46 to an unlatch circuit UC in the interrogation logic IL. Once the trouble is corrected so that the output of the gate EG remains LO owing to the presentation of both pulses P'1 and P'3, the unlatch circuit UL, activated at the same time through the line 46, turns the latch circuit LC OFF to restore its output line 38 to HI.
A backup timer circuit BT is provided in the output logic OL so that should the interrogation timer IT fail, the output of the timer BT through a line 48 will turn OFF the transistor Q3 and deactivate the trouble relay K2 to give a "trouble" signal. The backup timer BT is designed to provide signals at fixed 2 minute intervals, that is, at greater intervals than those of the interrogation timer IT. Each signal from the latter, in the form of a pulse P3 from the receiver R2, is applied through a line 30a to reset the backup timer BT. Hence, as long as the timer IT interrogates at least every 11/2 minutes, the timer BT never becomes operative upon the transistor Q3. At the same time, the pulses P3 are led through a line 30b and a diode D4 in the output logic OL to charge a capacitor C2 which is of sufficient size to maintain a transistor Q4 ON during the intervals between the pulses P3. The transistor Q4 keeps an alarm relay K3 in the alarm circuit AR energized through a line 50 to hold its contacts KK3 in the position illustrated in FIG. 2B.
Returning now to FIG. 3, in the event an alarm condition exists at the protected premises, power in the line 22 is interrupted by an alarm switch ASW (see FIG. 1), deactivating the relay K1 in the premises logic PL so that its contacts KK1a are opened and its contacts KK1b are closed. The latter contacts then complete a circuit through a line 52 to a transmitter T3 whose output in the form of a constant level AC signal or tone of audio frequency F3 is applied through a line 54 to the telephone lines 16 and at the central station to a receiver R3 through a line 56. The receiver R3 has two outputs, the first of which is normally LO and the second normally HI. When the tone F3 is received, the phase lock loop L3 of the receiver R3 provides a signal AS of constant level to the first output, changing it to HI, and a signal AS' of constant level to the second output, changing it to LO. The first signal AS is led through a line 58 to the input of the driver D of the interrogation timer IT and the second signal AS' through lines 60, 60a to the output logic OL and through lines 60, 60b to the interrogation logic IL. The signal AS overrides the interrogation timer IT and produces a constant level HI output AC in the line 12 and a constant LO output AC' in the line 34. The former output AC thus activates the transmitter T1 and in turn the receiver R1 at the protected premises but not the transmitter T2 owing to the open relay contacts KK1a in the premises logic PL. Hence, the output of the receiver R2 at the central station through line 32 to the gate EG in the interrogation logic IL remains HI. Since the same time both the output AC' through the line 34 and the output AS' through the lines 60, 60b are LO and applied to the gate AG, the latter changes to LO whereby the output of the gate EG would change to HI owing to the absence of LO pulses P'3 on the line 32 since receiver R2 is not activated. Hence the trouble circuit TR would be de-energized to drop out the trouble relay K2. However, the output AS' from the receiver R3 through the lines 60, 60a and a diode D5 in the output logic OL, since it is LO, turns OFF a transistor Q5 in an override circuit OC which in turn maintains transistor Q3 ON through a line 62 and a diode D6 and hence the trouble relay K2 energized. The override circuit OC also resets the backup timer BT through a line 64 in the output logic OL so that the absence of the pulses P3 on the line 30a will not cause the timer BT to affect the trouble relay K2. On the other hand, since the pulses P3 are not present on the line 30b, the capacitor C2 can thereafter no longer maintain the transistor Q4 ON, thus de-energizing the alarm relay K3 in the alarm circuit AR whereupon the contacts KK3 cause a reversal of polarity on the lines 44 to light a signal lamp and sound an appropriate alarm (not shown) at the central station. Tamper switches TPSW1 and TPSW2 are inserted into the line 22 at the protected premises and into the line 42 at the central station, respectively, and activated should the consoles of the system at either be disturbed. As will be apparent, when activated TPSW1 will cause an alarm alert by de-energizing the relay K1 and TPSW2 a trouble alert by de-energizing the relay K2.
A test switch TSW in a line 66 is also provided at the protected premises in order to check the operation of the system. As will be apparent from FIG. 3, when TSW is momentarily closed, transmitter T3 will be activated and hence receiver R3. The output TS of the latter through the line 58 produces a signal TP1 from the interrogation timer IT to activate transmitter T1 and receiver R1, the presence of the signal TP1 being indicated on the meter M at the premises logic PL. At the same time, transmitter T2 is activated and hence receiver R2 to provide a LO signal TP'3 through the line 32 to the gate EG in the interrogation logic IL. Since receiver R3 is activated, its output TS' through the lines 60, 60b is LO and is applied to the gate AG in the interrogation logic IL. Meanwhile, the output TP'1 from the interrogation timer IT through line 34 is also LO and applied to the gate AG. Hence the output of the gate EG remains LO and the trouble relay K2 energized so that no trouble signal is given. Owing to the fact that the output TP3 of the receiver R2 through the lines 30, 30b is HI, the transistor Q4 remains ON and the alarm relay K3 energized so that no alarm signal is given. Of course, should a trouble or an alarm condition happen to exist during a test, an appropriate signal would be given at the central station as will be obvious from the operation of the circuitry previously described.
It will be apparent that the durations of and the intervals between the pulses P2, P3 and P'3 and the tones T1 and T2 are all substantially the same as those of pulses P1 and P'1 in a particular installation. Should for some reason the former become out-of-phase with the latter a trouble condition would result owing to the action of the gate EG in the interrogation logic IL. Hence in a given installation the actual durations and spacing of the pulses P1 and P'1 are not critical, and of course durations and spacing other than those set forth above can be used. Nor need the output F3 of the transmitter T3 be of a constant level, i.e., of indefinite duration; a relatively short tone F3 plus a latching circuit would do just as well as the constant level to assure positive operation of the alarm circuit AR. Note that the transmitters T1, T2 and T3 are OFF unless a tone F1, F2 or F3 is actually being sent so that the telephone lines 16 have no signal upon them except at relatively momentary times. Hence there would be great difficulty picking them out of a large bundle of otherwise ordinary telephone lines. As indicated in FIG. 2A, the power supply for the circuitry at the central station is primarily by means of a battery which is maintained by a typical trickle charger, while as indicated in FIG. 3 at the protected premises power is supplied from a battery pack plus a backup battery also maintained by a trickle charger.
As will be observed also, the system for each protected premises is complete in and of itself and is not dependent upon or otherwise integrated with that for any other protected premises. Besides the savings in cost and complexity and the consequent increase in reliability, the independence of each system assures its uniqueness to which the non-critical aspect of its components contributes. Each system is also readily adjustable within itself, by means of the potentiometers illustrated, to provide whatever frequencies F1, F2 and F3 may be desired and so to differentiate it from all other systems of like nature. At the central station, it will be understood of course, that the trouble and alarm indicators for all the various premises being monitored would normally be displayed together on a single panel and appropriately labeled for each premises. Other details of the circuitry and its operation will be apparent to those skilled in the art who will also be readily able to determine the appropriate values and specifications of the components involved for particular installations of the system. Finally, even though the present invention has been described in terms of a particular embodiment, being a best mode known of carrying out the invention, it is not limited to that embodiment alone. Instead, the following claims are to be read as encompassing all adaptations and modifications of the invention falling within its spirit and scope.
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A system for monitoring a protected premises from a central station over telephone lines employs different audio tones sent back and forth over the lines. A random succession of audio tones from the central station interrogates the protected premises and is returned as a like succession of different tones to the central station where the latter tones are compared with the first to indicate a normal or a trouble condition at the protected premises or on the lines. When an alarm condition exists at the protected premises, still different tones are sent over the lines to cause an alarm alert at the central station. The entire system can be tested from the protected premises, including operation of the trouble and alarm circuits, without producing a trouble or an alarm alert at the central station.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional U.S. Patent application No. 60/320,294 filed on Jun. 20, 2003 the disclosure of which is hereby incorporated by reference.
BACKGROUND OF INVENTION
[0002] Alpha Lipoic acid is taken up by cells and is reduced to a pharmacologically active dithiol form in several physiological reactions. However this active dithiol form is effluxed out of the cell rapidly decreasing the effectiveness of α-Lipoic acid.
[0003] Various mechanisms have been devised to enhance the retention of the active dithiol form within the cell. One such approach is a structurally modified version of α-Lipoic acid called LA-plus, chemically N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide monohydrochloride, which is represented by the formula
[0004] The protonated form of the corresponding derived dithiol molecule under physiological conditions is more efficiently retained within the cell and performs much better in physiological reactions than the parent α-Lipoic acid. This has been the subject of research papers (Sen, Chandan K; Tirosh, Oren; Roy, Sashwati; Kobayashi, Michael S; Packer, Lester; Biochemical and Biophysical research Communications, (1998), 247, 223-228).
[0005] These workers demonstrated that the uptake of LA-Plus was much higher in certain cells and also the intracellular amount of the corresponding dithiol form within the cell was much greater compared to α-Lipoic acid. Hence they came to the conclusion that LA-Plus is an improved form of Lipoic acid with enhanced therapeutic potential.
[0006] The (R)-form of LA-Plus described in the above work was synthesized by the reaction of Lipoic acid to which three equivalents of N,N-dimethylethylenediamine were added followed by N-hydroxysuccinimide. Dicylohexylcarbodiimide was subsequently added and the reaction time was one day. The product was extracted into the aqueous phase using hydrochloric acid and extracted into chloroform after basification of the aqueous phase using sodium hydroxide. This organic phase was dried, filtered and evaporated to dryness. The residue was redissolved in dichloromethane and hydrogen chloride gas was passed through the organic solvent up to saturation. The dichloromethane solvent was evaporated and the HCl salt of N,N-dimethyl-N″-2-amidoethyl-lipoate was precipitated using anhydrous ether.
[0007] It should be noted that the preparation LA-Plus hydrochloride involves extraction and re-extraction of the product in and out of aqueous/organic media. Also it involves the passage of hydrogen chloride gas, which is corrosive and difficult to use. Several solvents such as chloroform, methylene chloride, and dry diethyl ether are employed in the process.
[0008] Hence the synthesis of LA-plus as described in prior art is involved and not easily adaptable to large-scale operations (Sen, Chandan K; Tirosh, Oren; Roy, Sashwati; Kobayashi, Michael S; Packer, Lester; Biochemical and Biophysical research Communications, (1998), 247, 223-228).
[0009] More particularly, the product, both the racemeic (±)-LA-Plus hydrochloride and chiral (R)-LA-Plus hydrochloride forms are not good solids. They were also found to be hygroscopic and not easily handled during transfer and other operations.
[0010] In spite of the difficulty of handling LA Plus hydrochloride, applications involving this hygroscopic salts have been claimed (U.S. Pat. No. 5,965,618, U.S. Pat. No. 6,090,842, WO 0180851). Hence there is a need for a new salt form of LA-plus base which would be a good solid, non-hygroscopic and easily handled for various operations.
[0011] The preparation and use of compositions containing Lipoic acid or its derivatives, including LA-plus, for nutraceutical and cosmetic applications is widely described in prior art for example in U.S. Pat. Nos. 6,743,433 and 6,365,623 that describe compositions for the treatment of acne; U.S. Pat. Nos. 6,387,945, 6,235,772 and 6,090,842 that describe Lipoic acid analogs. The preparations of the current invention were found to be similarly biologically active.
SUMMARY OF INVENTION
[0012] The present invention describes a convenient method of manufacture of of LA Plus base (N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide ((±)-N-1-[2-(dimethylamino)ethyl]-5-(1,2-dithiolan-3-yl) pentanamide) from Lipoic acid. In addition stable, crystalline salts of LA Plus are described which are easily stable, non-hygroscopic and handled. Uses of such salts are described in various cosmetic applications such as skin care and hair care applications.
DETAILED DESCRIPTION
[0013] Our present invention addresses these issues. In this invention, (±)-Lipoic acid is treated with a slight excess of 1,1′-Carbonyl diimidazole and the intermediate acyl imidazole is reacted with N,N-dimethylethylenediamine to form N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide (LA-Plus base) in methylene chloride solution. Removal of methylene chloride and precipitation of the LA-Plus base as its maleate salt, LA-Plus maleate, forms the rest of the process.
[0014] The structures of the materials referred in this patent are shown as follows
[0015] Even though the examples are illustrative of the invention, they do not limit the scope of the invention. Lipoic acid is reacted with carbonyl diimidazole in a solvent such as methylene chloride. It is then treated with N,N-dimethylethylene diamine in the same solvent. The solvent was removed, replaced by acetone and the acid component was added to precipitate the desired material. For example, a similar process can be conceived for N,N-Dimethyl propylene diamine replacing N,N-dimethyl ethylenediamine to give another analog of LA-Plus. Similarly, another reactive acyl imidazole could be formed with 1,1″-Carbonylbis(2-methylimidazole), CAS registry no. 13551-83-2, with similar results. Such variations also fall within the scope of this invention.
[0016] We also found that stable, non-hygroscopic salts of LA Plus could be formed with fumaric acid in place of maleic acid as another example illustrating this invention.
[0017] The method is applicable for (±)LAPlus maleate as well as its chiral forms. For example, instead of (±)-Lipoic acid, if one uses R-(+)-Lipoic acid as the starting material, one again obtains the corresponding R-(+)-LA Plus maleate or fumarate depending on the acid that is employed for salt formation.
[0018] The solubility data on the LA Plus salts described in this patent are given in Table 1
TABLE 1 Solubility Data WATER ETHANOL PROPYLENE SAMPLE (D. D.) (95%) GLYCOL Alpha lipoic acid 0.03% 57% 20% LA plus (Maleate) 60% 7.35% 13% LA plus (Fumarate) 100% 51% 23% R (+)-LA plus 60% 6.84% 10% (Maleate)
Results in gm/dl; tests were done at 35 to 40° C. temperature.
[0019] It is clear from the data that the solubilities of the maleate and fumarate salts in water are much higher than that of α-Lipoic acid. Hence these stable, nonhygroscopic salts are easy to formulate in water based formulations.
TABLE 2 Antioxidant assay by DPPH radical scavenging activity Exposure to sun light for Absence of sun light 5 minutes Sample/Batch No. Conc. % Scavenging Conc. % Scavenging Alpha lipoic acid 6 mg 50% 45 μg 50% LA plus (Maleate) 6.6 mg 54% 55 μg 53% R(+)-LA plus 6.6 mg 49% 55 μg 47% (Maleate) LA plus (Fumarate) 6.2 mg 57% 55 μg 50% Ascorbic acid 6 μg 71% 6 μg 59%
[0020] LA Plus maleate and fumarate salts and α-Lipoic acid showed a marked difference in scavenging the DPPH radical when exposed to sunlight which was not shown by Ascorbic acid. Even when the concentration was 120 times lesser, the activity was comparable with exposure to sunlight (5 minutes). This data attest to the unique antioxidant ability of LA Plus salts in particular.
[0021] The inhibitory properties of LA Plus salts of the enzyme tyrosinase is shown in Table 3. Tyrosinase inhibition is one of the established in vitro methods of evaluating the skin fairness property.
TABLE 3 Activity on Tyrosinase Tyrosinase Sample Conc. % Inhibition Alpha lipoic acid (KU030121) 100 μg 51% LA plus (Maleate) 120 μg 58% R(+)-LA plus (Maleate) 120 μg 58.6% LA plus (Fumarate) 120 μg 53%
[0022] LA Plus maleate, LA Plus fumarate and R(+) LA Plus maleate (the three water soluble LA Plus salts) and α-Lipoic acid have thus the property as skin fairness/de-pigmentation product.
[0023] The inhibitory studies of LA Plus maleate, LA Plus fumarate and R(+) LA Plus maleate (the three water soluble LA Plus salts) and α-Lipoic acid on Collagenase and Elastase disclosed that these Lipoic acid derived salts are good inhibitors of these enzymes. The IC 50 values for Collagenase were found to be the same, namely, 1.6 mg/ml for LA Plus maleate, LA Plus fumarate and R(+) LA Plus maleate (the three water soluble LA Plus salts) and α-Lipoic acid. Similarly the IC 50 values for Elastase were found to be the same, namely, 1.4 mg/ml for LA Plus maleate, LA Plus fumarate and R(+) LA Plus maleate (the three water soluble LA Plus salts) and α-Lipoic acid. The formulations containing these salts are thus useful in antiaging effects and in preventing wrinkle formations in the skin. Our research further disclosed that LA Plus maleate, LA Plus fumarate and R(+) LA Plus maleate (the three water soluble LA Plus salts) and α-Lipoic acid display very good inhibition properties against Propionibacterium acnes . The important findings from these studies are as follows.
[0024] Two of derivatives of α-Lipoic acid viz., R(+) LA+Maleate and α-LA+Maleate are giving good inhibition of P. acnes and are showing inhibition at the minimum concentration of 1.0%. This is well comparable with that of the control [Clindamycin].
[0025] The compound α-Lipoic acid and one of its derivatives, α-LA+Fumarate are giving inhibition of P. acnes at the concentrations of 5 and 2% respectively.
[0026] The inhibitory activity of these compounds are in the following order: R (+) LA Plus Maelate>LA Plus Maleate>LA Plus Fumrate>α-Lipoic acid
[0027] Our results show that the LA Plus salts show a better activity than a standard drug like Clindamycin.
[0028] The results are presented in the following Table 4
TABLE 4 Zone of inhibition (in mm) α-Lipoic R(+) LA Conc. of the acid Plus LA Plus LA Plus sample (%) (α- LA) Maleate Maleate Fumarate Clindamycin 10 8 15 11 10 20 5 7 12 9 8 15 2 0 10 8 7 9 1 0 8 7 0 7 0.5 0 0 0 0 0
[0029] Conclusion: From these studies it is evident that two derivatives of α-Lipoic acid, viz., R (+) LA Plus Maleate and LA Plus Maleate can work as good antiacne agents.
ILLUSTRATIVE EXAMPLES
Example 1
(±)-Maleate salt of N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide(±-Maleate salt of N-1-[2-(dimethylamino)ethyl]-5-(1,2-dithiolan-3-yl)pentanamide, (±)-LA Plus maleate salt)
[0030] 1,1″-Carbonyl diimidazole (43 g in 150 ml of methylene chloride under nitrogen atmosphere) was cooled to 5-10° C. To the cold solution (±)-Lipoic acid (52 g in 250 ml of methylene chloride) was added slowly. Stirring was continued at room temperature after completion of addition. A clear solution was obtained. This solution was cooled to 5-10° C. and N,N-Dimethylethylenediamine (27 g) was added slowly.
[0031] The resultant solution was stirred for 3 hours at room temperature The methylene chloride layer was dried over sodium sulfate and the solvent was removed. The residue was dissolved in dry acetone (250 ml) and to this well-stirred solution, maleic acid (28 g in 250 ml acetone) was added slowly. The precipitated product was filtered and dried.
[0032] Yield: 89 g; Mp: 125-127° C.; Elemental analysis (Calculated values for C 16 H 28 N 2 O 5 S 2 in parentheses) Carbon, 48.94% (48.96%); Hydrogen, 7.22% (7.19%); Nitrogen, 7.15% (7.14%).
Example 2
R-(+)-Maleate salt of N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide(R-(+)-Maleate salt of N-1-[2-(dimethylamino)ethyl]-5-(1,2-dithiolan-3-yl)pentanamide, (+)-LA Plus maleate salt)
[0033] Same procedure as in example 1 excepting that R-(+)-lipoic acid was used in place of (±)-Lipoic acid.
[0034] Mp: 125-127° C.; Elemental analysis (Calculated values for C 16 H 28 N 2 O 5 S 2 in parentheses): Carbon, 49.12% (48.96%); Hydrogen, 7.06% (7.19%); Nitrogen, 6.99% (7.14%)Specific rotation: 53.80 (c=10.52 mg/ml of water)
Example 3
(±)-Fumarate salt of N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide(±)-Fumarate salt of N-1-[2-(dimethylamino)ethyl]-5-(1,2-dithiolan-3-yl)pentanamide, (±)-LA Plus fumarate salt)
[0035] Same procedure as in Example 1 excepting that fumaric acid is used in place of maleic acid.
[0036] Mp: 76-78° C.; Elemental analysis: (Calculated for values C 16 H 28 N 2 O 5 S 2 in parentheses) Carbon, 48.87% (48.96%); Hydrogen, 6.99% (7.19%); Nitrogen, 7.22% (7.14%).
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A process for the manufacture of new crystalline salts of N-[2-(dimethylamino)ethyl]-1,2-dithiolane-3-pentanamide (racemic and chiral forms) is described. Such salts are stable, crystalline and have very good solubility in water. The salts exhibit antioxidant properties. They inhibit collagenase and elastase enzymes. They have excellent anti acne activity in addition tyrosinase inhibition. They are, by themselves and in combination with other known agents, important cosmetic ingredients.
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This application claims benefit, under U.S.C. §119(a) of French National Applications Number 03.09641, filed Aug. 5, 2003, and 04.00906, filed Jan. 30, 2004; and also claims benefit, under U.S.C. §119(e) of U.S. provisional application 60/523,480, filed Nov. 19, 2003.
FIELD OF THE INVENTION
The present invention relates to flexible semiaromatic polyamides with a low moisture uptake. These polyamides also have good elongation properties. These polyamides have a high thermomechanical strength. Polyamide-6 and polyamide-6,6 have high melting points but their conversion is difficult and, furthermore, their water uptake is too high, which is damaging to their mechanical properties and to their resistance to ageing. Furthermore, they are too rigid to be used as pipes; it is then necessary to render them flexible with plasticizers or impact modifiers. All the properties are then lost. Polyamide-12 and polyamide-11 are much used in the automobile industry because of their noteworthy mechanical properties, their ease of use and their resistance to ageing. However, their thermomechanical strength is inadequate beyond a working temperature of 160° C. The invention relates to polyamides which are to replace polyamide-12 and polyamide-11 but which have an improved thermomechanical strength while retaining their ease of conversion and their flexibility.
BACKGROUND OF THE INVENTION
There exist terephthalic copolyamides based on a 6 unit (for example, 6,6/6,T or 6/6,T or also 6,I/6,T, comprising predominantly 6,T) which have very high melting points, above 300° C. These products are very rigid and their elongation at break is less than 10%, which prevents them from being used in the field of extrusion of pipes. Patent EP 550 314 gives examples of copolyamides-12/6,T. U.S. Pat. No. 3,843,611 discloses copolyamides-12,12/12,T. U.S. Pat. No. 5,708,125 discloses copolyamides-10,6/10,T. None of these prior arts discloses a possible aptitude with regard to ageing. Furthermore, none of these prior arts discloses the need for flexible polyamides. The aim of the present invention is to find polyamides which have resistance to ageing when they are subjected to a high working temperature, while remaining flexible. Such compositions have now been found.
SUMMARY OF THE INVENTION
The present invention relates to a composition comprising, by weight, the total being 100:
60 to 99.5% (preferably 70 to 93%) of at least one copolyamide of formula X/Y,Ar in which:
Y denotes the residues of an aliphatic diamine having from 8 to 20 carbon atoms, Ar denotes the residues of an aromatic dicarboxylic acid, X denotes either the residues of aminoundecanoic acid NH 2 —(CH 2 ) 10 —COOH, of lactam-12 or of the corresponding amino acid, or X denotes the unit Y,x, residue from the condensation of the diamine with an aliphatic diacid (x) having between 8 and 20 carbon atoms, or X denotes the unit Y,I, residue from the condensation of the diamine with isophthalic acid,
0.5 to 40% (preferably 7 to 30%) of at least one product chosen from plasticizers, nanofillers, polyolefins, crosslinked polyolefins and additives.
The intrinsic viscosity of the copolyamide is advantageously between 0.5 and 2 and preferably between 0.8 and 1.8.
The advantage of these compositions is the low water uptake, which does not exceed 3% by weight.
Preferably, X/Y, Ar denotes:
11/10,T, which results from the condensation of aminoundecanoic acid, 1,10-decanediamine and terephthalic acid, 12/12,T, which results from the condensation of lactam-12, 1,12-dodecanediamine and terephthalic acid, 10,10/10,T, which results from the condensation of sebacic acid, 1,10-decanediamine and terephthalic acid, 10,I/10,T, which results from the condensation of isophthalic acid, 1,10-decanediamine and terephthalic acid.
The present invention also relates to structures comprising a layer composed of the above composition. This structure is of use in preparing devices for the storage or transfer of fluids, in particular in automobiles. The invention also relates to these devices. These devices can be tanks, pipes or containers. These structures can comprise other layers composed of other materials.
The compositions of the invention can replace rubbers or metals.
The compositions of the invention are also of use as materials for electrical cables and can replace fluoropolymers.
The compositions of the invention are of use as materials for formulations comprising fillers: e.g. magnetic fillers. The compositions of the invention then act as binder for fillers of this type.
DESCRIPTION OF THE INVENTION
As regards the aromatic diacid, mention may be made of terephthalic acid, isophthalic acid, bibenzoic acid, naphthalenedicarboxylic acid, 4,4′-biphenyldicarboxylic acid, bis(p-carboxyphenyl)methane, ethylenebis(p-benzoic acid), 1,4-tetramethylenebis(p-oxybenzoic acid), ethylenebis(para-oxybenzoic acid) or 1,3-trimethylenebis(p-oxybenzoic acid). Preferably, this is terephthalic acid; it is denoted by “T”.
As regards “Y”, the diamine can be an α,ω-diamine comprising a straight chain. It preferably has from 9 to 14 carbon atoms. According to a preferred form, this is 1,10-decanediamine. It can be branched or can be a mixture of a linear (straight-chain) diamine and of a branched diamine.
As regards “X”, and more particularly “x” in “Y,x”, this is advantageously an aliphatic α,ω-diacid comprising a straight chain. It preferably has between 9 and 14 carbon atoms.
As regards the proportions of X, Y and Ar, Y and Ar are in stoichiometric proportions or proportions very close to stoichiometric.
There is advantageously between 0.5 and 0.7 mol of X per 1 mol of Y (or one mole of Ar).
0.5 mol of X also means 0.5 mol of Y,x, that is to say 0.5 mol of Y and 0.5 mol of x in the Y,x group. Likewise, 0.5 mol of X also means 0.5 mol of Y,I, that is to say 0.5 mol of Y and 0.5 mol of I in the Y,I group.
If Y comprises a long chain, for example has at least of the order of 15 to 18 carbon atoms, then the proportions of X can be very low, indeed even zero. The copolyamide is reduced to Y,Ar. The invention also relates to the preceding compositions in which X/Y,Ar has become Y,Ar and Y denotes the residues of an aliphatic diamine having from 10 to 20(preferably from 15 to 20 and better still from 18 to 20) carbon atoms.
If X/Y,Ar denotes 10,10/10,T, then the proportions of X can be higher and can be between 0.5 mol per 1 mol of Y and 1 mol per 0.05 mol of Y.
As regards the plasticizer, it is chosen from benzenesulphonamide derivatives, such as n-butylbenzenesulphonamide (BBSA), ethyltoluenesulphonamide or N-cyclohexyltoluenesulphonarnide; esters of hydroxybenzoic acids, such as 2-ethylhexyl para-hydroxybenzoate and 2-decylhexyl para-hydroxybenzoate; tetrahydrofurfuryl alcohol esters or ethers, such as oligoethoxylated tetrahydrofurfuryl alcohol; esters of citric acid or of hydroxymalonic acid, such as oligoethoxylated malonate. Mention may also be made of decylhexyl para-hydroxybenzoate and ethylhexyl para-hydroxybenzoate. A particularly preferred plasticizer is n-butylbenzenesulphonamide (BBSA).
As regards the nanofillers, this term is used to denote particles of any shape, at least one of their dimensions being of the order of a nanometre. Advantageously, these are lamellar exfoliable fillers. In particular, the lamellar exfoliable fillers are silicates and in particular organophilic treated clays; these clays, which exist in the form of sheets, are rendered organophilic by insertion between the latter of organic or polymeric molecules and are obtained in particular according to a process as disclosed in U.S. Pat. No. 5,578,672.
Preferably, the clays used are of the smectite type, either of natural origin, such as, in particular, montmorillonites, bentonites, saponites, hectorites, fluorohectorites, beidellites, stibensites, nontronites, stipulgites, attapulgites, illites, vermiculites, halloysites, stevensites, zeolites, fuller's earths and mica, or of synthetic origin, such as permutites.
Mention may be made, by way of example, of the organophilic clays disclosed in U.S. Pat. No. 6,117,932. Preferably, the clay is modified with an organic substance via an ionic bond with an onium ion having 6 carbon atoms or more. If the number of carbon atoms is less than 6, the organic onium ion is too hydrophilic and thus the compatibility with the polymer (the blend of (A) and (B)) may decrease. Mention may be made, as examples of organic onium ion, of hexylammonium ions, octylammonium ions, 2-ethylhexylammonium ions, dodecylammonium ions, laurylammonium ions, octadecylammonium (stearylammonium) ions, dioctyldimethylammonium ions, trioctylammonium ions, distearyldimethylammonium ions, stearyltrimethylammonium ions and ammonium laurate ions. It is recommended to use a clay having the greatest possible contact surface with the polymer. The greater the contact surface, the greater the separation of the clay flakes. The cation exchange capacity of the clay is preferably between 50 and 200 milliequivalents per 100 g. If the capacity is less than 50, the exchange of the onium ions is inadequate and the separation of the clay flakes may be difficult. On the other hand, if the capacity is greater than 200, the bonding strength of the clay flakes to one another is so strong that the separation of the flakes may be difficult. Mention may be made, as examples of clay, of smectite, montmorillonite, saponite, hectorite, beidellite, stibensite, nontronite, vermiculite, halloysite and mica. These clays can be of natural or synthetic origin. The proportion of organic onium ion is advantageously between 0.3 and 3 equivalents of the ion exchange capacity of the clay. If the proportion is less than 0.3, the separation of the clay flakes may be difficult. If the proportion is greater than 3, decomposition of the polymer may occur. The proportion of organic onium ion is preferably between 0.5 and 2 equivalents of the ion exchange capacity of the clays. The nanofillers can be added to the monomers and can be present during the polymerization of the copolyamide or can be added after the polymerization.
As regards the crosslinked polyolefins, this phase can originate (i) from the reaction of two polyolefins having groups which react with one another, (ii) from maleicized polyolefins with a monomeric, oligomeric or polymeric diamino molecule, (iii) or from one (or more) unsaturated polyolefin carrying unsaturation and which can be crosslinked, for example, by the peroxide route. As regards the reaction of two polyolefins, this crosslinked phase originates, for example, from the reaction:
of a product (A) comprising an unsaturated epoxide, of a product (B) comprising an unsaturated carboxylic acid anhydride, optionally of a product (C) comprising an unsaturated carboxylic acid or of an α,ω-aminocarboxylic acid.
As regards the crosslinked polyolefins, mention may be made, as example of product (A), of those comprising ethylene and an unsaturated epoxide.
According to a first form of the invention, (A) is either a copolymer of ethylene and of an unsaturated epoxide or a polyolefin grafted by an unsaturated epoxide.
As regards the polyolefin grafted by an unsaturated epoxide, the term “polyolefin” is understood to mean polymers comprising olefin units, such as, for example, ethylene, propylene, 1-butene or all other α-olefin units. Mention may be made, by way of example, of
polyethylenes, such as LDPE, HDPE, LLDPE or VLDPE, polypropylene, ethylene/propylene copolymers, EPRs (ethylene/propylene rubber) or metallocene PEs (copolymers obtained by single-site catalysis), styrene/ethylene-butene/styrene (SEBS) block copolymers, styrene/butadiene/styrene (SBS) block copolymers, styrene/isoprene/styrene (SIS) block copolymers, styrene/ethylene-propylene/styrene block copolymers or ethylene/propylene/diene monomer (EPDM) terpolymers; copolymers of ethylene with at least one product chosen from salts or esters of unsaturated carboxylic acids or vinyl esters of saturated carboxylic acids.
Advantageously, the polyolefin is chosen from LLDPE, VLDPE, polypropylene, ethylene/vinyl acetate copolymers or ethylene/alkyl (meth)acrylate copolymers. The density can advantageously be between 0.86 and 0.965 and the melt flow index (MFI) can be between 0.3 and 40 (in g/10 min at 190° C. under 2.16 kg).
As regards the copolymers of ethylene and of an unsaturated epoxide, mention may be made, for example, of copolymers of ethylene, of an alkyl (meth)acrylate and of an unsaturated epoxide or copolymers of ethylene, of a saturated carboxylic acid vinyl ester and of an unsaturated epoxide. The amount of epoxide can be up to 15% by weight of the copolymer and the amount of ethylene at least 50% by weight.
Advantageously, (A) is a copolymer of ethylene, of an alkyl (meth)acrylate and of an unsaturated epoxide.
Preferably, the alkyl (meth)acrylate is such that the alkyl has 2 to 10 carbon atoms.
The MFI (melt flow index) of (A) can, for example, be between 0.1 and 50 (g/10 min at 190° C. under 2.16 kg).
Examples of alkyl acrylate or methacrylate which can be used are in particular methyl methacrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate or 2-ethylhexyl acrylate. Examples of unsaturated epoxides which can be used are in particular:
aliphatic glycidyl esters and ethers, such as allyl glycidyl ether, vinyl glycidyl ether, glycidyl maleate, glycidyl itaconate, glycidyl acrylate and glycidyl methacrylate, and alicyclic glycidyl esters and ethers, such as 2-cyclohexen-1-yl glycidyl ether, diglycidyl cyclohexene-4,5-dicarboxylate, glycidyl cyclohexene-4-carboxylate, glycidyl 5-norbornene-2-methyl-2-carboxylate and diglycidyl endo-cis-bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylate.
According to another form of the invention, the product (A) is a product having two epoxide functional groups, such as, for example, bisphenol A diglycidyl ether (BADGE).
Mention may be made, as examples of product (B), of those comprising ethylene and an unsaturated carboxylic acid anhydride.
(B) is either a copolymer of ethylene and of an unsaturated carboxylic acid anhydride or a polyolefin grafted by an unsaturated carboxylic acid anhydride.
The polyolefin can be chosen from the polyolefins mentioned above which has to be grafted by an unsaturated epoxide.
Examples of unsaturated dicarboxylic acid anhydrides which can be used as constituents of (B) are in particular maleic anhydride, itaconic anhydride, citraconic anhydride and tetrahydrophthalic anhydride.
Mention may be made, as examples, of copolymers of ethylene, of an alkyl (meth)acrylate and of an unsaturated carboxylic acid anhydride and copolymers of ethylene, of a saturated carboxylic acid vinyl ester and of an unsaturated carboxylic acid anhydride.
The amount of unsaturated carboxylic acid anhydride can be up to 15% by weight of the copolymer and the amount of ethylene at least 50% by weight.
Advantageously, (B) is a copolymer of ethylene, of an alkyl (meth)acrylate and of an unsaturated carboxylic acid anhydride. Preferably, the alkyl (meth)acrylate is such that the alkyl has 2 to 10 carbon atoms.
The alkyl (meth)acrylate can be chosen from those mentioned above.
The MFI of (B) can, for example, be between 0.1 and 50 (g/10 min at 190° C. under 2.16 kg).
According to another form of the invention, (B) can be chosen from aliphatic, alicyclic or aromatic polycarboxylic acids or their partial or complete anhydrides.
Mention may be made, as examples of aliphatic acids, of succinic acid, glutaric acid, pimelic acid, azelaic acid, sebacic acid, adipic acid, dodecanedicarboxylic acid, octadecanedicarboxylic acid, dodecenesuccinic acid and butanetetracarboxylic acid.
Mention may be made, as examples of alicyclic acids, of cyclopentanedicarboxylic acid, cyclopentanetricarboxylic acid, cyclopentanetetracarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanetricarboxylic acid, methylcyclopentane-dicarboxylic acid, tetrahydrophthalic acid, endo-methylenetetrahydrophthalic acid and methyl-endo-methylenetetrahydrophthalic acid.
Mention may be made, as examples of aromatic acids, of phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid, trimesic acid or pyromellitic acid.
Mention may be made, as examples of anhydrides, of the partial or complete anhydrides of the above acids.
Use is advantageously made of adipic acid.
It would not be departing from the scope of the invention if a portion of the copolymer (B) is replaced by an ethylene-acrylic acid copolymer or an ethylene-maleic anhydride copolymer, the maleic anhydride having been completely or partially hydrolysed. These copolymers can also comprise an alkyl (meth)acrylate. This portion can represent up to 30% of (B).
With regard to the product (C) comprising an unsaturated carboxylic acid, mention may be made, as examples, of the products (B) completely or partly hydrolysed. (C) is, for example, a copolymer of ethylene and of an unsaturated carboxylic acid and advantageously a copolymer of ethylene and of (meth)acrylic acid.
Mention may also be made of the copolymers of ethylene, of an alkyl (meth)acrylate and of acrylic acid.
These copolymers have an MFI of between 0.1 and 50 (g/10 min at 190° C. under 2.16 kg).
The amount of acid can be up to 10% by weight and preferably 0.5 to 5%. The amount of (meth)acrylate is from 5 to 40% by weight.
(C) can also be chosen from α,ω-aminocarboxylic acids, such as, for example, NH 2 —(CH 2 ) 5 COOH, NH 2 —(CH 2 ) 10 —COOH and NH 2 (CH 2 ) 11 —COOH and preferably aminoundecanoic acid.
The proportion of (A) and (B) necessary to form the crosslinked phase is determined according to the usual rules of the art by the number of reactive functional groups present in (A) and in (B).
For example, in the crosslinked phases comprising (C) chosen from α,ω-aminocarboxylic acids, if (A) is a copolymer of ethylene, of an alkyl (meth)acrylate and of an unsaturated epoxide and (B) a copolymer of ethylene, of an alkyl (meth)acrylate and of an unsaturated carboxylic acid anhydride, the proportions are such that the ratio of the anhydride functional groups to the epoxy functional groups is in the region of 1.
The amount of α,ω-aminocarboxylic acid is then from 0.1 to 3% and preferably 0.5 to 1.5% of (A) and (B).
As regards (C) comprising an unsaturated carboxylic acid, that is to say (C) being chosen, for example, from ethylene/alkyl (meth)acrylate/acrylic acid copolymers, the amount of (C) and (B) can be chosen so that the number of acid functional groups and of anhydride functional groups is at least equal to the number of epoxide functional groups and, advantageously, products (B) and (C) are used such that (C) represents 20 to 80% by weight of (B) and preferably 20 to 50%.
It would not be departing from the scope of the invention if a catalyst were added.
These catalysts are generally used for the reactions between the epoxy groups and the anhydride groups.
Mention may in particular be made, among the compounds capable of accelerating the reaction between the epoxy functional group present in (A) and the anhydride or acid functional group present in (B), of:
tertiary amines, such as dimethyllaurylamine, dimethylstearylamine, N-butylmorpholine, N,N-dimethylcyclohexylamine, benzyldimethylamine, pyridine, 4-(dimethylamino)pyridine, 1-methylimidazole, tetramethylethylhydrazine, N,N-dimethylpiperazine, N,N,N′,N′-tetramethyl-1,6-hexanediamine or a mixture of tertiary amines having from 16 to 18 carbons and known under the name of dimethyltallowamine 1,4-diazabicyclo[2.2.2]octane (DABCO) tertiary phosphines, such as triphenylphosphine zinc alkyldithiocarbamates.
The amount of these catalysts is advantageously from 0.1 to 3% and preferably 0.5 to 1% of(A)+(B)+(C).
As regards the noncrosslinked polyolefins, mention may be made of the polyolefins described in the preceding section and intended to be grafted by reactive groups. Mention may also be made of the products (A) or (B) or (C) of the preceding section but used alone in order not to crosslink. Mention may be made, by way of examples, of the EPR or EPDM elastomers, it being possible for these elastomers to be grafted in order to make it easier to render them compatible with the copolyamide. Mention may also be made of acrylic elastomers, for example those of the NBR, HNBR or X-NBR type.
As regards the preparation of the compositions of the invention, use may be made of any conventional process for the synthesis of polyamides and copolyamides.
The compositions according to the invention can additionally include at least one additive chosen from:
dyes; pigments; brighteners; antioxidants; flame retardants; UV stabilizers; nucleating agents.
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The present invention relates to a flexible semiaromatic polyamide composition with a low moisture uptake comprising, by weight, the total being 100:
60 to 99.5% (preferably 70 to 93%) of at least one copolyamide of formula X/Y,Ar in which:
Y denotes the residues of an aliphatic diamine having from 8 to 20 carbon atoms, Ar denotes the residues of an aromatic dicarboxylic acid, X denotes either the residues of aminoundecanoic acid NH 2 —(CH 2 ) 10 —COOH, of lactam-12 or of the corresponding amino acid, or X denotes the unit Y,x, residue from the condensation of the diamine with an aliphatic diacid (x) having between 8 and 20 carbon atoms, or X denotes the unit Y,I, residue from the condensation of the diamine with isophthalic acid, −0.5 to 40% (preferably 7 to 30%) of at least one product chosen from plasticizers, nanofillers, polyolefins, crosslinked polyolefins and additives.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to lock stitch sewing machines employing a bobbin on which under or locking thread is wound for concatination with loops of needle thread in the formation of lock stitches. More particularly this invention relates to a novel and advantageously reliable system for monitoring the supply of thread remaining on the bobbin and indicating to the machine operator impending bobbin thread exhaustion.
2. Description of the Prior Art
Low bobbin thread signaling devices are known, as disclosed, for instance, in U.S. Pat. No. 4,178,866, Dec. 18, 1979 of Adams in which reception of a beam of light directed tangentially of the bobbin hub is used to signal low bobbin thread when the bobbin thread is unwound sufficiently to pass the light beam. A problem with such signaling devices is the inability to distinguish from reception of ambient light with resulting frequent false alarms.
The U.S. Pat. No. 4,413,581, Nov. 8, 1983 of Logan discloses an optical low bobbin thread detecting system in which the beam of light tangential to the bobbin hub is generated only in predetermined phases by an LED which is controlled by an oscillator and driver, and an arrangement is provided in order to monitor light reception which is registered only in matching relationship with that of light generated by the LED. Although the phase locked loop does provide a high degree of protection against false signalling as result of ambient light it does involve the expense of LED, oscillator and driver dedicated specifically to low bobbin thread detection, and it is subject to unreliability due to fluctuations in the power supply.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an optical low bobbin thread detector system which is immune to false alarm due to ambient light detection. This is accomplished in this invention by combining an arrangement for establishing as valid only those light reception signals which occur during predetermined periods of signal light emission together with a system for monitoring spurious light detection signals and actuating a low bobbin thread alarm for the sewing machine operator only after reception of valid signals during a predetermined number of successive periods of signal light emission without intervention of any spurious light detection signals.
Another object of this invention is to provide a particularly cost effective low bobbin thread detector of the above description. This object is attained in a sewing machine which includes a matrixed group of LED's for display purposes by utilizing one of the group of LED's as the light emitter in the low bobbin detection system and utilizing the microprocessor logic which controls the matrixed group of LED's to perform the comparator function similar to that of the prior phase locked loop arrangement as well as the logic functions necessary to ensure that the proper number of successive valid low bobbin thread detection signals have been received before an alarm is activated. Where a matrixed group of LED's is included in the sewing machine for other purposes all of the control functions for low bobbin thread detection are available as part thereof without additional cost and as further cost saving the alarm indicating low bobbin thread condition may be provided by utilizing another of the matrixed group of LED's for this purpose.
DESCRIPTION OF THE DRAWINGS
With the above and other objects and advantages in view, as will hereinafter appear, this invention comprises the devices, combinations and arrangements of parts hereinafter described and illustrated in the accompanying drawings of a preferred embodiment in which:
FIG. 1 is front elevational view of the loop taker and bobbin area of a sewing machine shown partly in section in order to show more detail thereof and in which an embodiment of this invention may be incorporated;
FIG. 2 is a plan view of the loop taker and bobbin area of the sewing machine shown in FIG. 1 indicating the placement of the light detector and a light emitter cooperative therewith;
FIG. 3 is a block diagram illustrating a control system constructed in accordance with the principles of this invention for controlling the low bobbin thread detector;
FIG. 4 is a flow diagram illustrating the operation of the microcomputer shown in FIG. 3 to effect low bobbin thread detection and alarm when properly programmed in accordance with this invention.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 shows a portion of a sewing machine having a bed 12 and a sewing head 18 overhanging the bed 12. The bed 12 is formed with a cavity 13 in which a loop taker 14 is rotatably carried on one extremity of a shaft 15 oriented so as to have a vertical axis. The shaft 15 is driven by bevel gears 20 which are driven in the usual manner by the main sewing machine drive motor (not shown). The loop taker 14 rotates in timed synchronization to the reciprocation of the needle bar 16, the needle 17 carried by the needle bar 16 being driven in endwise reciprocation through a work material supported in the bed 12 for cooperation with the loop taker 14 carried therein in the formation of stitches. A feed dog 19 is visible which is a portion of a feeding system (not shown) for feeding work material under the sewing needle 17 in order to generate a pattern of stitches. The work material is pressed against the feed dog 19 by a presser foot 22 supported on the end of a presser bar 23 which is urged downwardly in a manner well known in the sewing machine art. A throat plate 24 supports the work material and is fashioned with an orifice (not shown) through which the sewing needle 17 may project. The throat plate 24 is further formed with slots 25 through which the feed dog 19 may extend.
The loop taker 14 supports on a race 27 thereof a bobbin case 28. The bobbin case 28 is restrained from rotary motion with the loop taker 14 by a position plate 52 (FIG. 2). The bobbin case 28 is fashioned with a cavity 29 within which is supported a bobbin 30 for the carrying of lower thread for a lockstitch. A further explanation of the loop taker 14, the bobbin case 28 and the bobbin 30 arrangement and how thread may be wound thereupon may be had by reference to U.S. Pat. No. 3,693,566. The teachings of this patent have been modified somewhat by extending the bobbin case 28 above the level of the loop taker 14 in order that bores 32, 33 might extend therethrough roughly tangent to the hub 31 of the bobbin 30 (FIG. 2). The purpose of the bores 32, 33 is to allow the passage of light from a light source 35 as focused by a lens 36. The light rays extending from the bore 33 pass through orifices 38 in a mask box 40, which box 40 supports a light detector 42 on an inner wall thereof aligned with the orifices 38 and the bores 32 33. A board 44 is affixed to the bed 12 by means of a screw 45 and the mask box 40 is supported on the board 44 with the light detector 42 having electrical connections thereto.
Referring now to FIG. 2, there is shown a plan view of the left side of the bed 12 showing the cavity 13 therein with the throat plate 24 removed and with a bed slide 50 thereof slid back to expose the loop taker 14, the bobbin case 28 and the bobbin 30. There is also visible a portion of the position plate 52 and a position finger 54 which serve to retain the bobbin case 28 in a stationary position against rotation with the loop taker 14 while permitting thread to be case thereabout.
It will be readily appreciated by one skilled in the art of sewing that it is inconvenient to exhaust the supply of bobbin thread while in the middle of a sewing project. Inasmuch as the bobbin is located within the sewing machine bed 12 over which is draped the garment or fabric being sewn. It will be appreciated that it is difficult to readily observe the quantity of thread remaining on the bobbin while carrying out the sewing process. To the end of alleviating the problems attendant with observing the quantity of bobbin thread, there is provided an indicator, illustratively a light emitting diode 61, preferably mounted on the head 18 of the sewing machine where it is readily visible to an operator, for informing the operator when the amount of thread remaining on the bobbin falls below a predetermined threshold FIG. 3 is a system block diagram of circuitry for controlling the illumination of the indicator 61 in response to the amount of thread remaining on the bobbin 30.
Referring to FIGS. 3 and 4, of the drawings a microprocessor 70 is shown which has for one of its primary purposes the control of a matrixed group of LED's 71 to display for the sewing machine operator the form and proportion of stitch pattern as it will be produced in accordance with the setting of the various sewing machine controls. The U.S. Pat. No. 4,341,170, July 27, 1982 of Beckerman et al may be referred to for a more complete disclosure of a microprocessor controlled matrixed group of LED's for display purposes, however, for purposes of the present invention it will be sufficient to understand that inputs 72 are provided to the microprocessor from the sewing machine stitch pattern memory, display instructions for each stored pattern in the stitch pattern memory, and from the various operator influenced controls on the sewing machine. The microprocessor delivers output controlling drivers 73 and 74 to the matrixed group of LED's 71. With this arrangement the LED's are multiplexed at a rate indistinguishable to the human eye so that compared with an arrangement in which each LED is provided with its own driver, the number of drivers is greatly reduced with consequent cost saving.
In the present invention, one of the matrixed group of LED's 71 is dedicated to providing the light source for monitoring bobbin thread exhaustion as indicated at 35 in FIG. 3. Another of the matrixed group of LED's 71 is dedicated to providing the alarm signal indicating to the sewing machine operator impending bobbin thread exhaustion as indicated at 61 in FIG. 3. The system of this invention is completed by providing an input line 75 from the light detector 42 to the microprocessor 70. It will be understood that the microprocessor 70 in order to be suitable for serving the purposes of the present invention in addition to controlling the visual display must include capacity for monitoring a timing function preferrably including a timer 80 of at least one second capacity and a counter 90 with ability to store a count of repetitive signal receptions preferrably with capacity of at least 5 repeats
FIG. 4 depicts a flow chart of the routine providing by the microprocessor for monitoring bobbin thread exhaustion indication in accordance with this invention. It will be understood that the routine depicted in FIG. 4 will be initiated at the same frequency that the drivers for the matrixed group of LED's 71 are multiplexed by the microprocessor, that is, substantially 30 times per second or more.
The microprocessor first checks the condition of the timer 80. The function of the timer 80 is to maintain the low bobbin thread alarm indicator, LED 61, on and off for approximately one second intervals when a low bobbin thread condition is sensed. If the timer 80 is at any condition other than 0, i.e. the off condition, the routine to the right of FIG. 4 is followed i.e. the microcomputer checks whether the timer 80 has progressed beyond one second, if not the system awaits the next interrogation routine. If the one second time has elapsed the microcomputer asks if the alarm signal LED 61 is on and if so it turns it off, resets the timer and awaits the next interrogation routine; if not it stops, resets the timer, and then initiates one interrogation of the routine depicted to the left in FIG. 4 which is the routine followed in each instance that the off condition of the timer 80 is sensed.
In the routine depicted to the left in FIG. 4 the microcomputer first determines whether the light emitter of the low bobbin thread detector, LED 35 is or is not on following which it determines whether the light detector 42 is or is not on. Only if both the LED 35 and the detector 42 are on simultaneously is valid low bobbin thread condition indicated and the counter 90 incremented. If such coincidence is not registed i.e. if the detector is not on when the emitter is on or if the detector is on when the emitter is off an invalid signal such as influence of ambient light or adequate bobbin thread supply is indicated and the counter is reset in either case.
If the counter 90 is incremented, the microcomputer inquires whether the count has reached a predetermined level, such as 5. If no the system awaits the next interrogation routine; if yes, the signal LED 61 is turned on and the timer 80 is started.
The system described above thus requires a predetermined number, for instance 5, successive valid low bobbin thread detections before the alarm can be actuated or the actuation of the alarm can be continued. In this manner virtually any possibility of false low bobbin thread alarm due, for instance. To ambient light detection is obviated Where matrixed LED's are employed in the sewing machine for other purposes, use thereof for low bobbin thread detection and alarm as taught in the present invention provides a particularly cost effective mode for utilizing the techniques of the present invention.
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An optical low bobbin thread detector is disclosed utilizing particularly cost effective matrixed light emitting diodes for bobbin thread detection and alarm, and virtually eliminating false alarms by employing a system requiring detection of a predetermined number of successive valid low bobbin thread detections to justify actuation of the alarm.
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SUMMARY OF THE INVENTION
The object of the present invention is to provide a method and an apparatus for smoothly driving a valve in a fuel injector and for easily measuring small amount of the fuel even under high-speed engine operation.
According to the present invention, there is provided an apparatus for driving a valve in an injector adapted to intermittently inject liquid fuel by the valve which is reciprocally moved by attraction force of an exciting coil and repulsive force of a spring, in which an armature secured to the valve to be attracted by the exciting coil and/or an iron core of the exciting coil is made of a permanent magnet.
Consequently, inductance of the solenoid is decreased without changing the way of winding of the exciting coil to facilitate quick attraction of the armature and measurement of small amount of the fuel injected by the injector.
According to the present invention, there is also provided a method of driving a valve in an injector in which the pulse shape of an electric current applied to the exciting coil in the aforementioned apparatus is formed in a stepped wave shape in which at least the electric current in the initial stage of application is larger than that in the later stage.
Consequently, consumption of electricity in the exciting coil is remarkably reduced and attraction characteristic of the armature is improved.
According to the present invention, there is further provided a method of driving a valve in an injector in which an inverse pulse for inversely exciting the exciting coil is formed to give the permanent magnet of the armature repulsive force upon fall of the pulse wave of the aforementioned electric current applied to the exciting coil.
Consequently, return characteristic of the armature is improved to remarkably raise the aforementioned response of the injector and prevent defective operation of the injector that may be caused by a mechanical accident.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a fuel injector to which an apparatus according to the present invention is applied;
FIG. 2 is an electrical circuit of the apparatus of FIG. 1;
FIG. 3 is a performance chart of the apparatus of FIG. 1;
FIG. 4 is a graph showing comparison of characteristics of the solenoid coil with respect to different materials;
FIG. 5 is a graph showing comparison of characteristics of the injector of the present invention and a conventional injector;
FIG. 6 is a longitudinal sectional view of a fuel injector to which a second embodiment of the present invention is applied;
FIG. 7 is an illustrative view in which an armature of the second embodiment is provided in the form of a composite magnet;
FIG. 8 is a longitudinal sectional view of a fuel injector to which a third embodiment of the present invention is applied;
FIG. 9 is an electrical circuit of a fourth embodiment of the present invention;
FIG. 10 is a performance chart of the fourth embodiment; and
FIGS. 11 and 12 are graphs showing modifications of operational characteristics of the fourth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the drawings, there is shown an injector 21 of which body 1 is made of non-magnetic material such as resin and aluminum. The body 1 is fitted at its forward end with a valve housing 3 through a retainer 2. Within the valve housing 3, there is provided a valve 4 which is limitedly movable in the axial direction between the end surface of the retainer 2 and a funnel-shaped inner surface 3a of the forward end of the valve housing 3 adjacent to an injection port 5 formed thereby. When the valve 4 moves toward the injection port 5 so that the forward end of the valve 4 is in close contact with the funnel-shaped inner surface 3a of the housing 3 communicating with the injection port 5, the injection port 5 is closed to stop injection of fuel therefrom. On the other hand, when the valve 4 moves toward the retainer 2 so that a flange 6 in the rear portion of the valve 4 is in contact with the end surface of the retainer 2, the injection port 5 is opened to inject fuel therefrom, which is fed through a channel 7 formed in the retainer 2 and a clearance 8 enclosing the valve 4.
A solenoid coil 11 is mounted in the injector body 1 through a cap 9 and an O-ring 10 for preventing leakage of the fuel. The solenoid coil 11 receives through another O-ring 14 for preventing leakage a fixed iron core 12 which is made of ferromagnetic material and serves as a fuel supplying pipe. A part of the fixed iron core 12, which is inserted into the solenoid coil 11 along the effective length thereof, is sized small in outer diameter so as to decrease inductance of the solenoid coil 11. The inductance of the solenoid coil 11 may also be decreased by making the end portion 13 of the fixed iron core 12 tapered, i.e., making its end surface 13 small for controlling magnetic force.
The valve 4 is provided at its rear end with an armature 15 made in the form of a plunger by a permanent magnet, which is attracted by the fixed iron core 12 upon excitation of the solenoid coil 11. A return spring 17 is interposed between a flange 16 integrally provided with the fixed iron core 12 and the armature 15 to urge the armature 15 and the valve 4 against attraction of the fixed iron core 12 so that the forward end of the valve 4 is in contact with the funnel-shaped inner surface 3a of the forward end of the valve housing 3. Numeral 18 indicates a cord for external wiring which is drawn out from the solenoid coil 11 through the cap 9.
Therefore, while the solenoid coil 11 is not excited, the fuel is never injected from the injection port 5 since the port 5 is closed by virtue of the force of the return spring 17 even when the fuel is supplied under pressure to the injector 21 from a fuel supplier hose (not shown) connected to a plug 19 which is integral with the fixed iron core 12 through a strainer 20. When the solenoid coil 11 is excited in this condition, the armature 15 is attracted by the fixed iron core 12 against the force of the return spring 17 so that the flange 6 of the valve 4 is in contact with the retainer 2 to open the injection port 5, and the fuel from the fuel supplier hose passes through a clearance defined between the end surface 13 of the iron core 12 and the armature 15 to be injected from the injection port 5.
FIG. 2 shows an electric circuit for changing the rectangular-shaped pulse of an electric current applied to the solenoid coil 11 in response to the volume of the fuel supplied to the engine to a stepped pulse as shown in solid lines in FIG. 3 under pure resistance load on the solenoid coil 11. A pulse PL1 from a pulse generator PG1 generating the pulse upon injection of the fuel by the injector 21 is inputted in a circuit 22 of a transistor TR1 through a condenser C1, resistors R1 and R2, a diode D1 and an inverter INT1 and in a circuit 23 of a transistor TR2 through an inverter INT2 and a resistor R3. The solenoid coil 11 of the injector 21 is connected to a DC battery of which voltage is 12 V through transistors TR3 and TR4 which are connected with each other in Darlington circuit and which are under on-off control of the transistor TR1 of the circuit 22. The solenoid coil 11 is connected to the 12 V-DC battery also through transistors TR5 and TR6 which are connected with each other in Darlington circuit and which are under on-off control of the transistor TR2 of the circuit 23 and a current limiting resistor R4. Further, a circuit consisting of a surge absorbing resistor R5 and a diode D2 is connected to the solenoid coil 11 and resistors R6 to R13 as circuit elements are connected to the transistors TR1 to TR6.
When the pulse PL1 is not generated from the pulse generator PG1 in the above-constructed electric circuit, the solenoid coil 11 is not excited since the transistors TR1 and TR2 become on through inversion output of the inverters INT1 and INT2 by output zero of the pulse generator PG1 to make the transistors TR3 to TR6 off.
Then, when the pulse generator PG1 generates the pulse PL1 in response to the volume of the fuel to be injected from the injector 21, the inverter INT1 of the circuit 22 is inverted for a certain period determined by the condenser C1, the resistor R1 and threshold voltage of the inverter INT1 to turn zero after rise of the pulse PL1 and the inverter INT2 of the circuit 23 is inverted during the pulse length to turn zero. Therefore, the transistors TR3 and TR4 for controlling application of electric current to the solenoid coil 11 become on through the transistor TR1 during output inversion of the inverter INT1 and the transistors TR5 and TR6 become on through the transistor TR2 during output inversion of the inverter INT2. Since the resistor R4 for controlling electric current is connected in series to the transistors TR5 and TR6, an electric current having a stepped pulse shape as shown in solid lines in FIG. 3 is applied to the solenoid coil 11 granted that the same is pure resistance load. Namely, in the initial stage of the electric current application, a large amount of electric current is applied to the solenoid coil 11 to increase the attractive force of the armature 15 against the fuel pressure and the force of the return spring 17, and after the valve is fully shifted with the armature 15, the amount of the electric current applied to the solenoid coil 11 for maintaining the armature 15 in the shifted condition is reduced.
However, if the transistors TR3 to TR6 are subjected to on-off control according to the pulse shape as shown in FIG. 3, the actual electric current applied to the solenoid coil 11 does not form the pulse shape as shown in FIG. 3 since the solenoid coil 11 is not in fact pure resistance. FIG. 4 shows the result of comparison made on inductance of the solenoid coil 11 which is varied by insertion of the iron core in the effective length of the solenoid coil 11 with respect to a non-magnetized ferromagnetic material and with respect to a permanent magnet. As shown in FIG. 4, the inductance is relatively large and is increased in proportion to insertion amount in case of the non-magnetized ferromagnetic material while the inductance in case of the permanent magnet is relatively small and is not influenced by the insertion amount.
When the armature 15 of the embodiment shown in the drawings is experimentally made of a non-magnetized ferromagnetic material and the electric current to be applied to the solenoid coil 11 is controlled in accordance with the pulse shape as shown in the solid line in FIG. 3, the actual electric current flows in the shape as shown in phantom line in FIG. 3 because the inductance of the solenoid coil 11 is large. Consequently, attraction force for the armature 15 in the initial stage of the electric current application becomes insufficient leading to insufficient fuel control by the injector 21, and even if the current limiting the resistor R4 is removed from the electric circuit of FIG. 2 to make the electric current in the rectangular shape corresponding to the initial electric current as shown in the solid line in FIG. 3, measuring of the fuel by the injector 21 in small amount is limited because of the delay in attraction of the armature 15, and cannot follow the high-speed rotation of the engine.
However, since the armature 15 in the present invention is made of the permanent magnet, the inductance of the solenoid coil 11 becomes small and the solenoid coil 11 receives the electric current of which pulse shape is as indicated by one-dot line in FIG. 3 to sufficiently attract the armature 15 in the initial stage of the electric current application. After that, the electric current becomes small but maintains the armature 15 in attracted condition. In consequence, measurement of the injected fuel during high-speed engine rotation, which is most necessary for improving engine performance can be controlled even the time of the electric current application to the injector 21 is under 1 m sec as shown in solid line in FIG. 5. Namely, measurement of the fuel injected from the injector 21 while the electric current is applied below 2 m sec, which is the lowest limit of the prior art as shown in phantom line in FIG. 5, can be conducted and thereby the injector 21 can sufficiently follow the high-speed rotation of the engine.
FIG. 6 shows a second embodiment of the present invention, in which a fixed iron core 24 is sized to be smaller in length than the iron core 12 in the first embodiment and an armature 25 is sized to be larger in length than the armature 15 in the first embodiment so that the armature 25 is attracted by the fixed iron core 24 in a position in which the magnetic field shows the largest inclination on the axis of the solenoid coil 11. The other portions of the second embodiment are constructed identically with those of the first embodiment. Therefore, no further description of the second embodiment would be necessary to anyone of ordinary skill in the art.
In place of the lengthened armature 25 as shown in FIG. 6, a composite magnet 28 substantially identical in length with the magnet 25 may be utilized (see FIG. 7). The magnet 28 comprises a permanent magnet 26 which is identical in length with the armature 15 in FIG. 1 and a pair of soft magnetic materials 27 disposed on both ends of the magnet 26. This structure functions in the same way as the second embodiment.
FIG. 8 shows a third embodiment of the present invention, in which a passage 30 for the fuel formed in a fixed iron core 29 is sized large in inner diameter in the vicinity of the forward end of the fixed iron core 29 to make the inductance of the solenoid coil 11 small, and a return spring 31 is inserted into the passage 30 having the large inner diameter. The other portions of the third embodiment are constructed identically with those of the first embodiment. Therefore, no further description of the third embodiment would be necessary to anyone of ordinary skill in the art.
Though the armatures 15 and 25 are made of permanent magnets in the aforementioned embodiments, the fixed iron cores 12, 24 and 29 may be made of permanent magnets instead, or, both the armatures 15 and 25 and the fixed iron cores 12, 24 and 29 may be made of permanent magnets. Further, though the injector body 1 is made of nonmagnetic material, it may be made of a ferromagnetic material to function as a yoke for the solenoid coil 11 and make a magnetic path for the solenoid coil 11 with the armatures 15 and 25 and the fixed iron cores 12, 24 and 29.
FIG. 9 shows a fourth embodiment of the present invention in which the shape of a pulse PL2 from a pulse generator PG2 to be sent to the solenoid coil 11 is changed in a stepped wave form through inverters INT3 and INT4, NOR circuits NOR1 and NOR2, a NAND circuit NAND1, transistors TR7 to TR21, resistors R14 to R43 and condensers C2 to C6. In this case, an inverse exciting current is applied to the solenoid coil 11 of the injector 21 in the first to the third embodiments upon fall of the pulse PL2 from the pulse generator PG2 to make end polarity of the fixed iron cores 12, 24 and 29 identical with that of the armatures 15 and 25 so that repulsive force is generated in the armatures 15 and 25, and thereby raise return characteristics of the valve 4 upon fall of the pulse PL2 and improve response of the injector 21 so that the valve certainly returns even if the flange 6 of the valve 4 bites into the retainer 2 and valve 4 cannot be returned by the force of the return springs 17 and 31 by some mechanical accident to prevent the injector 21 from abnormal condition.
While the invention has been described with reference to a few preferred embodiments thereof, it is to be understood that modifications or variations may be easily made without departing from the scope of this invention which is defined by the appended claims.
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A method of driving a valve in an injector for an internal combustion engine which intermittently injects liquid fuel by the valve reciprocally moving by attraction force of a solenoid coil and repulsive force of a spring and an apparatus for carrying out the method. An armature secured to the valve to be attracted by the solenoid coil and/or an iron core of the solenoid coil is made of a permanent magnet. The pulse shape of an electric current to be applied to the solenoid coil is made in the form of a stepped wave in which the electric power in the initial stage of application is larger than that in the later stage. An inverse pulse for inversely exciting the solenoid coil is formed to give the permanent magnet of the armature repulsive force upon fall of the pulse wave of the electric current applied to the solenoid coil.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the priority date of German application DE 10 2004 052 898.5, filed on Nov. 2, 2004, the contents of which are herein incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to a receiving apparatus for a mobile communications system, the receiving apparatus designed to demodulate received signals, which can be modulated using different modulation types at the transmitter end.
BACKGROUND OF THE INVENTION
[0003] In digital cordless communications systems which are based on the Bluetooth Standard Version 1.1, the data is transmitted at a rate of about 1 Mbit/s. A two-value GFSK (Gaussian Frequency Shift Keying) modulation method is used in this case. The GFSK modulation method is a frequency-keying modulation method (FSK—Frequency Shift Keying). Furthermore, a Gaussian filter is used at the transmission end in order to limit the frequency bandwidth for GFSK-based modulation. A filter such as this carries out pulse shaping of the frequency or data pulses, with the pulse for each data symbol extending over a time of more than one symbol time period T.
[0004] In order to achieve higher data transmission rates, one option is to use modulation methods with more values, such as the four-value DQPSK method (Differential Quadrature Phase Shift Keying) or, in general, the DMPSK method, in which an M-value symbol where M≧4 is transmitted instead of a two-value bit. Future versions of the Bluetooth Standard (possibly even from Version 1.2, but at the latest from Version 2.0) are planning on the data rate being increased by using modulation methods with more values.
[0005] In order to increase the data rate in later versions of a standard in standardized digital radio transmission systems, it is worthwhile changing from a modulation method with a small number of values (for example GFSK) to a modulation method with more values (for example DQPSK) once the radio link has been in existence for a certain time. This allows backward compatibility of the new versions of the Standard to the earlier versions of the Standard. The process of setting up a connection, or of setting up a so-called pico network in the case of the Bluetooth Standard, can in this case be carried out by means of the modulation method with a small number of values, which is used for all the appliances to that Standard. If both the appliances in a link that has been set up or in the pico network are designed for modulation with more values, they can be used for the subsequent data transmission.
[0006] In general, in digital TDMA (Time Division Multiple Access)-based mobile radio systems, the information is transmitted in the form of data bursts whose timings are defined. In the case of packet-oriented mobile radio systems, a data packet to be transmitted extends over one or more data bursts. A data burst comprises a first data burst header or data packet header. The header contains information required for addressing the remote location and for indication of the packet type, and should thus, for compatibility reasons, be transmitted using a modulation method with a small number of values for all versions of the Standard. In particular, it is also feasible for the header to be indicated to the respective remote location by switching to a second modulation method, which uses more values. Switching to a modulation method which uses more values is then carried out only in a second part of the data burst. If a plurality of data packets are transmitted in succession, the modulation method is thus switched alternately a number of times.
[0007] One fundamental problem with wireless communications systems is the frequency offset between the transmitter and the receiver, that is to say an error between the carrier frequency of the received signal and the frequency applied to the mixer in the receiver in order to down-mix the received signal. This may mean either the frequency which is supplied to a single mixer for direct down-mixing to baseband or else the frequency which is supplied to a first mixer for down-mixing to an intermediate frequency and the frequency which is supplied to a second mixer for down-mixing from the intermediate frequency to baseband.
[0008] In order to overcome this problem, the frequency offset must be estimated and corrected at the receiver end. In particular, wireless communications systems such as Bluetooth or DECT require a simple solution in terms of the implementation complexity and the power consumption, since the manufacturers are subject to stringent requirements for low costs and low power consumption at the same time. Receiving appliances for cordless communications systems preferably use low-cost crystal oscillators with a relative accuracy of typically 20 ppm. For a Bluetooth communications system, this means a frequency offset in one of two communication partners of 50 kHz. Since the frequency offset can also occur with an opposite mathematical sign in the two communication partners, that is to say the transmitter and the receiver, the maximum frequency offset may be about 100 kHz. Thus, in order to ensure good reception quality, it is absolutely essential to estimate and compensate for the frequency offset in the receiver.
[0009] FIG. 1 a illustrates the structure of a data burst which can be transmitted by radio in a Bluetooth transmission system based on a Bluetooth Standard higher than 1.1 between the subscribers in a pico network, which has been previously set-up. In FIG. 1 a , the data burst or the data packet has an access code which is arranged at the start, has a time duration of 72 μs and comprises a 4 μs-long preamble, a 64 μs-long synchronization word and a 4 μs-long trailer. The access code is modulated using the two-value GFSK modulation method. Identification and synchronization information for the pico network is sent on a standard-specific basis by means of the access code.
[0010] In this example, the data is sent at a first data rate of 1 Mbit/s. The access code is followed by a header with a time duration of 52 μs, which is likewise modulated using the two-value GFSK modulation method. In addition to addressing information and details relating to the packet type being used, the header can also contain information about a second data rate which is intended for transmitting subsequent payload data. The header is followed by a section which is formed from an optional, 5 μs-long guard time interval and an 11 μs-long synchronization or training sequence. No data is transmitted during the optional time period for the guard time interval. The guard time interval is used for switching of the modulation-dependent components at the transmission and reception ends.
[0011] The synchronization or training sequence has a sequence of training symbols which are known to the receiver and are used for channel estimation. This training sequence is followed by the payload data area. This is transmitted using a second modulation method, based on DMPSK modulation, where M≧4. The payload data end is then followed by a trailer that also ends the data burst.
[0012] FIG. 1 b illustrates in schematic form the tolerance requirements for the frequency offset over the data burst. According to the figure, the maximum error from a nominal carrier frequency F C during the access code is ±75 kHz. This value relates to the initial frequency offset, including any drift that may occur during the time period of the access code. Any drift that occurs after an initial frequency offset and throughout the rest of the data burst should not exceed ±10 kHz.
[0013] The receiver architectures which are known in the prior art, use a frequency offset compensation circuit which is used to set the reference frequency which is emitted from the crystal oscillator, based on an estimated value of the frequency offset. However, this is disadvantageous as additional hardware is required and a relatively long time is required for adjustment of the crystal oscillator.
SUMMARY OF THE INVENTION
[0014] The following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present one or more concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0015] Accordingly, one objective of the present invention is to specify a receiving apparatus for a mobile communications system designed to demodulate received signals which have been modulated using different modulation types, and in which a frequency offset can be estimated and compensated utilizing relatively low complexity while achieving a fast response time.
[0016] In accordance with one embodiment of the present invention a receiving apparatus for a mobile communications system comprises a first receiving section designed to demodulate received signals of a first modulation type, and a second receiving section designed to demodulate received signals of a second modulation type. The first receiving section contains a frequency offset estimation unit, and the second receiving section contains a frequency correction unit to correct the frequency offset. The first receiving section is connected to the second receiving section for the transmission of the estimated frequency offset.
[0017] The invention thus provides the capability for efficient compensation of the frequency offset between the transmitter and the receiver. The frequency offset can be estimated quickly and efficiently based on received signals using the first modulation type, and can then be transferred to the second receiving section, in which the received signals are processed based on the second modulation type. Accordingly, the second modulation type may be based on a modulation method with more values, which is used, for example, to modulate the payload data at the transmitter end.
[0018] The first modulation type may, for example, be a two-value frequency modulation method, and the second modulation type may be a modulation method with a value M≧4.
[0019] The frequency offset estimation unit in the first receiving section is, in one embodiment, designed to estimate the frequency offset by evaluation of a known bit sequence in a frequency-modulated received signal. In a burst transmission method such as Bluetooth or DECT, this bit sequence may be located at a known and fixed position in a data burst. If the structure of a data burst as used in a Bluetooth transmission system based on a Bluetooth Standard higher than 1.1, as is shown in FIG. 1 a , this bit sequence may be part of the access code which is arranged at the start of the data burst. The data burst is formed, for example, by the trailer arranged at the end of the access code and is formed by a bit sequence of “1010” or “0101”. Generally, it is advantageous for a bit sequence to be present which has the same number of 0 bits and 1 bits. If (G)FSK modulation is used as the first modulation type, it is then possible to calculate the average value of the sequence of the demodulated (G)FSK signals, and to use this result to determine the frequency offset.
[0020] In another embodiment of the present invention, the receiving apparatus is designed such that it comprises an analogue receiving section (or analogue front end) whose input is connected to an antenna and has two outputs which are respectively connected to the first receiving section and to the second receiving section. The analogue receiving section contains a mixer that is used to mix the analogue received signal to an intermediate frequency, or directly to baseband. Received signals which are modulated using the first modulation type are thus passed from the analogue receiving section via a first output to the first receiving section, and received signals which are modulated using the second modulation type are passed via a second output to the second receiving section.
[0021] In one embodiment, payload signals are demodulated at the transmitter end using the second modulation type, and are thus passed from the analogue receiving section via its second output to the second receiving section. The payload signals are then supplied as received signals which have been mixed to the intermediate bit frequency or directly to baseband to a first input of the frequency correction unit, and a signal which represents the estimated frequency offset is supplied to its second input. In this case, the frequency correction unit may comprise a digital frequency correction unit, utilizing an analogue/digital (A/D) converter provided in the signal path upstream of the frequency correction unit. The A/D converter may further be supplied with the received signal which has been mixed to an intermediate frequency or directly to baseband. The output of the A/D converter is then connected to one input of the digital frequency correction unit.
[0022] In particular, the digital frequency correction unit may be designed for frequency correction on the basis of the CORDIC algorithm. The CORDIC algorithm allows frequency correction to be carried out relatively easily. The CORDIC algorithm can be carried out with minimal circuit complexity, so that the costs of a circuit based on a low-cost oscillator and CORDIC correction are less than for an oscillator with complex compensation.
[0023] The CORDIC algorithm is described in J. E. Volder, “The CORDIC Trigonometric Computing Technique”, IRE Trans. Electronic Computers, Vol. 8, pp. 330-334, 1959. The algorithm includes N iterations and is used for rotation of a vector through a defined angle α n =arctan(2 −n ), n=0.1, . . . , N−1. If, as described initially, the vector represents the vector of a complex signal, this rotation allows the frequency of the signal to be changed by being multiplied by a frequency correction signal. The rotation angle becomes smaller with each iteration (α 0 =45°>α 1 =26.6°> . . . >α N-1 ) so that the frequency of the signal changes in ever smaller steps as the number of iteration steps increases. Digital frequency correction by means of the CORDIC algorithm is also the subject matter of the document DE 199 48 899 A1, which is hereby included in the disclosure content of the present application.
[0024] If the received signal is mixed to an intermediate frequency in the mixer which is contained in the analogue receiving section, then the received signal which has been mixed to the intermediate frequency can be supplied to the first input of the frequency correction unit. In addition, a signal which represents the sum of the frequency offset and the intermediate frequency can be supplied to its second input. However, when the received signal is mixed to an intermediate frequency, it is also possible to provide for a first frequency correction unit and a second frequency correction unit to be provided in the second receiving section. In this case the received signal which has been mixed to an intermediate frequency is then supplied to a first input of the first frequency correction unit, and a signal which represents the intermediate frequency is supplied to a second input of the first frequency correction unit. The output signal from the first frequency correction unit is supplied directly or indirectly to a first input of the second frequency correction unit, and a signal which represents the frequency offset is supplied to a second input of the first frequency correction unit.
[0025] If the received signal is mixed by the mixer to an intermediate frequency in the analogue section, it is also possible to provide a bandpass filter for the output signal from the mixer, in particular to a polyphase filter. The analogue circuit components which are contained in this bandpass filter are subject to certain tolerances, so that it is possible to connect the bandpass filter to a filter matching unit. This filter matching unit may be connected to a frequency error calculation unit, which uses the information signal transmitted from the filter matching unit to determine any frequency error of the filter curve of the bandpass filter. A first frequency correction unit and a second frequency correction unit can be provided in the second receiving section, such that the received signal which has been mixed to an intermediate frequency is then supplied to a first input of the first frequency correction unit. Further, a signal which represents the sum of the intermediate frequency and the frequency error calculated by the frequency error calculation unit is supplied to a second input of the first frequency correction unit, and a signal which represents the frequency offset is supplied to the second frequency correction unit.
[0026] If there are two frequency correction units, then one or both of them can operate using the CORDIC algorithm. As an alternative to mixing of the received signal to an intermediate frequency, it is, however, also possible to have the mixer which is contained in the analogue receiving section mix the received signal directly to baseband. In this situation, the baseband signal is then supplied to a first input of the frequency correction unit, and a signal which represents the frequency offset is supplied to a second input of the frequency correction unit.
[0027] The mobile communications system may be a communications system which operates on the basis of bursts, such as communications systems which operate in accordance with the Bluetooth or DECT Standard. The receiving apparatus according to the invention is in effect designed for data transmission in bursts. In one example embodiment, the frequency offset estimation unit is then designed to estimate the frequency offset once and only once for the duration of a burst, and the frequency correction unit is designed to carry out the correction on the basis of the frequency offset, which has been supplied from the frequency offset estimation unit, throughout the duration of the burst.
[0028] Thus, in the embodiment described above, the frequency offset is estimated once at the start of a burst, and this estimated value is used as the basis for the frequency correction throughout the remaining duration of the burst. Any drift in the frequency offset which occurs during the burst is in this case initially ignored. However, a further correction unit can be provided for this purpose. In particular, when a phase modulation method is used as the second modulation type, a phase correction unit may be arranged in the signal path downstream from the frequency correction unit in the second receiving section, and may be designed to continuously compensate for drift in the frequency offset, by means of phase correction. Frequency offset drift can be caused either by drift of the carrier frequency of the received signal, by drift of the reference frequency or frequencies supplied to the mixer or to the mixers, or by drift of all of these frequencies.
[0029] In this case, the signal path upstream of the phase correction unit may include a delay demodulator for production of the phase difference values of those sample values which are separated by the time duration of a data symbol. The phase correction unit is then supplied with the successive phase difference values from the delay demodulator. In an M-value DPSK modulation method, the phase is shifted from one data symbol to the next by multiples of (2π)/M or by φ offset +(2π)/M as in an offset DPSK modulation method (for example π/4-DPQSK). The minimum phase shift from one data symbol to the next for an 8-DPSK modulation method is (2π)/8=π/4. It is thus possible to use the phase correction unit to readjust the frequency offset within a range of ±π/8=±22.5°.
[0030] To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects and implementations of the invention. These are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 a is an illustration of the structure of the data burst;
[0032] FIG. 1 b is an illustration of the tolerance requirement for the accuracy of the carrier frequency and the frequency offset over the time period of one data burst;
[0033] FIG. 2 is a schematic block diagram of one exemplary embodiment of a receiving apparatus according to the invention;
[0034] FIG. 3 is a schematic block diagram of a first exemplary embodiment of a second receiving section, which is connected to an analogue receiving section, in the receiving apparatus;
[0035] FIG. 4 is a block diagram of a phase correction unit for compensation for the drift of the frequency offset during a data burst;
[0036] FIG. 5 is a block diagram of a second exemplary embodiment of the second receiving section, which is connected to the analogue receiving section, in the receiving apparatus according to the invention;
[0037] FIG. 6 is a block diagram of a third exemplary embodiment of the second receiving section, which is connected to the analogue receiving section, in the receiving apparatus according to the invention; and
[0038] FIG. 7 is a block diagram of an example of the implementation of an M-DPSK receiving apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention will now be described with reference to the attached drawings, wherein like reference numerals are used to refer to like elements throughout. It should be understood that the description of these aspects are merely illustrative and that they should not be interpreted in a limiting sense. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident to one skilled in the art, however, that the present invention may be practiced without these specific details.
[0040] FIG. 2 illustrates a schematic block diagram of one exemplary embodiment of a receiving apparatus in accordance with the present invention. The receiving apparatus comprises an analogue receiving section 10 (analogue front end), a GFSK receiver section 20 , and an M-DPSK receiver section 30 . In the analogue receiving section 10 , the received signal coming from the antenna is initially supplied to an amplifier 11 (LNA, low noise amplifier). The amplified received signal is supplied from there to a complex mixer 12 , in which the signal is mixed to an intermediate frequency or to baseband in a predetermined manner. This mixing is performed in an in-phase and a quadrature signal path, which are phase-shifted through 90° with respect to one another. The complex signals are then supplied to a polyphase filter 13 . At the output of the polyphase filter 13 the signal path then branches. The signals are supplied either via a limiter 14 to the GFSK receiver section 20 , or via a programmable gain control 15 (PGC) to the M-DPSK receiver section 30 .
[0041] The GFSK-modulated symbols in the data burst are supplied successively in the GFSK receiver section 20 to a demodulation/synchronization unit 21 , a decimation/filtering unit 22 , and a digital demodulator 23 . Real-value signals are input from the digital demodulator 23 into a frequency offset estimator 24 , in which the frequency offset is estimated from the 1010 or 0101 bit sequence of the 4 μs-long trailer of the access code in the data burst.
[0042] The data burst signals, which have been DPSK modulated with M values, are initially supplied to an analogue/digital (A/D) converter 31 in the M-DPSK receiver section 30 . The digitized signals are then passed to a unit 32 in which both digital demodulation as well as frequency offset compensation and phase readjustment are carried out. The signals which have been demodulated in this way are then supplied to a Gray decoder 33 . A clock recovery unit is arranged in the signal path downstream from the Gray decoder 33 , but is not required by the present invention and will therefore not be described in the following text.
[0043] FIG. 3 illustrates a first exemplary embodiment of an M-DPSK receiver section 30 connected to the analogue receiving section 10 . A frequency correction unit 310 is arranged downstream from the A/D converter 31 in the signal path, operates on the basis of the CORDIC algorithm, and is thus also referred to in the following text as a CORDIC mixer 310 . The digitized I and Q signal components are supplied to this CORDIC mixer 310 . The CORDIC mixer 310 is also supplied with a signal which represents the sum of the intermediate frequency f if and the frequency offset f offset , specifically with the term exp(−i·2·π·(f if +f offset )·T s1 )
[0044] The frequency offset f offset is, in the present example, obtained from the frequency offset estimator 24 in the GFSK receiver section 20 . The frequency offset can be determined in the frequency offset estimator 24 by calculation of the average value of the demodulated GFSK signal of the bit sequence 1010 or 0101 in the trailer of the access code. In one embodiment, this may be implemented as a simple digital accumulator, whose output is also scaled, and is supplied to the unit 32 in the M-DPSK receiver section 30 in order to calculate the above term. The variable T s1 is the sample period of the sample values which are supplied to the CORDIC mixer 310 from the A/D converter 31 , which operates at a sampling frequency of f s1 .
[0045] Decimation to a sampling frequency f s2 is carried out in a downstream decimation unit 32 . 1 . After this, the signals are supplied to a group delay time equalizer 32 . 2 , to a matched filter 32 . 3 , and to an interpolation filter 32 . 4 . The interpolation filter 32 . 4 emits interpolated signal values at a frequency f s3 .
[0046] The CORDIC mixer 310 operates, during a data burst, with the value of the frequency offset f offset transmitted to it from the frequency offset estimation unit 24 . The delay demodulator 350 , which is arranged downstream in the signal path, and the phase demapper 360 are also used to compensate for any drift in the frequency offset during the data burst. These are illustrated in greater detail in FIG. 4 .
[0047] Initially in FIG. 4 , the delay demodulator 350 produces phase difference values from sample values which are separated by one symbol period T sym (=T sample ). An angle CORDIC unit 351 is used for this purpose, wherein the complex sample values x(k) are supplied to the input of the CORDIC unit 351 , and wherein the phase values of these sample values are provided at the output of the CORDIC unit 351 . The phase difference values are then produced by means of the delay unit 352 and the adder 353 . The symbol space for an 8-DPSK modulation method is clearly indicated above the signal path between the units 350 and 360 in FIG. 4 .
[0048] Generally, in the M-DPSK modulation method, the phase rotates from one data symbol to the next by multiples of (2π)/M or by φ offset +(2π)/M(Offset−DPSK). The minimum phase shift from one symbol to the next for an 8-DPSK modulation method is (2π)/8=π/4. It is thus possible to use the phase difference correction unit or the phase demapper 360 to carryout readjustment within a range ±π/8=±22.5°. The phase difference correction unit 360 for this purpose has a modulo unit 362 , by means of which a modulo (2π/M) operation is carried out. The value 2π/(M+1) is subtracted from the remainder of the modulo operation in an adder 363 downstream. The output of the adder 363 is supplied to a time-discrete filter 364 whose transfer function is H(z) and the output value from the filter 364 is subtracted in an adder 361 from a subsequent phase difference value. The corrected phase difference values emitted from the phase demapper 360 are then also supplied to a Gray decoder 33 .
[0049] FIG. 5 illustrates a second exemplary embodiment of an M-DPSK receiving section 30 which is connected to the analogue receiving section 10 . FIG. 5 is similar in context to that of FIG. 3 , and as such may not be completely described again for the sake of brevity. Accordingly, similar reference symbols have been used for assemblies having similar functions. In contrast to FIG. 3 , two CORDIC mixers 320 and 330 may be used. The first CORDIC mixer 320 performs a digital multiplication operation by the intermediate frequency f if . As a result, the first CORDIC mixer 320 is supplied with a signal which represents the intermediate frequency f if , that is to say with the term exp(−i·π·f if ·T s1 ). The second CORDIC mixer 330 accomplishes a digital multiplication operation by the frequency offset f offset . Thus, the second CORDIC mixer 330 is supplied with a signal which represents the frequency offset f offset , that is to say with the term exp(−i·2·π·f offset ·T s2 ), where T s2 is the sample period of the signal values based on the decimation to the frequency f s2 .
[0050] FIG. 6 illustrates a third exemplary embodiment of an M-DPSK receiving section 30 which is connected to the analogue receiving section 10 . FIG. 6 is similar to that of FIG. 5 , and as such may not be completely described again for the sake of brevity. Accordingly, similar assemblies having the same function have been provided with the same reference symbols. The M-DPSK receiving section 30 in FIG. 6 also has two CORDIC mixers, wherein the second CORDIC mixer 330 may perform a digital multiplication operation by the frequency offset f offset , in the same way as in the exemplary embodiment shown in FIG. 5 .
[0051] In contrast to the embodiment shown in FIG. 5 , the first CORDIC mixer 340 of FIG. 6 performs a digital multiplication operation by a frequency which is the sum frequency of the intermediate frequency and a calculated frequency error f dev from the polyphase filter 13 . The polyphase filter 13 must be regularly adjusted because of tolerances in its analogue circuit components. This process is carried out by a filter adjustment unit 16 , which is arranged in the analogue receiving section 10 . The adjustment process can be carried out by a gate-controlled measurement of an RC time constant. The RC time constant is matched to the resistors and capacitors used in the active operational amplifiers.
[0052] The measurement is carried out by starting a counter, which is gate-controlled by the RC time constant. The output of the counter is connected to switch selectable resistors or capacitors in the operational amplifiers. The error between the count and a nominal count is used as a measure of the frequency shift of the filter curve. The count cv(f dev ) is supplied to a frequency error calculation unit 32 . 6 , which is contained in the M-DPSK receiving section 30 , for scaling the count and determining the frequency error. The output from this scaling unit is supplied to the CORDIC mixer 340 , in which the term exp(−i·π·(f if +f dev ) T s1 ) is calculated, using the intermediate frequency f if , as a result of which the CORDIC mixer 340 down-mixes the signal to baseband.
[0053] FIG. 7 illustrates one exemplary embodiment of a receiver architecture for a Bluetooth receiving system. The A/D converters 31 . 1 and 31 . 2 for the I and Q signal components operate at a sampling rate of 8 MHz, and with a word length of 7 bits for the amplitude quantization. The sampling rate is reduced by a factor of four to 2 MHz, which corresponds to twice the symbol frequency of 1 Msymbol/s, in the decimation unit 32 . 1 . After group delay time equalization, which is carried out in the equalizer 32 . 2 , and the filtering which is carried out in the matched filter 32 . 3 , the signal is interpolated by the factor 6 . 5 in the interpolation filter 32 . 4 to produce 13 Msamples/s. The reason for this interpolation by the factor 6 . 5 is that the sample phase detection unit is in one embodiment a correlator which is operated at 13 times the bit rate (1 MHz).
[0054] While the invention has been illustrated and described with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In particular regard to the various functions performed by the above described components or structures (assemblies, devices, circuits, systems, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component or structure which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising”. In addition, the term “exemplary” as utilized herein merely means an example, rather than the best.
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The present invention relates to a receiving apparatus for a mobile communications system which can be modulated using different modulation types at the transmitter end. According to one embodiment of the invention, in the middle of a data burst of a Bluetooth communications system, a GFSK modulation method is switched to an M-DPSK modulation method, which is used for the payload data. A frequency offset estimation unit is provided for GFSK-modulated signals in a first receiving section and estimates the frequency offset by averaging over a bit sequence of a trailer of a data burst. The frequency offset is corrected in a second receiving section, by means of a frequency correction unit which operates on the basis of the CORDIC algorithm.
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FIELD OF THE INVENTION
[0001] This present invention relates to pharmaceutical compositions comprising fixed dose combinations of capecitabine and cyclophosphamide, processes for the preparation thereof, and their use to treat cancer diseases.
BACKGROUND OF THE INVENTION
[0002] Among potential active cytotoxic drugs, capecitabine is the most commonly-used agent. Capecitabine has been approved by the Food and Drug Administration in the treatment of Metastatic breast cancer (METASTATIC BREAST CANCER) patients resistant to anthracyclines and/or taxanes. Capecitabine widely used in different combination regimen due to better therapeutic & safety profile with lower side effects. In addition, the combination partner of capecitabine play important role for the activation of thymidine phosphorylase (TP) enzyme, which convert the capecitabine to active 5-FU.
[0003] Cyclophosphamide is an anti-cancer chemotherapy drug. This medication is classified as an alkylating agent. Cyclophosphamide is a prodrug, converted in the liver to active forms that have slow down the growth of cancer cells. Cyclophosphamide requires enzymatic and chemical activation to produces active form. Cyclophosphamide is used alone or in combination with other drugs to treat various cancers like METASTATIC BREAST CANCER, ovarian cancer, leukemia. When given by orally, cyclophosphamide shows superior efficacy than when it is given intravenously.
[0004] Further interest in oral agents for the treatment of METASTATIC BREAST CANCER has increased because many patients prefer oral to intravenous regimens due to administered at home, no need to hospitalization, fear of needles, and lower associated costs. The combination of capecitabine and cyclophosphamide in present invention potentially provides an attractive, all oral alternative, giving patients more freedom and a sense of control over their treatment.
[0005] With increasing experience of capecitabine after its introduction, many clinicians found that oral administration of cyclophosphamide and capecitabine may have a greater potential for treatment of METASTATIC BREAST CANCER due to anti-angiogenesis resulting from the metronomic dosage and upregulation of thymidine phosphorylase by capecitabine. In particular, a marked reduction in the tumor volume was seen during the time period coincident with the dThdPase up-regulation. In addition several clinical studies show that the efficacy of cyclophosphamide in combination with capecitabine was more than just additive to synergistic effects.
[0006] In view of above, there is still an existing and continual need for a fixed dose oral combination comprising capecitabine and cyclophosphamide. The inventors of the present invention address the need to provide a fixed dose combination of capecitabine and cyclophosphamide to allow convenient administration of both the drugs as a single tablet and to effective treatment with good acceptability at lower dose.
[0007] Inventors of the present invention investigated the development of pharmaceutical composition for oral administration. However, a stable pharmaceutical composition was not obtained due to incompatibility between the two therapeutic agents, specifically total impurity levels were found to be increased drastically.
[0008] To overcome the issue related to incompatibilities of both therapeutic agents & pharmaceutical excipients, the inventors have provided herewith a novel stable pharmaceutical composition which can be formulated for oral administration.
[0009] Furthermore the present invention provide the advantages of combination therapy while reducing the number of prescriptions, number of tablets to be taken which results in better patient compliance and attendant administrative costs. Combination therapies with agents having complementary mechanisms of action may provide advantages of each type of agent and reduce some of the adverse effects of high-dose of individual drugs.
OBJECTS OF THE INVENTION
[0010] The object of the present invention is to provide a pharmaceutical composition comprising fixed dose combination of capecitabine and cyclophosphamide.
[0011] Another object of the present invention is to provide a pharmaceutical composition comprising fixed dose combination of capecitabine and cyclophosphamide in a solid dosage form for oral administration.
[0012] Another object of the present invention is to provide a pharmaceutical composition comprising fixed dose combination in the form of bilayer tablet.
[0013] Another object of the present invention to provide a pharmaceutical composition comprising a first layer & second layer, wherein the first layer comprises capecitabine and one or more excipients, and the second layer comprises cyclophosphamide and one or more excipients.
[0014] Another object of the present invention to provide a bilayer tablet comprising a first layer & second layer, wherein the first layer comprises capecitabine and one or more excipients, optionally a film coating that covers both layer.
[0015] In yet another object of the invention is to provide a process for the preparation of pharmaceutical composition comprising a first layer & second layer, wherein the first layer comprises capecitabine and one or more excipients, and the second layer comprises cyclophosphamide and one or more excipients.
SUMMARY OF THE INVENTION
[0016] The present invention relates to pharmaceutical compositions comprising fixed dose combinations of capecitabine and cyclophosphamide preferably in solid dosage form for oral administration, processes for the preparation thereof, and their use to treat cancer diseases. Further the combination of capecitabine and cyclophosphamide is an effective, convenient and well-tolerated regimen for Metastatic Breast Cancer.
DETAILED DESCRIPTION
[0017] Unless otherwise indicated, terms in this specification are intended to have their ordinary meaning in the relevant art.
[0018] The present invention relates to a fixed dose combination comprising capecitabine and cyclophosphamide in the form of bilayer tablet. Oral combination of capecitabine and cyclophosphamide are conventional drugs for the treatment and are an effective and well-tolerated regimen for Metastatic Breast Cancer.
[0019] According to present invention the pharmaceutical composition comprising fixed dose combination present in solid dosage form, particularly in oral form. The solid dosage can be bilayer tablet, multilayer tablet, film-coated tablet, preferably bilayer tablet.
[0020] According to one of the embodiments, a fixed dose combination according to present invention provide a pharmaceutically bilayer tablet composition comprising a first layer & second layer, wherein the first layer comprises capecitabine and one or more excipients, and the second layer comprises cyclophosphamide and one or more excipients.
[0021] Preferably, the present invention to provide a bilayer tablet comprising a first layer & second layer, wherein the first layer comprises capecitabine and one or more excipients, and optionally a film coating that covers both layer.
[0022] In general, excipients which may be used may typically be selected from the group consisting of one or more diluents or fillers, one or more binders, one or more glidants, one or more disintegrants, one or more lubricants, and the like. The amount of each excipient in a solid dosage formulation may vary within ranges conventional in the art.
[0023] The pharmaceutical composition described herein may be prepared by conventional technology well known to those skilled in the art such as wet granulation, dry granulation and direct compression and the like.
[0024] More preferably in the present invention, the first layer comprising capecitabine can be prepared by wet granulation as hereinafter described whilst the second layer comprising cyclophosphamide can be prepared by blending the excipients for direct compression.
[0025] Alternatively second layer comprising cyclophosphamide can be prepared by wet granulation. Both the layers can then be combined and compressed together as herein after described. Furthermore, the bilayer tablet dosage form may comprise a film coating. Suitable film coating is known and commercially available or can be made according to known methods.
[0026] According to present invention the film coating material is a polymeric film coating material comprising hydroxypropylmethyl cellulose, polyethylene glycol, polysorbate, sodium carboxy methyl cellulose, Talc, Titanium dioxide, simethicon, Eudragit, purified water and colorant.
[0027] According to one of the embodiments, a bilayer tablet according to present invention generally contains 50-1800 mg, preferably 100-1500 mg, more preferably 300-800 mg capecitabine; and 10-100 mg, preferably 20-80 mg. more preferably 20-60mg cyclophosphamide. Presently preferred forms are bilayer tablet comprising 300/20 mg, 400/20 mg, 600/40 and 700/30 mg of capecitabine and cyclophosphamide respectively.
[0028] According to one of the embodiments, the first tablet layer according to present invention comprises capecitabine as active agent and one or more excipients. Capecitabine containing first layer of the invention is prepared by wet granulation. Alternative method for granulation of the active ingredient and excipients with a granulation liquid are fluid bed granulation or top spray granulation.
[0029] In the wet granulation process the granulating liquid is a solvent such as purified water, ethanol, isopropanol, acetone or mixture thereof, preferably purified water. The solvent is a volatile component, which does not remain in the final product.
[0030] Excipients of the first layer may be particularly selected from the group consisting of one or more fillers, one or more binders, one or more disintegrants, and one or more lubricants.
[0031] According to present invention a bilayer tablet comprising first layer is prepared by wet granulation comprising following steps:
a) sifting of capecitabine, one or more filler, one or more disintegrant through appropriate mesh and mixing in a suitable mixer, b) dissolving a binder in a solvent to produce a granulation liquid, c) carrying out fluid bed granulation using the granulating liquid of step (b) for spraying onto the mixture of step (a), d) after completion of the granulation drying and optionally screening the granulate obtained in step (c), e) optionally blending the granulate obtained in step (d) with additional excipients; and f) lubricating the blended granules obtained in step (e) to prepare the final composition of first layer.
[0038] Alternatively, binder can be added with the blend obtained in step (a) & further granulation is done with suitable solvent which would act as a granulation liquid.
[0039] Examples of filler for first layer include, without being limited to microcrystalline cellulose, mannitol, sucrose or other sugar or sugar derivatives, low substituted HPC, dicalcium phosphate, lactose and combination thereof.
[0040] Examples of binder for first layer include, without being limited to polyvinylpyrrolidone, hydroxypropyl methylcellulose, hydroxypropyl cellulose, pregelatinized starch, maize starch, microcrystalline cellulose (e.g., cellulose MK GR), and combinations thereof.
[0041] Examples of disintegrant for first layer include, without being limited to croscarmelose sodium, crospovidone, sodium starch glycolate, starch, pregelatinized starch and combination thereof
[0042] Examples of lubricant for first layer include, without being limited to magnesium stearate, calcium stearate, aluminum or calcium silicate, stearic acid, talc and combinations thereof.
[0043] The second tablet layer according to present invention comprises cyclophosphamide as active agent and one or more excipients.
[0044] According to one of the embodiments, the second layer comprising cyclophosphamide having D90 particle size less than 300 microns, more preferably 100 microns.
[0045] According to present invention bilayer tablet comprising second layer is prepared by direct compression comprising following steps:
a) mixing the cyclophosphamide with one or more filler, one or more binder, one or more disintegrant in a suitable mixer b) adding one or more lubricant in mixture obtained in step (a) and blending them until obtaining a homogenous powder mixture; and c) compressing the final powder mixture to form final composition of second layer.
[0049] According to present invention bilayer tablet comprising second layer can also be prepared by wet granulation comprising following steps:
(a) Co-sift one or more pharmaceutically acceptable excipients and prepare a mixture, (b) granulate the above mixture by using solvent, (c) dry the above granulate and milling the dried granules, (d) prepare the drug mixture separately by co-sift cyclophosphamide and one or more pharmaceutically acceptable excipients. (e) Blend the granules obtained in step (c) and drug mixture of step (d), (f) Lubricate the blended mixture obtained in step (e) to form final blend for second layer.
[0056] Excipients of the second layer may be particularly selected from the group consisting of one or more fillers, one or more binders, one or more disintegrants, and one or more lubricants.
[0057] Examples of filler for second layer include, without being limited to dibasic calcium phosphate anhydrous, microcrystalline cellulose, lactose, mannitol, sucrose or other sugar or sugar derivatives, low substituted HPC, pregelatinized starch, and combination thereof.
[0058] Examples of binder for second layer include, without being limited to polyvinylpyrrolidone, povidone, copovidone, hydroxypropyl (methylcellulose, hydroxypropyl cellulose, pregelatinized starch, maize starch, microcrystalline cellulose (e.g., cellulose MK GR), and combinations thereof.
[0059] Examples of disintegrant for second layer include, without being limited to croscarmelose sodium, crospovidone, sodium starch glycolate, starch, pregelatinized starch and combination thereof.
[0060] Examples of lubricant for second layer include, without being limited to magnesium stearate, calcium stearate, aluminum or calcium silicate, stearic acid, talc and combinations thereof.
[0061] For preparing a bilayer tablet according to present invention, the first & second tablet layer prepared as described hereinabove may be compressed in the usual manner in a bilayer tablet press.
[0062] Another preferred aspect of the present invention also includes an optional film coating on the bilayer tablet. The details regarding the film coating material, component are as described herein above.
[0063] According to present invention capecitabine & cyclophosphamide are physically incompatible substances. When both the drugs were kept on 40° C. (open) for 1 month, different type of impurities related with cyclophosphamide are obtained during preformulation studies. The % impurities related with cyclophosphamide are obtained during the preformulation studies are as below.
[0000]
TABLE 1
Pre-formulation studies related to combination of Capecitabine +
cyclophosphamide
Time
Impurity
Impurity
Impurity
Impurity
Total
Sample
period
A*
B*
C*
D*
Impurity
Capecitabine +
Initial
ND
ND
ND
0.053%
0.234%
Cyclophosphamide
1 month
ND
ND
0.296%
13.758%
16.992%
[Capecitabine +
Initial
ND
ND
ND
0.033%
0.865%
Cyclophosphamide] +
1 month
ND
ND
0.235%
12.407%
14.499%
MCC PH101
[Capecitabine +
Initial
ND
ND
ND
0.025%
0.204%
Cyclophosphamide] +
1 month
ND
ND
0.113%
8.178%
10.146%
Lactose
[Capecitabine +
Initial
ND
ND
ND
0.575%
1.010%
Cyclophosphamide] +
1 month
ND
ND
0.086%
5.014%
5.893%
Croscarmellose
Sodium
[Capecitabine +
Initial
ND
ND
ND
0.022%
0.192%
Cyclophosphamide] +
1 month
ND
ND
0.091%
6.658%
8.220%
Magnesium
Stearate
*Impurity A of cyclophosphamide is chemically 3-[3-(2-chloroethylamino) ethyl amino] propyl dihydrogen phosphate.
*Impurity B of cyclophosphamide is 3-aminopropyl dihydrogen phosphate.
*Impurity C of cyclophosphamide is 3-3 chloroethyl-2-oxo-2-hydroxy-1,3,6,2 oxadiazaphosphonane.
*Impurity D of cyclophosphamide is Bis (2-chloroethyl)amine hydrochloride.
[0064] Acceptable limits of the above said impurities of cyclophosphamide according to the present invention are individually not more than 0.5% w/w and the total impurity of cyclophosphamide should not be more than 3% w/w, when determined after one month when kept at 40° C.
[0065] Accordingly, the pre-formulation studies for combination of capecitabine and cyclophosphamide does not comply with the above said acceptable limits Further the present invention provides a pharmaceutical composition comprising fixed dose combination of capecitabine and cyclophosphamide thereof have a greater potential for treatment of metastatic breast cancer.
[0066] In addition, the present invention provides a better therapeutic efficacy by combined administered of capecitabine and cyclophosphamide rather than when used separately.
EXAMPLES
[0067] The present invention has been described by way of example only. It is to be recognized that modifications falling within the scope and spirit of the claims, which would be obvious to a person skilled in the art based upon the disclosure herein, are also considered to be included within the scope of this invention. The scope of the invention is in no manner limited by the disclosed example.
Example 1 and 2
[0068]
[0000]
Example 1
Example 2
Ingredients
Mg/tab
Mg/Tab
Capecitabine
300.0
600.0
Microcrystalline Cellulose (Avicel PH 112)
57.0
114.0
Croscarmellose Sodium
16.0
32.0
HPMC E-5
15.0
30.0
Purified Water
q.s.
q.s.
Croscarmellose Sodium
4.0
8.0
Magnesium Stearate
8.0
16.0
Total of Layer I
400.00
800.00
Cyclophosphamide
21.40
42.80
Microcrystalline Cellulose (Avicel PH 112)
133.80
267.60
Povidone K-90
3.40
6.80
Croscarmellose Sodium
8.00
16.00
Magnesium Stearate
3.40
6.80
Total Layer II
170.0
340.0
Total Core Tablet weight
570.00
1140.00
Polyethylene glycol 4000
1.96
3.92
Polysorbate 80
0.40
0.80
Sodium carboxymethylcellulose
0.32
0.64
Talc
3.09
6.18
Titanium Dioxide
3.09
6.18
Eudragit NE30D
2.94
5.88
Ferric oxide Red
0.1
0.2
Ferric oxide yellow
0.1
0.2
Purified water
q.s.
q.s.
Total coated tablet weight
582.00
1164.00
Brief Manufacturing Process of Example 1 and 2
Preparation of Capecitabine Layer:
[0069] 1 . Sift capecitabine, microcrystalline cellulose (Avicel PH112), croscarmellose sodium, through ASTM 20# sieve.
[0070] 2. Place materials of step 1 in fluid bed energizer and dry mix for 5 min at 50° C.
[0071] 3. Dissolve hypromellose E5 in Purified Water using stirrer.
[0072] 4. Granulate materials in fluid bed energizer using binder solution of step 3.
[0073] 5. Dry the granules in fluid bed energizer at 55° C.
[0074] 6. Pass the dried granules through ASTM 20# sieve.
[0075] 7. Sift croscarmellose sodium through ASTM 20# sieve and mix with granules of step 6 in blender for 10 mins at 25 RPM.
[0076] 8. Sift magnesium stearate through ASTM 40# sieve and mix with blend of step 7 for 3 mins.
Preparation of Cyclophosphamide Layer:
[0077] 9. Separately, sift cyclophosphamide, microcrystalline cellulose (Avicel PH 112), povidone k-90 and croscarmellose sodium, through ASTM 20# sieve. Mix it in blender for 10 mins at 25 RPM.
[0078] 10. Sift magnesium stearate through 40# sieve and mix with blend of step 9 for 3 mins at 25 RPM.
Compression of Bilayer Tablet
[0079] 11. Bilayer tablets were compressed using blend of step 8 and blend of step 10 using rotary tablet compression machine.
[0080] 12. Tablets were coated using coating solution containing polyethylene glycol 6000, polysorbate 80, sodiumcarboxymethyl cellulose, talc, titanium dioxide, eudragit NE30D, ferric oxide red, ferric oxide yellow and purified water.
[0081] 13. Pack the film coated tablets in suitable pack using packaging machine.
Example 3 and 4
[0082]
[0000]
Example 3
Example 4
Ingredients
(mg/tab)
(mg/tab)
Capecitabine
400.0
700.0
Microcrystalline Cellulose (Avicel PH 101)
33.27
58.22
Lactose anhydrous
38.43
60.72
Croscarmellose Sodium (Ac-di-sol)
13.25
23.19
HPMC E-5
18.55
32.46
Purified Water
q.s.
q.s.
Croscarmellose Sodium (Ac-di-sol)
13.25
23.19
Colloidal silicon dioxide (Aerosil-200)
2.65
4.64
Magnesium Stearate
10.60
18.55
Total of Layer I
530.00
930.00
Microcrystalline cellulose (Avicel PH 101)
62.550
93.83
Dibasic calcium phosphate, dihydrate (milled)
38.400
57.60
Pregelatinized starch (Starch 1500)
21.000
31.50
Povidone K-90
3.40
5.10
Purified water
q.s.
q.s.
Cyclophosphamide
24.40
32.1
Pregelatinized starch (Starch 1500)
4.60
6.90
Croscarmellose Sodium (Ac-di-sol)
10.00
15.00
Talc
3.40
5.10
Colloidal anhydrous silica-E
1.70
2.55
Magnesium Stearate
3.40
5.10
Ferric oxide yellow
0.150
0.23
Total Layer II
170.0
255.0
Total Core Tablet weight
700.00
1185.00
Polyethylene glycol 4000
2.39
4.78
Polysorbate 80
0.49
0.98
Sodium carboxymethylcellulose
0.39
0.78
Talc
4.74
9.48
Titanium Dioxide
4.74
9.48
Eudragit NE30D
2.152
4.30
Ferric oxide yellow
0.09
0.18
Ferric oxide Red
0.004
0.01
Purified water
q.s.
q.s.
Total coated tablet weight
715.00
1215.00
Brief Manufacturing Process of Example 3 and 4
Preparation of Capecitabine Layer:
[0083] Process for the preparation of capecitabine layer was similar as per example 1 and 2.
Preparation of Cyclophosphamide Layer:
[0084] 9. Co-sift microcrystalline cellulose, Dibasic calcium phosphate dehydrate,
[0085] Pregclatinized starch and Povidone K-90 through 30#ASTM sieve.
[0086] 10. Dry mix and granulate the blend of step 9 using Purified water. Dry the granules at 60° C. Mill the granules through co mill.
[0087] 11. Separately, co-sift cyclophosphamide, pregelatinized starch (Starch 1500) and croscarmellose sodium through 40# ASTM sieve.
[0088] 12. Co-sift talc and colloidal anhydrous silica-E through 40#ASTM sieve. Ferric oxide yellow was sifted through 80# ASTM sieve.
[0089] 13. Blend the granules of step 10, 11 and 12 in blender.
[0090] 14. Sift magnesium stearate through 40# sieve and mix with blend of step 13.
[0000] Compression & Film coating of Bilayer Tablet
[0091] Process for preparation of film coating is similar as example 1 and 2.
In-vitro Dissolution Profile
[0092] The bilayer tablet of fixed dose combination of capecitabine and cyclophosphamide prepared as per the composition of Example 1 to example 4 were subjected to dissolution studies in 900 ml of phosphate buffer pH 6.8 at 37±0.5° C. using basket apparatus with rotational speed at 100 rpm.
[0093] Table 2 provides dissolution profile of tablets prepared according example 1 to example 4.
[0000]
Time
% Drug Release
(Min)
Example 1
Example 2
Example 3
Example 4
5
7
6
10
09
10
24
15
38
23
15
45
26
52
40
20
69
40
81
63
30
94
73
99
91
45
100
93
103
101
60
100
97
103
103
[0094] The above dissolution study data comply with the dissolution testing requirements of immediate release solid oral dosage forms.
Stability Study
[0095] The study of cyclophosphamide impurities A, B, C, and D profile of example 1 to 4 were carried out at 30° C./65% RH for 1 month.
[0096] The impurity profile results obtained are as below:
[0000]
Time
Total
period
Impurity A
Impurity B
Impurity C
Impurity D
Impurity
Example 1
Initial
ND
ND
ND
ND
ND
1 months
ND
ND
ND
ND
0.023
Example 2
Initial
ND
ND
ND
ND
ND
1 months
0.033%
ND
ND
0.045%
0.078%
Example 3
Initial
ND
ND
ND
ND
0.085%
1 months
ND
0.072%
ND
0.075%
0.308%
Example 4
Initial
ND
ND
ND
ND
0.106%
1 months
ND
0.058%
ND
0.025%
0.241%
[0097] Impurity profile of the pharmaceutical compositions according to examples 1 to 4 meets the acceptance criteria of individual and total impurities of cyclophosphamide as disclosed hereinabove.
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A pharmaceutical compositions having fixed dose combinations of capecitabine and cyclophosphamide, processes for the preparation thereof, and their use to treat cancer diseases.
| 0
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RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/555,723, filed Nov. 7, 2005, entitled “Method and Device for Breaking Separation of Bearing Caps”, which is a 35 U.S.C. §371 filing of International Application Number PCT/EP2004/002622 which was filed Mar. 12, 2004, which claims priority to German Application 103 20 372.9, filed May 7, 2003 in Germany. The contents of the applications are hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates to a method and device for the breaking or fracture separation of at least one bearing cap from a corresponding thrust block in the bearing assembly of engine cases provided with bearing bores which are arranged in-line, in particular crankshaft cases for reciprocating piston engines.
BACKGROUND
The known types of method and device usually involve the introduction of an extension mandrel comprising two half-mandrels into one or more bearing bores and the fracture separation force for separating the bearing cap from the thrust block is produced by spreading the two half-mandrels apart in a force-actuated manner.
This spreading-apart process is usually brought about by mechanically or hydraulically driving a separating wedge (cf. for example U.S. Pat. No. 4,684,267 or FIG. 1 of DE 44 13 255) or by positioning a hydraulically impacted expander between the half-mandrels. In addition, expanders in the form of knuckle joint assemblies are used (cf. for example DE 199 18 067).
It is also known to clamp the thrust block securely to a stationary support and to “sever” the bearing cap in a controlled manner by introducing a tensile force (cf. FIG. 2 of DE 44 13 255). For this purpose, a tie-rod half is placed within the bearing bore in the area of the bearing cap and this half-tie rod is attached, at both sides of the bearing cap, to tensioning tabs which are connected to a hydraulic pulling means that produces the tensile force needed to “sever” the bearing cap.
As a rule, breaking or fracture separation entails the problem of so-called bending strain. Such deformation phenomena are due to the fact that, during the breaking separation process, the fracture cannot be realized absolutely synchronously across the entire breaking separation face. On the contrary, the fracture begins at a point on the breaking separation face and propagates across the entire breaking separation face with a time delay (in the millisecond range). The already detached part bends up with respect to the part not yet separated, thus causing the breaking separation faces to be no longer fitted precisely together after the fracture has occurred. This effect arises particularly noticeably whenever bearing bores or bearing sleeves, the breaking separation face of which is formed by two spaced-apart surface portions, undergo fracture separation. Workpieces that exhibit these deformation phenomena do not comply with quality-related demands specified in bearing or engine construction and are consequently useless.
The prior art counters this type of bending strain in that the parts to be separated are flexibly pressed together at a specific pre-tension. This pre-tension must, however, be overcome during the breaking separation process, because it counteracts the force of fracture separation. To reduce bending strain to an economically viable degree whenever bearing assemblies undergo fracture separation, it will be necessary in practice to operate at relatively high pre-tensions and consequently with very high fracture-separation forces, too.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a method and device for the breaking separation of bearing assemblies that permit the fracture face to exhibit enhanced properties.
This object is solved in accordance with the invention by a method and device for the breaking separation of bearing assemblies comprising the features of independent claims 1 and 2 . Advantageous extensions are described in the dependent claims.
The present invention is based on the idea of improving the properties of fracture faces during breaking separation in that the bending strains that arise during fracture separation are reduced as far as possible. For this purpose, a completely novel approach is chosen by the invention while retaining the tried-and-tested extension mandrel system that comprises two half-mandrels which can be moved apart. Instead of fixing the corresponding bearing cap by way of a pre-tension, the fixing procedure is performed by a special clamping system. In accordance with the invention, the bearing cap is therefore secured against rotation, but is clamped in a manner that offers a limited degree of free movement—in the direction of breaking separation—between the corresponding half-mandrel and a fixing means.
In principle, this clamping system consists of the half-mandrel that corresponds to the bearing cap, and a fixing means, between which the bearing cap is fixed in a non-movable manner. The crux of the invention lies in the fact that this unit, consisting of the half-mandrel, bearing cap and fixing means, is supported in such a way that although the bearing cap cannot rotate, it can move freely to a limited degree in the direction of breaking separation. This makes it superfluous to use pre-tensions that have to be overcome by the respective breaking separation force. As a result, it is possible to work using relatively low breaking separation forces, which enables the device according to the invention to have a simple and relatively lightweight structural design.
Devices that operate on the basis of the principle described above can as a rule be designed in a very wide variety of ways. Nonetheless, a device that has a particularly simple structure in technical terms, yet which permits reliable and effective clamping, is obtained as a result of the fact that at least two gripping means that can be coupled, on both sides of the corresponding bearing cap, to a half-mandrel corresponding to the bearing cap are provided, and the corresponding bearing cap can be clamped, via a fixing means securely connected to the gripping means, between the corresponding half-mandrel and the fixing means in such a way that a unit consisting of the corresponding half-mandrel with the gripping means as well as the fixing means and the clamped bearing cap is freely movable to a limited degree in the direction of fracture separation, though this unit is supported in a manner secured against rotation. As a result, the corresponding bearing cap is prevented from rotating with respect to the thrust block during fracture separation, thereby largely ruling out bending strain.
In this way, the above-described disadvantages encountered in the prior art can be eliminated and the properties of the fracture surface can be enhanced considerably. It is particularly beneficial for the device according to the invention not to apply any external forces, which counteract the breaking separation process, to those components which are to be separated. This means that those fracture forces which are to be applied are slight, thus facilitating the breaking process and thereby making it even easier to design the device structure.
In principle, the gripping means can be formed and coupled to the corresponding half-mandrel in an arbitrary fashion. It is, however, an advantage for the extension mandrel, especially the corresponding half-mandrel, to comprise at least one recess that is adapted to the gripping means or for it to comprise at least one projection, with which the gripping means engage. This is a simple way of producing a reliable form-fit that helps to ensure the desired, rotationally secured arrangement of bearings.
Particularly in the case of rigid gripping means, an extension of the present invention makes it preferable to provide the corresponding half-mandrel with tangentially extending insertion slots on its periphery at mutually facing sides; these insertion slots can be used to slide the corresponding gripping means over the half-mandrel. Particular preference is given to placing the insertion slots in communication with the at least one recess so that the gripping means can engage rapidly and reliably with the at least one recess via the insertion slots.
In the case of such a structural design, it is an advantage for the at least one recess to be arranged axially adjacent to the insertion slots and for this recess to merge directly into these slots. In such a structural design, the gripping means can slide, through the insertion slots, over the corresponding half-mandrel and the act of coupling can be achieved by simply sliding the half-mandrel in an axial direction. The movement in an axial direction does in fact enable the gripping means to engage with the recesses disposed axially adjacent to the insertion slots, thus causing the gripping means to interlock positively with the corresponding half-mandrel.
A configuration that is particularly simple in technical terms and which exhibits static rigidity is obtained when the gripping means are formed by pincers which preferably each comprise fixed jaws, i.e. jaws which do not move against one another and which, in the region of their ends, have engagement members that face towards one another and which engage with the at least one recess in the corresponding half-mandrel.
The fixing means, too, may be designed in a very wide variety of ways. An especially simple and effective layout is obtained when the fixing means has at least one force-actuated detent. This approach enables the fixing means to be tensioned reliably with the bearing cap that is to be separated and with the corresponding half-mandrel. Preference is given to providing at least two spaced-apart detents ( 32 , 34 ) that act in a particularly preferred manner upon the bearing cap at that side which is opposite the corresponding half-mandrel. This approach produces a unit that is in itself tensioned and consists of the fixing means, bearing cap that is to be separated and the corresponding half-mandrel, without forces that impede subsequent fracture separation from being introduced into the bearing assembly as a result of tensioning. At the same time, the detents can be realized in a simple and economically viable manner, for example by means of hydraulic cylinders or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic perspective view of an illustrative embodiment of the breaking separation device in accordance with the invention;
FIGS. 2 to 6 each schematically show individual steps of an illustrative embodiment of the breaking separation method in accordance with the invention, which method makes use of the device shown in FIG. 1 .
DETAILED DESCRIPTION
Illustrative embodiments of the present invention will now be described in detail with reference to FIGS. 1 to 6 . Identical reference numbers in the drawings each designate identical components.
FIG. 1 depicts schematically a perspective view of one embodiment of a device 1 for breaking separation in accordance with the present invention. As can be identified in FIG. 1 , the device 1 in the present embodiment is used to machine, in a breaking separation manner, a crankshaft case 6 , as used for example in combustion engines. The crankshaft case 6 has a series of bearing bores 8 that are arranged in-line and which are each enclosed by a thrust block 4 and a bearing cap 2 that are intended to be separated from one another by means of breaking separation. During the breaking separation process, the crankshaft case 6 can be supported in a suitable manner. It must be borne in mind, however, that the present invention is not limited to the illustrated application, but may also be applied to other bearing assemblies or the like.
To begin with, the breaking separation device shown in FIG. 1 comprises an extension mandrel 10 that has two half-mandrels 12 , 14 and can be inserted into at least one of the in-line bearing bores 8 . An expander 16 for moving the half-mandrels 12 , 14 apart is interposed between the half-mandrels 12 , 14 . The expander 16 may, for example, be formed by a wedge or a hydraulic means that is capable of applying sufficient expansion force to the half-mandrels 12 , 14 .
The breaking separation device 1 also comprises two gripping means in the form of pincers 18 , 20 that can be coupled, at both sides of the corresponding bearing cap 2 , to the half-mandrel 12 that corresponds to the bearing cap 2 . The pincers 18 are securely connected to a fixing means 22 that is freely movable to a limited degree, but which is supported in a manner that is secured against rotation, in the direction of breaking separation, that is to say in a direction essentially perpendicular to the axis of the bearing bores 8 . Such a manner of support can be realized, for example, as a kind of sliding sleeve or the like.
In the present embodiment, the half-mandrel 14 , which faces away from the corresponding bearing cap 2 , has two recesses 24 so that the half-mandrel 12 , which faces towards the corresponding bearing cap 2 , protrudes like a projection above the other half-mandrel 14 . This makes it possible for the pincers 18 , 20 to engage positively with the half-mandrel 12 that is mated with the corresponding bearing cap 2 .
Furthermore, the half-mandrel 12 that is mated with the corresponding bearing cap 2 has, at its periphery on mutually facing sides, tangentially extending insertion slots 26 for the pincers 18 , 20 that are each in communication with the recesses 24 . In more precise terms, the recesses 24 , when viewed in the axial direction of the extension mandrel 10 , are each located axially adjacent to the insertion slots 26 and merge into them.
In the present embodiment, the pincers 18 , 20 are formed such as to have a stationary or rigid geometry. The pincers 18 , 20 each comprise two fixed jaws 28 that are arranged essentially in a U shape and each have on their inner periphery a tooth-like engagement member 30 facing towards one another in the case of each pincer 18 , 20 .
As can be identified in FIG. 1 , the thickness of the pincers 18 , 20 corresponds essentially to the width of the insertion slots 26 , thereby enabling the pincers 18 , 20 to be guided onto the extension mandrel 10 such that the engagement members 36 end up form-locked in the region of the recesses 24 and can engage behind the corresponding projection of the half-mandrel 12 .
In the present embodiment, the fixing means 22 comprises two force-actuated detents 32 , 34 , the detent 34 being hidden by the pincer 18 in FIG. 1 . The detents 32 , 34 are spaced apart from one another and are provided between the pincers 18 , 20 such as to face towards the corresponding bearing cap 2 . With regard to an even application of load, it is preferred that the detents 32 , 34 are located roughly mid-way between the pincers 18 , 20 and extend essentially parallel thereto. The force-actuated detents 32 , 34 may, for example, be protractable pistons of hydraulic or pneumatic cylinders. It goes without saying, however, that other suitable limit stop members can be used, too, within the framework of the present invention. In addition, it is conceivable that the detents do not move and that the pincers are force-actuated.
The operation of the breaking separation device 1 depicted in FIG. 1 will now be described, by way of example, on the basis of FIGS. 2 to 6 , which each schematically illustrate individual steps of one embodiment of the breaking separation method according to the invention, in which the device shown in FIG. 1 is used.
Starting out from the state shown in FIG. 1 , the extension mandrel 10 , in its relaxed state, i.e. without any considerable expansion force being applied to the half-mandrels 12 , 14 by the expander 16 , is first introduced into the first bearing bore 8 in such a way that at least the first insertion slot 26 ends up between the first and the second bearing cap 2 ( FIG. 2 , with that bearing cap which is located on the right side in the drawings being designated as the first bearing cap). The insertion slots 26 are preferably moved into such a position that they are essentially in alignment with the pincers 18 , 20 of the fixing means 22 .
As can be seen in FIG. 3 , the securely connected unit consisting of the pincers 18 , 20 and the fixing means 22 is now moved towards the extension mandrel 10 and the crankshaft case 6 such that the pincers 18 , 20 , with their jaws 28 and particularly their tooth-like engagement members 30 , plunge into the insertion slots 26 . The pincers 18 , 20 are moved towards the extension mandrel 10 to such an extent that the tooth-like engagement members 30 end up axially adjacent to the recesses 24 .
In the next step, as shown in FIG. 4 , the extension mandrel 10 is introduced further into the bearing bore 8 . The tooth-like engagement members 30 of the pincers 18 , 20 assume form-locked engagement with the recesses 24 of the extension mandrel 10 and therefore engage behind the extension sleeve 12 that faces towards the bearing block 2 that is to be separated. In other words, a positive transmission of power is now possible between the extension sleeve 12 that faces towards the bearing cap 2 which is to be separated, and the pincers 18 , 20 .
The force-actuated detents 32 , 34 are then protracted such as to come in contact with the facing surface 2 ′ of the bearing cap 2 that is to be separated and such as to apply a force thereto ( FIG. 5 ). This produces a pre-tension that securely tensions the fixing means 22 , the pincers 18 , 20 , the extension sleeve 12 that faces towards the bearing cap 2 that is to be separated, and the bearing cap 2 itself that is to be separated, to form a unit. Together with the bearing arrangement of the fixing means 22 —which arrangement is secured against rotation, but which moves freely to a limited degree—this approach reduces or largely eliminates, during the fracture separation process, any twisting or bending strain that affects the bearing cap 2 that is to be separated. In this way, a fracture surface can be obtained with a much improved quality and surface structure.
Finally, as can be identified in FIG. 6 , the actual breaking separation process is performed. For this purpose, the half-mandrels 12 , 14 are moved so far apart by means of the expander 16 until a separation fracture is obtained between the bearing cap 2 and the corresponding thrust block 4 . Within the scope of the present invention, it is unnecessary to apply tensile forces via the fixing means 22 to the bearing cap 2 that is to be separated, because, in the present embodiment, the fixing means 22 with the pincers 18 , 20 and the detents 32 , 34 serves merely to prevent twisting of the bearing cap 2 that is to be separated, but it does not serve to impede or assist the bearing cap's movement in the direction of breaking separation.
After the breaking separation process is complete, the clamping of the separated bearing cap 2 can be released by retracting the detents 32 , 34 , with the result that the separated bearing cap 2 can be removed and the pincers 18 , 20 disengaged from the extension mandrel 10 by retracting same and then retracting the pincers 18 , 20 . The aforementioned process can then be performed analogously for the next bearing cap 2 .
Although the above-described embodiment example of the present invention relates to the breaking separation of a single bearing cap 2 , the present invention does, of course, make it possible to separate a plurality of bearing caps 2 from the corresponding thrust block 4 during a breaking separation process. In this respect, it may be useful to provide, for example, a plurality of fixing means 22 having corresponding pincers or to equip a single fixing means 22 with a plurality of pincers and corresponding detents.
|
A device for breaking separation of at least one bearing cap of a corresponding thrust block in the bearing assembly of engine cases provided with bearing bores which are arranged in-line, in particular crankshaft cases for alternative piston engines is provided. The device includes an extension mandrel comprising two half-mandrels insertable into at least one of the bearing bores. The half-mandrels being distant from each other in order to produce breaking separation force between the thrust block and the bearing cap. The bearing cap is clamped in such a way that it is non-rotatable except in a limited manner in the direction of breaking separation between a corresponding half-mandrel and a fixing device.
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FIELD OF THE INVENTION
[0001] The invention pertains to a system and method for efficiently delivering content to multiple requesters over a communications network. The invention is especially suited to delivery of web content.
BACKGROUND OF THE INVENTION
[0002] Since its inception, the defining paradigm of the World Wide Web (WWW) has been the ability to distribute content to a user on demand rather than limiting the user to pre-programmed content as in the case of traditional broadcast media (e.g., television, radio). In an effort to provide the ability to distribute high bandwidth media, such as video, efficiently there has been an effort to develop multicasting protocols for the Internet. Today's multicast solutions are directed at live event telecasting. Distribution of content on demand to individual users is very different and is not served by these conventional multicast solutions.
[0003] As the commercialization of the Internet progresses, situations arise where certain commercial or other web servers that serve information on an on-demand basis (e.g. Hyper Text Transfer Protocol (HTTP) servers) are bombarded with more hits than they are able to service, given the bandwidth of their connections to the Internet. Such situations may arise during periods of heightened interest in the subject matter web sites that the server is hosting. Under such circumstances it may be the case that there is excess CPU capacity in the server that is not being utilized to service client requests. In other words the bandwidth of the connection is the limiting factor, not the server processing power.
[0004] It would be desirable to be able to make more efficient use of the bandwidth of a connection between a server and the Internet, while still being able to service requests for information on-demand (as opposed to following a predetermined multicasting schedule).
[0005] What is needed is a system and method that allows a server to handle more requests without increasing the actual bandwidth of a connection between the server and the Internet.
BRIEF DESCRIPTION OF THE FIGURES
[0006] The features of the invention believed to be novel are set forth in the claims. The invention itself, however, may be best understood by reference to the following detailed description of certain exemplary embodiments of the invention, taken in conjunction with the accompanying drawings in which
[0007] [0007]FIG. 1 is a schematic diagram of a computer network according to a preferred embodiment of the invention.
[0008] [0008]FIG. 2 is a schematic of web server software interrelationships according to a preferred embodiment of the invention.
[0009] [0009]FIG. 3 is a block diagram of a network router according to a preferred embodiment of the invention.
[0010] [0010]FIG. 4A is a first part of a flow diagram of a process performed by a web server according to a preferred embodiment of the invention.
[0011] [0011]FIG. 4B is a continuation of the flow diagram shown in FIG. 4A.
[0012] [0012]FIG. 5 is a flow diagram of a process performed by a network router according to a preferred embodiment of the invention.
[0013] [0013]FIG. 6 is a schematic representation of a packet according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] While this invention is susceptible to embodiment in many different forms, there are shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. Further, the terms and words used herein are not to be considered limiting, but rather merely descriptive. In the description below, like reference numbers are used to describe the same, similar, or corresponding parts in the several views of the drawings.
[0015] [0015]FIG. 1 is schematic diagram of a computer network 100 according to a preferred embodiment of the invention. The network 100 includes a server 102 communicatively coupled to a first network sub-part 106 through a first bi-directional data link 104 . The first network sub-part 106 can for example comprise an ethernet local area network or a T 1 line. The server 102 preferably comprises a web server. A first computer readable medium 126 is provided for loading software onto the server 102 for configuring it to carry out processes described below with reference to flow diagrams shown in the FIGS. The first computer readable medium can for example take the form of an optical disk.
[0016] The first network sub-part 106 is communicatively coupled via a second bi-directional data link 108 to a network router 110 . A second computer readable medium 128 is provided for loading software onto the network router for configuring it to carry out processes described with reference to flow diagrams shown in the FIGS. The network router 110 is communicatively coupled to a second network sub-part 114 , and a third network sub-part 118 , through third and fourth bi-directional data links 112 , and 116 respectively.
[0017] The second network sub-part 114 is communicatively coupled to a first client computer 124 through a fifth bi-directional data link 130 . The third network sub-part is communicatively coupled to a second client computer 122 through a sixth bi-directional data link 120 .
[0018] The server 102 , first client computer 124 , and second client computer 122 can for example comprise IBM PC compatible computers. IBM PC compatible computers include a microprocessor, Random Access Memory (RAM), Basic Input Output System Read Only Memory (BIOS-ROM), video driver card, network interface (e.g. an ethernet interface or a modem), removable memory media reader (e.g. CD-ROM drive) electrically coupled through a digital signal bus. The first and second client computers 124 , and 122 are loaded with web client software such as the Netscape Navigator web browser manufactured by America Online of Dulles, Va.
[0019] [0019]FIG. 1 is merely illustrative of a simplified network topology. An actual network with which the present invention will be useful may include a multiplicity of network routers, numerous sub-networks, servers, and clients.
[0020] [0020]FIG. 2 is a schematic of exemplary web server software 200 interrelationships according to a preferred embodiment of the invention. The web server software 200 includes a communication protocol stack 202 . The communication protocol stack, as shown, includes an HTTP server application 204 at the top of the stack 202 .
[0021] A significant advantage of the present invention is that the invention, according to one preferred embodiment, supports communication with a conventional HTTP server application 204 . The present invention therefore is compatible with existing HTTP server applications without having to change the software and/or operation of conventional HTTP server applications.
[0022] The HTTP server application 204 , as shown in the example of FIG. 2, is interfaced to a transmission control protocol (TCP) layer 206 . The TCP layer 206 is interfaced to an Internet Protocol (IP) layer 208 . The TCP layer 206 and IP layer 208 may be combined into a single software module. The IP layer 208 is interfaced to a network interface layer 210 , e.g., an Ethernet layer. The network interface layer 210 may include software that runs on a network interface card that is included in the server 102 (see FIG. 1). The network interface layer 210 includes a transmit queue management module 210 A. A transmit queue that is stored in a memory included in the server 102 is used to queue responses to web client requests until bandwidth is available to transmit the responses through the first network sub-part 106 . If the web server 102 receives client requests at a high rate or if the responses are large in size, the queue will increase in size, and responses to client requests will be delayed. The present invention reduces those delays.
[0023] A server response condenser module 212 includes a packet read/write module 218 , a packet comparator 216 , and a packet merger 220 . The packet read/write module 218 reads and writes packets to the transmit queue through the transmit queue management module 210 A. The packet comparator 216 compares the content of two or more packets to be transmitted that are read by the packet read/write module 218 . The packet merger 220 merges two or more packets that are determined to have common content payload by the packet comparator 216 into a single packet. The operations will be described in greater detail below.
[0024] The single packet produced by the packet merger 220 is passed by the packet read/write module 218 to the transmit queue management module 210 A for placement on the transmit queue, and the packets that were merged are removed from the queue. By combining multiple packets that have the same content into a single packet, the size of the transmit queue can be significantly reduced, thereby reducing the delay in sending responses to web clients 122 , and 124 and increasing the capacity of the server. The single packet preferably includes 1) a common content payload of the packets that were merged, 2) a list of at least one destination address identifying the destination(s) for the single packet, e.g., a list of addresses from the packets that were merged, and 3) additional information for each of the destinations that can be used to construct a packet of the type that the destinations are expecting. Preferably, this per destination additional information is TCP header information that can be used to construct a packet that can be handled by an ordinary unmodified web client, and TCP/IP stack. A preferred process by which these TCP/IP packets are generated will be described below in the description of FIG. 5.
[0025] The software interrelationships shown in FIG. 2 are merely illustrative of one possible arrangement that can be used in practicing the invention. The arrangement can be varied. Functionality can be combined in different software classes, modules, or subroutines, in different ways. The distribution of functions among different software modules is to some extent affected by the choice of programming language, and depends on prevailing trends in the computer programming art. Numerous alternative software arrangements are possible without departing from the true spirit and scope of the present invention.
[0026] [0026]FIG. 3 is a block diagram of an exemplary network router 110 according to a preferred embodiment of the invention. The router 110 includes a first input/output card 302 A and a second input/output card 302 B that are coupled to a switching fabric 312 . In general, the router 110 may include a different number of input/output cards; two are shown in FIG. 2 for purposes of illustration in this example. The switching fabric 312 can for example be implemented as shared memory. Other types of switching fabric 312 are also known in the art. A controller 316 is communicatively coupled to the input/output cards 302 A, 302 B, and switching fabric 312 , and serves to control the overall operation of the network router 110 . Although each input/output card 302 A, 302 B, can perform both input and output functions, the functions to be performed in carrying out the present invention in the present example are performed when an input/output card receives a packet, i.e., when the input/output card is functioning as an input. Accordingly the block diagrams of the input/output cards 302 A, 302 B, shown in FIG. 3 highlight functional blocks involved in processing a received packet. The input/output cards 302 A, 302 B, can also include other parts, as known to one of ordinary skill in the router art.
[0027] Each input/output card 302 A, 302 B, includes a number of modules, as will presently be described, that can be implemented as hardware, software or using a combination of hardware and software. (Alternatively, one or more of these modules could be implemented in the controller 316 .) A packet parser/address analyzer 304 A, 304 B, parses each packet to extract one or more addresses preferably more than one address, data, and optionally header data associated with each address. Address associater 306 A, 306 B, is communicatively coupled to the packet parser/address analyzer 304 A, 304 B, and to a forwarding table 310 A, 310 B. The forwarding table 310 A, 310 B, can be implemented as a table stored in a memory on the input/output port cards 302 A, 302 B. The forwarding table includes a plurality of records consisting of destination addresses, and corresponding next hop addresses. The address associater 306 A, 306 B, examines the one or more addresses parsed from a packet by the packet parser/address analyzer 304 A, 304 B, and associates together those addresses that are determined based on the forwarding table 310 A, 310 B, to have the same next hop address. New packet composers 310 A, 310 B, are communicatively coupled to respective address associaters 306 A, 306 B. The new packet composers 310 A, 310 B, compose one or more packets each of which includes at least one address that has been determined to correspond to the same next hop address by the address associater.
[0028] Consider the following illustrative example. A packet, that includes 10 different addresses, can be received by input/output card 302 A. These are parsed by the packet parser/address analyzer 304 A. It may so happen that five of these addresses are determined to correspond to a first next hop address, four to a second next hop address, and one to a third next hop address. In this case the new packet composer 308 A will compose three new packets each of which includes the same data payload as the packet received by the input port card 302 A. The first new packet will include the five addresses corresponding to the first next hop address, the second new packet will include the four addresses corresponding to the second next hop address, and the third new packet will include the address corresponding to the third next hop address. The new packets preferably also contain additional information that is parsed from the received packet and associated with the various addresses. More preferably, the new packets include TCP header information for each address in the new packets.
[0029] [0029]FIG. 4A and FIG. 4B show a flow diagram of a process 400 performed by web server 102 (FIG. 1) according to a preferred embodiment of the present invention. In process block 402 a first request for a web content item is received by the server 102 from a first networked device (e.g., client 124 ). In process block 404 a request for the same web content item is received by the server 102 from a second networked device (e.g., client 122 ). The first and second requests preferably include network addresses to be used in transmitting a requested item to the first and second networked device 122 , 124 , respectively. These network addresses correspond to the identity of the first and second networked devices 122 , 124 . More preferably the included network addresses are, respectively, addresses that identify the first and second networked devices 122 , 124 , as destinations of packets distributed in the network.
[0030] The requests received in process blocks 402 and 404 preferably take the form of an HTTP request. The requests are preferably received by the HTTP server application 204 (see FIG. 2) through the communication protocol stack 202 . The HTTP server application 204 , in accordance with a preferred embodiment of the present invention, conventionally services the requests by creating packets for distribution in the network in response to the requests and passing the packets through the communication protocol stack 202 . The packets are destined for reception in the network by the originators of the requests, e.g., the first and second networked devices 122 , 124 . The network interface layer 210 typically stores the packets in the transmit queue that is being managed by the transmit queue management module 210 A. The transmit queue stores responses to web client requests until network conditions, and available bandwidth, permit transmitting the responses, e.g., the packets, from the transmit queue through the first network sub-part 106 .
[0031] According to a preferred embodiment of the present invention, the first and second requests are received, serviced by the HTTP server application 204 , and corresponding first and second packets constituting responses to the first and second requests, respectively, are stored in the transmit queue. These first and second packets are contemporaneously stored in the transmit queue within a time interval that is less than the time for a packet to move completely through the transmit queue, given the length of the queue at the time that the first packet is stored in the transmit queue. The time interval provides opportunity for combining packets, e.g., the first and second packets, being stored in the transmit queue and during the entire pendency of packets in the transmit queue.
[0032] In process blocks 406 and 408 first and second packets are prepared in response to the first and second requests received in process blocks 402 and 404 , respectively. Each of the first and second packets includes a content payload that is the same in the first and second packets and further that constitutes at least a portion of the web content item requested by the first and second requests. Besides the content payload, the first packet includes 1) the first address to be used for identifying the first networked device in the network, and 2) a first request specific header. Likewise, besides the content payload, the second packet includes the second address to be used for identifying the second networked device in the network, and a second request specific header. The first and second request specific headers preferably include reliable unicast header information, e.g.,TCP header information. The TCP header information is used for connection management purposes. Additionally, the TCP header information preferably provides per destination tracking information, e.g. for tracking the flow of data to a particular destination such as the first and second networked devices 122 , 124 , in the network.
[0033] Referring now to FIG. 4B, in process block 410 the first and second packets are determined to include in the payload of the packet the same portion of the web content item. Process block 410 is preferably broken into a number of sub-steps. Process block 410 is preferably performed by a queue scan program module that reads packets in a queue (e.g., the transmit queue 210 A). According to a preferred embodiment of the present invention, the queue scan program module is preferably invoked when a packet is about to be added to the transmit queue. This queue scan program module attempts to find another packet that is already on the transmit queue and that has the same payload.
[0034] In one exemplary embodiment, the queue scan module first compares the payload size of a packet that is about to be added to the queue with the payload size of each packet that is already on the queue. If a packet on the queue has a different payload size it of course cannot have the same payload.
[0035] The queue scan module, according to a second exemplary embodiment, may compare a normalized or canonical checksum (described below) associated with the payload of the packet to be added to the transmit queue with that of packets already on the transmit queue. If the normalized checksum of the payload of the packet to be added is different from that of a packet already on the queue then it can be concluded that the packet to be added has a different payload.
[0036] The queue scan program module, according to a third exemplary embodiment, may perform a byte-by-byte comparison between the payload of the packet to be added and that of each packet already in the transmit queue. This byte-by-byte comparison is a very reliable way of determining a match between the payloads of packets. However, it is also the most time and resource consuming functional sequence for determining whether the payload in the packet to be added to the transmit queue matches the payload of one of the packets already in the transmit queue. Therefore, a more efficient approach is discussed below.
[0037] According to another alternative embodiment, the byte-by-byte comparison may preferably be limited to just those packets on the transmit queue that had matching normalized checksums as discussed above. Furthermore, checks for matching normalized checksums may be limited to packets that are found to have the same payload size. The latter tiered operational sequence of tests reduces the overall computational cost of finding a match between the payload of a packet to be added to the transmit queue and the payload of one of the packets already in the transmit queue.
[0038] According to an alternative embodiment of the invention, when each new packet that has been formed in response to a request, is received at a layer of the communication protocol stack at which the queue is maintained, it is immediately checked against packets already on the queue for matches.
[0039] If the queue scan module checks the queue for matches for each new packet that is to be added to the queue, and when a match is found forms a combined packet, then when the queue scan module finds a matching packet it need not search the queue further, because all other matching packets will have been combined in the packet that was found.
[0040] A TCP packet checksum varies as a function of TCP header information, even if the data carried by the TCP packet remains unchanged. For example two TCP packets that are addressed to two different destination, but carry the same data payload, will in general have different TCP checksums due to the fact that the destination addresses are different and because the TCP sequence numbers will in general be different on different connections. A normalized or canonical checksum that covers the payload but not the TCP header information can be obtained for comparison purposes by backing out the variable header data, from a computed check sum. According to one embodiment of the invention this is accomplished by recomputing a checksum based on the replacement of any variable data by one or more predetermined numbers. In one embodiment, the checksum is recomputed by applying the following formula for each variable data item:
HC′=˜ (˜HC+˜ m+m′)
[0041] where HC′ is a canonical checksum that does not depend on variable data;
[0042] HC is a computed checksum that depends on variable header data;
[0043] m is the variable header data;
[0044] m′ is a predetermined value to be used in lieu of the variable header data in computing the canonical checksum; and
[0045] ˜represents a ones complement operation.
[0046] The foregoing formula is presented in Request for Comment (RFC) number 1624 , Computation of the Internet Checksum via Incremental Update, published by the Internet Engineering Task Force.
[0047] In process block 412 a next hop address for the first packet is determined, and in process block 414 the next hop address for the second packet is determined. In process block 416 it is determined that the next hop address for the first packet and the next hop address for the second packet are the same. The next hop address can be determined using information contained in a routing table stored in a memory accessible to the server 102 . Some web servers have only one connection to the Internet. In the latter case, the steps of determining the next hop addresses for each packet 412 , and 414 , and the step of determining that the next hop addresses are the same 416 can be eliminated.
[0048] In process block 418 a third packet is composed that includes, according to a preferred embodiment of the present invention, 1) at least one address, e.g., the first address and the second address, and 2) information derived from the first and second request specific headers, and 3) a content payload that is the same as in the first and second packets. The information derived from the first and second request specific headers preferably comprises the first and second request specific headers themselves. More preferably, the first and second request specific headers are TCP headers used for tracking the flow of data to the first and second networked devices 122 , 124 , respectively. Preferably, this TCP header information can be used to construct a packet that can be handled by an ordinary unmodified web client and a conventional TCP/IP communication protocol stack. Alternatively, the information derived from the first and second request specific headers can be included in the third packet in a compressed form. At this point the third packet is stored in the transmit queue instead of storing the first and second packets. If either of the first and second packets were already stored in the transmit queue, then the particular packet is removed from the queue. According to a preferred embodiment of the present invention, the combined packet, i.e., the third packet, comprises a reliable multicast packet for distributing in the network.
[0049] In process block 420 , the third packet is transmitted to the next hop address. The next hop address, according to an exemplary embodiment, identifies the network router 110 in the network. Thus, the size of the queue is reduced by replacing multiple packets by a single packet. Note that packets need not be consecutive to be combined. Note too that although two packets were combined into a single packet in the above example, it is possible for 3, 4, 5, or more packets to be combined to further reduce the size of the queue. The process of combining packets can continue during the entire pendency of the combination packet in the transmit queue until it is time to transmit the combination packet into the network.
[0050] In the above discussed example, packets were combined in the transmit queue of a network interface module. A main advantage of this embodiment is that no changes are required in the HTTP server (or other server) application software. Note, that the process of combining responses to requests can also be done at other levels in the web server software 200 (e.g., in modules 208 , 206 , or 204 in FIG. 2).
[0051] Note that in some Internet applications such as HTTP, a response to a single request can take the form of a plurality of response packets, each including different parts of a request item (e.g., image file). Under certain conditions such as when the data rate of a first TCP/IP connection differs from that of a second TCP/IP connection, some of the first few pairs of packets that are prepared in response to two requests for the same item of information may not be matched up because the interval between when they are prepared is longer than a queue wait period, yet for the same two requests, subsequent packets may be matched up. In effect one connection catches up to the second.
[0052] [0052]FIG. 5 is a flow diagram of process 500 performed by a network router 110 according to a preferred embodiment of the present invention. In process block 510 , a third packet (e.g., the third packet transmitted in process block 420 ) is received by the router 110 . The third packet, according to one preferred embodiment of the present invention, includes a data payload (e.g., the portion of the web content item), a first address, a second address, a first request specific header (e.g., TCP header) and a second request specific header (e.g., a second TCP header). Although, in the interest of clarity in illustrating the invention, the discussion here is in terms of a third packet having a first and second address, the third packet can include any number of addresses and corresponding request specific headers.
[0053] In process block 512 , according to this exemplary operational sequence, a next hop address is determined based on the first address, and in process block 514 a second next hop address is determined based on the second address. In process block 516 , the first and second next hop addresses are compared. Process block 518 is a decision block, the outcome of which depends on whether the first and second next hop addresses are equal. If so, then the process continues with process block 520 , in which the third packet is forwarded to the next hop address. (This assumes that the third packet did not contain additional addresses that correspond to a different next hop. If other such addresses were present, then another packet would need to be generated based on the other addresses for transmission to the respective next hop addresses.)
[0054] If the first and second next hop addresses are not the same, then the process continues with process block 522 , in which a fourth packet including the first address, the first request specific header information and the data payload is composed. Following process block 522 , in process block 524 , a fifth packet including the second address, the second request specific header information, and the data is composed. In process block 526 the fourth packet is transmitted to the first next hop address, and in process block 528 the fifth packet is transmitted to the second next hop address.
[0055] In the example discussed above there were two destination addresses in the packet received by the router 110 . If there were more than two addresses, the processing of the received packet would likely be as follows. The router would determine a next hop address for each of the destinations, and then partition the destinations based on their next hops. The router 110 would send to each next hop a packet that contains the data payload from the original packet, the list of destinations that correspond to that next hop, and the request specific header information for those destinations.
[0056] Based on the content of the forwarding table 310 A a determination can be made as to whether or not the next hop is the final destination. If the next hop is the final destination then the next hop address corresponding to the destination address will be the destination address itself. If a next hop addresses corresponds to a final destination, e.g., a requesting network device, such as first client computer 124 or second client computer 122 , then the packet to be sent to the destination is composed in a format suitable for receipt by the destination. Preferably the packet is composed as a reliable unicast packet i.e., a packet that includes information for a reliable unicast header, e.g., a checksum, window size, and a sequence number used in a reliable connection, e.g., a TCP connection. More preferably, the packet is composed as a normal TCP/IP HTTP packet expected by a web client application (e.g., Netscape Navigator running over a TCP/IP communication protocol stack.). That is to say that any formatting used to encode multiple destination addresses and multiple TCP headers in the packet would be removed. The resulting packet would include a single TCP header for the final destination.
[0057] If the number of destinations for a next hop is one, even if the next hop address is not the destination address, according to the preferred embodiment, the packet is preferably composed in a format suitable for receipt by the final destination. Alternatively, the packet can be forwarded without conversion.
[0058] [0058]FIG. 6 is a schematic representation of a packet 600 according to a preferred embodiment of the present invention. Packet 600 indicates an exemplary form for the third packet composed in process block 418 , and received in process block 510 , according to a preferred embodiment of the invention. Although the third packet was discussed above as including two addresses, the packet can include two or more addresses as shown in FIG. 6. The packet includes a link layer header 602 (e.g., an Ethernet header) and an optional IP header 604 . The optional IP header 604 is useful for tunneling the packet 600 through existing technology routers, that do not support the present invention, to a router 110 such as shown schematically in FIG. 3 that is capable of carrying out the process 500 illustrated in FIG. 5. A reliable multi-cast protocol header 606 is followed by a plurality of pairs of destination IP addresses 608 A, 608 B, and 608 C, and corresponding request specific reliable unicast header information parts 610 A, 610 B, and 610 C, preferably including TCP header information. The packet, in this example, further includes a data payload 612 that preferably includes a portion of the web content item.
[0059] The present invention can be realized in hardware, software, or a combination of hardware and software. Any kind of computer system—or other apparatus adapted for carrying out the methods described herein—is suited. A typical combination of hardware and software could be a general purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
[0060] The present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which—when loaded in a computer system—is able to carry out these methods. Computer program means or computer program in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or, notation; and b) reproduction in a different material form.
[0061] Each computer system may include, inter alia, one or more computers and at least a computer readable medium allowing a computer to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium may include non-volatile memory, such as ROM, Flash memory, Disk drive memory, CD-ROM, and other permanent storage. Additionally, a computer medium may include, for example, volatile storage such as RAM, buffers, cache memory, and network circuits. Furthermore, the computer readable medium may comprise computer readable information in a transitory state medium such as a network link and/or a network interface, including a wired network or a wireless network, that allow a computer to read such computer readable information.
[0062] Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention.
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An Internet communication technique is provided for making efficient use of available bandwidth between network points by analyzing responses to received requests for information items to identify multiple responses that include the same item and optionally that also have a common next hop address, and responding to the multiple requests with a combined packet addressed to multiple addresses. The combined packets include sufficient information from which to generate reliable unicast packets, that will ultimately be formed from the contents of the combined packet. The combined packet is received by a network router identified by a common next hop address, and a sequence of addresses are associated in sub-groups corresponding to common next hop addresses. A plurality of packets are generated based on the combined packet, each of which includes addresses that correspond to destinations that share a common next hop address. The plurality of packets are then sent to their corresponding next hop addresses.
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FIELD OF THE ART
[0001] The dual-axis solar tracker, object of the present patent application, relates to a moving support system for solar panels favoring as much as possible the energy production thereof, upon allowing the positioning of the plane of the solar panels in the perpendicular to the rays of sunlight during the entire day.
[0002] The main application of the present invention is the solar energy sector, and particularly, solar trackers or devices.
PRIOR STATE OF THE ART
[0003] Solar trackers such as that object of the present invention are not known in the state of the art, however other solar trackers are known which can be grouped in:
Panels in a plane on a fixed monopost or the like, with a single central support, Panels in a plane on a lower non-rolling rotating frame, and Panels in multiple planes with multiple horizontal axes on an inclined structure (stands) with a lower rolling platform.
[0007] These types of trackers have their advantages and drawbacks but on the whole, considering that relating to manufacture, maintenance, reliability etc., the proposed invention provides a number of advantages since:
it minimizes particular components involving a high price, it requires very little labor and materials in its manufacture and assembly, and it is a simple and efficient device.
[0011] Likewise, an additional problem of the known solar trackers rolling on a running surface or track, is that they require a perfect horizontalness of said running surface or track since due to their high rigidity and in the case that said surface or track was not perfectly horizontal, the passage of a wheel on a lower point thereof would cause said wheel to be suspended without touching the surface, and therefore when the wheel losing contact with the support surface or track is a tractor wheel a lack of traction would occur and would consequently make the rotation of the assembly difficult.
[0012] In addition, the solar panels to be assembled on the boards of the solar trackers of the state of the art are not standardized, therefore different solar panels would require boards with different dimensions. In the current state of the art said solar panels are usually arranged screwed to the profile forming the plane or board of panels, its main drawback being the requirements in its execution, such as the making of boreholes, precision in construction, the need to check the screws in the event of galvanization, accessibility to the board by the two sides thereof, etc., although without a doubt, the most important factor is time and therefore the labor necessary for assembling the panels with screws since it will be necessary to place them on one face of the board and screw them on the other face. This action is made very difficult due to the large dimensions of the planes formed by the panels. Likewise, the fact of using screws as a fixing of the panels makes it easy to steal them.
[0013] U.S. Pat. No. 4,256,088-A, describes a solar concentrator which includes a modularized point focusing solar concentrating panel which is movably mounted to track the sun. This panel has an overall parabolic reflecting surface and a triangular or approximately triangular configuration which improves structural integrity, minimizes wind resistance and permits rapid and easy stowing.
[0014] US application number U.S. Pat. No. 2,001,036024-A1, describes a matrix solar dish concentrator with flexed glass mirrors is patterned from orthogonal planes parallel to the axis of symmetry of a paraboloid and intersecting the paraboloid, this pattern making all parabolic trusses uniform. The solar dish tracks the solar azimuth with a bicycle wheel and tracks the solar zenith with a television satellite dish actuator. A solar receiver is supported with a low shade structure outside a cone of concentrated sunlight.
DESCRIPTION OF THE INVENTION
[0015] As has already been mentioned, the present invention relates to a dual-axis solar tracker, specifically a vertical axis and another horizontal axis with respect to which it will rotate in order to track the path traced by the sun. Said axes are included as components of a metal profile structure supported at its center and on wheels in its periphery, in turn being supported on a running surface or track. The solar tracker, and therefore the mentioned structure, rotates on a fixed central point on which the vertical axis of the tracker is supported, said structure incorporating the horizontal axis on which at least one board is located for receiving the solar modules or panels, said board or boards being able to rotate on said horizontal axis so that the solar panels are maintained perpendicular to the rays of sunlight.
[0016] The solar panel or panels used for capturing solar energy are incorporated or assembled in the preferably metal solar tracker structure, specifically in one or more boards forming said structure. Said board or boards in turn form a plane which is maintained perpendicular to the rays of sunlight, i.e. the solar panels incorporated in the boards are maintained perpendicular for the purpose of achieving a better and greater capture of solar energy.
[0017] The board or board of the structure, and therefore the plane of solar modules or panels, is provided with two movements, a movement of rotation with respect to a vertical axis and a movement of rotation with respect to a horizontal axis, both axes being perpendicular to one another. The lower point of the vertical axis is fixed to the ground, such that the tracker rotates with respect to said fixed point, whereas the horizontal axis, perpendicular to the vertical axis, enables the rotation of the board or boards possible with respect to it. In the case of more than one board of panels, the rotation thereof in a synchronized manner, forming a single plane, is recommendable although such panels can evidently rotate in an asynchronous manner, i.e. independently, for example in those cases in which the means of the traction elements of any of the boards does not operate correctly.
[0018] The object of the present invention is therefore a dual-axis solar tracker which allows maintaining the perpendicularity of the solar modules or panels with respect to the rays of sunlight, independently of the position of the sun which changes throughout the day.
[0019] As has been mentioned the plane of panels is formed by at least one board, integrating the solar tracker structure and supporting the solar panels, said boards being supported on the mentioned rolling structure rotating with respect to the central point fixed to a footing for locking the entire assembly. The rolling structure, supported on the vertical axis at its center and on wheels in its periphery, some wheels being drive wheels and other wheels being support wheels, rotates due to the action of said drive wheels (motor-driven wheels with automated geared motors) on a running track or horizontal surface (ground, planar bed plate, concrete girder, metal profile, etc.).
[0020] The horizontal axis, which in the event that the tracker has two boards will be divided into two horizontal axes, is integrated in the rolling structure and determines and controls the rotation of the board or boards, and therefore of the plane of solar modules or panels, preferably by means of automated drives, for example worm screw mechanism geared motors. The rotation of the board or boards with respect to the horizontal axis or axes, and therefore of the solar panels with respect to the horizontal axis or axes is thus achieved with an easy automation for each day and time of the year. Said automated drives can be common for more than one board or be independent for each of the boards if these boards are independent, thus allowing the boards to be able to rotate in a synchronized manner but independently driven.
[0021] Both the rotation with respect to the vertical axis or point as well as with respect to the horizontal axis or axes is controlled by means of a control unit (of the optical type or programmable automaton type), being able to incorporate different sensors facilitating the position of the solar panels of the tracker depending on the position of the sun and of the meteorological conditions.
[0022] The rolling structure is formed by a structural assembly of lattice girders and as has already been mentioned, it is supported on the running surface through wheels and on a single, central and fixed vertical rotation point. The board or boards on which the solar panels are assembled form part of said structure as does the horizontal rotation axes. Said structure in turn has a projection at its front part by way of a nose providing great stability to the structural assembly and therefore to the solar device.
[0023] The solar tracker proposed by the invention likewise has a device allowing the correct operation thereof on a running surface which is not perfectly horizontal, thus adapting to the level variations of said surface.
[0024] Another object of the present invention is therefore a solar tracker which is able to prevent the level variations of its running and support surface, preventing the requirement of perfect horizontalness of the running surface on which the tracker is supported.
[0025] In order to achieve the foregoing, and more specifically in order to prevent the malfunction in the solar tracker due to the non-horizontalness of the running surface, the solar tracker object of the present invention will have its plane of panels formed by two boards of solar modules or panels.
[0026] Said two boards are anchored on a lattice girder which is part of the rolling support structure. The lattice girder forming the solar device is horizontally divided into two equal parts connected to the vertical axis given that each of the parts has an upper bar and a lower bar attached to the vertical axis by means of moving couplings. On the side opposite that of the coupling and at its lower part, i.e. at the outer lower ends of the lattice girder, there is at least a support and traction wheel on the running surface. The upper or lower side of the lattice girder defines a single imaginary horizontal axis in the event that the running surface is perfectly planar.
[0027] The need for the running surface on which the solar tracker rotates to be perfectly horizontal is prevented by means of the moving coupling mechanism which is detailed, since said mechanism allows the wheels to always make contact with the running surface or track regardless of the horizontalness thereof by means of the action of the actual weight of the wheels, therefore not losing traction and support.
[0028] Said moving couplings are formed, for example, by means of a hinge between the lower bars of the lattice girder and the vertical axis, said hinge transmitting all the stresses, except the rotating bending moment according to the hinge axis, generated between the girder and the central vertical axis. Meanwhile, in the coupling between the upper bars and the central axis, a tongue and groove joint transmitting all the stresses between the upper bar and the vertical axis is used, the tongue and groove joint being of the type allowing the axial stress in the upper bars of the lattice girder to be only transmitted in a direction approaching the central vertical axis.
[0029] Not transmitting this stress in the direction of moving away from the central vertical axis is what allows the wheel to be supported on the surface or track even though it is not horizontal and has level differences.
[0030] The maximum raising and lowering limitations of the wheels are determined by:
Maximum raising: the wheels can not be raised above the position in which the upper bar makes contact with the vertical axis in the tongue and groove joint. Maximum lowering: the wheels have the length of the tongue and groove joint located between the upper bars and central vertical axis as a lowering limit.
[0033] A final object of the invention is allowing the use of different dimensions in the tracker of solar panels, as well as the fixing thereof in the boards, solving the drawbacks of the non-standardization of the width, height and thickness of the solar panels or modules, allowing the use of different solar panels on the board or boards of the tracker according to the requirements of the final installer.
[0034] The system for fixing the solar modules or panels in the board or boards of the solar tracker requires the board or boards to be formed by a preferably rectangular frame inside which the girders having a metal profile slide, spacing them apart the width of the required panel. Said metal profiles form rails in which the solar panels will be housed and subsequently fixed without such solar panels needing to be screwed to the profiles of the boards. The flanges of said profiles must be equal to or less than the dimension of the framing of the panel for the purpose of not reducing the radiation emitted on the active surface of the panels. These profile girders can have any U-, I-shaped section etc.
[0035] Once the board incorporating a certain profile according to the measurement of the panel to be used in the rails of its profiles has been formed and assembled, the solar panels are introduced and slid therein, and if there are clearances it is then possible to use silicone points for preventing the movement of said panels in the rails due to the possible excessive clearance of the rail.
[0036] As has already been mentioned, each board is formed by a preferably metal frame with a UPN profile or the like and with guides or runners therein and preferably IPE or UPN profiles or the like, perpendicular to the main girders demarcating the perimeter of said frame and therefore of the board, said guides being coupled to the frame by means of attachments allowing the sliding thereof on the frame. With this arrangement the width between two guides can be adapted to the width of the solar modules or panels which must be slid between said guides.
[0037] The guides likewise have an eccentric flat bar dividing the height of said guide in its entire length into two parts, and as it is eccentric said two heights son different, also allowing the introduction of solar panels with different thicknesses. The guides have at their lower part a permanent closure or plug for preventing the solar panels from sliding and coming out of the rail when they are introduced between two guides. An opening and closing system is arranged at the upper part and in order to prevent the unwanted removal of the solar panels introduced in the rails.
[0038] In order to ensure the stiffening of each panel, steel cables with their corresponding tensioners are diagonally used, which cables attach the corners or edges of the board or boards with the central area of their frame, such that the cables structurally contribute to the maintenance of the “frame—guides—panel” assembly, providing a convenient and necessary securing (Saint Andrew's cross) in a simple manner.
DESCRIPTION OF THE DRAWINGS
[0039] The following drawings accompanying the description in a non-limiting manner are referred to below for the purpose of facilitating the understanding of the invention:
[0040] FIG. 1 shows a perspective view ( 1 a ), a front elevational view ( 1 b ) and a side elevational view ( 1 c ) of the solar tracker object of the present invention.
[0041] FIG. 2 shows the side elevational view of the lattice girder, central axis and running assembly.
[0042] FIG. 3 shows detail A of FIG. 2 .
[0043] FIG. 4 shows detail B of FIG. 2 .
[0044] FIG. 5 shows an exploded view of the assembly of the solar panels in a board according to the present invention.
[0045] FIG. 6 shows a possible solution of detail A of FIG. 5 .
[0046] FIG. 7 shows detail B of FIG. 5 .
[0047] FIG. 8 shows detail C of FIG. 5 .
[0048] FIG. 9 shows detail D of FIG. 5 .
[0049] FIG. 10 shows an alternative to detail D of FIG. 5 .
[0050] FIG. 11 shows the rotation sequence of the dual-axis solar tracker with respect to its vertical axis in ten of its positions.
[0051] FIG. 12 shows a front elevational view ( 12 a ) and a perspective view ( 12 b ) of the solar tracker object of the present invention with a single board of solar panels.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0052] The solar tracker object of the present invention is supported on a running surface or track, for example the ground, planar bed plate, or circular rail 6 and rotates with respect to its axis 8 and central point 30 , which is fixed to the ground through a footing for locking the assembly. The solar tracker is formed by a rolling support structure 5 rotating with respect to said central point 30 and axis 8 , said support structure 5 of the solar tracker being formed by a structural assembly 9 , 10 , 11 of metal lattice girders. As can be seen in the figures, particularly in FIG. 11 , sequences A, B, C, D, H, I, J, the support structure 5 has a projection at its front part by way of a nose providing great stability to the structural assembly and therefore to the solar device.
[0053] The rotation of the solar tracker with respect to the vertical axis and therefore with respect to its central anchoring point 30 is achieved by means of using support wheels 7 , at least two of which will be motor-driven. The fact of placing geared motors or rotation drives in the wheels, i.e. in the edge of the structure instead of in the vertical rotation axis, allows reducing the size of said geared motors upon requiring less power due to the large action arm.
[0054] The support structure 5 is likewise useful as a support for the horizontal axis 4 of each board 2 of the solar tracker. The solar panels 3 forming the plane of panels of the tracker and which are responsible for capturing rays of sunlight are fixed in said boards 2 .
[0055] Worm screw drive geared motors, for example, are used for the movement of the boards 2 , and therefore of the panels 3 , with respect to the horizontal axis 4 . The fact of being able to have a drive device for each board 2 allows the movement of each board 2 with respect to the horizontal axis 4 to be able to be synchronized but independent.
[0056] The boards 2 likewise have weighting elements in order to minimize the compression work of the drive as well as their buckling.
[0057] As has already been described, the dual-axis solar tracker 1 is formed by two support boards 2 of solar panels 3 and each board is integrated with a horizontal rotation axis 4 , each board rotating with respect to its corresponding horizontal axis 4 , said axes 4 being fixed on the rolling support structure 5 of the solar tracker.
[0058] Said structure 5 is formed by a structural assembly of lattice girders and is supported on the running surface 6 through wheels 7 as well as on a rotation point 30 .
[0059] The two boards 2 are supported on a lattice girder 9 , perpendicular to the running surface 6 and which is divided into two equal parts by the vertical axis 8 . Each of the parts of said lattice girder 9 has an upper bar 10 and a lower bar 11 which are secured by means of moving couplings to the vertical axis 8 , a tongue and groove joint 13 and a hinge 12 respectively. It likewise has, at its outer lower ends, support wheels 7 which are preferably motor-driven and drive the tracker 1 , making it rotate with respect to the central point 30 .
[0060] In the event that the running surface 6 is not perfectly horizontal, see FIG. 2 , and in order to prevent one of the wheels 7 from being in midair without making contact with the surface 6 and therefore making the traction impossible and affecting the rotating movement of the tracker 1 , the tongue and groove joint 13 of the upper bar 10 and the hinge 12 of the lower bar 11 allow the wheel 7 to keep making contact with the running surface 6 regardless of the level changes thereof. The hinge 12 allows the lower bar 11 to rotate lowering its end such that the tongue and groove joint 13 of the upper bar 10 slides the necessary distance. The maximum lowering limit of the wheel 7 is determined by the length of the tongue and groove joint 13 .
[0061] The system is equally functional when the running surface 6 is raised, but in this case the hinge 12 allows the lower bar 10 to rotate lifting its end and the tongue and groove joint 13 is shortened. The maximum raising limit of the wheel 7 is determined by the contact between the upper bar 10 and the vertical axis 8 .
[0062] If the horizontalness of the running surface is ensured it is possible for the solar tracker to have a single horizontal axis 4 with two boards 2 on each side of the vertical axis 8 instead of a horizontal axis for each board.
[0063] The objective of the solar tracker 1 is, as its own name indicates, to track the path traced by the sun attempting to capture the greatest amount of rays of sunlight. In order to do this, in addition to describing a rotating movement on the vertical axis 8 , it has the mentioned solar panels 3 in the two boards 2 located on a frame 14 so that by means of the rotating movement with respect to the horizontal axis 4 the panels remain perpendicular to the rays of sunlight.
[0064] Each of said boards 2 has a preferably rectangular frame 14 with its two main bars 16 parallel to the upper bar 10 of the lattice girder 9 . The sides of the frame 14 are formed by an IPN profile or the like. For supporting the panels 3 on said frame 14 , the tracker 1 has guides or runners 15 which are located on the frame 14 perpendicular to the main bars 16 . Said guides 15 are coupled and slide on the frame 14 , specifically on the main bars 16 of the frame 14 .
[0065] Said sliding and securing is achieved by means of sliding attachments 18 , of the folded sheet type sliding along the flanges of the frame, or screwed clamps 17 . Specifically, the clamps are formed by a semicircular shaped element which is screwed at its center to the sliding guide 15 , is connected to said guide 15 at one of its ends and is free at the opposite end. There is thus a space between the free end of the clamp and the guide 16 , a space in which a flange of the IPN profile of the longest side of the frame 16 is housed, and after sliding along said frame 14 until achieving the width of the solar panel 3 to be introduced between two consecutive guides 15 forming a rail, the inviolable screw of the clamp 17 is tightened, thus ensuring the position of the guide 15 on the frame 14 .
[0066] The sliding attachment, the folded sheet 18 sliding along the flanges of the frame, is connected to the sliding guides or runners 15 , determining a space between one side of the folded sheet 18 and the guide or runner 15 intended to partially house, as occurs with the previous example of the clamp, the main bar 16 , the longest bar of said frame 14 .
[0067] The foregoing are two preferred embodiments of the adaptation system for adapting the boards in order to house solar panels with different dimensions according to the needs or preferences of the installer, said adaptation and securing system being able to use other components both for facilitating the sliding of the guides and their subsequent securing and for securing the panels to said guides.
[0068] The guides 15 , preferably with an IPE profile, have an eccentric flat bar 19 dividing the height of said guide 15 in its entire length into two parts, and as it is eccentric said two heights (a, b) are different, which also allows using the solar tracker 1 not only with solar panels 3 with different widths but also with different thicknesses.
[0069] The assembly of the solar panels 3 in the solar tracker 1 through the boards 2 formed by the frame 14 and the guides 15 is simple and is carried out as is detailed below.
[0070] The guides 15 are first fitted to the width of the solar panels 3 which will be used in the tracker 1 by means of the sliding thereof along the sides 16 of the frame and the fixing of the clamps 17 . Once the rails for housing the panels 3 are ready, the panels 3 start to be introduced between the guides and according to their thickness supported on the flat bar 19 of the guide 15 or below said flat bar 19 .
[0071] The solar panels 3 are closed when they reach the end part of the guide 15 , thus preventing them from coming out of the rail, by a permanent closure 20 , and once all the panels have been introduced in the corresponding rail, said rail is closed by means of a UPN profile 21 or the like, which is fixed to the corresponding end by way of a lid by means of a nut which can be an inviolable or antitheft nut.
[0072] Finally, and once the panels 3 have been introduced into both boards 2 of the solar tracker 1 and in order to ensure the stiffening of each board 2 , steel cables 22 with their corresponding tensioners are used, which cables attach the corners and edges of each board with the central area of their frame, such that the cables structurally contribute to the maintenance of the “frame—guides—panel” assembly, providing a convenient and necessary securing in the form of a Saint Andrew's cross in a simple manner.
[0073] Another embodiment, shown in FIG. 12 , shows a solar tracker which only includes a single board of solar panels rotating with respect to a horizontal axis.
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The invention relates to a two-axle solar tracker, consisting of a moving supporting system for solar panels, which maximises the energy production of said panels and which is formed by a vertical axle and a horizontal axle in relation to which the system rotates in order to track the sun's path. The aforementioned axles are components of a structure supported at the centre and supported peripherally on wheels positioned on a running track or surface. The structure rotates about a fixed central point supporting the vertical axle of the tracker. At least one board is positioned on the horizontal axle of the structure in order to receive the solar modules or panels and said board(s) can rotate about the horizontal axle so that the solar panels are maintained perpendicular to the sun's rays.
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FIELD OF THE INVENTION
Embodiments of the invention relate to a method for the continuous cutting of fibers, and a cutting device for carrying out the method.
Along these lines, a generic method and a generic device for the continuous cutting of fibers are utilized in order to cut continuously converging endless fibers into short sections. In order to avoid oscillating movements the running fiber is guided across a wheel rotating at a circumferential speed corresponding to the fiber speed, wherein the wheel has a plurality of knives at the contact surface, wherein the blades of the knives are directed opposite of the fiber and are aligned in the direction of the desired cut. A press-on element presses the fiber against the blades of the knives such that the fibers are cut.
BACKGROUND
It is known from the printed publication DE 216 00 79 to arrange the knives on the outer circumference in axial direction, wherein the blades are aligned in the radial cutting direction. The fibers to be cut are guided around the wheel, wherein circumferential collars guide the fibers in axial direction. In this case the press-on element is embodied as a second wheel, the outer circumference of which rolls off the blades of the knives, thus pressing the fiber against the blades. The cut fiber sections can be pressed through channels provided between the knives, and are collected and discharged in the direction of a collection chamber arranged in the interior of the wheel in this manner.
As an alternative it is known from the printed publication DE 102 42 553 to arrange the knives radially with the blades being aligned in axial cutting direction such that the fibers are pressed against the blades of the knives in axial direction and the fiber sections are pressed through between the knives by means of channels that are aligned in axial direction.
SUMMARY
However, regardless of the arrangement of the knives, it has been shown that the generic method and the cutting device are not suitable for cutting short fiber sections at a high cutting performance. The length of the fiber sections is determined by the distance of the knives to one another, wherein a relatively short distance of the knives, and therefore short fiber sections, result in a higher cutting resistance and lower cutting performances. In this manner a cutting length of 3 mm, for example, could be achieved only at a significantly reduced cutting performance as opposed to a cutting length of 4 millimeters. The lower cutting performances have the effect of reduced fiber speeds of the fiber cable, and thus an adverse effect on the fiber street arranged in front of the same so that it becomes necessary to separate the fiber cable into two strands that are cut on separate cutting devices. In addition to the higher investment costs for the cutting devices therefore, a higher susceptibility to failure is also associated due to the separating of the fiber cable.
Another problem with the cutting of short fiber sections is that the same must be fed through the channel, which is formed between two adjacent knives. However, since the knives may not be embodied at any desired thin dimensions for larger yarn counts, the channels become disproportionately narrower with a decreasing cutting length. In short fiber sections this leads to face that the same are permanently deformed during the transport through two knives. Furthermore, high forces are exerted, which adversely affect the cutting performance. Such deformed fiber sections are unacceptable in many applications, and can be avoided only by means of discontinuous cutting operations.
It is therefore the object of the invention to eliminate said disadvantages of the generic method and of the generic device, and to provide a method and a device for the continuous cutting of fibers into short sections.
This object is solved by means of a method for the continuous cutting of fibers fed in the form of a fiber cable into fiber sections. The fiber cable is continuously fed to a cutting device, wherein the cutting device has a plurality of blades having a continuous movement. The fibers are initially separated into longer fiber sections by the cutting device. The longer fiber sections are then separated into shorter fiber sections by the same cutting device.
Additionally, this object is solved by means of a cutting device for carrying out the method. The cutting device has a rotationally driven knife carrier which includes a plurality of knives, having a channel that is connected to the knife carrier, which is penetrated by the knives, having a press-on element (or press-on means) for pressing the fiber cable onto the blades of the knives in a press-on direction. The knives are arranged in at least two groups, wherein the blades of the knives of the first group have a smaller distance to the press-on element in the press-on direction, than the blades of the knives of the second group.
The invention is based on the knowledge that in case of short fiber sections a significant amount of the press-on force to be exerted in the cutting direction must be applied in order to convey the fiber sections through the channel between the knives. The invention departs from the known principle and pursues a completely novel manner, wherein the fibers are initially cut into fiber sections in a first step, which have a larger length. In a subsequent second step said fiber sections are then separated into shorter fiber sections having a smaller length by means of the same knife carriers.
The advantage of the invention is that the fed fiber cable can be cut at greater distances between the knives such that the fiber cable can be fed at relatively high fiber speeds. In this manner the problems caused by the narrow distance between the knives can be avoided during the cutting of the fibers. After the first cut the fiber sections are separated by means of a subsequent cut in order to obtain the desired short fiber sections. For this purpose the distance of the blades required for the second step may also be arranged in a larger manner, thus also within a noncritical range.
In order to be able to create fiber sections that are as short as possible, the method variation is preferably utilized, wherein the fiber sections are created by means of multiple groups of knives with blades being arranged at an offset to each other. In this manner fiber sections may also be separated multiple times, wherein the cuts are preferably carried out in a successive manner.
During the cutting of the fiber cable into first fiber sections care should be taken that no lateral forces are generated at the blades of the knives, and that the movement of the blades is adjusted to the feed speed of the fiber cable. For this purpose the fiber cable is preferably fed at a partial loop of a first group of knives with blades and separated into the longer fibers sections by means of pressing the same on.
In order for the longer fiber sections to all be evenly cut, the fiber sections are each guided between adjacent blades of the first group along the knives to the blades of the next group of knives with blades, and are cut.
The final short fiber sections at a target length are directly discharged after the last cut between the knives of the last group. In this manner a continuous material flow can be realized in the press-on direction such that each cut can be carried out on the fibers at the same press-on conditions.
A device for carrying out the method according to the invention has a knife carrier, including a channel for conveying the fiber sections and knives penetrating said channel, wherein the knives are arranged in two groups. The first group of the knives is positioned closer to the fiber cable to be cut in the press-on direction such that the fibers are first pressed against the blades of said knives by the press-on element, and are then cut. A second group of the knives is arranged behind the same and carries out the second cut on the fiber sections.
Preferably the knives of the first and of the second groups are arranged successively. In this manner the distance between the knives is twice as large as the length of the fiber sections to be created. The press-on element presses the fibers of the fiber cable directly against the blades of the first knife group. The long fiber sections are continuously conveyed through the channel and pressed against the blades of the second knife group by means of additional subsequently cut fiber sections, which place themselves on top.
For this purpose the fiber sections may be separated via one blade or multiple blades such that one or multiple knives of the second group are arranged on the knife carrier between two adjacent knives of the first group.
Advantageously the knives of the second group are offset toward the back by a height offset that is at least half of a depth of the knives in the first group. Although a slight friction of the fiber sections cut to the final length between the knives of the first and of the second group may not be avoided in this manner, the friction forces can be significantly reduced. Furthermore, the effect of the fiber sections cut by the first knife group are conveyed through the channel directly after the cut, rubbing against the knives, thus experiencing a bending, but are then bent in the opposite direction during the cut made by the second knife group.
In a particularly advantageous embodiment of the cutting device according to the invention the height offset between the first knife group and the second knife group is so large that the blades of the second knife group are located completely behind the knives of the first knife group. In this case the depth of the knives of the first group is equally large as the height offset between the knives of both groups. In this manner friction forces occurring due to fiber sections rubbing between the knives of the first and second groups is avoided. Another substantial advantage of said embodiment is that relatively broad channel openings can be formed between the knives of the second group for discharging the fiber sections.
In a variation of the cutting device according to the invention the knives of the wheel-shaped knife carrier are arranged axially parallel at the outer circumference, having a blade facing toward the outside, wherein the press-on direction is directed radially toward the inside. This corresponds to a figuration according to the invention of the embodiment of cutting devices, which radially cut the fiber cable in the direction of the loop, as is described, for example, in the printed publication DE 216 00 79.
In another variation of the cutting device according to the invention the knives in turn are aligned radially with the blade facing in axial direction, having an axial press-on direction. This corresponds to a figuration according to the invention of the embodiment of cutting devices, which axially cut the fiber cable laterally to the direction of the loop, as is described, for example, in the printed publication DE 102 42 553.
BRIEF DESCRIPTION OF THE DRAWINGS
Some example embodiments of the cutting device according to the invention for carrying out the method according to the invention are described in further detail below, with reference to the attached drawings.
They show:
FIG. 1 : a schematic view of a first example embodiment of the cutting device according to the invention for carrying out the method according to the invention,
FIG. 2 : a schematic view of the example embodiment of FIG. 1 for illustrating the cutting process,
FIG. 3 : a schematic cross-sectional view of the example embodiment of FIG. 1 at a cross-section A-A of FIG. 1 ,
FIG. 4 : a schematic view of another example embodiment of the cutting device according to the invention for carrying out the method according to the invention,
FIG. 5 : a schematic cross-sectional view of the example embodiment of FIG. 4 at a cross-section B-B, having different knife arrangements,
FIGS. 6 and 7 : a schematic cross-sectional view of the example embodiment of FIG. 4 at a cross-section B-B having various knife arrangements.
DETAILED DESCRIPTION
FIG. 1 illustrates a first example embodiment of a cutting device according to the invention for carrying out the method according to the invention. FIG. 2 shows the cutting device of FIG. 1 as a detailed illustration in the contact area between a knife carrier 1 and a press-on element 2 . FIG. 3 illustrates a cross-sectional view of the example embodiment at a cross-section A-A of FIG. 1 . The following description applies to all figures insofar as no express reference is made to one of the figures.
The example embodiment of the cutting device consists of a rotating knife carrier 1 , which interacts with a press-on element 2 . The fibers in the form of a fiber cable 6 are continuously fed to the cutting device for cutting the fiber sections. The knife carrier 1 is embodied in the shape of a wheel, and consists of two collars 10 , between which the fibers of the fiber cable 6 are guided, and of a plurality of knives 4 . 1 and 4 . 2 , the blades 5 . 1 and 5 . 2 of which are directed in the direction of the outer circumference. A channel (or channel assembly) 3 is provided between the collars 10 , which is penetrated by the knives 4 . 1 and 4 . 2 such that penetrable openings are formed between the knives 4 . 1 and 4 . 2 . The fibers of the fiber cable 6 wind about the knife carrier 1 by means of the continuous rotation of the knife carrier 1 , and are positioned on top of the blades 5 . 1 of the knives 4 . 1 . The press-on element 2 , which in this case is embodied as a roller that rolls off the knife carrier 1 , presses the fibers of the fiber cable 6 against the blades 5 . 1 of the knives 4 . 1 such that the same are cut and pressed through the channel 3 , or through the openings formed between the knives 4 . 1 . Any fibers of the fiber cable 6 that are not cut are gradually wound onto the knife carrier 1 and can also be cut one rotation later at an increased press-on force.
The knives 4 . 1 and 4 . 2 are arranged in two groups. The blades 5 . 1 of the first knife group of the knives 4 . 1 clamp a cutting surface 7 , the blades 5 . 2 of the second group of the knives 4 . 2 clamp a further blade surface 8 , which has a greater distance to the press-on element 2 . This results in the fibers, as illustrated in FIG. 2 , being initially cut by the blades 5 . 1 of the first knife group of the knives 4 . 1 into long fiber sections, and being pressed in radial direction toward the inside through the openings of the channel 3 . Due to the fiber sections continuously being fed from the outside during the course of the cutting process, the same are gradually pressed toward the inside in radial direction by means of the openings of the channel 3 formed between adjacent knives 4 . 1 , until the same are cut by the blades 5 . 2 in the cutting surface 8 of the second knife group of the knives 4 . 2 .
The height offset of the knives 4 . 1 and 4 . 2 of both groups has the advantage that the intermediate spaces between the knives 4 . 1 are greater such that the fiber sections experience only little friction. In particular, the short fiber sections created by the second cut can be better discharged due to the free space behind the knife 4 . 1 of the first knife group.
For this purpose the cutting surfaces 7 and 8 may be arranged such that the knives 4 . 1 and 4 . 2 partially overlap each other so that the height offset between the knives 4 . 1 and 4 . 2 is smaller than a depth of the knives 4 . 1 of the first group. However, as an alternative it is also possible to embody the height offset at the same depth of the knives 4 . 1 so that the blades 5 . 2 of the knives 4 . 2 are arranged at a smaller or equal diameter as the rear of the outer knives 4 . 1 . In the example embodiment according to FIG. 1 the height offset is embodied smaller between the knives 4 . 1 and 4 . 2 than half of the depth of the knives 4 . 1 of the first knife group.
The size of the height offset resulting between the cutting plane 7 and 8 depends on the available installation space, the size of the knives 4 . 1 and on the required friction relationships, and represents a compromise that is easily found by the person skilled in the art.
After the cutting operation the fiber sections are conveyed further toward the inside in radial direction, and are transported away in a manner not illustrated herein.
FIG. 4 illustrates a further example embodiment of the cutting device according to the invention. FIG. 5 shows a cross-sectional illustration of the example embodiment having the cross-section B-B illustrated in FIG. 4 . The following description applies to both figures, unless express reference is made in the figures.
The example embodiment according to FIGS. 4 and 5 has a rotation symmetric knife carrier 1 , which has multiple knives within a channel 3 extending radially in circumferential direction. For this purpose the knives are arranged substantially radially, having blades within the channel 3 that face in axial direction. The knife carrier 1 interacts with a press-on element 2 , which is embodied as a rotating press-on ring, and penetrates into the channel 3 at a nose. Such a cutting device is described, for example, in DE 102 42 553, the teachings of which are hereby incorporated by reference in their entirety.
The main difference to the known cutting device is the fact that multiple groups of knives are arranged within the channel 3 in the example embodiment shown in FIG. 4 . The knife carrier 1 has a knife holder 9 having two groups of knives 4 . 1 and 4 . 2 , which are aligned radially. The blades 5 . 1 and 5 . 2 of the knives 4 . 1 and 4 . 2 face in axial direction toward the side of the press-on element such that a fiber cable guided in the channel 3 is pressed in axial direction against the blades 5 . 1 of the knives 4 . 1 . In this case the channel 3 is embodied as an axially parallel annular channel. The fiber cable 6 not illustrated herein is fed to the channel 3 in axial direction, and is pressed against the blades 5 . 1 and 5 . 2 of the knives 4 . 1 and 4 . 2 by means of the annular press-on element, which is embodied as a rotating cup wheel having a slightly tilted pivoting axis as opposed to the pivoting axis of the knife carrier 1 .
Analogous to the cylindrical cutting surfaces 7 and 8 of both knife groups of the knives 4 . 1 and 4 . 2 in FIGS. 1 to 3 plane cutting surfaces 7 and 8 are formed in the example embodiment shown by means of both groups of the knives 4 . 1 and 4 . 2 , which are clamped by means of the blades 5 . 1 of the knives 4 . 1 in a first knife plane, or by means of the blades 5 . 2 of the knives 4 . 2 of a second knife plane, respectively.
The arrangement of the knives 4 . 1 and 4 . 2 is clear particularly from the image shown in FIG. 5 . FIG. 5 illustrates a cutout of a cross-sectional illustration of the example embodiment of FIG. 4 at a cross-section B-B of FIG. 4 . Two groups of knives 4 . 1 and 4 . 2 are successively arranged at a distance to each other at the knife holder 9 . The blades 5 . 1 of the knives 4 . 1 of the first group form a first cutting surface 7 . The blades 5 . 2 of the knives 4 . 2 of the second group form a second cutting surface 8 . The cutting surface 7 and the cutting surface 8 are offset by a height offset that is set between the knives 4 . 1 and 4 . 2 in vertical direction, which in this case is equal to the axial direction of the cutting device. The height offset is denoted by the capital letter H. The height offset H in this example embodiment is selected such that the blades 5 . 2 of the knives 4 . 2 end at the base of the knives 4 . 1 . For this purpose the height offset H is embodied equal to a depth of the knives 4 . 1 . The depth of the knives 4 . 1 is denoted by the capital letter T.
Due to the offset arrangement at the height offset H equal to the depth T, correspondingly large openings are created between the knives 4 . 2 for the discharge of the fiber sections in the channel. In this manner the fiber sections can be discharged in the channel 3 directly after cutting by the knives 4 . 2 of the second group.
The function for cutting the fiber cable and the fiber sections in the example embodiment according to FIGS. 4 and 5 is identical to the example embodiment according to FIGS. 1 to 3 so that no further explanations are provided at this point.
In the example embodiments shown the fibers are cut in two steps by means of two knife groups. For this purpose the knives of the knife groups are successively arranged such that a fiber section created by the knives of the first knife group is cut in the center as much as possible by an offset knife of the second knife group. In this manner the longer fiber section is twice as long as the short fiber section of the fibers. However, it is generally also possible to cut a fiber section cut by a first knife group multiple times so that the longer fiber section has triple or four times the length of the shorter fiber section. For this purpose further example embodiments of knife arrangements are illustrated in FIGS. 6 and 7 , as the same could be utilized, for example, in the cutting device according to FIG. 4 .
FIG. 6 illustrates a knife holder 9 , wherein the knives 4 . 1 and 4 . 2 of two knife groups are arranged at an offset to one another. The blades 5 . 1 of the knives 4 . 1 form a first cutting surface 7 , and the knives 4 . 2 arranged by a height offset form a second cutting surface 8 with the blades 5 . 2 thereof. Two knives 4 . 2 of the second group are arranged between two adjacent knives 4 . 1 of the first knife group. The knives 4 . 1 and the knives 4 . 2 are symmetrical to each other and form an equal distance to each other.
In the example embodiment illustrated in FIG. 6 a fiber of the fiber cable is initially cut into long fiber sections, the length of which is determined by the distances between the knives 4 . 1 of the first knife group. Subsequently each of the long fiber section guided between two knives 4 . 1 is cut into three equally short fiber pieces by means of two knives 4 . 2 of the second group.
A further possible arrangement of knife groups is shown in FIG. 7 in order to cut the fibers in fiber sections that are as short as possible. In this example embodiment a total of three groups of knives 4 . 1 , 4 . 2 , and 4 . 3 are arranged on the knife holder 9 at an offset to each other. In this manner the blades 5 . 1 of the knives 4 . 1 form a first cutting surface 7 , the blades 5 . 2 of the knives 4 . 2 form a second cutting surface 8 , and the blades 5 . 3 of the knives 4 . 3 form a third cutting surface 11 . The knives 4 . 1 and 4 . 3 are arranged successively on the knife holder, wherein an equal distance is set between the knives 4 . 1 , 4 . 2 , and 4 . 3 . A first height offset is set between the knives 4 . 1 and the knives 4 . 2 , and a second height offset is set between the knives 4 . 2 and 4 . 3 so that the fibers are successively cut into fiber sections in three steps.
The arrangement of the knife groups illustrated in FIGS. 6 and 7 is shown by way of example. Generally, such knife arrangements may also be carried out in the cutting device according to the example embodiment of FIG. 1 . Furthermore, it is also possible that the knives are arranged at multiple knife holders in a distributed manner, interacting with each other for cutting the fiber and fiber sections.
LIST OF REFERENCE SYMBOLS
1 knife carrier
2 press-on element
3 channel
4 . 1 knife
4 . 2 knife
5 . 1 blade
5 . 2 blade
6 fiber cable
7 cutting surface of the first knife group
8 cutting surface of the second knife group
9 knife holder
10 collar
11 cutting surface of the third knife group
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A method and a cutting device for the continuous cutting of fibers fed in fiber cables into fiber sections of particularly short length is disclosed. In order to avoid high friction forces between the formed knives and the fiber sections, and furthermore, to prevent excessive deforming of the fiber section during the transport between the knives, the knives are arranged at an offset to each other such that the fibers are initially cut into longer fiber sections, and into shorter fiber sections in a second step. The respective free space between the knives is increased due to the offset arrangement of the knives.
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This application is a continuation of application Ser. No. 452,038, filed Dec. 18, 1989, abandoned.
FIELD OF THE INVENTION
This invention relates generally to an integrated system for space heating and for heating water for general service use. Specifically, the invention relates to a heating system having a water heating module employing the latent heat of condensation of the hot gases of combustion from the system burner to preheat fluids entering the relatively small fluid heating volume of the module and thus achieving a high thermal efficiency.
DESCRIPTION OF THE PRIOR ART
Conventional space heating systems using a central furnace all operate on the same general principles. Air for a space to be heated is circulated through and is heated by a heat exchanger. The heat exchanger may be in contact with the burning fuel and its hot gases of combustion or in contact with a secondary fluid which has been heated by a burning fuel. Such systems are usually either of the forced air or hydronic type, but may be a combination of both. Most such systems in general use have indirect furnaces, in which the air being heated is not in direct contact with the burning fuel or its gases of combustion.
In a conventional forced air heating system, the furnace has a combustion chamber in which a flame generates heat and gases of combustion. The heat and combustion gases rise through an attached heat exchanger before exiting through a flue or chimney. Air from the space to be heated is circulated around the exterior of the heat exchanger where it is heated by convection and conduction from the heat exchanger.
In a conventional hydronic heating system, a fluid is heated in a heat exchanger in contact with burning fuel within a furnace. The fluid heat exchanger is in a closed loop by which heated fluid is circulated to radiators located in the space to be heated. The air in the space is usually heated by convective flow around the radiators.
In a combination system, a fluid is heated as in a hydronic system, but then circulates through a closed loop to a heat exchanger, where forced air passes over the heat exchanger to be heated before being circulated as in a conventional forced air heating system.
Convection water heaters used to supply hot water for general domestic and other uses in houses and other buildings usually consist of a relatively large hot water storage tank. Cold water enters the tank, where it is heated by a flame burner located at the bottom of the tank. A flue generally passes from the combustion chamber at the bottom of the tank through the tank to carry gases of combustion produced by the burner to an external flue or chimney. In most residential and commercial installations, the system for heating water is separate from the system for space heating.
Both space heating furnaces and hot water heaters of conventional design exhaust the gases of combustion to the atmosphere through flues or chimneys while the gases are still relatively hot (sometimes in excess of 500° F.), resulting in relatively low thermal efficiencies, as much of the energy contained in the burning fuel is lost "up the flue" without heating air or water. Ambient heat losses from the relatively large volume of water in conventional hot water heaters contribute to the degradation of efficiency in those systems.
The relatively low thermal efficiency of conventional space and hot water heating systems result in higher operating costs over the life of such systems. In addition, those systems are relatively costly to install, because of the cost of the chimney or flue required, and, as is usually the case, the necessity to provide separate fuel lines and separate chimneys or flues for each of the separate space heating and water heating systems.
Economic and environmental considerations have led to increased interest in improving the thermal efficiency and eliminating energy waste in the design and construction of space and water heating systems. There is also interest in producing compact heating units which will occupy a minimum of space within buildings. Generally, however, an increase in furnace efficiency does not necessarily result in a reduction of size, because the structure of the furnace is determined by the requirement for relatively large heat exchanger surface areas to transfer heat from the burning fuel and hot combustion gases to the space air or heat transfer fluid. Similarly, hot water heater size has not decreased, but in some modern, more energy efficient designs, it has actually increased.
There is, therefore, a continued, demonstrated need for a compact, yet highly efficient integrated system for space and water heating.
SUMMARY OF THE INVENTION
An object of the present invention is to combine, in a single integrated system, the functions of both space and water heating.
Another object of the present invention is to achieve high thermal efficiency in a compact system for both space and water heating.
A further object of the invention is to attain the capability, in a compact system, to supply instantaneous and continuous hot water service and simultaneously to heat a space or spaces yet, at the same time, to minimize burner cycling during periods of lower intermittent demand for hot water.
These and other objects of the invention are attained in an integrated system having a heating module which supplies heated fluid to a fluid flow loop. The fluid is circulated in the loop to a space heating heat exchanger by a circulating pump. The module also supplies heated water for general domestic or other use. The heating module is of the high thermal efficiency condensing type and contains storage for a small volume of heated water to supply small intermittent hot water demands. The system may be configured to operate on an open loop principle, in which space heating and water heating subsystems are combined and share common lines, or a closed loop system, in which the space heating subsystem is isolated from the water heating subsystem.
The novel features embodied in the invention are pointed out in the claims which form a part of this specification. The drawings and descriptive matter describe in detail the advantages and objects attained by the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings form a part of the specification. Throughout the drawings, like reference numbers designate like or corresponding elements.
FIG. 1 is a schematic representation of one embodiment of the present invention, in which the system operates on an open loop principle, i.e. the entire system is filled with potable water and service hot water is drawn directly from the same source that supplies hot water to the space heating heat exchanger.
FIG. 2 is a schematic representation of another embodiment of the present invention, in which the system operates on a closed loop principle, i.e. the loop subsystem supplying heated fluid to the space heating heat exchanger is closed and separate from the subsystem for heating service hot water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts schematically one preferred embodiment of the invention, in which the system operates in an open loop principle, i.e. the entire system is filled with potable water and service hot water is drawn from the same source that supplies hot water to the space heating heat exchanger.
In FIG. 1, heating system 21 includes an integrated heating module 22, space heating heat exchanger 23 and a circulating fluid loop. Space heating heat exchanger 23 typically may be a plate fin heat exchanger or a radiator having air flowing through it in the direction of the large arrow into the space 32 to be heated. Air in space 32 may circulate through heat exchanger 23 by convection or be forced through by a fan. Heat exchanger 23 receives hot water from heating module 22 through inlet pipe 25. Water circulates from space heating heat exchanger 23 through outlet pipe 26 to circulating fluid pump 24, then is returned to heating module 22 through pump discharge pipe 27. Expansion tank 31 is connected to pump discharge pipe 27 to provide volume for expansion of water as it is heated and to dampen any pressure surges in the system.
Heating module 22 includes burner 41 in burner cavity 45 supplied with combustible gas 42 through regulator 43. The burner may be a conventional ribbon type, a jet or "inshot" burner or preferably, a radiant infrared burner. Ignition device 44, which initially lights the burner on start-up of the module, is a conventional furnace control not discussed in detail here. In such a control, a spark ignition or hot surface igniter system ignites the burner and a flame detector senses whether combustion actually occurs.
Within heating module 22 are heater tank 51 and preheater 52 separated by partition 57. Partition 57 may be insulated. Water in heater tank 51 is heated by heat from burner 41 and tank flue 53. The volume of heater tank 51 is sized to provide a small amount of stored hot water to reduce burner cycling during periods of low demand on the system. Pressure relief valve 55 protects heater tank 51 from overpressure. Tank flue 53 extends from burner cavity 45 through heater tank 51, partition 57 and preheater 52. Induction draft unit 56, such as a fan, draws on tank flue 53, causing a flow of gases of combustion from burner cavity 45, through tank flue 53 and out of the module to external vent flue 54 from which the gases are exhausted to the atmosphere. Gas flow through burner 41, burner cavity 45, tank flue 53 and vent flue 54 may also be effected by use of a blower upstream in the gas flow path. Heat is transferred to water in heater tank 51 and preheater 52 from the hot gases of combustion in tank flue 53.
Cold makeup water is supplied to the system via cold water inlet 61 from a source of water such as a potable water supply line. A check valve (not shown) may be installed in the potable water supply line upstream of cold water inlet 61 to prevent back flow into the line from system 21. Cool water returning from space heating heat exchanger 23 through pump discharge pipe 27 mixes with makeup water, if any, from cold water inlet 61 and enters preheater 52. In preheater 52, the cool water is preheated by hot gases of combustion in tank flue 53 before entering heater tank 51 via preheater-to-heater tank water transfer line 63. The preheating process also serves to condense combustion gases in tank flue 53, increasing the thermal efficiency of the module.
Hot water is drawn from heating module 22 via heater tank hot water outlet 64 on demand from either space heating heat exchanger 23 or from hot water service line 65. A thermostatic control device, not shown, is set to control the temperature of the hot water in heater tank 51. If the set temperature at heater tank hot water outlet 64 is greater than that desired in hot water service line 65, optional tempering valve 72, controlled by a thermostat (not shown), and tempering water supply line 71 can be provided to mix cold water from cold water supply 61 with hot water from heater tank hot water outlet 64 to achieve the desired water temperature in hot water service line 65.
FIG. 2 is a schematic representation of another of the preferred embodiments of the invention, in which the system operates on a closed loop principle, i.e. the loop supplying heat transfer fluid to the space heating heat exchanger is closed and separate from the subsystem for heating service hot water. The heat transfer fluid in the space heating loop may be water, but preferably a mix of water and glycol.
A number of elements of the closed loop embodiment of the present invention are common or have like function to similar elements of the embodiment disclosed in the above description of the open loop system. Features that are common to the two embodiments and function similarly have the same reference numbers in the closed loop embodiment depicted in FIG. 2 as in the open loop embodiment depicted in FIG. 1. The major differences in the two embodiments are in the internal configurations of the heating modules and the connections of the modules to the remainder of the system made necessary by the requirement, in the closed loop embodiment, to isolate the space heating subsystem from the hot water service subsystem.
Referring to FIG. 2 and the above description of the open loop system shown in FIG. 1, heat transfer fluid for space heating is heated within heating module 22 by fluid heater 83 which is immersed in the water volume of heater tank 51 of heating module 22. Heat transfer fluid circulates from heating module 22 through a closed loop from heater tank hot liquid outlet 67 through heat exchanger inlet pipe 25, space heating heat exchanger 23, where heat is transferred to air to be heated, heat exchanger outlet pipe 26, circulating fluid pump 24 and pump discharge pipe 27 before returning to heating module 22. There is no mixing of the heat transfer fluid with water from cold water supply 61. Within preheater 52 of heating module 22 is fluid preheater 81, immersed in the water volume of preheater 52. When system 21 is operating, the water volume in preheater 52 will generally be at a higher temperature than the returning heat transfer fluid in fluid preheater 81. The water volume will therefore preheat the heat transfer fluid in fluid preheater 81, thus reducing the temperature of the water volume in preheater 52 and enhancing the condensation of the gases of combustion in tank flue 53. From fluid preheater 81, the heat transfer fluid flows to fluid heater 83 in heater tank 51 of heating module 22 via fluid preheater-to-fluid heater transfer line 82. Water to be heated for hot water service is taken from cold water supply 61 and flows through preheater 52, where it is preheated by and condenses the hot gases of combustion in tank flue 53. The preheated water then flows through preheater-to-heater tank water transfer line 63 into heater tank 51, where it is heated by heat from burner 41 and tank flue 53. Hot water is drawn from heating module 22 via heater tank hot water outlet 64 on demand from hot water service line 65. If necessary optional tempering valve 72, controlled by a thermostat (not shown), which mixes water from cold water supply 61 with hot water from heater tank hot water outlet 64 via tempering water supply line 71, can be provided to achieve the desired hot water service supply temperature.
The physical size and operating parameters of the system embodying the invention are variable and depend on the specific application to which the system is put. For use in a typical residential application, the heating module would have a heating capacity of approximately 110,000 BTU/HR. In such an installation, the volume of the heater tank 51 in the heating module 22 would be about six U.S. gallons. Satisfactory space heating performance should be attained with heater tank outlet temperatures in the range of 120° F.-200° F. If that range is greater than that desired in the hot water service line, the heater tank output can be tempered to attain the desired service line water temperature.
The open loop embodiment offers the advantages of reduced cost and less complexity over the closed loop embodiment. However, the closed loop system may have advantages in certain applications, such as where local building or plumbing codes prevent the use of open loop systems.
While two preferred embodiments of the present invention are shown and described, those skilled in the art will appreciate that many variations may be constructed and yet remain within the scope of the invention. As discussed above, the system of the invention may be made in a wide range of sizes and heating capacity for use in a variety of applications. The drawings show a single space heating heat exchanger while the system may be configured with more than one such heat exchanger. The system could be used as solely a hydronic space heating system or solely as a water heating system. It is intended, therefore, that the scope of the present invention be limited only by the scope of the below claims.
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An integrated system for both space and water heating. Heating is accomplished in a condensing heating module having a small hot water storage reservoir to reduce burner cycling during periods of low demand. The space heating system includes a fluid flow loop with a fluid circulating pump for circulating a heat transfer fluid in the loop from the heating module to a remote space heating heat exchanger. The heating module can also supply hot water for service use. The system may be configured either as an open loop system, in which the space heating and water heating subsystem are combined and share common lines, or a closed loop system, in which the space heating subsystem fluid flow loop is isolated from the water heating subsystem.
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BACKGROUND OF THE INVENTION
This invention relates to a process for the preparation of amino-substituted penicillins and, more particularly, to an efficient process for producing α-aminobenzylpenicillin and related ring-substituted compounds in high yield and purity.
α-Aminobenzylpenicillin and α-amino-substituted-benzylpenicillins are well known in the art and numerous processes have been proposed for their production. In general these processes involve the reaction of 6-amino-penicillanic acid with an acylating agent such as the acid chloride, acid bromide, acid anhydride, and mixed anhydride of a derivative of α-aminophenylacetic acid or α-amino-substituted-phenylacetic acid in which the amino group is protected with a suitable protecting group.
These known methods for the preparation of α-aminobenzylpenicillins and α-amino-substituted benzylpenicillins by the acylation of 6-aminopenicillanic acid result in the preparation of mixtures which contain, in addition to the desired penicillin, unreacted starting materials, hydrolyzed acylating agent, and products of side reactions which are often difficult to separate from the desired penicillin reaction product.
Various ways have been proposed in the past to remove these unwanted materials such as, for example, the formation of insoluble arylsulfonic acid salts of α-aminobenzylpenicillin as described in U.S. Pat. No. 3,180,862, or the even more complex isolation process of U.S. Pat. No. 3,271,389, but in each case the known recovery procedures have been concentrated on removing the contaminants after the desired α-amino-substituted benzyl penicillins have been formed. Consequently, these known processes are characterized by complex procedures which at the very least increase the cost of producing the desired penicillin product.
SUMMARY OF THE INVENTION
It has now been discovered that α-aminobenzylpenicillin and α-amino-substituted-benzylpenicillins may be produced in high yield and purity by separately removing unwanted solid contaminants from a solution of aminopenicillanic acid (preferably in the form of a water-soluble salt) and removing unwanted solid contaminants from a solution of an acylating agent, preferably by filtration, before combining them in a reaction mixture. Because of the known instability of mixed anhydrides when used as acylating agents, a relatively low temperature, i.e., about -50° C, will preferably be maintained following its formation and its separation from unwanted contaminants prior to its mixture with the solution containing 6-aminopenicillanic acid or its water-soluble salt.
Accordingly, it is a principal object of the present invention to provide an efficient process for producing α-aminobenzylpenicillin and α-amino-substituted-benzylpenicillins in high yield and purity. This and other objects of the present invention are achieved in the manner briefly summarized above and described in greater detail in the ensuing discussion.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compounds produced according to the process of this invention include those having the general formula: ##SPC1##
wherein R 1 , R 2 and R 3 each represents a member selected from the group consisting of hydrogen, nitro, di(lower)alkylamino, (lower)alkanoylamino, (lower)alkanoyloxy, (lower)alkyl (including straight and branched chain saturated aliphatic groups having from 1 to 6 carbon atoms inclusive), (lower)alkoxy, hydroxy, sulfamyl, chloro, iodo, bromo, fluoro, trifluoromethyl, (lower)alkylthio, (lower) alkyl-sulfonyl, carbo(lower)alkoxy, benzyl, phenethyl, cycloheptyl, cyclohexyl and cyclopentyl; and their sodium, potassium, calcium, aluminum and ammonium salts with an amine selected from the group consisting of trialkylamines, procaine, dibenzylamine, N-benzylbeta-phenethylamine, 1-ephenamide, N,N'-dibenzylethylenediamine, dehydroabietylamine, N,N'-bis-dehydroabietylethylenediamine, N-(lower) alkylpiperidine, and other amines which have been used to form salts of benzylpenicillin, as well as easily hydrolyzed esters or amides which may be converted to the free form by chemical or enzymatic hydrolysis and the anhydrous and hydrated forms of these compounds. Also, recognizing the fact that the above compounds can exist in two optically active isomeric forms, i.e., the D- and L-diastereoisomers, as well as a racemic mixture of such forms, it should be understood that the process of this invention extends to the preparation of such isomeric forms of the compounds.
The products of the present invention may be prepared by reacting 6-aminopenicillanic acid, preferably in the form of a water-soluble salt such as the sodium salt or triethylamine salt, with an acylating agent such as a carboxylic acid chloride or bromide, an ester of chlorocarbonic acid, an acid azide, an acid anhydride of a carboxylic acid, or preferably, a mixed acid anhydride derived from a carboxylic acid.
The 6-aminopenicillanic acid or water-soluble salt thereof utilized in this invention may be produced by any of the known methods such as, for example, the procedure disclosed in U.S. Pat. No. 3,499,909.
The acylating agent may also be prepared by known procedures, an example of which may be found in U.S. Pat. Nos. 3,576,797 and 3,071,575. In a preferred embodiment the acylating agent will be a mixed anhydride prepared, for example, by reacting an N-protected amino-substituted carboxylic acid salt (such as described by Dane et. al., Angew Chem., 1962, 74,873. with an ester of chlorocarbonic acid, e.g., ethylchlorocarbonate.
Because of the known instability of mixed anhydrides, it is particularly useful in this embodiment to maintain the mixed anhydride in an anhydrous, inert and preferably water-miscible solvent, such as p-dioxane or acetone, which is kept at a temperature of about -50° C or below.
Whichever method is employed in producing the 6-aminopenicillanic acid and acylating agent according to this invention, before bringing them together in solution in a reaction mixture the reactants are separately treated to remove contaminants such as unreacted starting materials or impurities therein, reaction by-products, and the like, therefrom. Any conventional method may be used for this purpose although filtration is the most convenient and, therefore, the preferred procedure.
After the reactants are treated to remove the contaminants, they are mixed together according to known procedures to produce the α-amino- or α-amino-substituted-benzylpenicillins.
The following example will further illustrate the invention.
EXAMPLE
A mixed anhydride solution of 96 kg. of N-(2-carbethoxy-1-methylvinyl)-2- phenylglycine ethoxyformic anhydride in 785 liters of acetone was filtered to remove solid material therefrom and maintained at a temperature of about -50° C. In a separate mixing container, 60 kg. of 6-aminopenicillanic acid in 100 liters of water was mixed with 39 liters of triethylamine while maintaining the temperature between 5°-15° C and a pH of between 8.0-8.7. The resulting triethylammonium salt of 6-aminopenicillanic acid in solution was filtered, maintained at a temperature of about -20° C and rapidly added to the mixed anhydride solution where mixing was containued for about 1 hour while maintaining a reactor temperature below -42° C. The reaction mixture was diluted with water, brought to pH 1.5 with hydrochloric acid, and agitated at 0° C for 1/2 hour. It was then twice extracted with methylene chloride, the water phases being retained, and treated with ammonium hydroxide to precipitate a solid which was collected, washed with water, dried, and identified as D-(- )-α-aminobenzylpenicillin trihydrate.
When the term α-aminobenzylpenicillin is used in the ensuing claims it is intended to encompass α-amino-substituted-benzylpenicillins and all of the derivatives hereinbefore described.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A process for producing α-amino and α-amino-substituted-benzylpenicillins in high yield and purity by separately removing solid contaminants from a solution containing a 6-aminopenicillanic acid reactant and an acylating agent solution prior to combining them in a reaction mixture.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a rotor of a pressure wave machine in accordance with the preamble.
2. Discussion of Background
In pressure wave machines, when they are used as the supercharging unit for internal combustion engines, ambient air is compressed to boost air; when they are used as the high pressure compressor stage of a gas turbine, precompressed air is further compressed to produce driving gas for the high pressure turbine part. The compression of the air takes place in a rotor whose periphery has cells, which in present-day designs run parallel to the axis, in which cells the air comes into direct contact, without any solid separating element, with the exhaust gas from the engine or with driving gas branched off from the combustion chamber of the turbine group. In order to control the inlets and outlets of air and gas into or out of the cells, a casing with ports for the supply and/or removal of the two media participating in the pressure wave process is located at the two end faces of the rotor. If a cell filled with air which has to be compressed passes in front of a high pressure gas inlet, a pressure wave propagates into the cell where it compresses the air. This pressure wave reaches the end of the cell as soon as the latter passes the high pressure air outlet. At this point, the air is expelled and the cell is then completely filled with gas. On further rotation, expansion waves ensure that the gas leaves the cell again and that fresh air is induced, whereupon the compression process is repeated.
A critical circumstance, which is also decisive for the pressure wave machine process, consists in the fact that the dimensions of the cells cannot be arbitrarily increased without influencing the pressure wave machine process and that, for machines with different power, rotors with different diameters have to be provided in each case.
SUMMARY OF THE INVENTION
The object of this invention, as characterized in the claims, is to provide the cells in a rotor of a pressure wave machine of the type described at the beginning in such a way that they can be arbitrarily enlarged without influencing a process taking place in the pressure wave machine.
The essential advantage of the invention may be seen in the fact that the mixing processes on the opening of the cell and in consequence of the Coriolis forces take place in the same plane. The dimensions of the cell therefore only have to be kept small in the peripheral direction whereas, in the axial direction, there is no limitation to the dimensions of the cells. In consequence, the frictional resistance and the heat transfer can be reduced relative to an approximately square cell. In addition, machines with different powers can be manufactured simply by changing the rotor length at the same diameter.
A further advantage of the invention may be seen in the fact that it is possible for individual phases of the process to compensate completely or partially, by appropriate curvature of the cells in the peripheral direction, for the Coriolis forces, inter alia, which occur due to the radial motion in a rotating system.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 shows a cell rotor in cross-section and
FIG. 2 shows a side view of the cell rotor, which has curved cells.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, in which the direction of the media is indicated by arrows and in which all elements not necessary for immediate understanding of the invention are omitted, FIG. 1 shows a cell rotor 1 which consists of a hollow inner part and which carries rotor cells 2 in a plane normal to the axis of rotation of the cell rotor 1. On one side, the rotor body carries a hub 3 which has a bore hole for cooling or throughflow reasons. This hub 3 is connected to the axial physical boundary of the cells 2 by means of a number of connecting elements 4. The inflow 5 or 5a and the outflow 6 or 6a of the media therefore also occur normal to the axis of rotation of the cell rotor 1. This configuration has the effect that the mixing processes on the opening of the cell and in consequence of the Coriolis forces occurring due to the arrangement of the rotor cells 2 can take place in the same plane, which acts preferentially in a very advantageous manner for an energy exchange process. Because of this fact, the dimensions of the rotor cells therefore only have to be kept small in the peripheral direction whereas, in the axial direction, there is no limitation to the dimensions of the rotor cells. In consequence, the frictional resistance and the heat transfer can be reduced relative to an approximately square cell corresponding to the state of the art. Machines of different power can therefore be covered simply by changing the length of the cell rotor 1 without changing the diameter at all. This makes it possible to develop a more compact range of designs, and the possibilities for the application of this cell rotor 1 increase disproportionately because, in most cases, an increase in the diameter of the cell rotor 1 involves insuperable structural difficulties. Reference should be made to the comments under FIG. 2 for the geometrical design of the connecting elements 4.
FIG. 2 shows the same cell rotor 1 according to FIG. 1 in a side view. Coriolis forces, inter alia, occur during a radial motion in a rotating system. By means of appropriate curvature of the rotor cells 2 in the peripheral direction, as can be seen particularly well from FIG. 2, it is possible to compensate completely or partially for these Coriolis forces, or for the mixing processes caused by them, for individual phases of the energy exchange process. It is then important that the curvature of the rotor cells 2 should be curved against in the direction of rotation so that the postulate quoted above can be satisfied. In this configuration of the cell rotor 1, large differences in thermal expansion occur between the relatively hot rotor casing 1a and the relatively cool hub 3. This can be compensated by a so-called elastic configuration of the connecting elements which are shaped in such a way that they are only flexible with respect to radially symmetrical expansions of the cell rotor and the stress peaks can be displaced from the hot region into the cool region. This design has, firstly, the advantage that the hub 3 can be kept cool and that, therefore, only the tubular casing 1a has to be manufactured from a heat-resistant material. In addition, the expansion coefficients of the materials used can be different. Furthermore, very rapid temperature changes (e.g. changes to the operating condition or emergency shut-down) can be dealt with without stress problems because it is not necessary to wait for the temperature to even out. Furthermore, this connection is very stiff with respect to all deformations which are not radially symmetrical, so that there are no additional natural frequency problems. The geometry of the connecting elements 4 (spokes) should be selected in such a way that:
a) The stresses due to centrifugal force and different thermal expansions are superimposed on the cool hub whereas they partially compensate for one another on the hot cell rotor 1.
b) At the outer connecting point (cell rotor), the thermal stress should be approximately half as large as the centrifugal stress.
This ensures that, commencing from a starting condition (cold cell rotor at rated speed), the stress at the hub 3 increases with increasing cell rotor temperature and that at the cell rotor 1 decreases. This takes account of the decreasing load-carrying capacity of the material with increasing temperature. By means of the particular choice of the ratio of thermal stress to centrifugal stress, it is possible to ensure that the stress level at the outer connecting point for a hot cell rotor 1 over the complete speed range does not exceed half the value of the centrifugal stress. This is particularly important in the case of emergency shut-down and in machines which are subject to strong fluctuations during operation, such as is the case where the cell rotor 1 is employed as the pressure wave machine in an engine-driven vehicle.
These connecting elements 4 designed as spokes join the hub 3 tangentially so that the shape of these spokes 4 is kept curved as far as the rotor casing 1a. Owing to the technical stress considerations mentioned above, the curvature is preferably to be kept curved in the direction of rotation ω of the rotor 1. The number and material thickness of the spokes 4 depend on the particular size of the rotor 1 and on the dynamic forces to which the rotor 1 is subjected.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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In a rotor of a pressure wave machine, rotor cells (2) are evenly distributed at its periphery, these rotor cells being intended to accept two gaseous media during operation for the purpose of compressing the first by means of pressure waves of the second medium. The rotor cells are arranged in such a way that they extend in a plane normal to the axis of rotation of the rotor (1).
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THE INVENTION IN GENERAL
This invention relates to a pump assembly, and more particularly, to one wherein means such as a servo pump are employed to impulse a bladder-like device which in turn impulses a retention chamber to pressurize a fluid retained therein. The servo pump may be operated to provide a single, sustained pulse; or it may be operated to provide intermittent pulses which are interspaced with alternate intake or suction pulses in the chamber.
There is no necessity for contact between moving parts in the pump assembly, and the assembly can produce a high capacity flow, even of heavily slurried liquids. The assembly is also reducible to a highly compact form, and it can be directly driven by the servo pump, or it can be remotely operated at great distances from the site of the servo pump, including at great depths in the surface of the earth, as for example, when it is used as a down-the-hole pump. The assembly is also convertible in part to other purposes, including earth drilling. For example, as shall be seen, the assembly combines a conduit and an interior pulse generating mechanism, and if desired, the pulse generating mechanism can be removed from the conduit to enable the conduit to be used for these other purposes, such as for earth drilling purposes. Alternatively, the mechanism may be maintained in the conduit, and operated either concurrently with the drilling operation, or alternately therewith.
Other advantages will also become apparent as the invention is described in more detail.
According to the invention, the pump assembly comprises means defining a fluid retention chamber having an inlet opening and an outlet opening therein, and check valve means adjacent the inlet and outlet openings, which are operative to limit the fluid flow therethrough to relatively inward and outward of the chamber, respectively, when there is a fluid pressure differential thereacross. The pump assembly also comprises hollow pulse generating means in the chamber, having a volume of less than that of the chamber, but including a normally contracted, resiliently flexible portion which is responsive to a fluid pressure pulse in the hollow of the pulse generating means, to flex in relation to the normally contracted condition thereof. It also comprises impulsing means which are operative to impart a fluid pressure pulse to the hollow of the pulse generating means, to cause the flexible portion of the pulse generating means to flex and impart a fluid pressure output pulse to a fluid medium retained in the chamber.
The chamber defining means may be rigid such that the volume of the chamber remains the same as the resiliently flexible portion of the pulse generating means undergoes flexure therein. Or the chamber defining means may include a relatively shiftable portion which is interconnected with the pulse generating means and responsive to flexure of the resiliently flexible portion thereof to vary the volume of the chamber.
The pulse generating means and the chamber may be coaxial with one another; or they may have relatively offset axes. Also, the pulse generating means and the inlet and outlet openings may be coaxial with one another so that the fluid passes about the pulse generating means in flowing between the openings; or the pulse generating means and the openings may have relatively offset axes so that the fluid bypasses the pulse generating means in flowing between the openings. However, in the latter case, the inlet and outlet openings themselves are preferably coaxial with one another.
The impulsing means may include a servo pump which is operatively interconnected with the hollow of the pulse generating means. Also, the hollow of the pulse generating means may have a mandrel-like finger inserted therein, which occupies a substantial portion thereof. The finger may be closed to the hollow, or it may be open to the hollow and the servo pump may be operatively interconnected with the hollow through the opening of the finger.
In certain of the presently preferred embodiments of the invention, the pulse generating means is accordian-like in construction, and is connected at one end to the chamber defining means. Where the chamber defining means is rigid, the volume of the chamber remains the same as the pulse generating means deflects in accordian-like fashion. Where the chamber defining means includes a relatively shiftable portion, that portion is preferably interconnected with the other end of the pulse generating means, so that it is responsive to the lengthwise deflection of the same to vary the volume of the chamber. Where the hollow of the pulse generating means has a finger inserted therein, the finger is preferably coaxial with the pulse generating means. Where the finger is open to the hollow, and the servo pump is interconnected with the hollow through the opening of the same, the servo pump preferably includes a piston-like member which is reciprocably guided in the finger to impart the fluid pressure pulse adjacent the opening. Also, the finger is preferably cantilevered into the hollow from the one end of the pulse generating means, and the opening of the finger is adjacent but spaced from the other end thereof. The resiliently flexible portion of the pulse generating means is disposed about the outer periphery of the finger, and the finger has longitudinally extending flutes in the outer peripheral surface thereof, to enable the fluid in the hollow to move lengthwise of the finger when the resiliently flexible portion of the pulse generating means assumes the contracted condition thereof.
The servo pump may be operative to impart intermittent fluid pressure pulses to the hollow of the pulse generating means; or it may impart only a single pulse, whereafter the pulse is sustained by the servo pump. This will depend, of course, on the utility to which the invention is applied.
One utility for the invention is as a small diameter, large capacity down-the-hole pump. In this and other such cases, the chamber defining means may take the form of an elongated pipe having spaced partitions therein defining the chamber together with the pipe. The inlet and outlet openings are located in the partitions, and the servo pump is interconnected with the hollow of the pulse generating means by an elongated feed pipe passing through the bore of the chamber defining pipe and communicating with the hollow through the partition having the inlet opening therein.
BRIEF DESCRIPTION OF THE DRAWINGS
These features will be better understood by reference to the accompanying drawings wherein three of the aforementioned embodiments are illustrated.
In the drawings, FIG. 1 is a vertical cross section of one embodiment in use as a down-the-hole pump;
FIG. 2 is another such view in a different operative state;
FIG. 3 is an exploded perspective view of the pump assembly;
FIG. 4 is a part vertical cross section of the second embodiment;
FIG. 5 is a part longitudinal cross section of the third embodiment; and
FIG. 6 is a cross section along the line 6 -- 6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to the embodiment in FIGS. 1 - 3, it will be seen that the pump assembly comprises an elongated carrier pipe 2 which may or may not be assembled from a plurality of coaxial sections, and in either event, the distal end of which is occupied by a flanged plug 4 which is inserted in the end and keyed or otherwise fixed to the pipe. The plug 4 has an annular recess 6 in the upper end thereof, and there is a series of symmetrically arranged ports 7 opening into the lower end of the plug from the recess. The ports are controlled by an elastomeric valve ring 8 which is disposed in the bore 9 of the pipe 2 and yieldably biased into engagement with the recess 6 in the plug. The bias is provided by a coiled spring 10 which is interposed between the valve ring 8 and an annular washer 12 which is seated on an expansible C-ring type clip 14 that is interengaged in a groove 16 (FIG. 1) in the inner peripheral wall 17 of the pipe above the plug.
The pump assembly also comprises an interior pulse generating mechanism 18 which is operative to produce fluid flow through the carrier pipe 2. The mechanism 18 includes a smaller diameter feed pipe 20 which is inserted in the proximal end portion of the carrier pipe and equipped with a bushed enlargement or head 22 on the distal end thereof. The head 22 is slidably insertable in the bore 9 of the carrier pipe, and when the mechanism is suitably positioned in the bore at a level above the plug 4, the head is pinned or otherwise fixed to the wall 17 of the pipe to form a sealed head wall or partition therein. The partition is ported, however, in that the head 22 has an annular recess 24 in the upper end thereof and there is a series of symmetrically arranged ports 25 opening into the bottom of the head from the recess. As with the plug 4, moreover, the ports 25 are controlled by an elastomeric valve ring 26 that is spring loaded into engagement with the recess by a washer 27-seated coiled spring 28.
The bushing 30 on the head 22 is an extension of the feed pipe 20, and supports an elongated resiliently flexible sleeve 32 which is suspended from the head into the chamber 34 defined by the head 22 and the plug 4. The upper end of the sleeve is tightly secured within an annular recess 36 in the bushing 30, to seal the sleeve to the head, and an annularly recessed cap 38 is similarly secured over the lower end of the sleeve to plug and seal that end as well. The sleeve has a hollow finger 40 upstanding in the bore thereof. The finger is tightly secured within an annular recess 41 in the upper end of the plug, so as to be sealed to the plug, and is slightly smaller in diameter than the bore of the sleeve, so as to develop a thimble-like cavity or hollow 42 therewithin. The hollow 42 communicates with the feed pipe 20 through the head and an air impulse servo pump 44 is interconnected with the feed pipe to supply intermittent fluid pressure pulses to the hollow 42, or alternatively, a single pulse which is then sustained by the servo pump. Each pulse inflates the sleeve 32 in the manner of FIG. 2, and causes it to swell into engagement with the wall 17 of the carrier pipe. The pulse also causes the sleeve to contract in the lengthwise direction, and therefore, the finger 40 is considerably shorter in length to accommodate to the contraction without abutting the bushing 30. Of course, depending on the magnitude of the pulse, the sleeve 32 may swell to a diameter of less than that of the wall 17, so that the sleeve does not engage the wall in all cases. In every case, however, the input pulse to the sleeve has the effect of generating an output pulse in the chamber 34, thus pressurizing the fluid medium in the chamber and causing it to open the valve 24, 26 and escape through the same into the proximal end portion of the bore 9 of the carrier pipe 2. Simultaneously, the output pulse maintains the valve member 8 in closed condition; but upon cessation of the input pulse to the sleeve, the valve 6, 8 is opened and more fluid enters the chamber through the ports 7 to be pumped into the proximal end portion of the bore 9 on the next input pulse.
The distal end 4 of the pump assembly may be inserted in a hole 46 and immersed in the fluid to be pumped, such as a body of water 48 standing in the bottom of the hole. Or an intake pipe (not shown) may be added to the end of the assembly to reach the fluid.
Either a gas or liquid may be employed to pulse the sleeve 32. When a gas is used, the hoop tension in the sleeve may be relied upon to collapse it to the contracted condition of FIG. 1 after each pulse. However, when a liquid is employed, a suction effect must be generated in the sleeve alternately with the input pulses, to assure that the fluid in the chamber 34 collapses the sleeve at a practical rate.
The pump chamber 34 needs no priming inasmuch as the initial input pulses clear the chamber of any air, whereafter the resulting vacuum induces the liquid to enter the chamber through the valve 6, 8.
In FIG. 4, the bottom of the chamber 34 is closed by an annular member 62 which is interconnected with a cap 50 on the lower end of the sleeve 32, to vary the volume of the chamber as the sleeve flexes lengthwise during pulsing. The cap 50 is extended lengthwise of the sleeve to accommodate a T-valve 52 having a ball-check valve member 54 in the bore 56 thereof. The ball cooperates with an opening 58 at the lower end of the cap, and there are four symmetrically arranged ports 60 about the upper end of the bore which communicate with the chamber 9 or 34. The annular member 62 is disposed at a level below the ports, and takes the form of an annular diaphragm 62 of the rolling type having one or more inverted U-shaped folds 64 therein. The diaphragm is interconnected with the wall 17 of the pipe 2 whereby on contraction of the sleeve, the volume of the chamber is reduced by the fact that the diaphragm follows the sleeve and effectively shortens the length of the chamber.
Alternatively, a piston may be mounted on the lower end of the sleeve and slidably engaged with the wall 17 for this purpose. However, the diaphragm is preferred because it avoids the problem of moving parts which contact one another.
In FIGS. 5 and 6, the pump assembly includes a housing 66 which defines an elongated chamber 70 having eccentrically opposing nipples 72 and 74, respectively, on the opposite ends thereof. One of the nipples, 72, is ported and check valve controlled in the manner of the plug 4 in FIGS. 1 - 3, to perform as an inlet valve; whereas the other nipple, 74, is ported and check valve controlled in the manner of the head 22 in FIGS. 1 - 3, to perform as an outlet valve. Eccentric of the chamber, and on the opposite side thereof at the outlet end of the chamber, there is a third nipple 76 which has a bushed enlargement or head 78 thereon, that is similar to the head 22 in FIGS. 1 - 3, but unported. The nipple 76 is a separate fitting which is secured to the housing in an opening 80 so that the head 78 projects into the chamber. The head in turn is equipped with an elongated resiliently flexible sleeve 82 which has a plug 84 at the free end thereof. Interiorly, the sleeve is also equipped with a finger 86 which performs as a filler in the manner of the finger 40 in FIGS. 1 - 3. However, in this instance the finger is secured to the head and is open-ended adjacent the plug. Also, the finger has a piston 88 slidably engaged therein, the drive rod of which, 90, is slidably engaged in the bore 92 of the nipple 76. A hydraulic fluid 94 is captive in the sleeve and is compressed by the piston on its inward stroke, there being longitudinally extending flutes 96 in the exterior surface of the finger whereby the fluid moves lengthwise of the sleeve to inflate it as shown. Conversely, on its outward stroke, the piston generates a suction effect which collapses the sleeve around the exterior surface of the finger, as shown by the dot-dash condition of the sleeve in FIG. 5. Where the assembly is used as a force pump, the drive force for the piston is provided by a reciprocating drive mechanism (not shown) which is interconnected with the rod 90. Otherwise, such as where the assembly is used as a simple pressure applicator, the piston may be driven by a ram drive mechanism, also not shown.
Alternatively, the sleeve 32 or 82 may be secured at its ends to the surrounding walls of the chamber 34 or 70, and the walls may be equipped with one or more ports through which the inflation fluid is introduced and/or compressed around the sleeve, to flex the sleeve under tension inwardly of its diameter, rather than outwardly of its diameter as in FIGS. 1 - 6.
The sleeve 32 or 82 is preferably a braided wire reinforced elastomeric material. One such material is made by the Kleber Company of Paris, Cedex 16, France. Alternatively, the material can be expanded rubber or some other material which is suited to the function of the sleeve.
When the pulse generating mechanism 18 is employed in a convertible assembly, the subassembly 22, 26, 27, 28 is adapted as a piston-like member which is slidably engageable in the bore of a pipe such as the pipe 2, and equipped with latch means which are operative to interengage and lock the member to the pipe at a selected location therein. For example, see U.S. Pat. No. 3,292,717 for an example of such a latch means. The plug assembly 4, 8, 10, 12 may be adapted as a similarly equipped piston-like member which is engageable in the pipe at a more advanced location; or the pipe itself may be equipped with a preassembled plug assembly; or a single pipe section may be so equipped for insertion in a pipe string; or the sleeve 32 may have a piston-like member on the lower end thereof which is adapted to form the necessary lower chamber defining partition.
In some down-the-hole applications a column of liquid or similar medium may be used to maintain a piezometric head in the sleeve 32 or 82, which is substantially equal to the hoop tension of the same, so that on application of pressure to the medium the sleeve will immediately undergo expansion. That is, the height of the column can be set to assume a state of equilibrium with the hoop tension in the sleeve and any external pressure on the same, so that the applied pressure has an immediate effect on the sleeve. This also has the advantage of providing a constant relationship between the magnitude of the respective impulses and outpulses, such that the pump can be used to meter a steady flow.
Likewise, other means can be employed to equalize the flow from the pump. For example, the pump may be operated in conjunction with one or more other similar pumps to produce a smoother flow pattern, as for example, by interconnecting them through a swashplate or a shuttle valve.
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The pump assembly comprises means defining a fluid retention chamber having an inlet opening and an outlet opening therein, and check valve means adjacent the inlet and outlet openings, which are operative to limit the fluid flow therethrough to relatively inward and outward of the chamber, respectively, when there is a fluid pressure differential thereacross. The pump assembly also comprises hollow pulse generating means in the chamber, having a volume of less than that of the chamber, but including a normally contracted, resiliently flexible portion which is responsive to a fluid pressure pulse in the hollow of the pulse generating means, to flex in relation to the normally contracted condition thereof. It also comprises inpulsing means which are operative to impart a fluid pressure pulse to the hollow of the pulse generating means, to cause the flexible portion of the pulse generating means to flex and impart a fluid pressure output pulse to a fluid medium retained in the chamber.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S. Provisional Application Ser. No. 60/889,145, filed Feb. 9, 2007 which is incorporated herein by reference in its entirety.
FIELD
[0002] Inventive subject matter described herein relates to a flexible catheter system for navigating through tortuous paths within the vasculature of living beings and to method embodiments for making the flexible catheter system and to embodiments for using the flexible catheter system.
LIMITED COPYRIGHT WAIVER
[0003] A portion of the disclosure of this patent document contains material to which the claim of copyright protection is made. The copyright owner has no objection to the facsimile reproduction by any person of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office file or records, but reserves all other rights whatsoever. Copyright 2007, Steven Ferry.
BACKGROUND
[0004] Since the 1980's, microcatheter technology has advanced to become commonplace in the treatment of vascular lesions of the central nervous system and other systems having tiny, tortuous vasculature. Microcatheters have been used to treat cerebral aneurysms, fistulas, and arterial venous malformations, for example, by occluding the parent vessel. Microcatheters have been used as well to deliver agents to open occluded vasculature, including agents to dissolve clots. Balloon microcatheters have been used to open vessels narrowed due to atherosclerosis.
[0005] Microcatheters have also been used to treat pathological vascular abnormalities through an endovascular approach, using selective deposition of coils, particles, or liquid adhesives. Microcatheters have additionally been used to deliver chemotherapeutic agents to spinal, head and neck, or intracranial malignancies.
[0006] Conventionally, for some embodiments, microcatheters have advanced from a femoral puncture through the lumen of a guiding catheter which has terminated in a carotid or vertebral artery. The microcatheter is advanced beyond the guiding catheter using one of two known techniques. One prior art technique has been directing a guide wire through the lumen of the microcatheter which has had varying degrees of tip-shape, torqueability, stiffness and external coating. A second prior art method has included a flow-directed technique in which the microcatheter has been extremely flexible and has been carried by blood flow to the lesion, assisted by of injections of saline or contrast media through the flow directed microcatheter.
[0007] Each of the conventional methodologies for delivering a microcatheter has had drawbacks. The guidewire directed microcatheter has involved the risk of puncturing a vessel or aneurysm, which has had the potential of having devastating hemorrhagic consequences intracranially. With the flow-directed microcatheter, it has frequently been difficult to make precise turns and select individual vessels when complex vascular anatomy has been encountered.
[0008] A guidewire has not been usable in the flow-directed microcatheter because of the suppleness of the microcatheter and the significant possibilities of puncturing the wall of the microcatheter with a stiff guidewire. This risk has also prohibited the delivery of coils which have been used to assist in occlusion, through a flow-directed microcatheter. Thus, only liquid adhesive or tiny particles have been injected through the flow-directed variety of microcatheter for vascular occlusion, the tiny particles usually of insufficient size to achieve the desired vascular occlusion. Conversely, the guide-wire directed microcatheter often times has not been pushable from the groin over a guidewire through multiple turns in branching intracranial vascularity to reach the desired vessel.
[0009] In one prior art attempt at improvement of these techniques, a method has been developed to incorporate a balloon into the tip of a microcatheter to allow the blood flow to carry the distended balloon distally to the desired target vessel. The disadvantage with the balloon technology is that two lumens have been required, one for the lumen to deliver the embolic agent, and the second balloon to inflate and deflate the balloon. Alternatively, a calibrated leak balloon has been incorporated in the tip of the microcatheter. This, however, has not allowed for directionality and has not been usable with a guidewire.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a cross-sectional view of one embodiment of the catheter system of the invention.
[0011] FIG. 2 illustrates a cross-sectional view of one embodiment of the catheter system that includes an echogenic coated distal end.
[0012] FIG. 3 illustrates a cross-sectional view of one embodiment of the catheter system that includes a compliant balloon integral to the distal tip.
[0013] FIG. 4 illustrates a cross-sectional view of one embodiment of the catheter system that includes a one piece fluted support structure on the distal end.
[0014] FIG. 5 illustrates a cross-sectional view of a catheter system that includes a balloon effective for selective inflation.
DETAILED DESCRIPTION
[0015] Although detailed embodiments of the invention are disclosed herein, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art to variously employ the catheter embodiments. Throughout the drawings, like elements are given like numerals.
[0016] Referred to herein are trade names for materials including, but not limited to, polymers and optional components. The inventor herein does not intend to be limited by materials described and referenced by a certain trade name. Equivalent materials (e.g., those obtained from a different source under a different name or catalog (reference) number to those referenced by trade name may be substituted and utilized in the methods described and claimed herein. All percentages and ratios are calculated by weight unless otherwise indicated. All percentages are calculated based on the total composition unless otherwise indicated. All component or composition concentrations are in reference to the active level of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources.
[0017] Embodiments of the invention relate to a catheter, one embodiment of which is a microcatheter, that is useful for vascular organs thereof navigation within the coronary, thoracic and peripheral vasculature of the human or other animal body. Depending on the selected diameter, catheter embodiments described herein are well suited for distal navigation and for providing a working conduit within the fine vessels of the heart, brain, hepatics, lumbar, pancreatic and other organs with fine vessels.
[0018] Embodiments of the invention include a catheter main body that defines a lumen and also includes a liner within the lumen of the catheter main body. The catheter main body also includes marker bands which are used by a physician to gauge distance at the distal end of the catheter, a coil or braid for support and torque response, a multidurometer shaft for advancement and tracking of the catheter, a hub through which navigation aids or therapies are passed into the lumen of the catheter, a strain relief attached to the distal hub and a lubricious coating over a distance of 65 cm-100 cm of the catheter. The lubricious coating that includes an opacifying material in a concentration of about 1 to 45% aids in the tracking of the catheter through the vasculature. In addition, for some embodiments, a compliant distal balloon is utilized to provide support during delivery of a device or agent as well as for partial or full occlusion of the vessel for short periods of time.
[0019] Some embodiments of the catheter system invention include a catheter main body that defines a lumen and a liner within the lumen of the catheter main body. The liner has, for some embodiments, a wall thickness of between 0.001 inches and 0.0004 inches. The liner is either extruded or dip-coated on a mandrel with an outer diameter in a range from 0.0165 inches to 0.0225 inches.
[0020] Some embodiments of the catheter system also include a support coil or braid that includes a round or flat wire that includes β 3 Titanium metal or a polymeric monofilament material from a group that includes but not limited to PEEK, Nylon, Polypropylene, Dacron and the like. The catheter system further includes a marker band that includes a heat shrinkable material coated with a radiopaque material is applied to a catheter body for the purpose of providing reference marks on the distal end of a catheter shaft.
[0021] The catheter system also includes a multidurometer shaft that includes materials from the Grilamid family, PEBaX, Urethanes, Silicones and the like that may be utilized as jacketing material for the outer catheter shaft jacket. The jacketing material is filled with an opacifying agent in a range from 1% to 50% by weight, in order to be radiopaque, with materials identified as appropriate opacifiers for fluoroscopic imaging. The opacifying agents include but are not limited to Barium Sulphate, Bismuth Bicarbonate, Tungsten and Molybdenum and the like. The jacketing material is placed at varying intervals along the length of the catheter with a stiffer material being utilized on the proximal end of the catheter and successively softer materials utilized as one moves toward the distal end of the catheter. The distal most durometer contains no radiopaque filler in order to better visualize devices being placed through the catheter lumen and into the vasculature. A hub and strain-relief are added to the proximal end of the catheter to provide a channel into which devices can be placed and gain entrance into the catheter lumen.
[0022] One embodiment of the catheter system, illustrated generally at 10 in FIG. 1 includes a catheter main body 12 , having a proximal hub 14 , a distal tip 16 and a shaft 18 . The distal tip 16 is, for some embodiments, about one millimeter in length. The distal tip 16 is free of a support structure in order to ensure that the tip is atraumatic.
[0023] For some embodiments, the proximal portion of the shaft is more rigid than the distal portion. Markers, shown for one embodiment at 24 and 26 are placed within the distal portion of the shaft 18 wherein the markers 24 and 26 include a radiopacifying agent integrated onto a heat shrinkable material. When properly positioned, the markers 24 and 26 are drawn down onto the catheter shaft 18 . For some embodiments, the distal portion of the shaft 18 , proximal to the distal tip 16 includes a supporting structure 21 . The markers 24 and 26 are positioned over the supporting structure 21 and provides radiopacity and also positions the support structure 21 in place.
[0024] A liner 20 , having, for some embodiments, a wall thickness of between 0.001 inch and 0.0004 inch, extends the entire length of the shaft 18 . For some embodiments, the catheter 10 has an outer diameter ranging from 3.8 Fr (0.051″-1.23 mm) to 1.8 Fr (0.025″-0.6 mm) and an inner diameter ranging from (0.036″ 0.9 mm) to (0.010″-0.4 mm).
[0025] The liner 20 is, for some embodiments, extruded and for other embodiments, is dip-coated on a mandrel with an outer diameter within a range from 0.0165 inches to 0.0225 inches.
[0026] The catheter system embodiment 10 also includes a support coil or braid 22 that for some embodiments, includes a round or flat wire. For some embodiments, the round or flat wire includes β 3 Titanium metal. For other embodiments, the support coil or braid 22 includes a polymeric monofilament material selected from a group that includes PEEK, Nylon, Polypropylene, Dacron and other materials having similar physical and chemical properties. The support coil or braid 22 extends from a proximal end 31 of the catheter shaft to beneath a distal most marker band, shown at 24 in FIG. 1 .
[0027] The β 3 Titanium braid wire displays physical properties similar to stainless steel wire and the mechanical properties of the β 3 Titanium are similar to that of Nitinol wire. These properties provide strength, resiliency and torque response to the braided or coiled catheter shaft embodiment 22 in FIG. 1 . In addition, use of polymer filaments such as PEEK, Polyamide, Nylon, Polyester and other materials having similar chemical and mechanical properties as braid or coil components provide a surprisingly effective method of reinforcing a catheter shaft main body.
[0028] Further, the use of a tube made from β 3 Titanium, Nitinol or Stainless Steel or other material having similar chemical and mechanical properties into which flutes are ground, cut or etched provides a flexible frame capable of supporting the catheter shaft 18 . For some embodiments, one of which is shown at 50 in FIG. 4 , the flute 66 is integrated into the shaft 18 in a similar manner to a coil or braid. The flute, coil or braid provide strength, resiliency and torque response. Similarly, the extruded polymeric materials cited above such as PEEK, Polyamide, Nylon, Polyester and other similar materials, which, for some embodiments, are fluted are used to enhance catheter shaft strength, resiliency and torque response.
[0029] The catheter system embodiment 10 further includes one or more marker bands 24 and 26 . The marker bands 24 and 26 include a heat shrinkable material coated with a radiopaque material. The marker bands 24 and 26 are applied to the main body 12 of the catheter for the purpose of providing reference marks for the distal end 16 of the catheter main body 12 . While two marker bands, 24 and 26 , are shown in FIG. 1 , it is understood that catheter embodiments may include one or more marker bands. For one embodiment, the radiopaque, RO, heat shrinkable marker bands are placed one millimeter and three centimeters, respectively, from the distil tip 16 of the catheter embodiment, respectively, measured from a distil end of each marker 24 and 26 .
[0030] For some embodiments, the radiopaque marker 24 or 26 , includes a heat shrinkable material which is coated with a radiopaque coating and is applied to the catheter shaft 18 prior to over-jacketing the catheter with the multi durometer top jacket. The polymeric marker 24 or 26 is mechanically retained following the application of heat and subsequent shrinkage of the marker 24 or 26 to the catheter shaft 18 . This method of making the catheter is advantageous over conventional manufacturing processes in that conventional precious metal markers require bonding and are costly.
[0031] The non-radiopacified distal segment of the catheter allows for better visualization of devices being placed through the catheter lumen, and improves control during placement of GDC coils, embolics, guidewires and the like.
[0032] In addition, the catheter system embodiment 10 includes a multidurometer top jacket 28 that includes one or more of materials from the Grilamid family, PEBaX, Urethanes, Silicones and other materials having similar physical and chemical properties. The multidurometer top jacket includes jacket 28 , and, for the embodiment shown in FIG. 1 , includes five durometers that are placed at varying intervals along the length of the catheter shaft, with a stiffer material being utilized on a proximal end of the catheter main body and successively softer materials utilized as one moves toward a distal end of the catheter main body. For some embodiments, the distal most durometer contains no radiopaque filler in order to better visualize devices being placed through the catheter lumen and into the vasculature.
[0033] Many conventional intravascular catheters designed for fine navigation within small vessels have issues not only with tracking, but also with catheter retention at the treatment site. A combination of progressively softer durometer polymer segments coupled with alternating support geometries of coils braids or a combination thereof are employed by catheter embodiments described herein to achieve improved trackability and catheter retention.
[0034] The catheter system embodiment 10 also includes a hub and strain-relief 30 , which is added to the proximal end of the catheter embodiment 10 to provide a channel into which devices can be placed in order to gain entrance into the catheter lumen. The base and top strain relief's also provide protection from kinking and other delivery problems. The base strain relief is, for some embodiments, two-times the length of the top strain relief.
[0035] Embodiments of the invention address the problems described herein associated with prior art devices by employing coiling and braiding materials that display physical properties of Stainless Steel wire and mechanical properties similar to Super-elastic nitinol. Alternately, other reinforcing materials are taken from a family of polymeric filaments used to form the shaft support.—shape memory—Use of these materials results in improved tracking combined with better catheter retention at the site of treatment. The combination of materials, winding geometries and shaft over-jacket stiffness result in the desired performance characteristics. In addition, the use of a compliant distal balloon at the shaft tip ensures proper seating of the catheter during treatment.
[0036] For some embodiments, one of which is shown at 30 in FIG. 2 , an echogenic coating 32 is applied to the catheter shaft 34 to allow for catheter visualization within an ultrasound imaging system.
[0037] For some embodiments, one of which is shown at 40 in FIG. 3 , the catheter includes a compliant distensible distal balloon 42 integral to the catheter shaft 44 . The distal balloon 42 enables a user to inflate the balloon 42 in order to anchor the catheter tip 46 at a desired location within a vessel. The distal balloon 42 may also be deployed in order to occlude flow within a vessel. The distal balloon 42 is, for some embodiments, formed by dip-coating, using materials from the families of silicone elastomers, urethane copolymers, thermoplastic elastomers and other materials having similar physical and chemical properties.
[0038] For some embodiments, the compliant balloon 42 is integral to the distal end of the catheter shaft. The balloon 42 may be inflated and deflated from a manifold hub mounted on the proximal end of the catheter. The balloon is inherently radiopaque and does not require contrast media to inflate in order to visualize under fluoroscopy. The balloon may be inflated in order to provide distal catheter tip support while delivering a therapy through the catheter as well as totally or partially occlude flow in a vessel.
[0039] The distal balloon 42 is inflated by mechanisms such as a small tubular port 48 , which runs the length of the catheter shaft 44 and terminates at the distal end 46 of the catheter 40 . This port 48 includes a small diameter tube that is laminated to the primary catheter shaft and overlaid with PEBaX or an appropriate jacketing material and reflowed. The proximal end of the port 48 is terminated in a proximal hub 50 that functions to inflate the distal catheter balloon. The distal end 46 of the port 48 exits within that area where the distal balloon 42 is fit to the catheter shaft 44 to provide a method for inflating the balloon 42 . The distal catheter balloon 42 includes a radiopaque coating, which provides contrast when in use within a fluoroscopic field. The coating mitigates the need to use a contrast solution to fill and visualize the distal catheter balloon.
[0040] Another embodiment of the invention, illustrated at 50 in FIG. 4 , includes a catheter main body 52 that defines a lumen 54 and also includes a liner 56 within the lumen 54 of the catheter main body. The catheter main body 52 may, for some embodiments, include one or more marker bands which are used by the physician to gauge distance at the distal end 56 of the catheter main body 52 . The catheter system also includes a coil or braid 58 for support and torque response, a multidurometer shaft 60 for advancement and tracking of the catheter system 50 , a hub 62 through which navigation aids or therapies are passed into the lumen of the catheter, a strain relief attached to the distal hub and a lubricious coating over a distance of 65 cm-100 cm of the lumen. The lubricious coating aids in the tracking of the catheter system through the vasculature. In addition, for some embodiments, a compliant distal balloon 64 is utilized to provide support during delivery of a device or agent as well as for partial or full occlusion of the vessel for short periods of time.
[0041] For some embodiments, the coil pitch is altered or alterable at mid-shaft or at a distal end of the catheter to facilitate variable degrees of stiffness based on the number of the pitch. Alteration of pitch also facilitates catheter tip forming and shape retention in use. For system embodiments where braid is used, PICS per inch are altered or alterable at mid-shaft or at a distal end of the catheter to facilitate variable degrees of stiffness based on the number of the PICS.
[0042] One embodiment of the catheter system also includes a one piece fluted support structure 66 on or proximal to the distal catheter end 56 .
[0043] In accordance with embodiments of the invention, the catheter system 10 is intended for introduction and navigation within the fine vessels of the heart, brain, spine, liver, hepatics, lumbar, pancreatic and other organs with fine vessels.
[0044] Embodiments of the invention include making the catheter system by making or obtaining a luminous hollow tube wherein the hollow liner is covered with a supporting structure in the form of a braid or coil made by using materials from the Titanium family or polymer filaments such as PEEK, Polyamide, Nylon, Polyester or other materials having similar physical and chemical properties over which polymeric materials of varying durometers are place proximal to distal. The proximal portion of the shaft is more rigid than the distal segment.
[0045] Markers are placed at the distal end of the shaft. The markers include a radiopacifying agent integrated onto a heat shrinkable material. When properly positioned, the markers are drawn down onto the catheter shaft over the supporting structure, providing radiopacity and holding the support structure in place.
[0046] For some embodiments, an outer jacket of varying material durometers is applied over the liner/supporting structure and the jacketing segments are reflowed over the shaft resulting in a uniform transition of stiffer (proximally) to more compliant material (distally) at the end of the catheter shaft.
[0047] For some embodiments, a lubricious layer is bound to the outer surface of the catheter shaft for a distance of 65 Cm to 100 Cm for the purpose of making tracking of the catheter within a guiding catheter or vessel smoother and less traumatic.
[0048] The proximal end of the shaft has a hub and strain relief mounted onto the shaft by mechanisms that include but not limited to bonding and insert molding. The strain relief provides additional support to the hub and shaft transition.
[0049] Yet another embodiment of the invention includes the incorporation of an echogenic coating onto the catheter shaft which will enable device visualization within an ultrasound imaging system.
[0050] One more embodiment, illustrated at 90 in FIG. 5 , illustrates a system embodiment, previously described herein, having a balloon 92 , expandable in only one direction. The balloon 92 is mounted to a catheter shaft 94 . The direction of expansion depends upon how the balloon is formed and mounted to the catheter shaft 94 .
[0051] Since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes, which come within the meaning and range of equivalency of the claims, are intended to be embraced therein.
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Embodiments of the invention include a catheter, comprising: a lumen having a distal end and a proximal end; one or more marker bands circumferentially arranged around the lumen; a support structure extending from the proximal end of the lumen to the most distal marker band; and a top jacket positioned annularly with respect to the lumen, comprising five durometers of material, wherein the support structure and top jacket alternate along the length of the catheter.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/143,912, filed Oct. 26. 1993, now U.S. Pat. No. 5,504,933.
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to a system, in which a broadcasting program is offered on a pay basis in satellite television broadcasting, cable television broadcasting, or in terrestrial television broadcasting service via broadcasting satellite (BS) or communication satellite (CS).
2. BACKGROUND ART
In the information-oriented society of today, satellite television broadcasting via broadcasting satellite (BS) or communication satellite (CS), as well as cable television broadcasting, called CATV (cable television), using coaxial cable or optical fiber cable, are increasingly propagated.
Also, multiplex teletext broadcasting for separately transmitting character information via television wave is also being propagated.
In some of these satellite television broadcasting systems, unlike conventional type terrestrial television broadcasting, to which anybody is entitled to have access, a scrambled television program is transmitted so that only the subscribed viewers who signed the viewing contract can view the program, and the subscribed viewers receive the program on a pay basis using a tuner/decoder, which can descramble the program.
In order to view the program on such pay satellite television broadcasting, it is necessary to use a special-purpose tuner/decoder. The tuner/decoder is provided with an ID code, which is transmitted regularly (e.g. once monthly) from a satellite, and only the tuner/decoder receiving the transmitted ID code can descramble the program.
The procedure to select and transmit ID for a viewer who signed a viewing contract is very troublesome, and an ID code is not transmitted unless the contract is signed in advance. Even when the viewer wants to view a pay-per-view program, there is no method of contracting for pay-per-program on occasion, and thus, the viewer cannot view the program upon request.
Because the tuner/decoder is provided with ID which corresponds to each transmitting station, as many tuner/decoders as the number of transmitting stations are needed to view programs of many pay satellite television stations.
In CATV, which can transmit several tens of channels at the same time, special channels for broadcasting motion pictures, sports programs, music programs, etc. are broadcast in addition to general channels, which are not scrambled and can be viewed under a comprehensive contract. The programs of such special television channels are transmitted as scrambled pay television channels. To view the programs in the scrambled channels, it is necessary to sign a contract for descrambling. Because the contract period is normally renewed in approximately one month intervals, it is not possible to view the programs under a contract signed at any desired time.
In order to have access to a live sports program, motion picture program or music program to be broadcast through the scrambled satellite television broadcasting or CATV channels, there is a special system in which a viewing time recorder is installed on each television set, and the fee is to be paid by deferred payment based on the actually viewed programs. However, much labor is required for the control and fee collection for such system.
When a television viewer receives programs from terrestrial or satellite television broadcasting and secondarily distributes them to a number of display devices, general television viewers may have to pay for some of the programs due to copyright even though the programs are offered free of charge from the original broadcasting station.
In this way, if the viewer wants to distribute the program from terrestrial or satellite television broadcasting on a pay basis, there is no means to contract for individual programs as in the cases of viewing satellite television broadcasting or CATV programs, and each viewer must sign a subscription contract for each channel for the distribution.
To solve the above problems, the present inventors have filed Japanese Patent Application No. 4-199942, which discloses a charging system, whereby a charging center sends a viewing permit code for viewing a pay program to a data communication device in response to a request for viewing the pay program and a request for distribution of a broadcasting program, which are executed from a pay-per-program viewer via a public telephone line using a data communication device. The charging center also collects a fee for such program, and a receiving device displays a pay program according to the viewing permit code when it accepts the viewing permit code.
In the following, description will be given on the above invention.
FIG. 1 shows a television charging system of the present invention. The television charging system comprises a satellite television broadcasting system 1, a CATV system 2, a multiplex teletext broadcasting system 3 using terrestrial television broadcasting, and a charging system 4.
In the satellite television broadcasting system 1 using BS or CS, reference numeral 11 represents a terrestrial station of satellite television broadcasting, and television wave including a program code and a scrambled television signal is transmitted from a satellite communication transmitting antenna 12 to a geostationary satellite 13 on a geostationary orbit about 30,000 km above the equator.
When the television wave from satellite communication transmitting antenna 12 is received, the geostationary satellite 13 amplifies the received television wave, converts it to a frequency on the order of 10 GHz, and transmits it to the ground.
The viewer receives the television wave of 10 GHz from the geostationary satellite 13 by a satellite television broadcasting receiving antenna 14, and the wave is converted to a frequency on the order of 1 GHz and is sent to a satellite television broadcasting receiving tuner/decoder 15. The satellite broadcasting receiving tuner/decoder 15 picks up a video signal and an audio signal from the television wave, sends them directly as video and audio signals to a television set or converts them again to a frequency receivable by the television set.
This satellite broadcasting system itself is the same as a conventional system, while, in this satellite television broadcasting, the program is scrambled, and only the viewers having the viewing permit code for descrambling the program can view the television program.
In CATV system 2, reference numeral 21 represents a CATV broadcasting center, 22 represents a coaxial cable or an optical fiber cable for transmitting TV signal, and 23 represents a CATV adapter/decoder. CATV adapter/decoder 23 picks up a video signal and an audio signal from a CATV signal and descrambles them by a decode signal. Further, the signals are sent directly as video and audio signals to the television set or by converting them to a frequency receivable by the television set.
In the multiplex teletext broadcasting system 3, reference numeral 31 is a terrestrial multiplex teletext broadcasting station for transmitting a television signal with multiplex teletext on a television wave program as terrestrial television wave from a television transmitting antenna 32. The transmitted terrestrial television wave is received by a television wave receiving antenna 33, and multiplex teletext signal is picked up from the television signal by a multiplex teletext adapter 34. The signal is distributed to display devices 35, 35, 35 . . . such as a video monitor, LED (light emitting diode) display device, LCD (liquid crystal device) display unit, display-phone, personal computer display unit, etc.
On the other hand, the charging system 4 comprises a charging center 41, a public telephone line 42 and a data communication device 43.
In this charging system 4, the pay-per-viewer makes a request for viewing to the charging center 41 through the public telephone line 42 by the data communication device 43 such as display-phone.
Upon receipt of the request from the pay-per-viewer, a viewing permit code for viewing a pay program is sent from the charging center 41 to the data communication device 43.
The viewing permit code sent to the data communication device 43 is sent to a satellite broadcasting tuner/decoder 15, a CATV adapter/decoder 23 or a multiplex teletext adapter 34 on-line via a parallel data line, a serial data line of RS-232C standard, or an ordinary public telephone line using a modem, or off-line via a semiconductor memory unit, such as IC card, memory card, etc., or a magnetic memory unit such as a magnetic card, magnetic disk, etc.
Upon receipt of the viewing permit code, the satellite broadcasting tuner/decoder 15, CATV adapter/decoder 23 or multiplex teletext adapter 34 descrambles the program, to which an identifying information corresponding to the viewer permit code had been given, and a television signal is sent to a television set 16 or 24 or teletext signal is sent to display devices 35, 35, 35, . . .
Thus, the viewable picture is displayed on the television set 16 or 24, and the character signal is displayed on the display devices 35, 35, 35, . . .
On the other hand, the information of a fee for each pay program and the viewing permit code for each pay program are sent in advance from the satellite broadcasting terrestrial station 11, the CATV center 21 or the terrestrial wave broadcasting station 31 to the charging center 41. The charging center 41 collects the fee from the viewers who request for viewing on behalf of the satellite broadcasting terrestrial station 11, the CATV center 21 or the terrestrial wave broadcasting station 31.
The charging center and the communication device are connected by public telephone line, and account is settled via the public telephone line.
As the charging system, various methods can be utilized such as a method to use a fee collecting system included in the public telephone line system, a method to use a home banking system by banks, a method to use a mail sales system in credit system, or a VAN system.
In order that only the viewers who paid the fee can view the broadcasting program and the others cannot view it, the broadcasting program is scrambled. Various methods have been proposed for the scrambling, and typical methods include a line permutation system and a line rotation system for the video signal and a PN signal adding system for the audio signal.
Description will be given below on the information to be transmitted and received in this system, referring to FIG. 2 and FIG. 3. Shown in these figures is the information to be transmitted and received in this system, and each information is transmitted and received between broadcasting stations such as BS, CS, CATV, etc., receiving devices with tuner and decoder, charging centers, and data communication devices such as display phones, modem, etc. The broadcasting station and the receiving device are connected by radio wave or cable, and the charging center and the data communication device are connected by public telephone line. The broadcasting station and the charging center, and further, the receiving device and the data communication device are coupled directly, or by on-line communication means such as radio wave or cable, or by off-line means such as magnetic card, magnetic disk or memory card.
FIG. 2 shows a system for viewing a pay broadcasting program. The broadcasting station sends a viewing permit code for viewing a broadcasting program to a charging center before the program is broadcast, and also sends scrambled broadcasting program, which can be descrambled by the viewing permit code, to the receiving device. In this case, a program number for identifying the broadcasting program can be transmitted with the broadcasting program.
When the viewer makes a request for viewing a television program to the charging center via a public telephone line using the data communication device, the charging center sends the viewing permit code, which has been sent from the broadcasting station before the program is broadcast, to the data communication device. The viewing permit code sent to the data communication device is sent to the receiving device. The program is descrambled according to the viewing permit code by the receiving device when the desired broadcasting program is broadcast, and the desired program is displayed or recorded when the receiving device outputs the program to a television set (TV) or to a video tape recorder (VTR).
FIG. 3 represents a system to distribute a program such as multiplex teletext broadcasting program. In this broadcasting distribution system, the broadcasting station sends a distribution permit code for distributing a broadcasting program and a program number for identifying the broadcasting program to a charging center before the program is broadcast, and the program, such as multiplex teletext broadcasting program, which can be distributed according to the distribution permit code, to the receiving device together with the program number.
When a viewer, who wants to distribute a program, requests the distribution to the charging center via public telephone line, the charging center sends a distribution permit code and a program number, which have been sent from the broadcasting station before the program is broadcast, to the data communication device. The distribution permit code and the program number sent to the data communication device are sent to the receiving device when the requested program is broadcast, and the receiving device distributes the program to the display unit (DSP) according to the distribution permit code.
SUMMARY OF THE INVENTION
In the charging system according to the present invention, the broadcasting system comprises a broadcasting station for broadcasting a program via terrestrial waves, CATV, and satellites, such as BS, CS, etc., and a charging center for operating the entire charging system.
On the other hand, the viewing system on the side of viewers to view the broadcasting program comprises a receiving device coupled with a tuner/decoder and a data communication device for communicating with the charging center.
It is an object of the present invention to provide a system, by which it is possible to actualize the so-called pay-per-program for viewing each program on a pay basis or the so-called pay-per-view for viewing a program on a pay basis without signing a contract, using a charging system.
To attain the above system, it is disclosed in the present invention how the scrambled pattern can be protected, how the program to be viewed is identified, how a viewing request should be made, and how these means are applied on a pay broadcasting system.
To maintain security of the scramble, it is proposed to adopt a method to use a scramble pattern fixed for a certain period, a method to prepare a plurality of scramble patterns and select a scramble from them, or a method to use a scramble pattern by changing it.
For the method to use a scramble pattern by fixing it for a certain period, the currently used system can be utilized without any change, but the scramble pattern may be decoded.
In the method to prepare a plurality of scramble patterns and use one of them, it is difficult to decode the scramble patterns because the scramble patterns must be decoded only during the broadcasting of the program, but there may be some possibility to decode the scramble patterns because the same scramble patterns are repeatedly used.
In the method to change scramble pattern for each program, it is virtually impossible to decode the scramble pattern because the scramble pattern must be decoded during the broadcasting of the program.
As the method to identify the program, there are a method to identify according to broadcasting time and a method to provide the broadcasting program itself with an identifying information.
As a method to request viewing, there are proposed a method to request according to the broadcasting time and a method to request by using an identifying information of the program itself. If the identifying information is not made public, the viewing request is made using a temporary identifying information.
In case the broadcasting program is not identified according to the time, an identifying information is needed. In case the broadcasting program has an identifying information, which is open, the identifying information is used. If it is not open, a temporary identifying information is used for a viewing request.
The method to identify the program according to the broadcasting time is simple, but it comes to a deadlock if the broadcasting time is changed for some reason.
In contrast, the method to identify the program according to the identifying information requires a more complicated system, but this method can be relied on even when the broadcasting time is changed.
The receiving device identifies the program for which a viewing request has been made and descrambles the requested program using the corresponding decode data.
In case the broadcasting program is identified according to the broadcasting time, the program is descrambled by decode data at the specified broadcasting time.
In case the program number is open, the program number in the broadcasting signal is monitored, and the program is descrambled using decode data when the program number of the requested program is detected.
In case the program number is not made public, the non-opened program number in the broadcasting signal is monitored, and the program is descrambled using decode data when the same program number as encoded number sent from the charging center is detected.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a general block diagram of a system, to which the present invention is applied;
FIG. 2 is a schematic diagram of the present invention;
FIG. 3 is another schematic diagram of the present invention;
FIG. 4 is a diagram of a first embodiment of the present invention;
FIG. 5 is a diagram of a second embodiment of the present invention;
FIG. 6 is a diagram of a third embodiment of the present invention;
FIG. 7 is a diagram of a fourth embodiment of the present invention;
FIG. 8 is a diagram of a fifth embodiment of the present invention;
FIG. 9 is a diagram of a sixth embodiment of the present invention;
FIG. 10 is a diagram of a seventh embodiment of the present invention;
FIG. 11 is a diagram of an eighth embodiment of the present invention;
FIG. 12 is a diagram of a ninth embodiment of the present invention;
FIG. 13 is a diagram of a tenth embodiment of the present invention;
FIG. 14 is a diagram of an eleventh embodiment of the present invention;
FIG. 15 is a diagram of a twelfth embodiment of the present invention;
FIG. 16 is a diagram of a thirteenth embodiment of the present invention;
FIG. 17 is a diagram of a fourteenth embodiment of the present invention;
FIG. 18 is a diagram of a fifteenth embodiment of the present invention;
FIG. 19 is a diagram of a sixteenth embodiment of the present invention;
FIG. 20 is a diagram of a seventeenth embodiment of the present invention;
FIG. 21 is a diagram of an eighteenth embodiment of the present invention; and
FIG. 22 is a diagram of a nineteenth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Description will be given on the present invention in connection with the drawings.
In the following, description will be given on embodiments of the present invention, referring to FIG. 4 to FIG. 22.
FIG. 4 to FIG. 8 each represents an embodiment in which a pattern used to scramble is fixed and used and the broadcasting station scrambles the program by a fixed scramble pattern and broadcasts it. Also, the broadcasting station sends a decode data, serving as descramble data, to a charging center before the program is broadcasting from the broadcasting station.
In the embodiment of FIG. 4, no program number is used. Of course, the broadcasting station may use the program number, but the program number is not used in this system.
A viewer, who wants to view a program, sends a viewing request to the charging center by specifying the broadcasting time via public telephone line using a data communication device.
The charging center sends decode data of the program, to which the viewing request has been made, to the data communication device via public telephone line and collects a fee for the program.
The data communication device sends the received decode data and broadcasting time information to a receiving device.
Upon receipt of the decode data and the broadcasting time information, the receiving device descrambles the broadcasting program using the decode data.
When a broadcasting station broadcasts a program, a program number is put on each program for control purpose. There are program numbers which are opened or not opened.
FIG. 5 and FIG. 6 each represents an embodiment, which uses an open program number.
In the embodiment shown in FIG. 5, an applicant for viewing a broadcasting program sends a viewing request to the charging center by specifying a program number via public telephone line using a data communication device.
The charging center sends decode data for the broadcasting program, to which the request has been sent, to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the received decode data and the program number to the receiving device.
Upon receipt of the decode data and the program number, the receiving device monitors the program number of the receiving program and descrambles the broadcasting program by the received decode data when the program number of the requested program is detected.
In the embodiment of FIG. 6, the broadcasting station sends the program number to the charging center before the program is broadcast from the broadcasting station.
The applicant for viewing the program sends a request for viewing to the charging center by specifying broadcasting time via a public telephone line using a data communication device.
The charging center sends decode data and the program number of the requested broadcasting program to the data communication device via a public telephone line and also collects a fee for the program.
The data communication device sends the received decode data and the program number to the receiving device.
Upon receipt of the decode data and the program number, the receiving device monitors program number of the receiving program and descrambles the program using the received decode data when the program number of the requested program is detected.
By the system as described above, it is possible for an applicant to request for viewing a program without knowing the program number.
FIG. 7 and FIG. 8 each represents an embodiment, which uses a nonopened program number, which is not open for operation purpose. In these embodiments, the applicant for viewing uses a non-opened program number, and the program number is used as an encoded program number. The broadcasting station sends the encoded program number to the charging center before the program is broadcast from the broadcasting station.
In the embodiment of FIG. 7, the applicant for viewing sends a request for viewing to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends the decode data and the encoded program number of the requested broadcasting program to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the received decode data and the encoded program number to the receiving device.
Upon receipt of the decode data and the encoded program number, the receiving device monitors the non-opened program number of the receiving program and descrambles the requested program by the decode data when the encoded program of the requested program agrees with the non-opened program number.
In the embodiment of FIG. 8, the encoded program number has a temporary program number for requesting the program, and the broadcasting station also sends this temporary program number to the charging center before the program is broadcast from the broadcasting station.
The applicant for viewing the program sends a request for viewing to the charging center by specifying the temporary program number via public telephone line using the data communication device.
The charging center sends the decode data and an encoded program number corresponding to the temporary program number of the requested program to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the received decode data and the encoded program number to the receiving device.
Upon receipt of the decode data and the encoded program number, the receiving device monitors the non-opened program number of the receiving program, and descrambles the program using the received decode data when the encoded program number of the requested program agrees with the nonopened program number.
FIG. 9 to FIG. 17 each represents an embodiment in which a plurality of patterns to be used for scramble are prepared and selected for each program or for each time period, such as day, week, etc., and the broadcasting station scrambles the broadcasting program by a scramble pattern selected from a plurality of scramble patterns.
In the embodiment of FIG. 9, no program number is used. The applicant for viewing a program sends a request for viewing to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends the decode data of the requested broadcasting program via public telephone line to the data communication device, and also collects a fee for the program.
The data communication device sends the received decode data and the broadcasting time information to the receiving device.
Upon receipt of the decode data and the broadcasting time information, the receiving device descrambles the broadcasting program using the decode data when it is the specified broadcasting time.
FIG. 10 represents another embodiment, in which no program number is used.
In this embodiment, a plurality of decode data are provided with decode data number and stored in advance in the receiving device.
The broadcasting station sends a decode data number for identifying the decode data to the charging center before the program is broadcast from the broadcasting station.
The applicant for viewing sends a request for viewing to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends the decode data number of the requested program to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the received decode data number and broadcasting time information to the receiving device.
Upon receipt of the decode data number and the broadcasting time information, the receiving device descrambles the program by decode data corresponding to the decode data number at the broadcasting time.
FIG. 11 to FIG. 14 each represents an embodiment in which a program number is used as explained in FIG. 5 and FIG. 6.
In the embodiment of FIG. 11, the applicant for viewing sends a request for viewing to the charging center by specifying broadcasting time using the data communication device via public telephone line.
The charging center sends decode data and a program number of the requested program to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the program number and the received decode data.
Upon receipt of the decode data and the program number, the receiving device monitors program number of the receiving program, and descrambles the program using the received decode data when the program number of the requested program is detected.
In the embodiment of FIG. 12, a plurality of decode data are provided with decode data numbers and are stored in advance in the receiving device as in the embodiment of FIG. 10.
The broadcasting station sends a decode data number for identifying the decode data to the charging center before the program is broadcast from the broadcasting station.
In this embodiment, the applicant for viewing sends a viewing request to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends the decode data number and the program number of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data number and the program number to the receiving device.
Upon receipt of the decode data number and the program number, the receiving device monitors program number of the receiving program, and descrambles the program using decode data corresponding to the received decode data number when the program number of the requested program is detected.
In the embodiment of FIG. 13, the applicant for viewing sends a viewing request to the charging center by specifying a program number via public telephone line using a data communication device.
The charging center sends decode data of the requested program to the data communication device via public telephone line, and also collects a fee for the program.
The data communication device sends the program number and the received decode data to the receiving device.
Upon receipt of the decode data and the program number, the receiving device monitors program number of the receiving program and descrambles the program by the received decode data when the program number of the requested program is detected.
In the embodiment of FIG. 14, a plurality of decode data are provided with decode data numbers and are stored in advance in the receiving device as in the embodiment of FIG. 10.
The broadcasting station sends a decode data number for identifying the decode data to the charging center before the program is broadcast from the broadcasting station.
In this embodiment, the applicant for viewing sends a viewing request to the charging center by specifying a program number via public telephone line using the data communication device.
The charging center sends the decode data number of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the program number and the received decode data number to the receiving device, and the receiving device monitors the program number of the receiving program upon receipt of the program number, and descrambles the program using decode data corresponding to the received decode data number when the program number of the requested program is detected.
FIG. 15 to FIG. 17 each represents an embodiment in which a non-opened program number is used as in the embodiments of FIG. 7 and FIG. 8. In these embodiments, the non-opened program number is encoded and is sent to the charging center before the program is broadcast from the broadcasting station.
In the embodiment of FIG. 15, the applicant for viewing sends a viewing request to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends a decode data and an encoded program number of the requested program to the data communication device via public telephone line and collects a fee for the program.
The data communication device sends the received decode data and the encoded program number to the receiving device.
Upon receipt of the decode data and the encoded program number, the receiving device monitors a non-opened program number of the receiving program and descrambles the program using the received decode data when the encoded program number of the requested program agrees with the non-opened program number.
In the embodiments shown in FIG. 16 and FIG. 17, a plurality of decode data are provided with decode data numbers and are stored in advance in the receiving device as in the embodiment of FIG. 10.
The broadcasting station sends a decode data number for identifying the decode data to the charging center before the program is broadcast from the broadcasting station.
In the embodiment of FIG. 16, the applicant for viewing sends a viewing request to the charging center by specifying broadcasting time via public telephone line using the data communication device .
The charging center sends a decode data number and an encoded program number of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data number and the encoded program number to the receiving device.
Upon receipt of the decode data number and the encoded program number, the receiving device monitors non-opened program number of the receiving program and descrambles the program using decode data corresponding to the received decode data number when the encoded program number of the requested program agrees with the non-opened program number.
In the embodiment of FIG. 17, the encoded program number is provided with a temporary program number as in the embodiment of FIG. 8.
The broadcasting station sends also the temporary program number to the charging center before the program is broadcast from the broadcasting station.
The applicant for viewing sends a viewing request to the charging center by specifying a temporary program number via public telephone line using the data communication device.
The charging center sends a decode data number and an encoded program number corresponding to the temporary program number of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data number and the encoded program number to the receiving device.
Upon receipt of the decode data number and the encoded program number, the receiving device monitors non-opened program number of the receiving program and descrambles the program by decode data corresponding to the received decode data number when the encoded program number of the requested program agrees with the non-opened program number.
FIG. 18 to FIG. 22 each represents an embodiment in which pattern used in the scramble is not fixed in advance and the broadcasting station changes the scramble pattern for each program as appropriate. For this reason, it is impossible to decode the scramble pattern.
In these embodiments, decode data is sent to the charging center in advance from the broadcasting station.
In the embodiment of FIG. 18, the applicant for viewing sends a viewing request to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends the decode data of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data and broadcasting time information to the receiving device.
Upon receipt of the decode data and the broadcasting time information, the receiving device descrambles the program using the decode data at the specified broadcasting time.
FIG. 19 and FIG. 20 each represents an embodiment in which open a program number is used as in FIG. 5 and FIG. 6.
In the embodiment of FIG. 19, the applicant for viewing sends a viewing request to the charging center by specifying the broadcasting time via public telephone line using the data communication device.
The broadcasting station sends the program number to the charging center before the program is broadcast.
The charging center sends the decode data and the program number of the requested program to the data communication device via public telephone line.
The data communication device sends the received program number and the decode data to the receiving device.
Upon receipt of the decode data and the program number, the receiving device monitors program number of the receiving program and descrambles the program using the received decode data when the program number of the requested program is detected.
In the embodiment of FIG. 20, the applicant for viewing sends a viewing request to the charging center by specifying the program number via public telephone line using the data communication device.
The charging center sends the decode data of the requested program to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the program number and the received decode data to the receiving device.
Upon receipt of the program number, the receiving device monitors program number of the receiving program and descrambles the program using the receive d decode data when the program number of the requested program is detected.
In the embodiments of FIG. 21 and FIG. 22, a non-opened program number is used as in the embodiments of FIG. 7 and FIG. 8. In these embodiments, the non-opened program number is encoded and is sent to the charging center before the program is broadcast from the broadcasting station.
In the embodiment of FIG. 21, the applicant for viewing sends a viewing request to the charging center by specifying broadcasting time via public telephone line using the data communication device.
The charging center sends decode data of the requested program and an encoded program number to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data and the encoded program number to the receiving device.
Upon receipt of the decode data and the encoded program number, the receiving device monitors the non-opened program number of the receiving program and descrambles the program using the received decode data when the encoded program number of the requested program agrees with the nonopened program number.
In the embodiment of FIG. 22, the encoded program number is provided with a temporary program number as in the embodiment of FIG. 8, and the broadcasting station sends this temporary program number to the charging center before the program is broadcast.
The applicant for viewing sends a viewing request to the charging center by specifying a temporary program number via public telephone line using the data communication device.
The charging center sends decode data of the requested program and an encoded program number corresponding to the temporary program number to the data communication device via public telephone line and also collects a fee for the program.
The data communication device sends the received decode data and the encoded program number to the receiving device.
Upon receipt of the decode data and the encoded program number, the receiving device monitors non-opened program number of the receiving program and descrambles the program by the received decode data when the encoded program number of the requested program agrees with the nonopened program number.
As means for preparing the scramble code, the encoding method disclosed in Japanese Patent Application 4-164380, invented by the inventor of the present invention and filed by the applicant of the present application, may be used to ensure the security of the scramble code.
In the embodiments as described above, data relating to time is limited to "hour". As already explained, however, time information such as month, day, and hour is broadcast together with the program in pay satellite television broadcasting.
By utilizing the above time information, it is possible to achieve pay-per-view in hour, day, week or month.
In FIG. 1, a display phone is used as the data communication device 43, while the data communication device may include a telephone set capable of achieving data communication, such as a pushbutton telephone, portable telephone, etc., or a device such as personal computer or word-processor coupled to a modem.
In the embodiments as described above, description has been given on the charging system for television broadcasting. However, the present system can be applied to the other information transmitting means which require charging a fee for each program, for example, broadcasting and communication means utilizing satellite such as audio broadcasting or data broadcasting, data communication, etc. or various broadcasting and communication means utilizing terrestrial waves such as audio broadcasting or data broadcasting and data communication such as FM multiplex broadcasting.
Also, in case of data broadcasting, in which the secondary use of the broadcasting program is offered on a pay basis, a fee can be easily collected without fail if the system of the present invention is applied.
When requesting for viewing the program, it is possible to use program code system currently adopted for video tape recording.
By the method to include program code in the broadcasting program as described in the above embodiments, it is possible not only to view the scrambled pay program but also to more reliably perform video tape recording and television receiving of the program offered free if program code is monitored on the receiver side and video tape recording or television receiving is controlled by the program code.
In the above, a charging system for each broadcasting program, i.e., a pay broadcasting system for actualizing pay-per-program, has been described.
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A system for the so-called "pay-per-program" is provided for viewing individual program on pay basis without signing a comprehensive contract. In response to a request for viewing a pay program executed via public telephone line from an applicant for viewing, a charging center sends a viewing permit code for viewing a pay program to a data communication device and collects a fee for the pay program. Upon receipt of the viewing permit code, a receiving device offers the pay program according to the viewing permit code. The broadcasting program is scrambled by three modes of fixed, selective and change. The request for viewing is executed in three modes by specifying time, program number and temporary number. As the viewing permit code, one of three modes is adopted: decode data, non-opened program number or decode data number.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to novel film-forming, functionalized polymers having 1,2-dicarboxylic acid monoester groups.
Film-forming, functionalized polymers which have long been known are used for coating metals, papers and textiles and in the cosmetics industry, for example in hairsprays. Such polymers are also used in the pharmaceutical industry, for example for encapsulating or for immobilizing active substances. Electronic applications are, for example, in the area of NLO polymers, i.e. nonlinear optically active polymers, and of photoresists. In the latter case, mixtures of the polymers and photoactive, i.e. radiation-sensitive, components are used, for example for structuring semiconductor components. An important requirement here is a high transparency of the polymers at the exposure wavelength. Polymers which are used in the printing plate industry or in photocuring also have to meet similar requirements.
The preparation of monoesters of maleic acid copolymers and their use in photoresists is disclosed, for example, in International Application WO 96/24621. International Application WO 97/14079 likewise discloses the use of polymers having vicinal dicarboxylic acid monoester groups in photoresists. International Application WO 89/07786 describes the alcoholysis of copolymers of maleic anhydride and cycloaliphatic hydrocarbons.
SUMMARY OF THE INVENTION
It is the object of the invention to provide novel film-forming, functionalized polymers which have 1,2-dicarboxylic acid monoester groups, are suitable for various applications and can be used in particular in photoresists.
This and related objects are achieved, according to the invention, by film-forming polymers functionalized with 1,2-dicarboxylic acid monoester groups, comprising an acid-labile, hydrolysis-stable polymer unit (A) of structure:
a thermally stable polymer unit (B) of structure:
a second thermally stable polymer unit (C) of structure
and a polymer unit (D) bearing reactive groups and having a structure
in which the amount of (A) is from 1 to 99 mol %, the amount of (B) is from 1 to 99 mol %, the amount of (C) is from 0 to 50 mol %, and the amount of (D) is from 0 to 50 mol %, provided that the amounts of (A), (B), (C), and (D) total 100 mol %; and in which
n=0, 1, 2 or 3,
R 1 is a hydrocarbon radical which is bonded via a tertiary C atom to the O atom and having a total of 4 to 10 C atoms, or a 2-tetrahydrofuranyl or 2-tetrahydropyranyl radical,
R 2 , R 3 and R 4 —independently of one another—are C 1- to C 6- alkyl or C 1- to C 6- alkoxy, C 6- to C 18- aryl or C 6- to C 18- aryloxy or aralkyl having a C 6- to C 18- aryl group and a C 1- to C 4- alkylene radical,
R 5 is H or C 1- to C 6- alkyl,
R 6 , R 7 , R 8 and R 9 —independently of one another—are H, C 1- to C 6- alkyl, C 6- to C 18- aryl, halogen, CN, methoxyphenyl or a radical of structure
where
R 15 is H, C 1- to C 6- alkyl, C 6- to C 18- aryl, CH 2 ═CH—(vinyl), CH 2 ═CH—CH 2 -(allyl), or CH 2 ═CH—CO—;
R 10 is H, C 1- to C 6- alkyl, C 2- to C 6- alkenyl, C 6- to C 18- aryl, halogen or halogen-substituted C 1- to C 6- alkyl;
R 11 and R 12 —independently of one another—are linear C 1- to C 18- alkyl;
R 13 and R 14 —independently of one another—are linear C 1- to C 18- alkyl or tert-butyl;
X is Si or Sn and
Y is O or NH.
The amounts of the polymer units (A) and (B) sum to 100 mol % when only such polymer units are present. When polymer units (C) and/or (D) are present in amounts greater than 0 mol %, the amounts of polymer units (A), (B), (C) and/or (D) sum to 100 mol %. By suitable choice of amounts of these polymer units and the corresponding ratios of the unsaturated monomer source of these polymer units, the polymer properties, such as glass transition temperature and solubility, can be controlled.
The amount of polymer unit (A) of the polymer is preferably from 5 to 50 mol %. The amount of polymer units (C) and or (D) when present is in the range from 1 to 50 mol %, preferably from 5 to 15 mol % and 1 to 10 mol %, respectively.
As a feature of this invention, the hydrolytically stable and acid labile polymer units (A) are resistant to exposure to water and acidic solutions up to 70° C. As a further feature of this invention, the thermally stable polymer units (B) and (C) resist depolymerization and degradation of the polymer chain up to 230° C. under thermal conditions and the polymer units (A) decompose thermally above 150° C. and at 135° C. or more under acid-catalyzed conditions, while the film forming polymers of the invention can be selectively converted to either positive or negative photoresist by controlled heat treatment at a suitable temperature followed by development in an aqueous alkaline solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the polymer of this invention, the radical R 1 may be, for example, a tert-butyl radical —C(CH 3 ) 3 , a tert-pentyl radical —C(CH 3 ) 2 —C 2 H 5 or a 1-adamantyl radical (—C 10 H 15 ). An important feature of the polymer unit (B) is its metallic component, i.e. the presence of silicon Si or tin Sn.
The polymer according to the invention can have 1,2-dicarboxylic acid monoester groups as in the structural units(1), (2), or (3), on the chain or as pendant groups. A polymer comprising units (A) and (B) having groups on the chain can be prepared, for example, by reacting a maleic anhydride copolymer with tert-butanol. The mono-tert-butyl 1,2-dicarboxylate groups can also be introduced into the polymer by homo- or copolymerization of mono-tert-butyl fumarate or maleate.
Polymers having pendant 1,2-dicarboxylic acid monoester groups, i.e. having groups which are not bonded directly to the polymer main chain but are situated outside the main chain, can be obtained, for example, by homopolymerization of or copolymerization with 1-alkyl-2-(3-alkylenesuccinic anhydride)-ethylene and subsequent reaction with tert-butanol or by homopolymerization of 1-alkyl-2-(mono-tert-butyl 3-alkylenesuccinate)-ethylene. In the case of the structural unit (3), the 1,2-dicarboxylic acid monoester groups are bonded via a norbornyl radical to the polymer main chain.
The polymers according to the invention have weight average molecular weight in the range from 5000 to 15000, typically approximately 12000, and glass transition temperatures in the range from 110 to 150° C., typically 130° C. The characteristic vibrational bands in the infra-red spectrum of the monoester moieties (polymer unit A) are at 1730 and 1710 cm −1 . Tert-butyl succinate monoester moieties also have a characteristic band at 1150 cm −1 . Bands characteristic of anhydride groups are found at 1750 and 1780 cm —1 .
For the preparation of polymers according to the invention, in general an unsaturated monomer source for the polymer units (A) is copolymerized with an electron-rich monomer source for the polymer units (B). The monomer source for polymer units (a) of structure (1) is a monoester of maleic acid or fumaric acid in which the esterifying group R 1 is as defined above. The monomer source for polymer unit (A) of structure (2) can be monoester of alkylidenesuccinic acid, alkylmaleic acid or alkylfumaric acid in which the esterifying group R 1 is as defined above. The monomer source for polymer unit (A) of structure (3) can be a norbornenedicarboxylic acid monoester in which the esterifying group R 1 is as defined above. The monomer source for polymer unit (B) is an unsaturated compound with high electron density at the double bond, such as an allyl compound (leading to structure (4)) or an acrylic ester or amide (leading to structure (5)). As a result of this copolymerization, on the one hand high polymer yields are achieved and on the other hand the physical properties of the polymers can be controlled. Thus for example, a specific Si content can be realized.
In addition to the polymer units (A) and(B), the polymers according to the invention advantageously can include a further thermally stable polymer unit (C) as defined above and also a further polymer unit (D) as defined above.
The polymer unit (D) has reactive groups which permit an after treatment of the polymer. For this purpose, (D) contains either an imido group (structural unit 7) or an anhydride or lactone group (structural unit 8) or a dialkyl dicarboxylate group (structural unit 9). The anhydride group is based on succinic anhydride (structural unit 8a) or glutaric anhydride (structural unit 8b) and the lactone group is based on γ-butyrolactone (structural unit 8c). An R substituent in polymer unit (D) can be, for example, an ethyl group.
Modifying agents advantageously used in reaction with polymer units (D) for effective aftertreatment include amines such as bis(aminoalkyl)oligodimethylsiloxane.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in film-forming polymers, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments.
The invention is to be explained in more detail with reference to Working Examples, in which pbw is used to indicate parts by weight.
EXAMPLE 1
Preparation of a Copolymer Having Mono-tert-butyl 1,2-dicarboxylate Groups
11.3 pbw of tert-butyl trimethylsilylfumarate (prepared by reacting tert-butyl fumarate with hexamethyldisilazane or with trimethylchlorosilane analogously to J. Polym. Sci., Part A: Polym. Chem. Vol. 25 (1987), pages 979 to 986) are dissolved under an inert gas atmosphere together with 5.7 pbw of allyltrimethylsilane and 0.08 pbw of azobisisobutyronitrile in 15 pbw of dry ethyl acetate and then heated to the boil. After 24 hours, 1 pbw of water is added and the mixture is heated to the boil for a further 3 hours; it is then cooled to room temperature. By dropwise addition of the polymer solution to petroleum ether (boiling range from 60 to 80° C.), subsequent filtration and drying at 50° C. for 24 hours in vacuo, 10 pbw of colorless polymer powder are obtained.
EXAMPLE 2
Preparation of a Copolymer Having Mono-tert-butyl 1,2-dicarboxylate Groups
8 pbw of tert-butyl fumarate (prepared analogously to J. Heterocyclic Chem. Vol. 32 (1995), pages 1309 to 1315) are dissolved together with 5.7 pbw of allyltrimethylsilane and 0.08 pbw of azobisisobutyronitrile in 15 pbw of ethyl acetate. The solution is heated to the boil for 24 hours and then cooled to room temperature. By dropwise addition of the polymer solution to petroleum ether (boiling range from 60 to 80° C.), subsequent filtration and drying at 50° C. for 24 hours in vacuo, 10 pbw of colorless polymer powder are obtained.
EXAMPLE 3
Preparation of a Terpolymer Having Mono-tert-butyl 1,2-dicarboxylate Groups
6 pbw of tert-butyl fumarate (prepared analogously to J. Heterocyclic Chem. Vol. 32 (1995), pages 1309 to 1315) and 2.5 pbw of 1-hexene are dissolved together with 5.7 pbw of allyltrimethylsilane and 0.08 pbw of azobisisobutyronitrile in 15 pbw of ethyl acetate. The solution is heated to the boil for 24 hours and then cooled to room temperature. By dropwise addition of the polymer solution to petroleum ether (boiling range from 60 to 80° C.), subsequent filtration and drying at 50° C. for 24 hours in vacuo, 9.5 pbw of colorless polymer powder are obtained.
EXAMPLE 4
Preparation of a Quaterpolymer Having Mono-tetrahydrofuranyl 1,2-dicarboxylate groups
4 pbw of tetrahydrofuranyl fumarate, 2 pbw of maleimide and 2.5 pbw of 1-hexene are dissolved together with 5.7 pbw of allyltrimethylsilane and 0.08 pbw of azobisisobutyronitrile in 15 pbw of ethyl acetate. The solution is heated to the boil for 24 hours and then cooled to room temperature. By dropwise addition of the polymer solution to petroleum ether (boiling range from 60 to 80° C.), subsequent filtration and drying at 50° C. for 24 hours in vacuo, 10.5 pbw of colorless polymer powder are obtained.
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Film-forming, functionalized polymers having 1,2-dicarboxylic acid monoester groups have at least two polymer units, one of which is acid-labile and hydrolysis-stable and the other is thermally stable. These polymers are used in particular in photoresists.
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FIELD OF THE INVENTION
This invention relates to a process for making fasteners and more particularly to a process for making plated, case hardened, self-drilling, self-piercing and self-tapping screws where the screw has been specially heat treated. The invention also relates to the product resulting from the hardening process.
BACKGROUND OF THE INVENTION
Case hardened self-drilling, self-piercing and self-tapping screws are often used to reduce fastener joint complexity and fastener assembly. Self-drilling screws have point and thread configurations that allow the screws to cut threads into the mating materials. Self-piercing screws have point configurations that allow the screws to form their own pilot holes and then tap or cut threads into a mating component. Self-tapping screws, also referred to as thread forming screws, have point and thread configurations that allow the screws to form threads in mating components. These screws simplify the assembly process and provide economic benefits by eliminating the need for pre-drilled and pre-threaded holes, by helping to align fastener joints during assembly, and by reduced fastener joint packaging space.
There are many industrial applications where case hardened fasteners can be used to provide economic cost savings. A common usage of case hardened fasteners is in the assembly of thin sheet metal components such as the mounting of body panels to the frame of vehicles and the assembly of paneling to the structural components of a building. Case hardened screws are used in many industries such as appliance, automotive, aerospace, as well as others.
In order for self-tapping, self-drilling and self-piercing fasteners to perform the their intended functions, the surface hardness of the threads must be harder than the materials into which threads are being cut or formed. Typically, case hardened fasteners have been manufactured from steel which is case hardened by carbonnitriding or, less commonly, gas carburizing. This produces a fastener with a hardened steel surface, referred to as the “case,” and a less hard, more ductile core. The hardened surface extends to a specified depth, which depends on the diameter of the fastener, and typically has a hardness greater than 45 HRC. The core hardness typically ranges from 28 to 39 HRC.
Many of the above applications for case hardened fasteners involve long term exposure to corrosive environments. The process for making self-tapping metal screws, in particular, customarily includes the step of plating the screws with a corrosion resistant barrier or sacrificial metal layer coatings after the hardening operation. Prior to plating, fasteners are cleaned of heat treat scale, oil and contaminants using either acid or caustic cleaning baths. The type of coating and the process in which a coating is applied depends on the desired corrosion resistance, cosmetic appearance, electrical conductivity, and friction characteristics. Coatings can be applied after cleaning by one of several methods including, but not limited to electroplating, mechanical plating, dip-spinning, and spraying.
Unfortunately, when hardened steel is either acid cleaned or electroplated it can become embrittled through a process called “hydrogen embrittlement.” Hydrogen embrittlement is a process of time dependent subcritical crack formation and crack growth resulting from the cooperative interaction between static stress and hydrogen. The susceptibility of steel to hydrogen embrittlement has typically been related to increasing hardness, stress and the amount of hydrogen available for diffusion to tri-axial stresses. Case hardened fasteners are particularly susceptible to hydrogen embrittlement due to their high surface hardness and their processing under traditional manufacturing methods. The formation and growth of cracks due to hydrogen embrittlement typically result in the separation of the head of the fastener from the shank or threads and can occur within minutes or days after assembly.
In order to relieve the hydrogen embrittlement and reduce the danger of cracking, standard specifications call for electroplated fasteners to be baked, heat treated for 4 to 24 hours at 400° F. within one hour of electroplating. Baking is not always completely successful in relieving the hydrogen embrittlement and adds cost to fasteners. A more certain method for preventing hydrogen embrittlement is therefore needed.
Hardened steel fasteners that are susceptible to hydrogen embrittlement are also susceptible to “stress corrosion cracking”, also referred to as “environmentally assisted hydrogen embrittlement”. Stress corrosion cracking of fasteners is similar to hydrogen embrittlement in that hydrogen is involved in embrittling the steel. However, in stress corrosion cracking, hydrogen is supplied by the corrosion reaction between the steel surface, the sacrificial coating and the environment. As with hydrogen embrittlement, fastener failure occurs some time after assembly and can vary from minutes to any time during the lifetime of the fastener. There are no known methods of relieving stress corrosion cracking susceptibility.
Soft steels are typically not as susceptible to hydrogen embrittlement. Unfortunately, soft steels do not contain a sufficient hardness to cut, pierce and form threads as self-drilling, self-piercing, or self-tapping fasteners. Any solution to prevent hydrogen embrittlement and stress corrosion cracking in self-tapping, self-piercing and self-drilling screws must address material susceptibility yet preserve the ability of the fasteners to perform their intended functions. Baking, choosing alternate coatings, and attempting to manage the fastener stress state have proved to be unreliable solutions to hydrogen embrittlement and stress corrosion cracking. The invention below describes a process and recommended materials in which self-tapping, self-piercing and self-drilling screws can be manufactured that are resistant to hydrogen embrittlement and stress corrosion cracking, yet can still perform their intended functions.
SUMMARY OF THE INVENTION
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The present invention relates to the material selection and process of making a case hardened fastener wherein the entire fastener is subject to a special heat treating regime. It has been found that when a case hardened fastener has been subject to a specific heat treating regime, the chances of hydrogen embrittlement and stress corrosion cracking are greatly reduced. This regime calls for the tempering of the fastener at temperatures higher than those normally seen in the heat treatment of such fasteners. Whereas this reduces the chance of hydrogen embrittlement and stress corrosion cracking, it also reduces the core and case hardness of the material.
The method for producing the case hardened fastener of the current invention consists of reducing wire to a working diameter, cold heading the wire into fastener blanks, followed by threading. Fasteners are then gas carburized or carbonitrided at 1700° F. and 1550° F. respectively followed by an oil or water quench. After quenching, fasteners are tempered between 600 and 770° F. for a period of one hour. The typical materials used for case hardened tapping screws include, but are not limited to, 1022, 1021, 10B22 or 10B21 steel materials. A preferred method for adjusting the susceptibility to hydrogen embrittlement and stress corrosion cracking is described.
Tempering at temperatures greater than 770° F. has been proven to reduce hydrogen embrittlement and stress corrosion cracking susceptibility for 1022 and 10B21 case hardened fasteners. Tempering at 800° F. eliminated the potential for hydrogen embrittlement and stress corrosion cracking for these same materials, as shown in FIG. 1 . The results show an apparent link between hydrogen embrittlement and stress corrosion cracking to tempered martensite embrittlement. The results of this analysis can be extrapolated for like materials heat treated by carbonitriding and gas carburizing atmospheres. Like materials would encompass plain carbon steels from 1) 1000 series alloys, including but not limited to, 1021, 1022 and 1026; 2) 1500 series alloys, including but not limited to, 1518 and 1525; 3) boron steels from 10B00 series alloys, including but not limited to 10B21, 10B22 and 10B26; 4) 4000 series alloys, including but not limited to 4023, 4120; 5) 5000 series alloys, including but not limited to 5120; and 6) 8000 series alloys, including but not limited to 8620 and 8622. References to the materials are described in Metals Handbook, 8 th Edition copyright 1961 by the American Society for Metals, which is herein incorporated by reference as if fully set forth herein. The exact tempering temperature in which susceptibility is eliminated depends on the material grade but can be determine using an incremental load method described in ASTM 16.24.
As previously mentioned, increasing the tempering temperature reduces the case and core hardness of the material. For standard case hardened fastener materials such as 1022 and 1021, the higher tempering temperatures can reduce the case and core hardness below that necessary for self-tapping, self-piercing and self-drilling screws to perform their intended function. The use of higher carbon plain carbon steels, boron steels, and alloyed steels increase the likelihood that case hardened fasteners tempered at higher than industry standard temperatures can achieve surface and core hardness targets. Due to economics, other than 10B21, these materials are not used currently in the manufacturing of case hardened fasteners. These new materials, when subject to the increased tempering temperature, should be able to achieve hardness targets, perform the intended function of cutting and forming threads while exhibiting no susceptibility to hydrogen embrittlement or stress corrosion cracking.
The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the article possessing the features, properties and the relation of elements, which are exemplified in the following detailed disclosure and scope of the invention will be indicated in the claims. For a further understanding of the invention, reference is had to the following descriptions taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a front elevated view of a screw fastener as it appears in the final step of production of clotting and core layers of the fastener;
FIG. 2 is a chart showing stress corrosion cracking results for 1022 and 10B21 materials;
FIG. 3 is a flow chart of the method for producing the case hardened fastener; and
FIG. 4 is a chart showing stress corrosion cracking susceptibility as a function of tempering temperature 10B21 case hardened fasteners.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention being thus described, it will be understood that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
FIG. 1 is an enlarged front view of an exemplary fastener constructed in accordance with the teachings of the present invention. The fastener is illustrated as a self-drilling screw 10 generally including a head 12 , which is customarily impressed with either a lateral or crossed (phillips head) slot 13 to facilitate engaging and driving the screw. Screw 10 also comprises a threaded shank 14 which may be either cylindrical or conical and terminates at a tip area 16 . In the preferred embodiment, tip area 16 is configured as a drill comprising a pair of flutes 17 (one of which is shown) and a drill point 18 .
When the screw 10 is driven into the work surface, the sharp points and cutting edges of the tip area 16 cut into the softer work surface. As the screw penetrates into the work material, the a lower portion of threads or cutting threads 20 cut mating threads into the work. This process continues with an upper portion of threads 22 on the screw 10 following the cutting threads 20 until the screw is fully seeded. The upper portion of threads 22 are substantially non-cutting threads.
In order for the tip 16 and cutting threads 20 to cut properly, they must be hardened. For cost and manufacturing reasons, the entire surface of case hardened fasteners is hardened. The high surface hardness, greater than 45R c allows case hardened fasteners to pierce holes for self-piercing fasteners, and cut or form threads for self-piercing, self-tapping and self-drilling screws. The case depth is typically defined as the depth at which the case hardness equals 45R c and can vary from 0.002 to 0.011 inches (0.051 to 0.279 mm) in depth depending on the size of the screw. To provide ductility and to prevent brittle failure during assembly, the specified core hardness range is 28 to 39R c . Most specifications call for a core hardness range between 28 to 36R c .
As is known, to meet this industrial standard, steel materials, such as 1021 and 1022, are case hardened in gas carburizing or carbonitriding atmospheres at about 1700° F. and 1550° F. respectively. Fasteners are then quenched in either water or oil and tempered between 600° F. to 770° F. for about an hour depending on the size an material of the fastener. The process of the present invention begins with the formation of a steel screw 10 . Incoming steel wire made of 1) 1000 series alloys, including but not limited to, 1021, 1022 and 1026; 2) 1500 series alloys, including but not limited to, 1518 and 1525; 3) boron steels from 10B00 series alloys, including but not limited to 10B21, 10B22 and 10B26; 4) 4000 series alloys, including but not limited to 4023, 4120; 5) 5000 series alloys, including but not limited to 5120; and 6) 8000 series alloys, including but not limited to 8620 and 8622 is reduced in diameter.
As shown in FIG. 3, the fastener 10 is then cold headed in a conventional manner and threaded. The fastener 10 is then gas carburized at approximately 1550° F. or carbonitrided at about 1700° F. and quenched to room temperature. The fastener 10 is then tempered at a temperature greater than 770° F. for approximately an hour, or more particularly, 800° F. for the greatest benefit. The exact tempering temperature minimum is dependent on the material and material response to stress corrosion testing. The fasteners are then cooled to room temperature. After heat treatment, fasteners can be coated with a variety of coatings, such as tin, tin zinc, nickel, etc, using standard plating and coating processes such as mechanical plating, electroplating, spray, etc.
Testing has shown that fasteners subject to the method of production and heat treat regime as described in the current invention are not susceptible to hydrogen embrittlement and stress corrosion cracking. FIG. 4 shows the stress corrosion cracking test results of 10B21 case hardened fasteners. The fasteners were testing in bending in air and then in a 3.5% salt water solution under an imposed potential of −1.2 volts. The bending load was incrementally increased in steps of 5% of the ultimate bending strength of the fastener. At tempering temperatures above 770° F., the stress corrosion fracture strength approaches that of the fracture strength in air indicating a substantial reduction in susceptibility to hydrogen embrittlement and stress corrosion cracking. At a tempering temperature of 800° F., susceptibility to hydrogen embrittlement and stress corrosion cracking is eliminated.
It will thus be seen that the objects set forth above, among those made apparent in the preceding description are effectively attained and, since certain changes may be made in carrying out the above method and in the articles set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrated and not in a limited sense.
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A method for heat treating a metal article such as a fastener comprising the step of case hardening the fastener in a gas carborizing atmosphere at a temperature of about 1700° F. or in a carbonitriding atmosphere at a temperature of about 1550° F., and quenching the fastener in water or oil and tempering the fastener at a minimum temperature of 770° F. for approximately one hour.
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BACKGROUND OF THE INVENTION
In fabric dryers, notably of the type such as are used in commerical laundries, dyeing plants, etc., heated air is drawn through the dryer at a constant rate over the anticipated drying time at considerable volume. Commonly, the burner which heats the air is a two stage burner which operates initially at a high output level to bring the load and the dryer itself quickly up to an elevated temperature and when that temperature is sensed by a sensor in the exhaust system, drops to a lower output level for drying. The high stage may cycle on and off to keep the contents up to temperature and compensate for the evaporative cooling effect of the water in the wet load. The input of large quantities of heat together with large volumes of air results in a considerable wastage of heat or fuel during the early stages of the drying process when the load and dryer are being brought up to drying temperature which, of course, has the effect of extending the time of the drying cycle.
SUMMARY OF THE INVENTION
I have found that if the rate of air movement through a dryer is reduced during the early stages of the drying process, less heat and fuel is wasted through the exhaust of the system, the load is more quickly brought up to drying temperature, the high output stage shuts off more quickly, and cycles on less.
More specifically, dryers are conventionally furnished with a damper to match the air flow rate through the dryer to the maximum capacity of the exhaust blower system. The more unimpeded the flow rate is through the dryer, the greater will be the current draw of the motor. To obtain maximum efficiency of the fan (or its motor) the flow passage is formed to overload the motor and then variably choked down to the stated current draw, to fit variations in installations and downstream exhaust configurations. Normally, once the damper is properly adjusted for optimum air flow it is left fixed in that position.
This invention contemplates an automatic control of that damper such that the air flow is sharply reduced when the dryer is started so as to permit an efficient application of the incoming hot air to the warming of the load and a discharge of such air as is exhausted in a relatively fully saturated condition. At a timed interval after start-up, the damper is opened to its predetermined position for maximum passage of air therethrough to flush out the residual moisture and to cool the load quickly after the flame is shut down.
It has been found that by the use of this invention, both fuel consumption and drying cycle time may be reduced by 20 to 25%.
The modification of a dryer to incorporate this capability is inexpensive and simple.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a dryer embodying the invention shown with certain covering panels removed;
FIG. 2 is a rear elevation of the drier of FIG. 1;
FIG. 3 is a part section, past elevation taken along the line 3--3 of FIG. 2 looking in the direction of the arrows;
FIG. 4 is a fragmentary elevation of one of the bearing shelf ribs; and
FIG. 5 is an electric and pneumatic circuit diagram of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIG. 1, the dryer shown comprises a pair of spaced, generally rectangular pedestals or towers, a support tower 12, and a control tower 14 connected by a tie 16 across the bottom. A dryer tumbler housing 18 is supported on trunnions 20 received in appropriate bearings in the two towers to support the housing for rotation. A driven sprocket 22 is mounted on the support tower trunnion 20. The tower 12 includes an internal motor 24 and an external driving sprocket 26 chain-28-connected to sprocket 22 for rotating the housing 18.
The housing has a loading port 30 in the front face thereof capable of being closed by doors (not shown), and the chain and sprocket assembly 22, 26, and 28 serve to rotate the housing so that the loading port may be faced upwardly to receive a charge of wet fabric from an overhead loader, be restored to the illustrated position where the loading port faces front in the drying position, and tilted somewhat downwardly to facilitate unloading. In some installations, the housing may be rotated so that the loading port faces directly downwardly for gravity unloading where the installation affords such space utilization or may be rotated through more than 180° to permit unloading on that side of the machine opposite to the loading side.
The control tower 14, in addition to the conventional controls which need not be described here, contains a combustion chamber 32 in its upper part having an air intake 34, a burner 36, and an outlet port 38 on that surface thereof facing the upper part of the tumbler housing. An exhaust fan 42 is situated in the bottom of the control tower having an intake 44 in the surface of the tower facing the lower part of the tumbler housing and an exhaust port 46 at the back of the control tower.
The tumbler housing 18 includes a top 46, sides 48 and 50 mounting the trunions 20, a floor 52, a front face 53 in which the loading port 30 is formed, and a back plate 54 to define a rectilinear enclosure. The housing is covered on all sides with insulation (not shown) for retention of heat and to make the dryer ambience comfortable.
The tumbler 56 is a cylindrical basket situated within the housing 18 having a perforated cylindrical wall 58 and a solid back wall 60. A trunnion 62 extends centrally outwardly from the back wall 60 through an appropriate hole in the plate 54 and is received in a bearing 64 on the back side of the plate 54. Ribs 66 extend from the cylindrical wall of the basket inwardly to agitate and tumble the fabrics placed therein. In the side wall 50 facing the control tower 14, a hot air inlet hole 68 and an air exhaust hole 70 are formed to conform to the hot air outlet port 38 of the combustion chamber 32 and the exhaust air inlet 44 for the blower 42. The ports 68 and 70 of the tumbler housing 18 conform to and register with the ports 38 and 44 respectively in the control tower when the housing 18 is in the illustrated drying position, and are exteriorly flanged to approach each other very closely to limit the introduction of ambient air. The fit between the exhaust ports 44 and 70 should be particularly close, and an adjustable telescoping flange may be provided on one of these openings to obtain the desired exactness of fit.
Shrouding 72 is provided within the drying compartment between the back plate 54 and the front face 53 of the housing to encompass the drying drum closely, to provide an air inlet passage 74 for incoming hot air and an outlet passage 76 communicating with the outlet port 70 for the exhaust of warm saturated air. Baffles 78 extend from the shrouding to the tumbler surface to prevent direct communication by way of the shrouding from the inlet 74 to outlet 76 and compel the passage of air between these passages through the perforations of the cylindrical wall of the tumbler 56. The exhaust end 80 of the outlet passage is formed by the floor 52 of the housing, a portion of shrouding 82 parallel thereto, the front face 53, and the back plate 54 to be rectangular in section, and communicates, as stated, directly with the outlet port 70. The damper 84 is contained in the exhaust end of the outlet passage.
FIG. 2 shows the back side of the dryer. The back plate 54 mounts in about its center the bearing 64 which contains the trunion 62 of the tumbler 56. The bearing is mounted on a horizontal shelf 86 welded along its edge to the back plate 54 and along its sides to the facing surfaces of vertical shelf ribs 88, elongated flat parallel plates welded along one of their long edges also to plate 54. The combination of the shelf 86 and the ribs 88 stiffens the back plate 54 to withstand the load imposed by damp fabrics within the tumbler and provides stable support for the trunion 62. The trunion 62 mounts a large diameter pulley 90. The tumbler motor 92 is mounted between inclined shelves 94 for belt tension adjustment and has a small pulley 96 thereon to belt-drive a large diameter pulley 98 mounted on a countershaft 100 which also carries a small diameter pulley 102 belt-connected to pulley 90. Countershaft 100 is mounted for rotation on a shelf 104 similar to the shelf 86. Thus, a double reduction of motor speed is effected which serves to rotate the basket at the desired slow rate of revolution to obtain a continuous tumbling of the contained fabric.
A clean-out door 106 is provided in the back plate, opening into the outlet passage adjacent its exhaust end for the removal of coins, buttons, etc. which may lodge therein.
The back of the housing 18 will be covered by removable screening (not shown) for reasons of safety.
The damper 84 (FIG. 3) is a rectangular plate adapted to substantially close off the exhaust end 80 of the outlet passage and is welded to a steel shaft 108 along its top edge which has a projecting end 110 toward the front face 53 of the housing extending through an appropriate hole 112 in the front face but concealed behind the insulation covering the front face. The other end 114 of the shaft extends through a hole 116 in the back plate 54 to project substantially outward from the back plate and its covering insulation and has one end of a crank arm 118 welded thereto. The crank arm is oriented on shaft 108 such that it moves in an arc through a vertically upward position from the shaft end 94 as the damper moves between open and closed positions. Associated with the crank arm is a track member 120, a U-shaped bracket having a longitudinally slotted back portion 122 defining a pair of rails 124 extending horizontally and parallel to and spaced from the back plate 54 adjacent the inside surface of the crank arm 118, and a pair of inturned ends 126 by which the track is secured to the back plate 54 as by welding, etc. A clamp 128 is mounted to the rails to be fixed at any position therealong. The clamp consists of an internally threaded block 130 on the inside of the rails, a washer 132 on the outside of the rails and a thumb screw 134 for tightening the block and washer against the rails. The crank arm 118 has a slot 136 therein such that a portion of the slot overlies the space between the rails 124 throughout the range of movement of the crank arm. As normally furnished, the thumb screw of the clamp extends through the slot 136 of the crank 118 and the space between the rails 124. The damper 84 is adjusted to produce the rated current demand in the exhaust motor, and the thumb screw is tightened to clamp the crank to the rails 124 in a fixed position.
The device of the present invention will be described as a modification of the dryer described above in the way of an accessory package, although it may be provided as original equipment as will appear hereafter.
The present invention contemplates the operation of the damper 84 by a pneumatic cylinder between the position determined by the current draw of the blower motor as described above and a relatively closed position. The first of these positions will be referred to as the open position.
To this end, the crank 118 is disengaged from the clamp 128 and its upper free end is connected to the rod 138 of a pneumatic cylinder 140, which in turn is mounted to a post 142 secured to the back plate 54 of the housing.
More specifically, it will be noted from the drawings that the damper 84 is accessible through the clean-out door 106. For installation of the automatic air flow control, a one inch spacer is inserted between the lower edge of the damper 84 and the floor 52 of the housing 18. A hole is drilled at the top end of the crank 118. The rod 138 of the pneumatic cylinder 140 has a clevis 144 on the free end thereof which embraces free end of the crank and is pinned through the hole drilled therethrough. With the rod of the pneumatic cylinder 140 fully extended and the cylinder oriented generally parallel to the rails 124 and shortly thereabove, the location for the post 142 is ascertained and a hole drilled and tapped into the back plate 54 of the housing. Thereafter the post 142 is threaded into the hole and a headed bolt 146 is passed through an eye on the head end of the pneumatic cylinder 120 and into an appropriate threaded socket in the free end of the post 142. The clamp 128 is then adjusted on the rails to provide an abutment stop for the crank 118 at the desired open position.
A mercury switch 148 is mounted to the face of one of the shelf ribs 88 to be open when the housing 18 is in drying position but to close when the housing is rotated to load-discharge position with the loading port 30 faced downwardly.
The circuitry controlling the damper is illustrated in FIG. 5. The primary 200 of a transformer 202 powers a control circuit 204 through the transformer secondary 205. The primary is illustratively a 220 volt circuit which also powers the exhaust blower, the combustion blower, the basket motor, and the housing rotating motor with switches in the circuits to each of these under the control of elements in the control circuit 204. As the powering and the control of the motors is old and plays no part in this invention, illustration is believed unnecessary. Only that part of the circuit having to do with the variable exhaust air flow is illustrated.
The secondary 205 of the transformer is connected to line 206 on one side thereof and to line 208 on the other side thereof. Line 206 is connected through a normally closed stop switch 210 to a line 212. Line 212 is connected to line 208 across the transformer by a line 214 which includes a normally open starting switch 216 and a starting relay 218. The starting relay 218 includes normally open contacts 218a in a holding circuit 220 around the starting switch 216 to maintain energization of the starting relay 218.
It will be appreciated that the starting relay 218 also closes the circuit to the main blower and conditions the burner for operation which will start as soon as the appropriate vacuum has been developed by the main blower. Again, however, these aspects of the operation are old, and description is believed unnecessary.
Line 212 is also connected to line 208 by line 224 which includes the normally open mercury switch 148 and a relay 226. The mercury switch 148 has a holding circuit 228 thereabout with normally open, relay-226-actuated contacts 226a therein. A terminal 230 is situated in line 214 between the starting switch 216 and the relay 218, and a line 232 extends to terminal 234 and has normally open, relay-226-actuated contacts 226b therein. From terminal 234, a line 236 extends to line 208 and includes a timer 238, a relay 240, and a winding 242 on one side of a pneumatic directional control valve 244. The timer 238 is of the type which, when energized, conducts for the desired time period and then opens the circuit. Terminal 234 is also connected to line 208 by a line 246 which includes normally closed, solenoid-240-operated contacts 240a and the opposite winding 248 of pneumatic valve 244.
The operation of the circuitry is as follows. Prior to starting a cycle of drying operation, the dryer will have been emptied of a previous load by tilting the dryer housing 18, so closing mercury switch 148 and energizing relay 226 which in turn closes the holding contacts 226a of the holding circuit 228 for relay 226. The energized relay 226 also closes the contacts 226b in line 232. Before the start of the drying cycle, the housing is restored to its drying position, but the holding circuit 228, now being closed, continues energization of relay 226.
When the start button 216 is pushed, relay 218 is energized so closing the holding contacts 218a of the holding circuit 220 for relay 218. This energizes winding 242 of the pneumatic valve 244 through terminal 230, line 232, the now closed contacts 226b, the timer 238 and the relay 240. The valve 244 thus directs air under pressure into the head end of the pneumatic cylinder 140, so extending the rod 138 thereof to move the damper to its closed position. Winding 248 of the pneumatic valve 244 is deenergized by virtue of energization of the relay 240, so opening the normally closed contacts 240a.
The timer 238 is conductive for its predetermined time interval and at the expiration of the time, opens line 236. This deenergizes relay 240 and permits contacts 240a to close. Thus, winding 242 is deenergized and winding 248 is energized to move the valve 244 to its alternative position, so admitting air into the rod end of the cylinder 140 and moving the damper to its open position.
It will occasionally happen that a load of fabric, at the end of a drying cycle, will still not be fully dry. It is therefore necessary to start the dryer up again for a short period to complete the drying. Obviously, however, the damper should be open during such final drying, both for reasons of efficiency and speed of drying and to avoid damage to the fabrics from overheating which, in that nearly dry condition, are not protected by the cooling effect of the water. It is to this end that the mercury switch 148 is provided.
At the end of the estimated time of drying, the stop button 210 is operated, so breaking the circuit to the line 212. This deenergizes the relays 218 and 226 and thus breaks their associated holding circuits 220 and 228. With relay 226 deenergized, contacts 226b will open, leaving the pneumatic valve 244 in the position of directing pressure into the rod end of the cylinder 140. Assuming then that the fabrics are determined to be not completely dry and the start button is again pushed, the circuit to relay 226 will remain open by virtue of the open mercury switch 148 and the normally open, relay operated contacts 226a. Thus, contacts 226b remain open and the pneumatic valve 244 is unaffected by the restarting of the dryer. To condition the damper for reclosing, it is necessary to tilt the tumbler housing 18 to the fabric discharging position to close mercury switch 148 and energize relay 226. Thereafter, when a new load of wet fabric is introduced and the drying cycle started, the damper will again close.
The above description is directed to the invention in terms of accessory equipment for dryers as previously sold. A dryer embodying the invention as original equipment is very simply described. Such a dryer will lack the track member 120 and its associated clamp 128. A collar clamp can be adjustably fixed along the length of the projecting rod 138 of the cylinder 140 to limit the retraction of the rod and so determine the open position of the damper, the position which must be determined in reference to the current draw of the blower motor. The mercury switch 148 may be employed as a part of the original equipment dryer. Possibly better, however, is a cam operated switch reflecting rotation of the tumbler housing 18 from its drying position. The advantage of the mercury switch as a part of the accessory pack is its ease of installation.
The switch may respond to any position of the housing 18 incident to the loading process (of which unloading is a necessary part) or any displacement from the drying position which necessarily occurs in each drying cycle.
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A fabric dryer including a damper in the air flow system thereof which reduces air flow through a load in the initial stages of drying and increases air flow during the terminal stages of drying to promote a faster drying cycle with less consumption of fuel.
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BACKGROUND
Cloud computing, as is well known, is Internet-based computing in which shared resources, software, and information are provided to computers and other devices on demand, as happens analogously with an electricity grid. Applications, that is, different programs that can be downloaded to computers and mobile devices, increasingly are becoming widely available on the cloud, as are larger amounts of information and data that can be widely shared. For instance, Amazon.com Inc. of Seattle, Wash. hosts scientific data for free.
One problem that is increasingly being encountered is that with an increase in structured data volumes in telecom, retail, finance and government domains, there is lacking a low-cost, easy to deploy data management arrangement that provides seamless connectivity to existing enterprise data management solutions.
Generally, conventional data management solutions cannot scale. By way of example, adequate solutions are not found for scaling to store and process increasingly large numbers of call data records (CDRs), nor for collecting and managing increasingly large numbers of data points from several sources maintained by both public and private sector organizations
BRIEF SUMMARY
In summary, one aspect of the invention provides a method comprising: accommodating a query; directing the query to datasets; creating partitions and partitioning the datasets; and returning a response to the query, the response being structured in accordance with the created partitions.
Another aspect of the invention provides an apparatus comprising: one or more processors; and a computer readable storage medium having computer readable program code embodied therewith and executable by the one or more processors, the computer readable program code comprising: computer readable program code configured to accommodate a query; computer readable program code configured to direct the query to datasets; computer readable program code configured to create partitions and partition the datasets; and computer readable program code configured to return a response to the query, the response being structured in accordance with the created partitions.
An additional aspect of the invention provides a computer program product comprising: a computer readable storage medium having computer readable program code embodied therewith, the computer readable program code comprising:
computer readable program code configured to accommodate a query; computer readable program code configured to direct the query to datasets; computer readable program code configured to create partitions and partition the datasets; and computer readable program code configured to return a response to the query, the response being structured in accordance with the created partitions.
For a better understanding of exemplary embodiments of the invention, together with other and further features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawings, and the scope of the claimed embodiments of the invention will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 depicts a cloud computing node according to an embodiment of the present invention.
FIG. 2 depicts a cloud computing environment according to an embodiment of the present invention.
FIG. 3 depicts abstraction model layers according to an embodiment of the present invention.
FIG. 4 schematically illustrates an arrangement for query optimization in accordance with at least one embodiment of the invention.
FIG. 5 sets forth a process more generally for structured query optimization in accordance with at least one embodiment of the invention.
DETAILED DESCRIPTION
It will be readily understood that the components of the embodiments of the invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations in addition to the described exemplary embodiments. Thus, the following more detailed description of the embodiments of the invention, as represented in the figures, is not intended to limit the scope of the embodiments of the invention, as claimed, but is merely representative of exemplary embodiments of the invention.
Reference throughout this specification to “one embodiment” or “an embodiment” (or the like) means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” or the like in various places throughout this specification are not necessarily all referring to the same embodiment.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the various embodiments of the invention can be practiced without one or more of the specific details, or with other methods, components, materials, et cetera. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
The description now turns to the figures. The illustrated embodiments of the invention will be best understood by reference to the figures. The following description is intended only by way of example and simply illustrates certain selected exemplary embodiments of the invention as claimed herein.
It should be noted that the flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, apparatuses, methods and computer program products according to various embodiments of the invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
It is understood in advance that although this disclosure includes a detailed description on cloud computing, implementation of the teachings recited herein are not limited to a cloud computing environment. Rather, embodiments of the present invention are capable of being implemented in conjunction with any other type of computing environment now known or later developed.
For convenience, the Detailed Description includes the following definitions which have been derived from the “Draft NIST Working Definition of Cloud Computing” by Peter Mell and Tim Grance, dated Oct. 7, 2009.
Cloud computing is a model of service delivery for enabling convenient, on-demand network access to a shared pool of configurable computing resources (e.g. networks, network bandwidth, servers, processing, memory, storage, applications, virtual machines, and services) that can be rapidly provisioned and released with minimal management effort or interaction with a provider of the service. This cloud model may include at least five characteristics, at least three service models, and at least four deployment models.
Characteristics are as follows:
On-Demand Self-Service: a cloud consumer can unilaterally provision computing capabilities, such as server time and network storage, as needed automatically without requiring human interaction with the service's provider.
Broad Network Access: capabilities are available over a network and accessed through standard mechanisms that promote use by heterogeneous thin or thick client platforms (e.g., mobile phones, laptops, and PDAs).
Resource Pooling: the provider's computing resources are pooled to serve multiple consumers using a multi-tenant model, with different physical and virtual resources dynamically assigned and reassigned according to demand. There is a sense of location independence in that the consumer generally has no control or knowledge over the exact location of the provided resources but may be able to specify location at a higher level of abstraction (e.g., country, state, or datacenter).
Rapid Elasticity: capabilities can be rapidly and elastically provisioned, in some cases automatically, to quickly scale out and rapidly released to quickly scale in. To the consumer, the capabilities available for provisioning often appear to be unlimited and can be purchased in any quantity at any time.
Measured Service: cloud systems automatically control and optimize resource use by leveraging a metering capability at some level of abstraction appropriate to the type of service (e.g., storage, processing, bandwidth, and active user accounts). Resource usage can be monitored, controlled, and reported providing transparency for both the provider and consumer of the utilized service.
Service Models are as follows:
Software as a Service (SaaS): the capability provided to the consumer is to use the provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through a thin client interface such as a web browser (e.g., web-based e-mail). The consumer does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities, with the possible exception of limited user-specific application configuration settings.
Platform as a Service (PaaS): the capability provided to the consumer is to deploy onto the cloud infrastructure consumer-created or acquired applications created using programming languages and tools supported by the provider. The consumer does not manage or control the underlying cloud infrastructure including networks, servers, operating systems, or storage, but has control over the deployed applications and possibly application hosting environment configurations.
Infrastructure as a Service (IaaS): the capability provided to the consumer is to provision processing, storage, networks, and other fundamental computing resources where the consumer is able to deploy and run arbitrary software, which can include operating systems and applications. The consumer does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, deployed applications, and possibly limited control of select networking components (e.g., host firewalls).
Deployment Models are as follows:
Private Cloud: the cloud infrastructure is operated solely for an organization. It may be managed by the organization or a third party and may exist on-premises or off-premises.
Community Cloud: the cloud infrastructure is shared by several organizations and supports a specific community that has shared concerns (e.g., mission, security requirements, policy, and compliance considerations). It may be managed by the organizations or a third party and may exist on-premises or off-premises.
Public Cloud: the cloud infrastructure is made available to the general public or a large industry group and is owned by an organization selling cloud services.
Hybrid Cloud: the cloud infrastructure is a composition of two or more clouds (private, community, or public) that remain unique entities but are bound together by standardized or proprietary technology that enables data and application portability (e.g., cloud bursting for load-balancing between clouds).
A cloud computing environment is service oriented with a focus on statelessness, low coupling, modularity, and semantic interoperability. At the heart of cloud computing is an infrastructure comprising a network of interconnected nodes.
Referring now to FIG. 1 , a schematic of an example of a cloud computing node is shown. Cloud computing node 10 is only one example of a suitable cloud computing node and is not intended to suggest any limitation as to the scope of use or functionality of embodiments of the invention described herein. Regardless, cloud computing node 10 is capable of being implemented and/or performing any of the functionality set forth hereinabove.
In cloud computing node 10 there is a computer system/server 12 , which is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with computer system/server 12 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputer systems, mainframe computer systems, and distributed cloud computing environments that include any of the above systems or devices, and the like.
Computer system/server 12 may be described in the general context of computer system-executable instructions, such as program modules, being executed by a computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, and so on that perform particular tasks or implement particular abstract data types. Computer system/server 12 may be practiced in distributed cloud computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed cloud computing environment, program modules may be located in both local and remote computer system storage media including memory storage devices.
As shown in FIG. 1 , computer system/server 12 in cloud computing node 10 is shown in the form of a general-purpose computing device. The components of computer system/server 12 may include, but are not limited to, one or more processors or processing units 16 , a system memory 28 , and a bus 18 that couples various system components including system memory 28 to processor 16 .
Bus 18 represents one or more of any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnects (PCI) bus.
Computer system/server 12 typically includes a variety of computer system readable media. Such media may be any available media that is accessible by computer system/server 12 , and it includes both volatile and non-volatile media, removable and non-removable media.
System memory 28 can include computer system readable media in the form of volatile memory, such as random access memory (RAM) 30 and/or cache memory 32 . Computer system/server 12 may further include other removable/non-removable, volatile/non-volatile computer system storage media. By way of example only, storage system 34 can be provided for reading from and writing to a non-removable, non-volatile magnetic media (not shown and typically called a “hard drive”). Although not shown, a magnetic disk drive for reading from and writing to a removable, non-volatile magnetic disk (e.g., a “floppy disk”), and an optical disk drive for reading from or writing to a removable, non-volatile optical disk such as a CD-ROM, DVD-ROM or other optical media can be provided. In such instances, each can be connected to bus 18 by one or more data media interfaces. As will be further depicted and described below, memory 28 may include at least one program product having a set (e.g., at least one) of program modules that are configured to carry out the functions of embodiments of the invention.
Program/utility 40 , having a set (at least one) of program modules 42 , may be stored in memory 28 by way of example, and not limitation, as well as an operating system, one or more application programs, other program modules, and program data. Each of the operating system, one or more application programs, other program modules, and program data or some combination thereof, may include an implementation of a networking environment. Program modules 42 generally carry out the functions and/or methodologies of embodiments of the invention as described herein.
Computer system/server 12 may also communicate with one or more external devices 14 such as a keyboard, a pointing device, a display 24 , etc.; one or more devices that enable a user to interact with computer system/server 12 ; and/or any devices (e.g., network card, modem, etc.) that enable computer system/server 12 to communicate with one or more other computing devices. Such communication can occur via I/O interfaces 22 . Still yet, computer system/server 12 can communicate with one or more networks such as a local area network (LAN), a general wide area network (WAN), and/or a public network (e.g., the Internet) via network adapter 20 . As depicted, network adapter 20 communicates with the other components of computer system/server 12 via bus 18 . It should be understood that although not shown, other hardware and/or software components could be used in conjunction with computer system/server 12 . Examples, include, but are not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems, etc.
Referring now to FIG. 2 , illustrative cloud computing environment 50 is depicted. As shown, cloud computing environment 50 comprises one or more cloud computing nodes 10 with which local computing devices used by cloud consumers, such as, for example, personal digital assistant (PDA) or cellular telephone 54 A, desktop computer 54 B, laptop computer 54 C, and/or automobile computer system 54 N may communicate. Nodes 10 may communicate with one another. They may be grouped (not shown) physically or virtually, in one or more networks, such as Private, Community, Public, or Hybrid clouds as described hereinabove, or a combination thereof. This allows cloud computing environment 50 to offer infrastructure, platforms and/or software as services for which a cloud consumer does not need to maintain resources on a local computing device. It is understood that the types of computing devices 54 A-N shown in FIG. 2 are intended to be illustrative only and that computing nodes 10 and cloud computing environment 50 can communicate with any type of computerized device over any type of network and/or network addressable connection (e.g., using a web browser).
Referring now to FIG. 3 , a set of functional abstraction layers provided by cloud computing environment 50 ( FIG. 2 ) is shown. It should be understood in advance that the components, layers, and functions shown in FIG. 3 are intended to be illustrative only and embodiments of the invention are not limited thereto. As depicted, the following layers and corresponding functions are provided:
Hardware and software layer 60 includes hardware and software components. Examples of hardware components include mainframes, in one example IBM® zSeries® systems; RISC (Reduced Instruction Set Computer) architecture based servers, in one example IBM pSeries® systems; IBM xSeries® systems; IBM BladeCenter® systems; storage devices; networks and networking components. Examples of software components include network application server software, in one example IBM WebSphere® application server software; and database software, in one example IBM DB2® database software. (IBM, zSeries, pSeries, xSeries, BladeCenter, WebSphere, and DB2 are trademarks of International Business Machines Corporation registered in many jurisdictions worldwide)
Virtualization layer 62 provides an abstraction layer from which the following examples of virtual entities may be provided: virtual servers; virtual storage; virtual networks, including virtual private networks; virtual applications and operating systems; and virtual clients.
In one example, management layer 64 may provide the functions described below. Resource provisioning provides dynamic procurement of computing resources and other resources that are utilized to perform tasks within the cloud computing environment. Metering and Pricing provide cost tracking as resources are utilized within the cloud computing environment, and billing or invoicing for consumption of these resources. In one example, these resources may comprise application software licenses. Security provides identity verification for cloud consumers and tasks, as well as protection for data and other resources. User portal provides access to the cloud computing environment for consumers and system administrators. Service level management provides cloud computing resource allocation and management such that required service levels are met. Service Level Agreement (SLA) planning and fulfillment provide pre-arrangement for, and procurement of, cloud computing resources for which a future requirement is anticipated in accordance with an SLA.
Workloads layer 66 provides examples of functionality for which the cloud computing environment may be utilized. Examples of workloads and functions which may be provided from this layer include: mapping and navigation; software development and lifecycle management; virtual classroom education delivery; data analytics processing; transaction processing; and, in accordance with at least one embodiment of the invention, optimization of structured queries.
The disclosure now turns to FIG. 4 . It should be appreciated that the processes, arrangements and products broadly illustrated therein can be carried out on or in accordance with essentially any suitable computer system or set of computer systems, which may, by way of an illustrative and non-restrictive example, include a system or server such as that indicated at 12 in FIG. 1 and as carried out on layer 66 in FIG. 3 . In accordance with an example embodiment, most if not all of the process steps, components and outputs discussed with respect to FIG. 4 can be performed or utilized by way of a processing unit or units and system memory such as those indicated, respectively, at 16 and 28 in FIG. 1 , whether on a server computer, a client computer, a node computer in a distributed network, or any combination thereof. In accordance with embodiments of the invention, the system on which embodiments of the invention is carried out is embodied by a mobile device such as a laptop computer or a mobile phone, such as a “smart phone” with numerous functions analogous or similar to those found on many laptop or desktop computers.
Broadly contemplated herein, in accordance with at least one embodiment of the invention, is the use of a map-reduce cluster that works as live archival solution. In accordance with at least one embodiment of the invention, the map-reduce cluster is a Hadoop cluster. (Hadoop is a distributed file system, particularly, a “cloud” file system designed to run on commodity hardware, as developed by the Apache Software Foundation of Forest Hill, Md.)
In accordance with at least one embodiment of the invention, an enterprise can effectively perform analytics over very large amounts of data, while data on the Hadoop or other distributed file system can be used to build customer profiles, model churn, create marketing plans, and perform other worthwhile tasks. The time-consuming and lossy process of moving data to/from tape is avoided, and analysts become able to seamlessly query over data both from a data warehouse and from that archived or created in a distributed file system such as a Hadoop.
In accordance with at least one embodiment of the invention, data coherency is pursued via employing a “write-once-read-many” access model, where a client can only append to existing files.
In accordance with at least one embodiment of the invention, files are broken up into blocks. An intelligent client finds the location of blocks.
FIG. 4 schematically illustrates an arrangement for query optimization in accordance with at least one embodiment of the invention. An agent 402 sends a query to a query/report compiler 404 . A repository 406 includes data models and definitions, a mapping to business process framework and UML (Unified Modeling Language) descriptions. Compiler 404 draws on this for data models and definitions.
Some queries are directed to a conventional DB2 enterprise data warehouse 408 , which itself draws on repository 406 for data models and definitions. Other queries are directed to a SQL-to-map/reduce adapter 410 . Replies to queries from warehouse 408 and adapter 410 are returned to agent 402 in the form of reports; reports from adapter 410 need not necessarily be run through compiler 404 .
This adapter 410 is in communication with a Hadoop distributed file system 412 . (A Hadoop distributed file system is presented here merely as an illustrative and non-restrictive example. Essentially any suitable distributed file system may be employed.) The Hadoop , itself accessible via a query language designed for Javascript Object Notation (JSON) and employing Hive, which as known is a database/data warehouse on top of Hadoop. Hive, in accordance with at least one embodiment of the invention, supports the SQL-like querying of data. Also included in Hadoop 412 are data models and definitions. Such data model and definitions, in accordance with at least one embodiment of the invention, are artifacts that may be designed by subject matter experts and incorporated into a database or data warehouse. The data models and definitions are then copied over to the HDFS 412 when data is to be moved from the data warehouse 408 or elsewhere to the HDFS 412 .
HDFS 412 is in communication with vast stores of data 414 via the cloud; such data may include, but need not necessarily be limited to: CRM (customer relation management) strategy; CDR's; VAS (value added services); identity documents; and customer complaint data.
In accordance with at least one embodiment of the invention, query optimization over the HDFS 412 takes place via a smart partitioning and replication strategy. Particularly, smart partitioning with indexing is involved.
Accordingly, in accordance with at least one embodiment of the invention, datasets (from the warehouse 408 and from the distributed file system 412 ) are partitioned into horizontal subsets such that tuples having high similarity fall together. Each sub-partition may be further partitioned in a locally optimal manner, and partition keys may be mapped to Hive. Query responses based on the partitions are then returned to the agent 402 . By way of clarification, “partitions” can be regarded here as data divided into several similarly-sized pieces by a map-reduce system (e.g., HDFS), whereby a new map task is allocated to each piece. In accordance with at least one embodiment of the invention, in Hive, a partition is defined for an attribute whereby, all tuples having the same value for this attribute belong to the same partition. In this manner, if a query contains a search predicate for this attribute, the query can be executed efficiently.
In accordance with at least one embodiment of the invention, indexing takes place via Lucene (a free/open source information retrieval software library originally created in Java and supported by Apache). Inverted index maps can be employed to identify pairs where attributes are equivalent to predetermined values, and indicate their occurrence among the partitions.
In accordance with at least one embodiment of the invention, given a SQL query from agent 402 , the query is parsed by compiler 404 and values are looked up in the Lucene index (itself associated with Hadoop or other distributed file system 412 ). Partitions are identified and the query is rewritten into Hive (at 412 ) with partition information. Partitioning can take place essentially anywhere, e.g., via a suitable separate software component.
In accordance with at least one embodiment of the invention, smart replication is undertaken via keeping replicas that are sorted over different attribute sets. Queries may then be redirected to correct replicas at query execution time. More particularly, the HDFS 412 allows one to maintain multiple copies (or replicas) of files stored in the system. However, these are exact replicas with no change in the ordering of the content. In accordance with with at least one embodiment of the invention, there is a mimicking of the default process yet instead of keeping exact copies, the process reorders the content inside files by sorting the content on the values mapped to some attribute. This can apply to files in HDFS that are storing structured data that originated in some relational database or data warehouse. A “smart replica” refers to the set of the same records that likely are reordered. The reordering can be done based on sorting, e.g., on one or more attributes, information gain based heuristics algorithms, or clustering, or can involve further exhaustive algorithms.
FIG. 5 sets forth a process more generally for structured query optimization in accordance with at least one embodiment of the invention. It should be appreciated that a process such as that broadly illustrated in FIG. 5 can be carried out on essentially any suitable computer system or set of computer systems, which may, by way of an illustrative and on-restrictive example, include a system such as that indicated at 12 in FIG. 1 and as carried out on layer 66 in FIG. 3 . In accordance with an example embodiment, most if not all of the process steps discussed with respect to FIG. 5 can be performed by way a processing unit or units and system memory such as those indicated, respectively, at 16 and 28 in FIG. 1 .
As shown in FIG. 5 , a query is accommodated ( 502 ) and the query is directed to datasets ( 504 ). Partitions are created and the datasets partitioned ( 506 ), and a response to the query is returned ( 508 ), the response being structured in accordance with the created partitions.
It should be noted that aspects of the invention may be embodied as a system, method or computer program product. Accordingly, aspects of the invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wire line, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java®, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer (device), partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
This disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limiting. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen and described in order to explain principles and practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
Although illustrative embodiments of the invention have been described herein with reference to the accompanying drawings, it is to be understood that the embodiments of the invention are not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the disclosure.
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Methods and arrangements for accommodating a query, directing the query to datasets, creating partitions and partitioning the datasets, and returning a response to the query, the response being structured in accordance with the created partitions.
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FIELD OF THE INVENTION
The present invention relates to improved recovery of aluminum values from the aluminum hydroxide production process such as the Bayer process. In particular, the invention relates to the compositions and methods providing the increase of particle size of aluminum hydroxide product without a significant decrease in precipitation yield.
BACKGROUND OF THE INVENTION
Aluminum hydroxide is produced on an industrial scale by well-established methods such as the Bayer process. The precipitation process operators optimize their methods so as to produce the greatest possible yield from the aluminate process liquors while trying to achieve a given crystal size distribution of aluminum hydroxide product. It is desirable in most instances to obtain the product of relatively large crystal size since this is beneficial in subsequent processing steps required to produce aluminum metal. Production is often limited by processing conditions under which the crystallization and precipitation is conducted. These processing conditions vary from one plant to the next and include, but are not limited to, temperature profiles, seed charge, seed crystal surface area, purge of carbon dioxide or flue gases, liquor loading, liquor purity, and the like.
Extensive efforts have been invested into finding chemical additives and methods limiting the factors negatively affecting particle size and yield in order to achieve the optimal economic recovery of aluminum hydroxide product. One of such factors is the presence of oxalate anion in the precipitation liquor. Sodium oxalate crystallizes and co-precipitates from solution over essentially the same temperature profiles, as does the desirable aluminum hydroxide product. If left undealt with, oxalate precipitation results in a decrease of the average particle size and yield of aluminum hydroxide product through a number of mechanisms. Oxalate crystals act as seed sites resulting in generation of undersized aluminum hydroxide crystals during the precipitation stage. Oxalate crystals adhere to the surfaces of growing aluminum hydroxide and incorporate within the precipitated product agglomerates. Thus created agglomerates disintegrate during the washing and calcination stages that follow. Also, under certain conditions, these agglomerates grow to significant sizes (sometimes greater than 0.5 inch) and accumulate at the bottom of precipitation vessels hindering mixing. The removal of these agglomerates results in shutdowns for cleaning as well as the loss of aluminum values.
Therefore, effective oxalate removal from the process is crucial for economical recovery of a high quality aluminum hydroxide product.
Washing with water the fine aluminum hydroxide returning to the process as seed is a common method of oxalate removal. Untreated precipitation liquors yield sodium oxalate crystals with needle like morphology that incorporate into the aluminum hydroxide product as mentioned above. Organic crystal growth modifiers are known to force oxalate crystallize as spherical agglomerates of such needles also known as “oxalate balls.” For the seed washing method, it is desirable that these balls do not overgrow the size that can be effectively dissolved in the duration of the washing stage.
Another common method of oxalate removal is the side-stream destruction. This method requires that oxalate does not crystallize during the precipitation stage, but rather is carried with the spent liquor until removal. Commonly in this method, oxalate is removed by precipitation in a side stream circuit, and therefore, it is also critical that a crystal growth modifier does not act as an oxalate precipitation poison.
Despite the continuous and ongoing development worldwide, the industry demands for economical resolution of the above-described process needs remain unfulfilled. A method of such resolution suitable for obtaining aluminum hydroxide crystals with increased particle size and yield, while facilitating oxalate removal is provided by the present invention.
SUMMARY OF THE INVENTION
To satisfy the industry needs identified above, a method and compositions for obtaining aluminum hydroxide crystals with increased particle size and yield, while facilitating oxalate removal have been developed.
According to the method of the present invention, the suitable compositions are blended and introduced into the process through in-line injection in an amount effective to obtain the changes desired. The compositions are introduced in their primary form without any further preparation or as water emulsions.
The principal ingredients of the suitable compositions are the oligomeric or polymeric compounds with a single or multiple carboxylic groups produced through ene or Diels Alder synthesis. Suitable can be such oligomeric or polymeric compounds, their precursors, salts, and derivatives such as amides, esters or blends thereof.
In one embodiment of the present invention the principal ingredient is introduced neat or as a carefully prepared water emulsion. In another embodiment the principal ingredient is first blended with an oil carrier and then introduced into the process neat or as a water emulsion.
DETAILED DESCRIPTION OF THE INVENTION
The following are definitions that apply to the relevant terms as used throughout this specification.
A: Stands for aluminum concentration expressed as g/L Al 2 O 3
C: Stands for sodium hydroxide or caustic concentration expressed as g/L Na 2 CO 3
S: Stands for total alkali concentration expressed as g/L Na 2 CO 3
A/C: Refers to the alumina to caustic ratio
BET: Refers to the Brunauer-Emmett-Teller method for experimental determination of surface area. The method employs the analysis of adsorption isotherm of nitrogen or other gases on the material.
SEM: This acronym stands for “scanning electron microscope.”
CGM: This acronym stands for “crystal growth modifier.”
Commercial Product: Describes a crystal growth modifier incorporating fatty acids with chains of greater than ten carbons. The Commercial Product discussed in the Examples is available from Nalco Company, Naperville, Ill. as Nalco Product No. 7837.
Oil carrier: Describes a hydrophobic liquid that can be comprised of the aliphatic or aromatic compounds such as paraffinic oils, naphthenic oils, or fuel oils.
Also, bottoms or residual waste materials remaining from the production of aliphatic alcohols represent a suitable hydrophobic liquid. The preferred waste material is the CIO alcohol distillation residue having a boiling point of about 250° C. (482° F.). It is light yellow to yellowish brown in color and has a specific gravity of about 0.862, OH— number about 90, SAP number about 50, weight percent acetic group about 0.07 and carbonyl group about 0.5. Chemically, it is 57-73 weight percent of primary branched chain C10-C22 alcohols (classified as fatty alcohols) and 29-41 weight percent of mixed long chain esters and ethers (C18-C33 ester; C18-C22 ether).
The materials suitable as an oil carrier can be used neat or as a mixture of any proportion. The oil carrier needs only be a solvent for the fatty acid and have a boiling point safely above the temperature of the hot aluminate liquor undergoing precipitation (about 80° C., 176° F.).
Weight percent ratio: The total weight fraction of one reagent within 100 grams of the composition or mixture. The corresponding fraction of the other component is the latter subtracted from 100.
Percent (%) increase over control quantile particle size: The particle size distribution is conventionally given by the three quantiles, d(0.1), d(0.5) and d(0.9). Thus, 10%, 50% and 90%, respectively, of the total particle volume (or mass) is less than the size given in the tables. The percent (%) increase over the control quantile particle size is the difference between the quantiles particle sizes obtained in the tests with a CGM and control divided by the control quantile particle size.
Effective amount: An effective amount is deemed any dosage of any additive that affords an increase in one of the three quantiles when compared to an undosed control sample.
Increased product yield: Describes when a greater aluminum hydroxide solid content within the precipitating vessel at the end of the precipitation run is achieved. This is generally indicated by a lower aluminum hydroxide concentration in the liquor of the corresponding vessel.
Precipitation liquor: Refers to aluminate containing liquor in an aluminum hydroxide precipitation step of an alumina production process. The aluminate liquor may be referred to as various terms known to those of ordinary skill in the art, for example, pregnant liquor, green liquor, and aluminum hydroxide precipitation feed. The Bayer process is one example of an alumina production process.
The term precipitation liquor may also include the aluminate solution directed to decomposition in a sintering-carbonation process or combined Bayer-sintering process as accomplished by the methods well known to those skilled in the art as described, for example, in U.S. Pat. Nos. 4,256,709 and 3,642,437 and RU. U.S. Pat. Nos. 2,184,703, 2,257,347, and 2,181,695, which are herein incorporated by reference.
As described in U.S. Pat. No. 4,737,352 assigned to Nalco, the invention in practice is unaffected by different proprietary precipitation techniques involving proprietary process parameters. This is of great significance because it establishes that regardless of the proprietary processing parameters maintained inside the precipitating tank, the present invention for actual practice only requires blending and in-line injection of the proposed treatment.
Precipitation feed liquor: refers to the precipitation liquor that flows into a precipitator of an aluminum hydroxide precipitation process.
Heated precipitation liquor: Any liquor within the aluminum hydroxide production process having a free alkalinity level above 50 g/L of Na2CO3 and a temperature above ambient or 25° C.
Spent liquor: Describes the liquor resulting from the removal of precipitated aluminum values, such as the spent liquor after the final classification stage that returns back to digestion in the Bayer process.
While the invention is susceptible of embodiment in many different forms, this disclosure will describe in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
The CGM treatment of the present invention incorporates the products of ene or Diels Alder synthesis derived from organic substrates of natural and synthetic origin. Thus, the suitable materials can be prepared by reacting
A1: Unsaturated polycarboxylic acids, their precursors, salts, amides, esters or blends thereof with at least one of the following: A2: Fatty acids and esters thereof of natural or synthetic origin including triglyceride oils. A3: Polyolefins with the molecular weight in the range from about 400 to about 10,000 Daltons.
The suitable polycarboxylic acids (A1) may contain at least two replaceable hydrogen atoms per molecule. The preferable unsaturated polycarboxylic acids are maleic acid, fumaric acid, glutaconic acid, citraconic acid, mesaconic acid, aconitic acid and itaconic acid, 5-norbornene-2,3-dicarboxylic acid, 1,2,3,6-tetrahydrophthalic acid, their precursors, salts, amides, esters or blends thereof.
Fatty acids (A2) may include C6-C24 unsaturated fatty acids with a straight or branched carbon chain. Particularly preferable are palmitoleic, oleic, linoleic, linolenic, ricinoleic, eleostearic, docosahexaenoic acids, elcosapentaenoic acid, and the likes. Any combination of the unsaturated monobasic acids listed above may be used. In the synthesis of the instant materials, the fatty acids can also be used as their esters with C1-C4 alcohols, including but not limited to methyl ester or ethyl esters.
Additionally, natural esters of the fatty acids can be utilized as Reactant A2, which include crude or processed triglyceride oils of vegetable or animal origin such as soybean oil, linseed oil, castor oil, dehydrated castor oil, corn oil, safflower oil, sunflower oil, canola oil, fish oils, lard oil, beef oil, oiticica oil, tung oil, and tall oil, or their combinations. The usefulness of the fatty acids and oils is directly related to the density of double-bond in the fatty acid chains. The suitable processed oils can be those processed by means of refining, heat polymerization, isomerization-conjugation, boiling, blowing, epoxidation, dehydration, copolymerization with ethylenic monomers selected from but not limited to the group of acrylate, methacrylate, styrene, acrylamide, acrylonitrile, vinyl carboxylate esters and vinyl halides, mixtures thereof, and salts thereof. In an exemplary embodiment, the suitable oils may be the crude and refined oils available, for example, from Archer Daniels Midland Company, Decatur, Ill., USA; blown, heat polymerized in the absence of air, and boiled plant oils available, for example, from Cargill Inc., MN, USA; epoxidized oils available, for example, under the trade name Vikoflex® from ATOFINA Chemicals, Inc., PA, USA; dehydrated castor oil available, for example, under the trade name Castung from G. R. O'Shea Company, IL, USA; acrylated soybean oil available, for example, from Sartomer Company, PA, USA.
An exemplary embodiment of the present invention contemplates the use of CGM compounds produced by the reaction of maleic anhydride with unsaturated fatty acids or esters thereof including triglyceride oils of vegetable and animal origin. Such maleinization reaction is well known to those skilled in the art to form a condensation product in the presence of heat and/or pressure. Depending on the amount of the anhydride reacted, maleinization may proceed in several steps. The addition of the first mole of the anhydride may proceed through an “ene” reaction, which may result in the addition of a succinic anhydride group to the allylic functionality of the fatty chain. For the oils (and fatty acids) having more than one double bond in the fatty chains, such as linseed or soybean oil, the first step may be followed by rearrangement of the double bonds of the fatty chain into a conjugated system and addition of the second mole of the anhydride through Diels Alder reaction.
Additionally, elevated temperatures may also cause a direct intermolecular and intramolecular ene and Diels Alder reactions between the fatty acid chains of triglyceride oils, which are particularly known for natural oils rich in polyunsaturated carbon chains such as linseed, tung, and fish oils. Such ene and Diels Alder reactions can further cross-link the unsaturated fatty acid fragments forming saturated or unsaturated rings of five or six atoms, which apparently improves CGM performance of the instant materials.
Thus obtained reaction products may be further cross-linked to create higher molecular weight species useful in the present invention. Such cross-linking may be accomplished through the esterification of the anhydride functionalities with polyols. For this purpose, mono-, di-, and tri-glycerol, pentaerythritol, sorbitol, polyvinyl alcohol, alpha-methyl-O-glucoside and polyallyl alcohol can be used by those skilled in the art. The useful polyols may be bifunctional glycols or poly(alkylene) glycols derived from at least one unit selected from but not limited to the group of ethylene oxide, propylene oxide, butylene oxide, pentylene oxide, and hexylene oxide.
If subjected to alkaline hydrolysis, the CGM materials produced through the method described above generate from about 50% to 90% of the species having an average molecular weight from 500 to 10,000 Daltons and from about 10% to 50% of the species with a molecular weight in the range from 10,000 to 100,000 Daltons as determined by gel permeation chromatography.
In another embodiment of the present invention the suitable CGM materials can be produced by reacting unsaturated polycarboxylic acids A1 with olefin polymers (A3).
The suitable olefin polymers are usually those prepared by polymerization of olefins containing up to 7 carbon atoms. Polymers derived from both monoolefins and diolefins can be utilized. Suitable monoolefins include ethylene, propylene, 1-butene, 2-butene, isobutene and the pentenes, hexenes and heptenes (all isomers included). The diolefins may be conjugated or nonconjugated; suitable conjugated diolefins include butadienes, isoprene, 1,3-pentadiene and 1,3-hexadiene, and suitable nonconjugated diolefins include 1,4-pentadiene, 1,4-hexadiene and 1,5-hexadiene.
The preferred olefin polymers are those derived from monoolefins, especially mono-1-olefins and more especially C2-6 mono-1-olefins such as ethylene, propylene and the butenes. Homopolymers and interpolymers are suitable, and the interpolymers may be ordinary chain interpolymers or graft interpolymers. The preferred polymers are homopolymers and interpolymers derived from mixtures of monomers differing in size by at most about two carbon atoms, such as ethylene-propylene interpolymers and the polybutenes more fully described hereinafter.
The suitable olefin polymers can contain minor proportions of alicyclic or aromatic carbon atoms which may be derived from such monomers as cyclopentene, cyclohexene, methylene cyclopentene, methylene cyclohexene, 1,3-cyclohexadiene, norbornene, norbornadiene, cyclopentadiene, styrene and α-methylstyrene.
The olefin polymer usually contains about 30-300 and preferably about 50-250 carbon atoms. The number average molecular weight of the polymer, as determined by gel permeation chromatography, is ordinarily about 420-10,000, especially about 700-5,000 and more especially about 750-3,000.
A particularly preferred class of olefin polymers comprises the polybutenes, which are prepared by polymerization of one or more of 1-butene, 2-butene and isobutene. Especially desirable are polybutenes containing a substantial proportion of units derived from isobutene. The polybutene may contain minor amounts of butadiene which may or may not be incorporated in the polymer. Most often the isobutene units constitute 80%, preferably at least 90%, of the units in the polymer. These polybutenes are readily available commercial materials.
The preferable materials produced using olefin polymers (A3) are polyisobutenyl succinic anhydrides (PIBSA) as described, for example, in U.S. Pat. Nos. 3,445,386, 3,912,764, 4,110,349, and 5,041,622 incorporated by reference herein. Such materials, for example, derived from 1000 and 1300 molecular weight polybutenes are available from the Chevron Oronite Company, TX, under the trade names OLOA 15500 and OLOA 15667, respectively. Suitable PIBSA materials are also available from the Lubrizol Corporation, OH, under the trade names Addconate H, Addconate S, Lubrizol 5620, and others.
In one embodiment of the present invention the CGM product can be prepared as a solution of the above-described reaction products in an oil carrier. For example, a suitable carrier is paraffinic oil available from Exxon Mobil Corporation under the trade name Escaid 110.
In another embodiment, the improved CGM treatment can be prepared as water-in-oil or oil-in-water emulsion. The CGM formulations prepared as microemulsions are preferred.
Microemulsions are significantly different in structure from regular emulsions. Regular emulsions are comprised of separate oil droplets in water or water droplets in oil with a sharp transition between the two phases. Microemulsions have a particle size in the range from 10 to 600 nm, so that they appear as clear or opalescent one-phase formulations.
Unlike regular emulsions, microemulsions are thermodynamically stable. This means that microemulsions form spontaneously when the components are brought together and stay stable as long as the components are intact. Thus, their manufacturing may be reduced to simple kneading without the need for expensive high energy mixing. Also, microemulsions are not prone to separation or settling, which results in their long storage stability. Only gentle mixing is required to restore microemulsions upon their freezing or high temperature exposure.
The emulsified crystal growth modifier may be introduced into the precipitation liquor via various routes. In one embodiment, the emulsified crystal growth modifier is added to the precipitation liquor at the following steps of a Bayer process: a) to a precipitation feed liquor, b) to a seed slurry, c) directly into a precipitation tank, and d) a combination thereof.
The emulsified crystal growth modifier can be added to the precipitation liquor via various modes of addition. In-line injection of the emulsified crystal growth modifier is one mode of addition.
The amount of crystal growth modifier required to produce desirable effect depends upon the precipitation process parameters. Most often, this amount is determined by the surface area of available hydrated alumina solids in the precipitation liquor. The solids comprise the aluminum hydroxide introduced as seed or originated as new crystals or agglomerates during the decomposition of precipitation liquor. The suitable amount of crystal growth modifier can range from about 0.01 to about 30 mg per square meter of the available aluminum hydroxide seed area, and preferably, from about 0.1 to about 15 mg per square meter. Commonly, less than about 8 mg/m2 of CGM can be used.
In case the available aluminum hydroxide area may not be reliably determined, the precipitation operators can dose the crystal growth modifier by the volume. In this case, the crystal growth modifier amount may range from about 0.01 to about 400 mg/liter of precipitation liquor, preferably from about 0.05 to about 200 mg/liter of precipitation liquor. Commonly less than about 100 mg/liter of CGM can be used.
The addition of the crystal growth modifier product to the precipitation liquor reduces the percent of alumina trihydrate crystal fines formed in the Bayer process substantially without any decrease in the overall product yield and thereby increases the yield of alumina trihydrate crystals of optimal particle size for aluminum metal production.
In one embodiment, the addition of emulsified crystal growth modifier results in at least half of the recovered crystals by weight exceed 325 mesh (44-45 microns).
The addition of crystal growth modifier also provides a more effective aluminum hydroxide production process wherein the yield of coarser alumina trihydrate particles is increased, and the separation and collection of alumina trihydrate from the alkaline liquor is improved.
The examples below are offered to aid in understanding the present invention and are not to be construed as limiting the scope thereof.
EXAMPLES
The foregoing may be better understood by reference to the following examples, which are intended to illustrate methods for carrying out the invention and are not intended to limit the scope of the invention.
Precipitation Test Procedure: Each set of tests was run using fresh pregnant liquor, obtained from the reconstitution of plant spent liquor. A desired weight of spent liquor was measured into a stainless steel beaker and the volume was reduced by evaporation to about 30%. To this a set weight of aluminum hydroxide solid was added and the mixture stirred until it was dissolved. This solution was removed from the hot plate and placed on a weighing balance and de-ionized water added until a desired weight was attained. The pregnant liquor was filtered to remove any insoluble material.
All precipitation tests were performed in 250-mL Nalgene® bottles rotated end-over-end, at 10 rpm, in an Intronics temperature-controlled water bath. The pregnant liquor having a density of 1.30 kg/L (˜72° C.) was placed into the bottles by weight (200 mL=260.0 g), for improved precision. The additive was dosed, with respect to the total surface area of the seed crystals (mg/m 2 ), to the lid of the appropriate bottles using a micro-syringe and the bottles were then placed in the rotating bath for equilibration at 72° C. (20 minutes). After equilibration, the bottles were removed, quickly charged with the required quantity of seed (50 g/L, based on liquor volume) and immediately returned to the water bath. The temperature of the water bath was set to 72° C. The bottles were rotated overnight for 15 hours.
On completion of the 15 hours, the bottles were removed and for each bottle a 20-mL sample of the slurry was filtered through a syringe filter and submitted for liquor analysis. To prevent any further precipitation, 10 mL of a sodium gluconate solution (400 g/L) was added to the remaining slurry and mixed well. The solids were collected by vacuum filtration and were thoroughly washed with hot deionized water and dried at 110° C. The particle size distribution and specific surface area were determined on a Malvern Particle Sizer, which is well known in the art. The particle size distribution is conveniently given by three quantiles, d(0.1), d(0.5) and d(0.9). These represent the particle size at which the total particle volume (or mass) is less than about 10%, 50% and 90% respectively.
Example 1
The following tests were conducted to support the contention that employing the above-described products of ene and Diels Alder synthesis results in the CGM compositions with superior performance. The tests used the precipitation procedure as described above.
The green liquor with A/C ratio=0.66˜0.70 was reconstituted from the spent liquor. The precipitation temperature was 72° C., holding time 15 hours, and seed charge 50 g/L. The seed was the C31 alumina trihydrate with BET specific surface area of 0.38 m 2 /g obtained from Alcoa Inc.
The following CGM composition (Composition 1) was prepared as a 15% solution of a linseed oil derived polymer in 85% paraffinic solvent available from Exxon Mobil Corporation under the trade name Escaid 110. The linseed oil derived polymer was prepared by heat polymerizing linseed oil in presence of maleic anhydride under oxygen deficient conditions with further cross-linking using pentaerythritol. However, cross-linking using pentaerythritol may be optional. Oxygen deficient condition refers to a condition wherein oxygen is present at less than about 20% of the environment in which the polymerization occurs, including all values and ranges therein, e.g. 10%, 5%, etc.
Table 1 compares the performance of Composition 1 to the control (no CGM) and the commercial product described above. The CGM products were tested using duplicate runs at the equal dosage of 3 mg/m2 seed surface (60 ppm vs. green liquor).
TABLE 1
Coarsening Effects of Commercial Product and Composition 1 Compared.
% Increase in Mean
Quantile Particle Size,
of Control Quantile
Dose
μm
Particle Size
Example
(mg/m 2 )
d(0.1)
d(0.5)
d(0.9)
d(0.1)
d(0.5)
d(0.9)
Control 1
—
48.2
77.6
123.5
Control 2
—
48.6
78.3
125.0
Average
—
48.4
78.0
124.3
Commercial product
3
53.6
86.0
136.5
Commercial product
3
52.6
84.4
134.1
Average
3
53.1
85.2
135.3
9.7
9.2
8.8
Composition 1
3
54.1
87.5
140.0
Composition 1
3
54.3
87.7
140.3
Average
3
54.2
87.6
140.2
12.0
12.3
12.8
Example 2
The CGM compositions below were tested under the same conditions as in the previous example, but were prepared using the spent liquor from a different plant.
Composition 2 (Microemulsion) Comprised of
10% Linseed oil polymerized by heat and by reaction with maleic anhydride, 5% C8-10 fatty acid blend, 30% ethoxylated propoxylated C14-C18 alcohol emulsifier, 2% polypropylene glycol blend with the molecular weight in the range from 100 to 1500 Daltons and 53% water
Composition 3 (Microemulsion) Comprised of
10% Linseed oil polymerized by heat and by reaction with maleic anhydride, 5% C8-10 fatty acid blend, 20% ethoxylated propoxylated C14-C18 alcohol emulsifier, 10% C10 alcohol distillation residue, 2% polypropylene glycol blend with the molecular weight in the range from 100 to 1500 Daltons and 53% water
Composition 4 (Microemulsion) Comprised of
10% Linseed oil polymerized by heat and by reaction with maleic anhydride, 5% C8-10 fatty acid blend, 20% ethoxylated propoxylated C14-C18 alcohol emulsifier, 10% paraffinic oil (dearomatized aliphatic fluid), 2% polypropylene glycol blend with the molecular weight in the range from 100 to 1500 Daltons and 53% water.
TABLE 2
Coarsening Effect Of Commercial Product And Compositions 2 and 3 Compared.
% Increase in Mean
Quantile Particle Size,
of Control Quantile
Dose
μm
Particle Size
Example
(mg/m 2 )
d(0.1)
d(0.5)
d(0.9)
d(0.1)
d(0.5)
d(0.9)
Control 1
—
42.3
70.8
113.7
Control 2
—
43.2
69.5
113.9
Average
—
42.7
70.1
113.8
Commercial product
3
48.5
77.2
121.5
Commercial product
3
48.8
77.9
123.3
Average
3
48.7
77.6
122.4
14.1
10.7
7.6
Composition 2
3
49.0
77.9
122.9
Composition 2
3
50.6
80.7
127.6
Average
3
49.8
79.3
125.3
16.6
13.1
10.1
Composition 3
3
49.6
78.6
123.4
Composition 3
3
48.5
77.1
124.4
Average
3
49.1
77.9
123.9
15.0
11.1
8.9
Composition 4
3
49.4
78.4
123.4
Composition 4
3
50.0
79.5
125.3
Average
3
49.7
79.0
124.4
16.4
12.7
9.3
Example 3
The CGM compositions below were tested under the same conditions as in the previous example, but were prepared using the spent liquor from another plant.
Composition 5
15% polyisobutyl succinic anhydride and 85% mineral seal oil.
As shown in Table 1, Composition 5 provides higher coarsening of precipitated aluminum hydroxide than the existing Commercial Product.
TABLE 3
Coarsening Effect Of Commercial Product And Composition 5 Compared.
% Increase in Mean
Quantile Particle Size,
of Control Quantile
Dose
μm
Particle Size
Example
(mg/m 2 )
d(0.1)
d(0.5)
d(0.9)
d(0.1)
d(0.5)
d(0.9)
Control 1
—
43.0
72.9
118.3
Control 2
—
43.5
73.0
120.6
Average
—
43.3
73.0
120.5
Commercial Product
3
46.5
77.1
124.6
Commercial Product
3
46.3
76.9
126.7
Average
3
46.4
77.0
125.9
7.2
5.5
4.5
Composition 5
3
48.0
79.1
128.6
Composition 5
3
47.8
80.2
130.2
Average
3
47.9
79.7
129.4
10.6
9.2
7.4
Example 4
The effect of the instant CGM compositions on oxalate stability was examined using the critical oxalate concentration (break-point) tests. All these tests were carried out with 250-ml Nalgene® bottles rotated end-over-end in an Intronics temperature-controlled water bath. Typically, eight bottles for each condition were used. Each bottle was filled with hot 200 ml precipitation liquor and CGM (on the lid, if required), charged with 10 gram seed (Alcoa C31 standard aluminum hydroxide blended with 0.05% oxalate powder), and mixed sufficiently. After rotating in the water bath for 30 minutes at 70° C., the bottles were taken out, quickly spiked with different amounts of concentrated oxalate solution (30 g/L sodium oxalate) and returned to the water bath. The total oxalate concentrations achieved in the liquor ranged from 0 to 5 g/L. After holding in the water bath for 17 hr at 64° C., a 10-ml sample of the supernatant of the slurry was sampled from each bottle with a syringe filter (0.45 um) for oxalate analysis using ion chromatography. From the oxalate analysis of spent liquor and final liquor, and the spiked oxalate, the smallest oxalate concentration in the initial liquor at which oxalate starts to precipitate was determined as the “Break-point” for oxalate.
The effects of Commercial Product and Compositions 1 and 5 on the critical oxalate concentration (COC) are compared in Table 4. The CGMs are dosed at 3 mg/m2 seed surface. The results show that Commercial product and Composition 2 stabilize oxalate (increase the breakpoint concentration). On the other hand, Composition 5 does not stabilize oxalate (does not change the oxalate breakpoint concentration vs. blank test).
TABLE 4
Effect of Commercial Product and Compositions 1 and 5
on Oxalate Stability (Breakpoint Data).
Treatment
Estimated Breakpoint (g/L oxalate)
Blank
4.27
Commercial product
4.45
Composition 1
4.52
Composition 5
4.27
It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
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The present invention relates ways to increase the output of a high quality product from the aluminum hydroxide recovery processes such as the Bayer process. The invention is a method of increasing the size of precipitated aluminum hydroxide while not reducing the total production amounts. The invention relates to the use of a crystal growth modifier compositions added to the precipitation liquor to increase the particle size distribution of the precipitated alumina trihydrate.
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BACKGROUND OF THE INVENTION
This invention relates generally to a method and device for soldering that includes an integrated solder feed. It further relates to a cartridge that is a compact, self-contained solder supply and to a combination of the device and the cartridge.
It has long been recognized that various advantages are realized by incorporating into a soldering iron or a soldering gun some attendant structure that will bring a supply of soldering material to a location that is near that of the heated tip of the soldering device. Many proposed methods and devices of this nature require the use of only one hand of the operator, thereby freeing the other hand for other useful functions such as securing the article being soldered or readying the next article to be soldered. Important advances in this art have been achieved by Frenzel U.S. Pat. No. 3,171,374 and Schurman U.S. Pat. No. 3,824,371.
Prior art methods and structures are disadvantageous in that either they are not themselves self-contained supplies of solder or they require the addition of cumbersome structural elements that often require solder advancing means that are operated separately from the heat actuating means of the solder device itself. In prior structures, before use can begin, the operator must actually feed the solder itself, usually the leading end of a length thereof, into that portion of the device which advances the solder toward the heating tip.
With these previously known structures, this required feeding aspect results in inefficiencies brought on by the time and inconvenience needed to initiate and carry out the actual feeding process. These disadvantages are aggravated when the solder utilized is in the form of a soft wire that must be passed into the feeding mechanism and through the advancing mechanism of the device. The feeding and advancing operations can require careful attention to be certain that the solder is initially inserted in the proper location and in the proper manner. Additional problems and difficulties can arise if the means used to advance the solder through the advancing mechanism itself is so forceful as to damage or even break the solder supply, resulting in a jamming of the advancing apparatus.
It is accordingly an object of the present invention to provide an improved method and device for soldering and for supplying solder that is compact and efficient both in its ability to feed the solder and also in its facilitation of the task of providing a fresh supply of solder.
A further object of this invention is an improved method and device that provide a compact, self-contained unit for supplying solder with a minimum of difficulty and that provide the heat required to effect customary soldering operations.
Another object of this invention is an improved soldering method and device incorporating an integrated supply of solder and requiring but a single control means for the operation of both the soldering and advancing functions.
Yet another object of this invention is an improved method and an improved self-contained soldering device, having a single control means which permits the operator to choose among performing the heating function only, performing the advancing function while maintaining the heating function, or performing the advancing function while intermittently performing the heating function.
Still another object of this invention is a new cartridge for providing a convenient and compact supply of soldering materials.
Another object of this invention is a new cartridge that is structured for mating and feeding engagement with a soldering device.
SUMMARY OF THE INVENTION
The present invention is an improved soldering device including a single finger control for activating both a heating means and a means for advancing a supply of solder, the finger control being capable of activating either the heating means only, both the heating means and advancing means simultaneously, or the advancing means together with intermittent actuation of the heating means. The present invention is also a method and an apparatus that combine self-feeding, self-actuating soldering features with a compact, encased supply of solder. This invention is also a cartridge having a supply of solder therein and structured for providing solder to a self-feeding soldering device.
We provide an improved method of soldering, comprising: providing a compact, encased supply of solder; inserting said encased supply within a cavity and into mating relationship with an elongated guiding zone; pawling a portion of said solder from out of said encased supply and into said guiding zone to a location remote from said encased supply; and supplying heat to an area that is proximate to said remote location.
We also provide an improved solder device, comprising: a body portion; a soldering member and a guiding conduit projecting from said body portion; a control member pivotally mounted within said body portion; an electrical switch means for actuating said soldering member, said switch means being located for arcuate communication with said pivotally mounted control member; and a pawl means for advancing a supply of solder through said guiding conduit, said pawl means being located for communication with said control member.
We further provide a cartridge for providing a supply of solder, comprising: a plurality of panels forming an encasing means; a supply of solder within said encasing means; and a finger member projecting from said encasing means, said finger member having a sleeve, and said sleeve opening into said encasing means for receiving said supply of solder.
The invention also is directed to a combined solder device and solder cartridge, comprisng: a body portion of said device; a pocket within said body portion; a soldering member and a guiding conduit projecting from said body; a cartridge within said pocket, said cartridge being in a mating relationship with said guiding conduit; a supply of solder within said cartridge; and a means for advancing said solder out of the cartridge and through said guiding conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects, if not set forth specifically herein, will be readily apparent to those skilled in the art from the detailed description of the invention which follows and from the drawings in which:
FIG. 1 is an elevation view of the preferred soldering device, the casing having been broken away for clarity, showing the control member when it is fully extended;
FIG. 2 is an elevation view of the preferred device and cartridge, with the casing broken away for clarity and with the control member fully depressed;
FIG. 3 is a partial view of FIG. 2, except that the finger control member is only partially depressed;
FIG. 4 is an end elevation view of the preferred device;
FIG. 5 is a perspective view of the preferred cartridge;
FIG. 6 is an elevation view of an alternate embodiment of the cartridge;
FIG. 7 is a plan view of an alternate embodiment of the cartridge;
FIG. 8 is an elevation view of an alternate embodiment of the device and cartridge, with the casing broken away for clarity; and
FIG. 9 is an elevation view of alternate embodiments of the pawling means of the device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has been determined that more efficient and convenient soldering can be brought about by an improved soldering method. The method includes providing a compact, encased supply of solder which is subjected to pawling action to advance the solder supply to a location remote from the encased supply and close to a source of heat which may be provided for the purpose of bringing the solder to a soldering temperature.
More particularly, the preferred method includes encasing a supply of solder in a compact manner, the encasing step being accomplished in a manner that facilitates removal of the supply of solder at a single, precisely positioned location. This can be brought about, for example, by winding an elongated supply of solder around itself, encasing the wound supply while maintaining its leading portion unwound and accessible from outside of the encasing material, and automatically aligning the leading portion into mating readiness with a point immediately outside the encased supply.
In the preferred method, the encased supply of solder is then inserted into a substantially enclosed cavity within a soldering device. This cavity is generally shaped and sized to closely accommodate the encased supply of solder.
Another step in the preferred method includes pawling a portion of the supply of solder while it is within the encased, compact location. This pawling step initiates an advancing step whereby the leading portion of the solder is passed out of the encased supply and directly into an elongated guiding zone. The guiding zone generally includes an entrance that is in mating readiness with said point immediately outside the encased supply. In the elongated guiding zone, a guiding step is accomplished for advancing the solder from the encased supply to a location remote therefrom.
The method also includes supplying a source of heat proximate to said remote location by closing an electrical switch means. The heat is provided to achieve soldering temperatures at this location which may be transmitted to the leading portion of the supply of solder by appropriate conduction methods.
In the preferred method, the pawling and heating steps are brought about during a single controlling step which utilizes a unitary pivoting action upon a pawling means and the electrical switch means. The preferred pivoting step includes a simultaneous rearward displacement toward the switch means to accomplish a switch closing step and a forward displacement toward the pawling means to accomplish the pawling step.
The pivoting step may include three alternate and/or sequential steps. One such step is activating the electrical switch means for effecting the heating step. Another is performing the pawling step while simultaneously activating the switch means to accomplish a heating step that constantly adds heat to said source of heat proximate to the remote location. The other is intermittently activating the switch means while simultaneously performing the pawling step.
As shown in FIG. 1, the device, generally indicated by reference numeral 11, includes a body portion 12 and a handle portion 13. Projecting from body portion 12 is a soldering member, generally referred to by reference numeral 14. Member 14 includes a shank 15 having a heating element therein (not shown) and a soldering tip 16. Member 14 is secured to body member 12 by any suitable means, such as a bracket 17 and a screw 18 as depicted.
Mounted above member 14 is a guiding conduit 21 that is open both at its remote end 22 and at its receiving end 23. Attachment of conduit 21 to body 12 may be accomplished by a bracket 24 and a screw 25. Member 14 and conduit 21 are mounted in cooperative relationship such that the open remote end 22 is close proximity to soldering tip 16.
A pocket 26 is provided with body portion 12. Located between the pocket 26 and the open receiving end 23 is a passageway 27.
A pivot 31 is provided on body member 12. Rotatably positioned on pivot 31 is a control member 32. The upper end of control member 32 is in communication with a pawl means, generally indicated by reference numeral 33. The lower portion of control member 32 is generally in communication with an electrical switch means, generally referred to by reference numeral 34. This single control member 32, when manipulated by the operator of the device 11, accomplishes a variety of effects upon pawl means 33 and switch means 34.
Pawl means 33 includes a pawl member 35 and a biasing means, such as spring 36. Spring 36 supplies a combined rearward and upward bias upon pawl 35. A securement member, such as tooth 37, provides the necessary pivotal-type communication between pawl 35 and spring 36. The other end of spring 36 rests against and may be secured to a stop 38 within the body member 12.
Pawl 35 rests within a recess or notch 39 of control member 32. With this arrangement, as the operator's finger moves control member 32 rearwardly, notch 39 moves generally forwardly in opposition to the bias of spring 36. This accomplishes a pawling effect that can be communicated by the edge 41 of pawl 35 to a source of solder 42. Edge 41 may be substantially flat, may be beveled, may be rounded, or may have any other surface configuration that will achieve positive pawling action with minimal damage to the particular solder supply used.
Electrical switch means 34 is likewise activated by control member 32. Switch means 34 includes a front flexable contact arm 43 and a rear flexable contact arm 44. Respective ends of arms 43 and 44 are in electrical contact with a transformer 45 and an electrical plug 46 by means of standard electrical circuitry, generally referred to by reference numeral 47. The transformer 45 is in electrial communication with the heating element within shank 15, whereby heat may be provided to soldering tip 16 when current is passed to transformer 45.
With control member 32 being in the position shown in FIG. 1, pawl means 33 is in its rearwardmost, loading position. At the same time, electrical switch means 34 is open; that is, arm 43 is not in contact with arm 44.
FIG. 2 shows the preferred device with control member 32 in its rearwardmost position. This attitude of control member 32 places pawl means 33 in its fully spent position. Also, switch means 34 is closed when control member 32 is in its rearwardmost position as shown. With switch 34 closed, electrical current supplied through plug 46 passes to transformer 45. This activates the heating element within shank 15 to bring soldering tip 16 to soldering temperatures.
A cartridge, generally referred to by reference numeral 51, is shown in FIGS. 2 and 3 when it is fully inserted into pocket 26. The cartridge 51, described in more detail hereinafter, provides an encased supply of solder 52. Only a portion of the solder supply 52 is shown in FIGS. 2 and 3. The supply of solder 52 is provided inside of cartridge 51 so that it rests within a finger member 53 of cartridge 51.
Finger 53 is structured such that, when cartridge 51 is fully inserted by a simple sliding motion into pocket 26, the leading end of solder supply 52 is poised for mating relationship with guide 23. When cartridge 51 is thus inserted, finger 53 lies within passageway 27. Located along the underside of finger 53 is opening 54. Access to the underside solder source 52 is provided by this opening 54. Pawl means 33 is structured and located so that its edge 41 may utilize this access through opening 54 in order to communicate with solder source 52.
Accordingly, when pawl means 33 moves from its loading position as shown in FIG. 1 through its spent position as shown in FIG. 2, the solder supply 52 moves forward through finger 53 for a distance approximately equal to the length of opening 54. As this occurs, the leading end of solder supply 52 passes through the open receiving end 23 of guiding conduit 21, then within conduit 21, eventually emerging through open remote end 22. This leading end is shown in FIG. 2 as reference numeral 55. Accordingly, when the operator proceeds with a number of movements of control member 32 between its forwardmost position and its rearwardmost position, the solder supply 52 is conveniently provided through the open remote end 22 of conduit 21, in close proximity to soldering tip 16.
Ideally, leading end 55 exits conduit 21 such that one-half of its exposed front surface contacts tip 16 and the other half contacts the workpiece, to provide a further path for heat from tip 16 to the workpiece. Accordingly, to position leading end as exactly as possible for each use of the device, remote end 22 is positioned as near to tip 16 as is practical, without allowing the solder within conduit 21 to melt or soften. A distance of approximately 1/8 inch to 3/16 inch has been found quite effective.
The i.d. of the conduit 21 will preferably be dimensioned to restrict closely the solder 52 so that the leading end 55 can be accurately positioned with respect to tip 16. A clearance on the order of thousandths of an inch has been found to be effective for this purpose.
FIG. 3 shows the preferred device with control member 32 in a position that is only slightly rearward of its forwardmost, loading position. This position is referred to herein as the solder-contacting position. In the position depicted, contact arm 43 has been bent slightly by control member 32 to engage contact arm 44, thus energizing the heating element within shank 15. In this same position of control member 32, the edge 41 of pawl means 33 is placed into contact, although not moving contact, with solder supply 52. This structure permits the operator to utilize device 11 solely as a soldering gun; that is, the soldering tip 16 is heated to a soldering temperature, but the supply of solder 52 is not advanced so as to emerge at the open remote end 22.
With the structure shown, the operator of device 11 may, if desired, operate only the electrical switch means 34, as shown in FIG. 3, to raise soldering tip 16 to a soldering temperature, without advancing solder supply 52, even when cartridge 51 is fully inserted within pocket 26.
Alternatively, the operator may manipulate control member 32 so as to bring a steady supply of heat to tip 16 while at the same time advancing solder supply 52 through open remote end 22 as desired. Such a steady supply of heat will generally cause an increase in temperature of tip 16. This is accomplished by moving control member 32 between the position shown in FIG. 3 and that shown in FIG. 2.
The operator also has the further option of moving control member 32 between the positions shown in FIG. 1 and in FIG. 2. When this is done, the solder supply 52 is advanced as desired, but the switch means 34 opens and closes intermittently, thereby avoiding a continuous supply and buildup of heat at solder tip 16. This later alternative gives the operator some flexability in maintaining a desired soldering temperature while advancing solder supply 52 through guiding conduit 21.
In an alternate embodiment shown in FIG. 2, a light 56 is in communication with switch means 34, preferably through transformer 45. This brings with it two advantages. The light 56 provides useful illumination of the soldering tip 16 and the open remote end 22. It also can serve the useful function of aiding the operator in determinating when the switch means 34 is closed. This later advantage can be especially useful to the operator in selecting the desired alternative combined operations of the pawling means 33 and the switch means 34.
In general, the mating relationship between the open receiving end 23 of the conduit 21 and the finger 53 of cartridge 51 is a simple end-to-end abutting relationship, such as depicted in FIG. 2. As an alternate embodiment, a mating relationship such as that shown in FIG. 3 can be utilized in order to lessen frictional build-up at the point of mating and in order to provide a more precise mating relationship. This structure incorporates a ferrule 57.
In the embodiment depicted in FIG. 3, the outside diameter of ferrule 57 is slightly less than the inside diameter of the open receiving end 23 of guiding conduit 21. Accordingly, when cartridge 52 is inserted into the pocket 26 of the device 11, the ferrule 57 passes into open receiving end 23 to provide a precise, friction-reduced relationship, thereby facilitating passage of solder supply 52 through guiding conduit 21. If desired, and if space permits, the outside surface of the leading edge of ferrule 57 may be beveled or flared, with the outside surface of the open receiving end 23 of conduit 21 being correspondingly flared or beveled. In such arrangements, shown in more detail in FIGS. 6 and 7, the bevel angle and the flare angle are approximately the same, resulting in further improved mating relationship.
FIG. 4 provides an elevation rear end view of device 11 without cartridge 51 inserted within pocket 26. It affords another view of the communication between the control member 32 and the pawl 35, as well as the communication between the control member 32 and the flexible front contact arm 43.
The preferred cartridge 51 is depicted in perspective in FIG. 5. It includes finger member 53, having underside opening 54. In the arrangement shown, the supply of solder 52 is provided as a winding of length of solder that is positioned within the body of the cartridge 51 so that the solder supply 52 can be unwound in the direction toward finger member 53. It is preferred that the cartridge 51 includes a sleeve 61 throughout the length of finger member 54. Preferably, sleeve 61 continues for a short distance into the top panel 62 of the cartridge 51. Sleeve 61 includes an opening 63 to the inside volume of the cartridge 51. The sleeve 61 also has an external opening 64. This structure allows for the supply of solder 52 to pass through internal opening 63, through sleeve 61, and out of external opening 64.
In addition, the portion of sleeve 61 that is in communication with opening 54 is not enclosed. This means that when cartridge 51 is inserted into the pocket 26 of device 11, the edge 41 of pawling means 33 may contact the supply of solder 52 while it is within sleeve 61.
If desired, the supply solder 52, when wound as shown in FIG. 5, may be contained on and within a spool 65. Spool 65 may contain an axle 66 around which the supply of solder 52 is wound.
Axle 66 need not be attached to the side panels 67 of cartridge 51, although this cartridge structure is within scope of this invention. In the preferred form shown in FIG. 5, the function that would be performed by having axle 66 in rotatable communication with side panels 67 is accomplished by sizing spool 65 such that it is freely rotatable within cartridge 51. Rotation of spool 65 may be further aided by providing finger grip indentation 68. Grip 68 is preferrably of a generally triangular figuration to permit the operator to grip the cartridge 51 for its removal from pocket 26 of device 11. This configuration of grip 68 likewise provides a surface for sliding, suspending and resting contact for spool 65 to facilitate its rotation when axle 66 is not in rotatable communication with side panels 67.
In the preferred cartridge 51, a slot 71 is provided in its bottom panel 72. This slot 71 is dimentioned to receive a securement clip 73 (FIG. 3) which is securely fasened to the bottom, inside surface of pocket 26. The combination of slot 71 and clip 73 assists in holding cartridge 51 in place within pocket 26 and accomplishes a positive, snap-in type of fit.
FIG. 6 shows a cartridge 51 having an alternate means for effecting the snap-in type of fit. Instead of slot 71, there is provided a projection 74. Projection 74 is structured for mating relationship with a suitable means such as clip 73 or one or more beads 75 (FIG. 2). Projection 74 may take any suitable form, such as a single tooth, a plurality of teeth positioned in a row along the width of bottom panel 72, a single ridge along the width of bottom panel 72, or the like.
FIGS. 6 and 7 illustrate the additional optional embodiments of cartridge 51 when it includes ferrule 56 on finger member 53 at its external opening 64. Ferrule 56 may be untapered as shown in FIG. 3, it may be beveled outwardly as shown in FIG. 6, or it may be tapered inwardly as shown in FIG. 7. Whatever the structure of ferrule 56, a complementary structure is provided for in open receiving 23 of the guiding conduit 21.
It is preferred that cartridge 51 include friction plate 76. Plate 76 provides a frictional contact upon the supply of solder 52 as it passes through sleeve 61. In its preferred form, plate 76, as shown in FIG. 6, has its upper edge angled forwardly in order to impart greater frictional forces upon solder supply 52 when solder 52 tends to move rearwardly through sleeve 61. By the same token, only minimal frictional forces are applied by pressure plate 76 as the supply of solder 52 passes forwardly through sleeve 61 and out of external opening 64.
When a cartridge 51 that employs this preferred structure of plate 75 is used in combination with device 11, advantageous effects can be achieved. Since plate 76 provides minimal frictional force as solder 52 moves forwardly, it provides little resistance as pawling means 33 passes from its loading position (FIG. 1) through its spent position (FIG. 2). Then, advantageously, as pawling means 33 moves from its spent position back to its loading position, plate 76 provides adequate frictional forces so as to prevent the bias of spring 36, transmitted to edge 41 of pawl 35, from passing the supply of solder 52 back into cartridge 51.
FIG. 8 depicts an alternate embodiment of the device, generally indicated by reference numeral 111, and the cartridge, generally referred to by reference numeral 151. This embodiment is especially useful when it is important to provide an encased supply of solder 152 through an open remote end 122 that is below a soldering tip 116.
The embodiment of FIG. 8 includes a pawling means generally indicated by reference numeral 133, that is positioned beneath the soldering member, generally referred to by reference numeral 114. Also, when compared with the cartridge 51 of the preferred embodiment, the cartridge 151 of this alternate embodiment is upside-down. This being the case, opening 154 of cartridge 151 is located on finger member 153 on its side that is opposite to that of opening 54 in finger member 53.
By the same token, looking at cartridge 151 itself, finger grip indentation 168 is on the same general surface as opening 154. And, snap-in means 170 is located above cartridge 151.
FIG. 8 also clearly illustrates a structural feature that can be relied upon in order to bring about the two different functions depicted in FIGS. 1 and 3. This shows that edge 141 of pawling means 133 can be in communication with a projection 181 within body 112. This is a resting communication, and it occurs when pawling means 133 is in its rearwardmost, loading position.
When control member 132 is moved slightly rearwardly so as to close the electrical switch means, generally referred to by reference numeral 134, the pawling means 133 moves from its loading position to its solder-contacting position, on the order of that shown in FIG. 3. The advantages of providing both a loading position and a solder-contacting position are discussed elsewhere herein.
FIG. 9 depicts an alternate structure for providing both a loading position and a solder-contacting position to permit closing the switch means 134 without advancing the solder supply 142. In this embodiment, the pawling means, generally referred to by reference numeral 233, includes a resilient member 282. Member 282 may be a leaf spring such as that shown or it may be a coil spring or the like. Resilient member 282 provides a resilient force that is lower in magnitude than that of biasing means 236. It will be noted that biasing means 236 is shown as a piston and cylinder; it may take any suitable form, including that of the coil spring depicted in the other figures.
The structure of this embodiment makes possible the closing of switch means 134 without a forward movement of the edge 241 of pawling means 233. As control member 232 is moved until switch means 134 is initially closed, the weak resistance provided by resilient member 282 is overcome until that member 282 is prevented from moving farther by the inside surface of detent 283. The resilient member 282 remains in this position as control member 232 is moved until pawl means 233 moves to its spent position.
Obviously, many modifications and variations of the invention as hereinbefore set forth may be made without the parting from the spirit and scope thereof, and only such limitations should be imposed as are indicated in the appended claims.
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An improved soldering device is provided, one that is structured for the reception of and use with a new cartridge that is a self-contained supply of solder. When the cartridge is inserted within the soldering device, an operator, using only one hand, is able to advance the solder from out of the cartridge and to a location in close proximity with the soldering tip of the device. With that same single hand, the operator can energize the heating element to supply heat to the soldering tip. The advancing and energizing structure permits the device to remain energized throughout the advancing operation or, optionally, to smoothly effect an intermittent energization and deenergization of the heating element to reduce the total quantity of heat supplied to the soldering tip even while the solder is being advanced.
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BACKGROUND OF THE INVENTION
The invention relates to a drum beater device which is typically used with a bass drum and a drum beater foot pedal. The present invention discloses a novel self-aligning beater which allows the head to self-align with a flat striking surface of a bass drum.
The self-aligning beater device comprises a drum beater head having preferably two impact surfaces which may be selectively rotated to expose one of the impact surfaces to the striking surface of a bass drum.
The impact surface of the head free for angular displacement relative to the shaft and for circumferential rotation about the shaft, whereby, the impact surface of the head may independently align itself with the striking surface of a drum by swiveling angularly relative to the shaft and by rotating circumferentially about the shaft as the impact surface of the head engages the flat striking surface of the drum.
Moreover, in the way the impact surface of the head may independently align itself with the striking surface of the drum by swiveling angularly relative to the shaft and by rotating circumferentially about the shaft as the impact surface of the head engages the flat striking surface of the drum.
It uniquely employs a unitary axle independent of moving parts for mounting the head to an upwardly extending shaft while leaving the impact surface of the head free for angular displacement relative to the shaft and for circumferential rotation about the shaft.
The self-aligning drum beater may be used with a bass drum pedal and a flat striking surface of a bass drum.
ADVANTAGES OF THIS INVENTION
The instant invention is an improvement over current bass drum beaters because it allows the drummer to play the bass drum with no adjustment of the beater. Because the instant invention is self-adjusting, it remains centered when impacting the bass drum head, causing maximum sound projection.
How it remains centered is a function of its design. It can rotate circumferentially about the shaft. It also will move angularly relative to the shaft. The best mode contemplated provides the head may angularly displace relative to the shaft up to 15° to accommodate changes in the distance of the beater head from the point where it attaches to the foot pedal relative to the position of the bass drum head (striking surface).
Most current beater heads are fixed, and do not move relative to the shaft without manual adjustment requiring a tool. Once set up in the foot pedal, they are tightened and no adjustment can be made unless they are loosened and repositioned.
These fixed beaters have the tendency not to hit the bass drum squarely unless set-up by the drummer is perfect. Imperfect settings affect sound quality due to poor surface contact.
In addition, during play, the bass drum foot pedal, which the beater is attached to, will sometimes loosen from the bass drum particularly if the pedal was not squarely aligned initially. Under such circumstances, the skewed contact between a fixed beater and the head of the bass drum tends to move the pedal in a lateral direction which eventually becomes unplayable causing the drummer to stop playing and reset the pedal position. This problem is reduced substantially by the present invention.
With the instant invention, this tendency is reduced, even eliminated, because the beater aligns itself to hit square at all times.
The instant invention beater head design described herein has two different contact surfaces, 180 degrees apart. One side has a high impact, maximum surface area shape, the other a minimal tangent line of contact (oval ended side). Because of style changes in music and songs, it makes things easier if the drummer can turn the beater head around quickly for a different bass drum sound, without having to use tools or stopping to reset the beater in the foot pedal, and just keep playing. In other words, with the same foot pedal motion, two different sounds can be made with the instant invention simply by turning the head around 180 degrees.
A preferred material of the head is HYTREL®. This material was chosen for its ability to resist heat (from friction), retain its shape (from impact) and not "color" or change the sound in an undesirable manner. Hard beater heads made of wood or other hard plastics tend to cause a loud sharp "click" when impacting the bass drum head. Beater heads made of compressed felt are very soft sounding and extremely limited to their ability in shaping for manufacture. The HYTREL® combines the best features of these beaters to produce a new unique sound, only available from using the instant invention bass drum beater of the disclosed invention.
A preferred material for the center cap which holds the head, is a glass filled nylon which is used for durability, strength and resistance to stretch, bending, and brittleness which results in breakage. The shaft is made of stainless steel which is superior in resisting permanent bending.
In conclusion, because of the shape, material, and mechanical function of the instant invention beater, it has a new unique sound producing capability never before available to drummers. In addition, it works better with the foot pedal, because it inhibits loosening by remaining square during play. Also, the drummer using the instant invention needs no tools to set it up, other than fastening the shaft into the foot pedal.
The instant drum beater device provides an efficient and convenient means for self-alignment.
Still other advantages will be apparent from the disclosure that follows.
SUMMARY OF THE INVENTION
The invention relates to a drum beater apparatus which is typically used with a bass drum and a drum beater foot pedal. The present invention discloses a novel self-aligning beater which allows the head to self-align with a flat striking surface of a bass drum.
The self-aligning beater apparatus comprises a drum beater head having at least one impact surface and an elongated passageway extending from the bottom thereof to receive a shaft, and a means for mounting the head to an upwardly extending shaft while leaving the impact surface of the head free for angular displacement relative to the shaft and for circumferential rotation about the shaft, whereby, the impact surface of the head may independently align itself with the striking surface of a drum by swiveling angularly relative to the shaft and by rotating circumferentially about the shaft as the impact surface of the head engages the flat striking surface of the drum.
The self-aligning drum beater may be used with a bass drum pedal and a flat striking surface of a bass drum. It uniquely employs a unitary axle independent of moving parts for mounting the head to an upwardly extending shaft while leaving the impact surface of the head free for angular displacement relative to the shaft and for circumferential rotation about the shaft. In the way the impact surface of the head may independently align itself with the striking surface of the drum by swiveling angularly relative to the shaft and by rotating circumferentially about the shaft as the impact surface of the head engages the flat striking surface of the drum.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described hereinafter with reference to the accompanying drawing wherein:
FIG. 1 is a perspective view of a preferred embodiment of the self-aligning beater of the present invention with the head thereof attached to an upstanding shaft;
FIG. 2 is an exploded perspective view of the self-aligning beater of FIG. 1 with the caps exploded outwardly to show the interior structure of the head and the snap fastening projection disposed on the interior side of the caps;
FIG. 3 is a side elevation view of the self-aligning beater of FIG. 1;
FIG. 4 is a side elevation view of the self-aligning beater of FIG. 1 with the proximate cap removed to show the relationship between the interior structure of the head and the snap fastening projection disposed on the interior side of the distal cap;
FIG. 5 is a side elevation view of the self-aligning beater of FIG. 4 with the head angularly displaced relative to the shaft;
FIG. 6 is a cross-sectional take along the line 6--6 of FIG. 3 showing the snap fastening projection disposed on the interior side of each of the caps in a locking engagement with each other and further showing the orifice thereby created for the circumferential groove of the shaft; and
FIG. 7 is a cross-sectional take along the line 7--7 of FIG. 3. showing the snap fastening projection disposed on the interior side of each of the caps in a locking engagement with each other and further showing some of the frictional contact surfaces disposed internally in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiments depicted in the drawing include a self-aligning beater which allows the head to self-align with a flat striking surface of a bass drum. The beater depicted has two impact surfaces disposed on opposite sides of the head which can be selectively positioned. Without departing from the generality of the invention disclosed herein, the head should have at least one and could be provided with additional impact surfaces, and with varying ranges of angular displacement relative to the shaft. The discussion that follows, without limiting the scope of the invention, will refer to the invention as depicted in the drawing.
As best shown in FIG. 2 of the drawing, the present invention provides a self-aligning drum beater adapted for use with a bass drum pedal and a flat striking surface of a bass drum (not shown). The device comprises a drum beater head 1 having at least one impact surface (2, 6) and an elongated passageway 8' extending from the bottom thereof to receive a shaft 8. A means for mounting the head 1 to an upwardly extending shaft 8 is provided that leaves the impact surface of the head 1 free for angular displacement relative to said shaft (as shown in FIG. 5) and for circumferential rotation about said shaft, as illustrated by the arrow in FIG. 1. This embodiment of this important invention allows the impact surface (particularly 2) of the head 1 to independently align itself with the striking surface of a drum by swiveling angularly relative to the shaft and by rotating circumferentially about the shaft as the impact surface of the head engages the flat striking surface of the drum.
In a preferred embodiment, as shown in FIG. 2, the beater head 1 comprises an elongated housing having a generally flat impact surface 2 disposed on one end and an arcuate surface 6 on the other.
The head 1 further has laterally disposed openings 14 on the sides thereof, said openings 14 have a resilient seating area disposed in said housing. The instant device further comprises a pair of identical caps, each of which may be disposed in one of said openings 14.
Referring again to FIG. 2, the self-aligning drum beater comprises a unitary axle independent of moving parts for mounting the head to the upwardly extending shaft. The self-aligning drum beater employs a pair of caps (4a, 4b) as a means for mounting the head 1 to the shaft 8.
Each cap has a disk-like shape with an exterior side and an interior side with an irregularly shaped elongated projection disposed on the interior side thereof. As shown on cap 4b, each such projection comprises a snap fastener having a male snap fastening member 18b and a female snap fastening member 16b disposed on the other end thereof. As shown in FIG. 2, the male snap fastening member 18b is arranged and adapted to lockingly engage female snap fastening member 16a of cap 4a as the respective caps are joined with the projections in a face to face relationship.
The projection of the cap 4b, as shown in FIG. 2, reveals a female snap fastener 16b having a channel shaped body 13b disposed horizontally with a horizontal recess 11b disposed therein which is arranged and adapted to receive a male snap fastener (not shown) of cap 4a (identical to 18b of cap 4b). Said female snap fastener 16b has a opening disposed in the channel shaped body 13b for receipt of the male snap fastener. This aspect of the invention can be seen on cap 4a, wherein the opening 19a is disposed in channel shaped body 13a for receipt of the male snap fastener 18b.
As shown in FIG. 6, each of said caps further comprises a centrally disposed web (20a and 20b, respectively). The webs of the respective joined caps are arranged and adapted to form an orifice 30' in which the shaft 8 having laterally grooved section 30 may be rotatingly disposed. Whereby, the joined caps may rotatingly secure the head 1 to the laterally grooved section 30 of the shaft 8.
As shown in FIG. 3, the beater head 1 is positioned on the upstanding shaft 8 which shaft is extended into the passageway 8' of the head. Since the head is designed to angularly displace relative to the shaft, the passageway 8' of the head 1 has a tapered entrance 24.
FIG. 4 shows the preferred embodiment of the current invention with cap 4a removed disclosing the arrangement of the head 1, cap 4b, and the shaft 8. On the head is shown that an interior wall 21 with the chamfered edge is disclosed. The interior wall 21 has lower edges 15 and 17. With the head having the angular displacement as shown in FIG. 4., edge 15 engages the top of the female snap fastener 16b of cap 4b. The web 20b of said cap engages the grooved section 30 of the shaft 8. To the right of the shaft the web 20b widens vertically disposing a contact surface 23b which abuts chamfered edge 24 of interior wall 12. Additionally, a downwardly projecting nub 32 of the head is positioned laterally to engage both cap 4a and shaft 8. This aspect can be more clearly viewed in FIG. 7.
FIG. 5 is like FIG. 4, with only with the head 1 angularly displaced maximally relative to shaft 8, such that the edge 14 of interior wall 12 is now in contact with the female snap fastener 16b of cap 4b and the vertically extended section of the web 23b is in contact with edge 17 of interior wall 21. Moreover, if the tapered angle of the passageway 8' is equal to the chamfered angle of the edges of the respective interior walls (12 and 21, respectively) then the shaft 8 will be in contact with surface 25 of the passageway 8' of the head 1.
As best shown in FIG. 7, the means for mounting further provides frictional engagement with the head to dampen angular movement of the head relative to the shaft. Such frictional engagement exist between wall 21 and the cap 4b and the shaft 8, and between wall 12 and the shaft 8 and the cap 4a. Additionally, each cap's peripheral edge (22a and 22b, respectively) frictionally engages the head. The frictional resistance allows the head to angularly displace in an infinite number of positions between the physical limits referenced herein.
Moreover, frictional engagement between the respective webs (20a and 20b) of the caps and the circumferential groove 30 of the shaft 8 to dampen circumferential rotation of the head about said shaft is provided, as best shown in FIGS. 4, 5, 6, and 7.
In a preferred embodiment, the means for mounting provides a first frictional engagement with the head to dampen angular movement of the head relative to the shaft and a second frictional engagement with the head to dampen circumferential rotation about said shaft.
The circumferential groove 30 is disposed proximate to the end disposed in the passageway 8' of the head 1. For shafts that are not cylindrical a lateral groove having a circular cross-section may be employed.
In the embodiments disclosed, the means for mounting the head to the shaft is movable relative to said shaft. Moreover, it is also movable relative to said head. Furthermore, in the preferred embodiments disclosed, the means for mounting the head to the shaft is movable relative to the shaft and to the head.
As shown in FIG. 2, the means for mounting comprises a pair of identical caps (4a and 4b). Each cap has a disk-like shape having an exterior side and an interior side and a irregularly shaped elongated projection disposed on the interior side thereof. The projection comprises a snap fastener having a male snap fastening member (18a and 18b, respectively, see FIG. 6) disposed on one end and a female snap fastening member (16a and 16b, respectively) disposed on the other end. Each male snap fastening member is arranged and adapted to lockingly engage the female snap fastening member disposed on the other cap as the respective caps are joined with the projections in a face to face relationship with one of the caps rotated 180° from a mirror image of the other cap.
Each of the caps further comprises a web (20a and 20b) disposed between its male and female snap fastening members. The webs of the respective joined caps are arranged and adapted to form an orifice in which a lateral groove of the shaft may be rotatingly disposed. In this way, the caps may rotatingly secure the head to a lateral grooved shaft.
The self-aligning drum beater of the present invention further comprises a means for limiting the angular displacement of the head relative to the shaft. This comprises at least one partial vertical wall (12 and 21, respectively) disposed internally with a chamfered exposed edge (14 and 24, respectively for wall 12, and 15 and 17, respectively for wall 21). The respective edges are arranged and adapted to limit the angular displacement of the head relative to the shaft as it engages the respective projections of the joined caps. See FIGS. 4 and 5, respectively. In another embodiment, the edges of the disk-like section of the cap may be beveled.
The head 1 further comprises an outwardly tapering passageway 8' to allow the head to angularly displace relative to the shaft free from binding the shaft. See tapered wall 24 of FIG. 3.
In a preferred embodiment, as shown in all of the figures of the drawing, the head 1 of the self-aligning drum beater comprises two impact surfaces (2 and 6, respectively) disposed on opposite sides thereof.
In a preferred embodiment, at least one of the impact surfaces is generally disk-like with a slight convex aspect 2 and at least one of the impact surfaces is an arcuate surface 6 comprised of a plurality of parallel lines, each of said parallel lines being perpendicular to the axis of the passageway of said head. As shown in FIG. 1, a first impact surface 2 is generally disk-like with a slight convex aspect and a second impact surface is an arcuate surface 6 comprised of a plurality of parallel lines, each of said parallel lines being perpendicular to the axis of the passageway of said head.
Although not shown in the drawing, a preferred embodiment of the instant invention reveals a means for breaking vacuum between the impact surface of the head and the striking surface of the bass drum. Such means for breaking vacuum may comprise a surface recess disposed on at least one peripheral edge of the impact surface and many other commonly known methods.
Although frictionally resisted, the head 1 may be manually rotatable circumferentially about an upstanding shaft 8, whereby each of the impact surfaces may be selectively disposed proximate to the striking surface of a bass drum.
The instant invention may further comprise a shaft 8 having a lateral groove 30 disposed proximate to an end which may be disposed in the passageway of the head 1.
While this invention has been described in connection with the best mode presently contemplated by the inventor for carrying out his invention, the preferred embodiments described and shown are for purposes of illustration only, and are not to be construed as constituting any limitations of the invention. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
Further, the purpose of the foregoing specification is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms of phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The foregoing is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
These together with other objects of the invention, along with 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 the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, 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.
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A self-aligning bass drum beater that allows the drummer to play without the need to make any adjustments to the beater. Because it is self-aligning, it remains centered when impacting the bass drum head, producing maximum sound projection.
The beater also has two different contact surfaces 180° apart which may be selectively rotated to create different sounds wren striking the head of a bass drum.
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This is a continuation-in-part application of my pending U.S. patent application Ser. No. 09/130,909 filed Aug. 7, 1998, and continued under 37 CFR §1.53(d) entitled “VACUUM HAIR CUTTER” which was a continuation-in-part application of my U.S. patent application Ser. No. 08/670,548 filed Jun. 27, 1996, abandoned and continued under 37 CFR §1.53(d) Jun. 26, 1998, entitled “VACUUM HAIR CUTTER” which was a continuation-in-part application of my U.S. patent application Ser. No. 08/387,475 filed Feb. 13, 1995, entitled “VACUUM ASSIST FOR HAIR CUTTING”, now abandoned.
This invention relates generally to a hair cutting apparatus, and more particularly to a mechanism for cutting hair and pneumatically removing the cut hair.
As background material, U.S. Pat. No. 4,679,322 and U.S. patent application Ser. No. 08/387,475 filed Feb. 13, 1995, and 08/670,548 filed Jun. 27, 1996, are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Prior art hair cutting devices which incorporate a vacuum to remove cut hair include scissors or electric shears incorporated in a housing. The scissors and/or electric shears cut hair as it is being drawn into the housing by a vacuum. Examples of such devices are illustrated in U.S. Pat. Nos. 3,900,949; 4,473,945 and 4,679,322. An alternative arrangement is illustrated in U.S. Pat. No. 4,000,562 wherein a vacuum source is applied to an individual's scalp and slots are incorporated in the vacuum source for scissors to cut the hair. Although these prior arrangements dispose of the cut hair, they have many disadvantages. A major disadvantage is that two hands are required to position the cutting apparatus on an individual's scalp and to cut the hair. The use of two hands makes the cutting operation more difficult and does not give the operator a free hand to steady a cuttee's head, or to comb or otherwise prepare a section of the hair while simultaneously cutting another section. Many of the prior art devices also do not incorporate an adequate vacuum sealing arrangement to insure that a proper vacuum is applied to the hair and to further prevent the hair from straying from the cutting zone. Prior art devices also suffer from back pressure flow problems during operation due to the hair inlet being blocked at times, the improper cutting or uneven cutting of the hair during operation and/or inadvertent tangling or pulling of the hair from the scalp of the individual during cutting. Such operations are unsatisfactory and painful to the individual. Electric cutters similar to ones illustrated in U.S. Pat. No. 4,679,322 are also heavy and very bulky due to the need for an electric motor and room for the complicated blade movement arrangement.
In view of the numerous disadvantages associated with prior art vacuum-assisted cutting devices, there has developed a need for a light-weight vacuum-assisted cutting device which can easily and effectively cut hair, can be positioned on an individual's scalp and actuated by a single hand of an operator, and has a simple yet effective cutting mechanism. This invention satisfies the need.
Other advantages and attributes will be readily discernible upon a reading of the text hereinafter.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a device for cutting hair which can be easily operated with a single hand, can easily and effectively cut an individual's hair and can conveniently remove the cut hair from the cutting chamber.
Another object of the present invention is to provide a device for cutting hair which includes a vacuum source for drawing the hair from the cutting chamber.
Yet another object of the present invention is to provide a device for cutting hair which insures that the cutting blades are properly positioned when cutting an individual's hair.
Still yet another object of the present invention is to provide a cutting mechanism which includes blades which lie in a cutting plane that is substantially perpendicular to the plane in which the hair is drawn into a cutting chamber.
Another object of the present invention is to provide a cutting mechanism wherein the blade edges of the blades are designed to cut hair in a guillotine fashion.
Still yet another object of the present invention is to provide a cutting mechanism which applies pressure to the blades which is preferably perpendicular, but can be at some other angle, to the cutting plane of the blades to insure that the blade edges are closely adjacent during the cutting of the hair.
Another object of the present invention is to provide a cutting mechanism wherein at least one blade has a bowed cutting edge angled with respect to the other blade which results in the cutting edges of each blade making shearing contact at a point which travels along the edges.
An additional object of the present invention is to provide a cutting mechanism wherein the airflow through the device aids in maintaining a positive shearing contact between the blades during the cutting action.
An additional object of the present invention is to provide a cutting mechanism wherein the airflow through the device is maintained regardless of the position of the blades during the cutting action.
Yet another object of the present invention is to provide an opening in the device for cutting which controls the amount of hair drawn into the cutting chamber to facilitate in the proper operation of the cutting device.
Another object of the present invention is to provide a device for cutting which includes a spacing mechanism for adjusting the length of hair to be cut.
In accordance with yet another feature of the present invention, the cutting mechanism includes at least two cutting blades. At least one of which is slidably moveable between an open position and a shear position. Preferably, the two blades are disposed within the cutting chamber in a plane which is substantially perpendicular to the plane in which the hair is being vacuum drawn into the chamber. This provides for an easier and more complete shearing of the hair. In the open position, the hair is drawn into the cutting chamber and between the cutting edges of the two blades. As the blades are moved toward the shear position, the hair disposed between the two blades is cut by the blades. The cut hair is then drawn through the hollow outlet body and into a disposal chamber of the vacuum source. Preferably, one of the blades is substantially affixed in a single position in the cutting chamber and the second blade is slidably moveable between the open position and the shear position. In the open position, the cutting edge of one blade is preferably spaced from the cutting edge of the second blade. When the hair is to be cut, at least one blade is drawn and/or pushed toward the second blade. This type of cutting arrangement greatly simplifies the design of the cutting arrangement and reduces the jamming or freezing of the blades during cutting since the blade edges completely separate after cutting as opposed to a constant blade overlapping design which is susceptible to jamming. The blade movement mechanism preferably directly applies the blade movement force. Indirect blade movement force arrangements such as those that incorporate a cam to move one or more blades significantly complicate the cutting arrangement, applying large indirect forces which are typically perpendicular to the plane of the movement of the blade thus making the blades more susceptible to damage and more susceptible to jamming. By directly drawing one blade toward another blade, only the needed force to cut the hair is applied to the blade. Such an arrangement greatly simplifies the design, operation and effectiveness of the cutting mechanism. Preferably, the two blades are biased in the open position and require the operator to manually activate the cutting mechanism to move the blades into the shear position. The blades can be biased in the open position by a spring or other resilient mechanism. The edges of the two blades may be designed so that they are not parallel, i.e. an edge is angled with respect to the other edge, so as to resemble a guillotine cutting arrangement. Such a blade edge design facilitates in the ease and efficiency of the cutting of the hair when the blades are moved into the shear position.
In accordance with yet another aspect of the present invention, the cutting chamber includes a pressure arrangement for applying pressure to at least one of the cutting blades. Preferably, the pressure applied is substantially perpendicular to the plane of movement of the blades between the open and shear positions. The applied pressure prevents the blades from separating as they move from the open position to the shear position. Unintended separation of the blades during cutting can result in uncut or miscut hair. The pressure arrangement may also be designed to allow the blades to slightly separate when cutting a large volume of hair and/or relatively thick hair to increase the ease and effectiveness of cutting large volumes of hair and/or very thick hair. The pressure arrangement preferably includes one or more springs and a pressure frame. The springs are preferably positioned to cause the pressure frame to be biased against one or more of the cutting blades. This spring arrangement both directs pressure to the blades and further allows the blades to slightly separate as described above. In a first embodiment, several springs are used in the pressure arrangement so that the pressure applied to the blades by the pressure frame is substantially uniform during the operation of the cutting mechanism. An alternate pressure arrangement uses resilient pads instead of springs to apply pressure to the pressure frame.
In accordance with still yet another aspect of the present invention, a blade guide is incorporated in the cutting mechanism to insure that the blades properly move between the open position and the shear position. The blade guide preferably limits the movement of the blades in a slot when the blades slide between the open position and the shear position. Preferably, the blade guide substantially affixes one of the cutting blades into a single position and provides a slot arrangement for the second blade to slide between the open and shear position. The slot arrangement also preferably allows the cutting edges of the two blades to slightly separate as they close together so that large volumes of hair and/or thick hair can be easily and effectively cut.
In accordance with another aspect of the present invention, at least one of the cutting blades includes a blade extension which extends between the two blades in both the open and shear position. The blade extension insures that when the blades move together, the cutting edges of the two blades do not abut against one another thus interfering with the cutting of the hair between the blades. As can be appreciated, other arrangements can be used to insure the proper position of the blades during the movement between the open position and the shear position.
In still yet another aspect of the present invention, at least one blade is bowed along the length of its edge. The bowed blade design ensures that the cutting edges of the blades meet at a shearing point which moves progressively along the edges as the blades close together.
In accordance with another aspect of the present invention, a slotted opening which includes at least one rake is connected to the opening of the inlet section. Preferably, two or more rakes are connected to the slotted opening. The rakes are preferably attached to and/or positioned adjacent to the slotted opening. The rakes and the slotted opening receive a defined volume of hair and direct such hair through the inlet section opening and into the cutting chamber. The slotted opening is preferably disposed to draw hair into the cutting chamber substantially perpendicular to the cutting plane of the blades. This alignment of the slot opening improves the ease and effectiveness of cutting hair, but it can be appreciated that the slotted opening can be positioned to direct hair into the cutting chamber angled to the cutting plane. The rakes are designed to comb the hair as the cutting device is moved on an individual's head. The combing of the hair helps separate tangled hair so that the hair will be properly drawn into the cutting chamber. The rakes are preferably positioned substantially parallel to one another. The rakes extend from the slotted opening a distance which is sufficient to position the device on an individual's head to provide sufficient spacing for air flow into the slotted opening. By providing sufficient air flow into the slotted opening while the cutting device is positioned on an individual's head, the problems associated with static airflow in the cutting chamber and increased load on the vacuum source due to airflow blockage are essentially eliminated. It can be appreciated that additional air passageways can be incorporated into the cutting device to further prevent airflow blockage. It can be further appreciated that the rake surfaces can be curved to facilitate the movement of the rakes through an individual's hair and to further ensure that air properly flows into the slotted opening.
In accordance with still yet another aspect of the present invention, a spacing device is connected between the slotted opening and the inlet opening. The spacing device allows the operator to cut the hair of an individual at a desired length. A longer spacer results in an individual having longer hair after the haircut whereas a shorter spacer results in shorter hair. The spacing device preferably has a cross-sectional shape which is substantially similar to the cross-sectional shape of the slotted opening and the inlet opening; however, it can be appreciated that the spacing device can have other cross-sectional shapes. The spacing device preferably is a substantially straight tubular device which does not alter the course of the hair entering into the slotted opening and extending into the cutting chamber; however, the spacing device may be angularly shaped.
The spacing device may include corrugated ribs to allow the spacing device to be easily adjustable between an angular and straight position to facilitate in the positioning of the cutting device during the cutting of an individual's hair.
In accordance with yet another aspect of the present invention, the manual mechanism for operating the cutting mechanism includes a squeeze lever to the outlet body. The squeeze lever is preferably biased in the open position so that when the operator is not grasping the squeeze lever, the blades of the cutting mechanism are in the open position. When the squeeze lever is pivotally drawn toward the outlet section, it causes the blades of the cutting mechanism to move together to cut hair. As can be appreciated, the squeeze lever may be alternatively attached to a switch which activates and/or de-activates an electrical motor or the like that moves the blades.
These and other objects and advantages, expressed or implied, hereinafter are accomplished by a device for cutting hair which includes a cutting chamber is connected between an inlet section and an outlet section. The outlet section is connected to a vacuum source which creates a vacuum at the outlet section and causes air to be drawn into an opening in the inlet section. The air drawn into the inlet opening causes hair on an individual's scalp to be drawn into the cutting chamber when the device is placed upon the head of an individual. Disposed in the cutting chamber is a cutting mechanism which cuts the hair being vacuum drawn into the cutting chamber. The cutting mechanism is preferably manually operated; however, it can be appreciated that the cutting mechanism may be operated by an electric motor or the like. The outlet section preferably includes an elongated hollow body which an operator can easily grasp to position the device at a desired area on an individual's head. The cutting mechanism is manually activated by a switch or lever which is preferably located adjacent the grasping portion of the outlet body so that the operator can simultaneously position the cutting device and activate the cutting mechanism with a single hand.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a first embodiment of the present invention.
FIG. 2 is a bottom view of the cutting device of FIG. 1 .
FIG. 3 is a cross-sectional view of the cutting device as shown in FIG. 1 .
FIG. 4 is a cross-sectional view of the cutting device taken along line 4 — 4 of FIG. 3 .
FIG. 5 is a cross-sectional view of the cutting device taken along line 5 — 5 of FIG. 4 .
FIG. 6 is front view illustrating an angular spacer attachment.
FIG. 7 is an exploded view of the cutting chamber and components positioned therein of FIG. 1 .
FIG. 8 is a side elevation view of a second embodiment.
FIG. 9 is a bottom view of the cutting device of FIG. 8 .
FIG. 10 is a cross-sectional view of the cutting device as shown in FIG. 8 .
FIG. 11 is a cross-sectional view of the cutting device taken along line 11 — 11 of FIG. 10 .
FIG. 12 is a cross-sectional view of the cutting device taken along line 12 — 12 of FIG. 10 .
FIG. 13 is a partial cross-sectional view of FIG. 10 illustrating airflow through the cutting chamber when the blades are open.
FIG. 14 is a partial cross-sectional view of FIG. 10 illustrating airflow through the cutting chamber when the blades are closed.
FIG. 15 is an exploded view of the cutting chamber and components positioned therein of FIG. 8 .
FIG. 16 is a cross-sectional view taken along line 16 — 16 of FIG. 15 .
FIG. 17 is a cross-sectional view of another embodiment of the cutting device taken along a line identically situated as line 12 — 12 of FIG. 10 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings which are for the purpose of illustrating the preferred embodiments of the invention only and not for the purpose of limiting the same, FIGS. 1-3 illustrate a cutting device 10 for vacuum cutting an individual's hair 12 . Cutting device 10 incorporates an outlet section which includes an outlet body 30 which is connected between a cutting housing top 50 and a vacuum hose 20 . Outlet body 30 preferably is cylindrical and includes a vacuum channel 40 which runs the length of the outlet body. At the end of the outlet body distal from the housing top is an outlet flange 32 , an outlet extension 34 and a connection rib 36 . The outlet extension telescopically inserts into the vacuum hose 20 . At least one connection rib 36 is positioned on the exterior of outlet extension 34 and is used to help secure the outlet extension in the vacuum hose 20 . Outlet flange 32 contacts and covers the face of vacuum hose 20 .
Referring to FIGS. 1, 3 and 7 , the cutting housing includes the top 50 and a base 52 , and several housing screw holes 54 to receive housing screws 56 for affixing the top and base together. Top 50 defines a cutting chamber 60 between a front partition wall 62 and a rear partition wall 66 . Both of the partition walls include a partition slot 64 , 68 to guide a segment of a blade rod 130 . Positioned about the base of cutting housing top 50 is a housing ridge 72 which inserts into housing base 52 to seal the two housing sections. Also positioned about the base of top 50 are several spring recesses 74 each of which receive a blade guide spring 120 . Housing top 50 further includes a blade rod partition 76 rearwardly spaced from rear partition wall 66 . Blade rod partition 76 includes a partition slot 78 which receives front blade rod support 84 located on housing base 52 . Positioned at the rear base of housing top 50 is a rear housing slot 79 which receives rear blade rod support 88 positioned on housing base 52 . Housing base 52 includes an opening 80 to receive hair 12 into the cutting chamber 60 . Housing base 52 also includes a blade guide wall 82 to receive a set frame (as described below) 102 . Positioned on the rear wall of blade guide wall 82 is front blade rod support 84 . Rod support 84 includes a rod slot 86 to support and guide a blade actuating rod 130 . Positioned rearwardly from rod support 84 is a rear rod support 88 . Rear rod support 88 includes a rod slot 90 which functions similarly as blade slot 86 . Both rod supports 84 , 88 preferably include a support reinforcement tab 92 to rigidify and strengthen the two rod supports.
Referring again to FIGS. 1, 3 and 7 , a blade guide includes a pressure frame 100 and the set frame 102 . The frame 102 seats in guide wall 82 . Both the pressure frame 100 and set frame 102 define a central opening, 101 and 103 respectively, to allow hair to pass therethrough. Set frame 102 includes a blade slot 108 which receives and rigidly secures in position a set blade 110 . Clips 106 extending normally from the set frame 102 hook respective notches 104 defined along the lateral edges of the pressure frame 100 . The Clips 106 also accurately locate the pressure frame 100 which guides the movement of shear blade 112 when it is moved. The height of the clips 106 allows the shear blade 112 to freely move between the open position and the shear position, and allows the blade edges to slightly separate when the blades are moved into the shear position. Shear blade 112 includes cutting edge 116 A that is preferably angled with respect to the cutting edge 116 B of set blade 110 with both blades having overlapping extensions 114 . Though not shown, the shear blade is longitudinally bowed. Shear blade 112 includes a hole 118 to receive an elbowed end 132 of the blade actuating rod 130 . The rod also includes an opposite, threaded end 138 . Between the elbow and threaded end there is a rod flange 134 , and restricted at its other end by the rear rod support 88 . The threaded end receives a rod spring 136 which is restricted at one end by rod flange 134 . Washer 140 is inserted into the rod following the spring and is retained thereon either by the rear rod support 88 or by nut 142 which is threaded onto thread end 138 .
Referring now to FIGS. 1, 3 , 5 , and 7 , a handle 150 is pivotally connected to the front portion of outlet body 30 and preferably has a loop strap 160 . Handle 150 includes two handle flanges 158 each defining a mount slot 154 . Mount slots 154 receive a pivot pin 156 inserted through handle mount 152 , which in turn is connected to outlet body 30 . In the front of handle 150 is a rod slot 162 which receives the threaded end of blade rod 130 . As illustrated in FIG. 3, the threaded end of blade rod 130 is inserted into rod slot 162 until the threaded end is completely passed through rod nut abutment 164 of handle 150 . Blade rod 130 is then connected to handle 150 by applying the rod nut 142 onto the threaded end.
Referring now to FIGS. 1, 2 , 3 and 5 , a spacer 170 is attached to base opening extension 94 of the housing base 52 . Spacer 170 includes a top spacer slot 172 and a top spacer tab 174 which slides onto and connects to extension groove 96 of base opening extension 94 . This connection also provides an essentially vacuum tight seal between the spacer and base housing opening. Spacer 170 defines a hollow passageway 178 which extends therethrough. The cross-sectional shape of the passageway is preferably substantially the same as the cross-sectional shape of base housing opening 80 . At the bottom of spacer 170 , is a slot 176 which receives a platform body 180 . This connection produces an essentially vacuum tight seal between the spacer and platform body. Platform body 180 includes a platform slot 186 and platform tab 188 which fits into the slot 176 . At the base of platform body 180 are two side ribs 182 and one or more rake ribs 190 between the two side ribs. The ribs 182 , 190 are profiled to follow smoothly over the scalp 14 of the individual 16 . The platform body also includes an opening 184 which has a cross-sectional shape which is substantially the same as the cross-sectional shape of spacer passageway 178 . As can be appreciated, the spacer can be eliminated and the platform body can be directly attached to the base opening extension.
Referring now to FIG. 6, illustrated is an alternative embodiment of the platform body 180 wherein the side ribs 182 and rake rib 190 extend at differing distances from the platform tab 188 end of the platform body. As can be appreciated, other designs of the bottom of the platform body may be incorporated.
Referring to FIG. 7, blades 110 and 112 can be easily replaced by removing the housing screws to separate base 52 from top 50 . The blade guide pressure and set frames 100 , 102 are then removed. The two frames can then be easily unsnapped from each other so that new blades can be substituted into the blade guide. Once the blades are replaced, the housing is re-assembled.
To operate the cutting device, the vacuum source is activated which draws air through the platform body 180 and spacer 170 , and into the cutting chamber 60 . The drawn air causes hair to be drawn into cutting chamber. As best illustrated in FIG. 3, the vacuum drawn hair passes between set blade 110 and shear blade 112 when the two blades are in the open position. The hair between the blades is cut by an operator drawing handle 150 toward outlet body 30 . The drawing of the handle causes blade rod 130 to move rearwardly which in turn causes the cutting edge of shear blade 112 to move toward the cutting edge of set blade 110 . Blade rod 130 is held in position and guided during movement by front and rear rod slot 86 , 90 , partition slot 78 , rear housing slot 79 and rear partition slot 68 . As shown in FIGS. 3 and 4, the movement of shear blade into the shear position closes the space between the two blades and results in the blade edges cutting any hair extending between them. The shear blade edge acts similar to a guillotine when cutting the hair. The cut hair is drawn through cutting chamber 60 and into vacuum passageway 40 as shown in FIG. 3 . The hair in vacuum passageway 40 proceeds through vacuum hose 20 and into a hair disposal bin.
The cutting of the hair is facilitated by two special designs in the cutting device. As shown in FIGS. 4 and 7, shear blade 112 has a cutting edge 116 A which is angled with respect to the cutting edge 116 B of set blade 110 . This orientation of blade edge 116 A of shear blade 112 results in the hair being cut at different times as shear blade 112 is moved toward set blade 110 . In other words, the shear point moves along the edges. This results in more efficient and easier cutting than if the two cutting edges where parallel. The bowed edge of shear blade 112 keeps the cutting edges in closed contact at the shear point as it moves along. This combination of the guillotine blade design with the bowed blade design easily, efficiently, and effectively cuts the hair between the two blades without causing the hair to mat or lay down during cutting. Furthermore, the pressure frame 100 applies pressure to shear blade 112 as it moves to keep the two blades closely adjacent. However, the spring biasing of the pressure frame also allows shear blade 112 to slightly lift away from set blade 110 when they are cutting a large amount of hair and/or very thick hair. These special features significantly improve the ease and effectiveness of cutting hair.
Once a cut has been made, the operator releases handle 150 which then moves back into its open position. The handle is biased in its open position because rod spring 136 is between rod flange 134 and the inner face of rear blade rod support 88 . In such an arrangement, the drawing of the handle causes the blade rod to move rearwardly and cause the rod spring to be compressed between the rod flange and blade rod support 88 . The release of the handle results in the rod spring moving the rod flange forward which in turn causes the handle to move into the open position. The movement of handle 150 back into the open position causes shear blade 112 to move into its open position to allow additional hair to be cut.
The sealing of the cutting chamber to ensure that a proper vacuum is achieved between vacuum passageway 40 and base housing opening 80 is accomplished by several components incorporated in housing top 50 and housing base 52 . The peripheral edge of the housing is substantially vacuum sealed by top ridge 72 abutting against the inner side surface of the housing base. The heads of housing screws 56 substantially seal each housing screw hole 54 . Finally, blade rod is substantially vacuum sealed between front blade support 84 and blade rod partition 76 . Additional sealing is provided by rear blade rod support 88 and rear housing slot 79 . It will be appreciated that sealing rings can be provided in the cutting housing to provide additional sealing.
As illustrated in FIGS. 3, 5 and 6 , a spacer 170 can be used to extend the distance of platform body 180 from base housing opening 80 . The increase in spacing results in less hair being cut. As a result, an operator can select a specific spacer to cut an individual's hair at a desired length. As shown in FIG. 6, platform body 180 may be designed to cut hair at an angle and for cutting hair on different shaped heads and/or to produce various styles of haircuts. As can be appreciated, the rake ribs 190 help position the platform body 180 upon an individual's scalp and further direct the hair into the opening of the platform body.
Referring to FIGS. 8-16, a second embodiment is illustrated. As best seen in FIG. 15, the second embodiment operates in a manner similar to that of the first embodiment. However, the blade guide, which includes a set frame 302 and a pressure frame 100 , is inverted, i.e. rotated 180° on the guide's longitudinal axis, as compared with the first embodiment. Also, the set blade 110 , also known as the fixed blade, and the shear blade 112 , also known as the moving blade, are inverted in the same manner. In addition, the springs 120 have been deleted and resilient pads 320 are instead used between the housing base 52 and the pressure frame 100 to apply pressure to the pressure frame. The pressure frame seats in the guide wall 82 over the resilient pads. This keeps the blades, which are operably confined within the blade guide (set frame 302 and the pressure frame 100 ), under yielding compression. Referring to FIGS. 12, 15 and 16 it can be seen that the shear blade 112 is slightly bowed, concavely in relation to set blade 110 . This bow in the shear blade causes its narrow end, the end opposite the blade extension 114 , to be raised above the set blade when the blades are in the open position as shown. This raised position of the shear blade's narrow end is accommodated in set frame 302 by elongated recess 303 . The bowing serves to maintain a positive shearing action at a cutting point which moves along the length of the blades, from proximate their extensions 114 to the end of the blades, as the shear blade is pulled toward the set blade during cutting action of the device.
Referring to FIGS. 13 and 14, the cutting action of the blades is enhanced in this embodiment because the shear blade 112 is positioned on the inlet side of the set blade 110 . This allows the force of the airflow, represented by the arrow 305 , to push against the shear blade as the blade moves into the shear position, thus helping to keep the shear blade in positive shearing action with the fixed blade. When the shear blade is in the fully closed shear position there is no longer a gap between the blades for the airflow but airflow through the cutting chamber is not substantially interrupted because air can flow around behind the shear blade.
Referring to FIGS. 8-17, a third embodiment is illustrated. The third embodiment operates in a manner similar to that of the second embodiment disclosed in FIGS. 8-16. However, referring to FIG. 17, the shear blade 113 of the third embodiment is slightly bowed, convexly in relation to set blade 110 . (The illustrated bow of 113 is very exaggerated for clarity of understanding.) For about a three-inch wide blade, the bow is such that the distance between the blade and a chord between the ends of the blade is preferably about 0.003 inches. When the blades are in the open position, as shown, the blades are contained in the blade guide, which includes a set frame 302 and a pressure frame 100 . The blades' ends are controlled by the set frame and the pressure frame with the blades' extensions 114 overlapping, the shear blades' extension being disposed beneath (closer to the housing base 52 containing opening 80 ) the fixed blade's extension 114 . Within the blade guide the set blade 110 is held in fixed position and the shear blade 113 is held so that it can move only in sliding, translational movement with respect to the set blade. In the open position, the shear blade 113 curves so that it is raised slightly at its center, proximate elbowed end 132 of the blade actuating rod 130 , causing its cutting edge 116 A to be curved above the straight cutting edge 116 B of set blade 110 . This bow in the shear blade serves to maintain a positive shearing action at a cutting point which moves along the length of the blades, from proximate their extensions 114 to the opposite end of the blades, as the shear blade is pulled toward the set blade during cutting action of the device. The bowing of the shear blade is accommodated by the elongated recess 303 defined in the side of set frame 302 opposite the blade extension 114 . The shear blade 113 flexes slightly, tending to straighten, as its cutting edge engages and is pulled under the fixed blade's cutting edge, during the cutting action. With the blades' ends confined by the blade guide's set plate and pressure plate, the shear blade's bow assures that the blades' cutting edges maintain shearing contact during the cutting action.
The components of the haircutting device are preferably light weight, durable, corrosion-resistant materials such as aluminum, stainless steel, plastic, rubber, etc. As can be appreciated, additional housing designs may be used to accommodate the unique cutting components and arrangements of the present invention.
The present invention relates to a hair cutter, and more particularly, to a vacuum hair cutter which easily and effectively cuts hair; however, it can be appreciated that the concept of the vacuum cutter can be used to cut and dispose of many other types of materials.
The invention has been described with reference to a preferred embodiment and alternates thereof. It is believed that many modifications and alterations to the embodiments disclosed will readily suggest themselves to those skilled in the art upon reading and understanding the detailed description of the invention. It is intended to include all such modifications and alterations insofar as they come within the scope of the invention.
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A hair cutting device is connected to a vacuum source to draw hair into a cutting chamber and includes a mechanism for cutting which allows an operator to both position the cutting device and to activate the cutting mechanism with one hand. The cutting mechanism includes two blades and preferably at least one blade slidably moves against the other to cut hair. The cutting mechanism also maintains the blades in proper position and applies pressure to at least one of the blades to ensure the proper cutting of the hair. Preferably non-parallel cutting edges and the bowing of at least one of the blades act to provide an effective moving shear point between the blades. The cutting mechanism also allows for continued airflow through the cutting chamber regardless of the position of the blades during the cutting operation.
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FIELD OF THE INVENTION
The present invention relates to a method of removing ozone remaining in water. More specifically, the present invention relates to a method of removing ozone which remains in the form of micro bubbles in water such as ballast water after killing microorganisms mixing in water with ozone, offering a solution to the problem of corrosion of ballast tanks by ozone.
BACKGROUND
Cargo ships carrying crude oil, etc are provided with ballast tanks to balance their body during navigation.
Usually, the ballast tanks are filled with ballast water when crude oil, etc are not on-board, while the ballast water is discharged before crude oil, etc are loaded.
Ballast water is necessary for safe navigation of ships, and it is usually taken from sea water in the port where cargo handling is undertaken. The total quantity of ballast water used in the world is estimated at 3 to 4 billion tons a year.
Ballast water contains aquatic organisms which inhabit in ports where the ballast water is drawn, and the aquatic organisms are conveyed to other countries as the ships move. Consequently, destruction of ecological system is increasingly serious that alien organism species take the place of indigenous species in the sea area.
As seriously considered the above background, a diplomatic conference at the International Maritime Organization (IMO) adopted the International Convention for the Control and Management of Ships' Ballast Water and Sediments to make the obligation of implementing ballast water control by use of any ballast water treatment apparatus be applied to ships to be built from 2009 onward.
In addition, the convention prescribed the ballast water discharging standard as shown in Table 1:
TABLE 1
Ballast Water
Items
Quality Criteria
Size
Aquatic Organisms
10 unit/ml
10-50 μm
Aquatic Organisms
10 unit/m 3
50 μm or more
Indicator
Escherichia Coli
250 cfu/100 ml
/
Microbes
Vibrio cholerae
1 cfu/100 ml
/
(O1 and O139)
Genus Enterococcus
100 cfu/100 ml
/
Accordingly, it is now a matter of great urgency to develop a sterilization and/or elimination technology in the ballast water which can solve the above problem.
Conventionally, a technology for sterilization by means of injecting ozone into ballast water in parallel with injecting steam and further generating micro bubbles of ozone to promote formation of hydoxyradicals to reduce consumption of ozone has been offered, as seen in Unexamined Patent Application Publication No. 2004-160437(JP).
SUMMARY
Ozone is mixed into ballast water to perform sterilization, as a result, ozone left unused for sterilization remains in the form of micro bubbles. When water containing this residual ozone is poured into a ballast tank, the residual ozone causes a problem of corroding the ballast tank, transfer piping, etc.
In case of building a new ship it may be considered to use corrosion-resistant materials for ballast tanks, transfer piping, etc to solve this problem; however, it will cause a problem of increasing shipbuilding costs remarkably. In case of an existing ship it may be considered to apply corrosion-resistant paint or corrosion-resistant rubber lining, etc.; however it will also cause a problem of higher costs.
On the other hand, if the water containing residual ozone is left alone at atmospheric pressure for dozens of minutes, the residual ozone will separate from the water and escape into the air. However, in order to do so, it will be necessary to have a tank of large volume sufficient for leaving the water containing residual ozone alone before pouring it into a ballast tank. It will be very costly and impractical.
Furthermore, it may be considered to hold the water containing the residual ozone in a tank for a time to accelerate deaeration of the residual ozone by reducing the pressure in the tank to remove the residual ozone; however, it will require a transfer pump as well as a pressure-reducing pump, causing a problem of higher costs.
It is to be noted that holding ozonized water will cause a problem of corrosion by residual ozone; therefore, the problem is not peculiar to ballast water, but common to any usual water.
The object of the present invention is to provide a method of removing ozone remaining in water to remove ozone remaining in water inexpensively and efficiently.
Other objects of the present invention will be disclosed in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the present disclosure will be or become apparent to one with skill in the art by reference to the following detailed description when considered in connection with the accompanying exemplary non-limiting embodiments, wherein:
FIG. 1 shows an example of an apparatus for implementing the method of removing ozone remaining in ballast water embodying the present invention;
FIG. 2 is an illustration of how micro bubbles of ozone are separated and removed;
FIG. 3 shows an example of another apparatus for implementing the method of removing ozone remaining in water embodying the present invention;
FIG. 4 shows an example of an apparatus for mixing ozone in ballast water;
FIG. 5 is a cross-sectional view along line X-X in FIG. 4 ;
FIG. 6 shows an example of device to reduce the quantity of ozone to be mixed into ballast water;
FIG. 7 shows another example of device to reduce the quantity of ozone to be mixed into ballast water; and
FIG. 8 shows an example of a jet generating device.
DETAILED DESCRIPTION
A pressure tank 1 in FIG. 1 stores ballast water 100 sterilized with ozone.
The ballast water 100 is water picked to be poured into a ballast tank (not shown) of a ship such as a tanker.
Sea water is usually used as the ballast water 100 . In order to pour the ballast water 100 into the ballast tank, sea water is sucked with a pump 2 and sent to the pressure tank 1 through a pipe 3 .
A filter (not shown) may be installed between the pressure tank 1 and the pump 2 to remove litter and trash.
The ballast water 100 sucked with the pump 2 is mixed with ozone injected in the process of its transfer to the pressure tank 1 through the pipe 3 . The injected ozone is mixed into the ballast water and kills microorganisms (e.g. aquatic organisms, colon bacillus, etc. as shown in Table 1).
There is no specific limitation placed on methods of mixing ozone into the ballast water 100 .
FIG. 1 shows an embodiment of mixing ozone into the ballast water 100 by use of a static mixer 4 capable of mixing gas and liquid.
The static mixer 4 is supplied with the ballast water 100 and ozone. Ozone is fed from an ozonizer 5 through an ozone injection tube 6 . The ballast water 100 and ozone are mixed each other in the static mixer 4 , and ozone is instantly mixed with the ballast water. As a result, microorganisms in the ballast water 100 are killed by ozone in a few seconds.
The static mixer 4 is preferably such a mixer as is small in pressure loss and excellent in mixing efficiency.
An aeration pipe 7 is equipped with at the lower part of the pressure tank 1 . The aeration pipe 7 is connected to a compressor 8 , which is an example of compressed air supply means through a pipe 9 . The pipe 9 has a regulating valve 10 which controls the air pressure from the compressor 8 . Driving the compressor 8 , compressed air controlled a predetermined pressure is supplied to the aeration pipe 7 .
Numeral 11 is an exhaust pipe 11 , providing at the upper part of the pressure tank 1 , which discharges exhaust gas containing the residual ozone separated from the ballast water 100 . The exhaust pipe 11 has a pressure-regulating valve 12 that controls the inner pressure of the pressure tank 1 .
Numeral 13 is a pressure sensor that senses the inner pressure of the pressure tank 1 , and transmits signals to control the opening and closing of the pressure-regulating valve 12 to regulate the inner pressure of the pressure tank 1 at a predetermined pressure.
Numeral 14 is a transfer pipe, providing at the lower part of the pressure tank 1 , which transfers the ballast water 100 rid of the residual ozone to the ballast tank (not shown). The transfer pipe 14 is equipped with an on-off valve 15 .
The pressure tank 1 can be equipped inside with an agitator 16 , if necessary. The agitator 16 is driven by a motor 17 .
A method of removing residual ozone from the ballast water 100 in the pressure tank 1 is then described as follows:
The inner pressure of the pressure tank 1 is maintained at a certain level by the pressure of the pump 2 through regulation by the pressure-regulating valve 12 .
The ballast water 100 in the pressure tank 1 contains the residual ozone not used for sterilization in the form of micro bubbles 300 , as shown in FIG. 2 . It is because ozone is injected into the ballast water 100 excessively since it is not realistic to inject ozone in the quantity corresponding to the quantity of microorganisms in water subject to treatment at the ratio of 1:1 to meet the regulatory standards perfectly.
Most of the ozone mixed in the ballast water 100 is used to kill microorganisms and does not corrode ballast tanks, etc. However, surplus ozone is not used for sterilization and is left in the ballast water 100 in the size of micro bubbles 300 that is 0.5 μm to 500 μm. The ozone remaining in the form of these micro bubbles 300 causes the problem of corroding ballast tanks, etc.
In experiments conducted by the present inventors, if the inner pressure of the pressure tank 1 is, for example, about 0.3 MPa (3 kgf/cm 2 ), the ozone remaining in the ballast water 100 takes a form of micro bubbles 300 of about 50 μm.
While the higher the inner pressure of the pressure tank 1 is, the finer the micro bubbles 300 become, the size of the micro bubbles 300 does not become larger than about 50 μm if the inner pressure of the pressure tank 1 is maintained at the level as abovementioned.
High-pressure air is sent by means of the drive of a compressor 8 through the pipe 9 to the aeration pipe 7 in which ozone remains in the form of micro bubbles 300 in pressurized condition. This generates coarse bubbles 200 larger than the micro bubbles 300 contained in the ballast water 100 from the aeration pipe 7 . These coarse bubbles 200 go up through the ballast water 100 because of high buoyancy.
Since the inside of the pressure tank 1 is kept in pressurized condition, the micro bubbles 300 in the ballast water 100 adhere to the sphere of the coarse bubbles 200 as the coarse bubbles 200 go up through the ballast water 100 as shown in FIG. 2 .
That is to say, the present invention ensures that the coarse bubbles 200 larger than the micro bubbles 300 contained in the ballast water 100 are generated in the pressure tank 1 under pressurized condition and the micro bubbles 300 adhere to the coarse bubbles 200 and separate from the ballast water 100 .
The size (diameter) of the coarse bubbles 200 is preferably 10 to 100 times as large as that of the micro bubbles 300 in the ballast water 100 . If, for example, the size of the micro bubbles 300 is about 50 μm as abovementioned, the size of the coarse bubbles 200 is preferably 500 μm to 5 mm.
The size of the coarse bubbles 200 can be adjusted by adjusting the pressure of the compressor 8 or the construction of the aeration pipe 7 .
If the pressure sensor 13 detects the inner pressure of the pressure tank 1 having reached a predetermined pressure, it transmits a signal to open the pressure-regulating valve 12 . This signal regulates the travel of the pressure-regulating valve 12 . In this way, the exhaust gas (O 2 , O 3 , N 2 ) containing the residual ozone separated from the ballast water 100 by the coarse bubbles 200 is discharged outside through the exhaust pipe 11 . The pressure tank 1 is preferably supplied at this point with compressed air so that the exhaust gas can be discharged more easily.
The following is a preferable example of conditions for pressurizing the pressure tank 1 :
Let P 1 be the pressure at the inlet of the water from the pipe 3 connected the pressure tank 1 , P 2 be the pressure at the inlet of the air from the pipe 9 and P 3 be the set pressure of the pressure-regulating valve 12 . P 1 is 0.02-0.7 MPa (0.2-7 kgf/cm 2 ), P 2 is 0.01-0.7 MPa (0.1-7 kgf/cm 2 ) and P 3 is 0.01-0.6 MPa (0.1-6 kgf/cm 2 ). P 1 and P 2 are preferably identical each other in substance or P 2 is preferably set to be 0.01-0.2 MPa (0.1-2 kgf/cm 2 ) higher than P 1 . P 3 is preferably set to be identical to or lower than P 1 or P 2 .
More specifically, if P 1 is set at about 0.3 MPa (3 kgf/cm 2 ), P 2 is set at about 0.4 MPa (4 kgf/cm 2 ) and P 3 is set at about 0.3 MPa (3 kgf/cm 2 ), the pressure tank 1 is pressurized at the pressure of P 2 . As P 2 is set higher than the set pressure of P 3 , the pressure-regulating valve 12 opens under the control of the pressure sensor 13 , and exhaust gas containing residual ozone is discharged through the exhaust pipe 11 . On-off control of opening and closing of the pressure-regulating valve 12 makes it possible to discharge exhaust gas from the exhaust pipe 11 continuously.
While high-pressure air is sent to the aeration pipe 7 , the ballast water 100 is preferably agitated moderately by rotating the agitator 16 to accelerate contact of the coarse bubbles 200 with the micro bubbles 300 in the ballast water 100 .
The high-pressure air from the compressor 8 may also be sent to the pressure tank 1 from the pipe 3 in whole or in part through the pipe 18 .
In the present invention, ozone remaining in the pressure tank 1 can be removed continuously. Since the pressure tank 1 is in pressurized condition, no other pump is required to transfer the ballast water 100 rid of the residual ozone to the ballast tank (not shown).
In the present invention, the time required for removing the residual ozone is extremely short since high-pressure air is sent from the aeration pipe 7 in pressurized condition. In the present invention, the residual ozone is removed in 1 to 5 minutes of processing. Therefore, the required retention time of the ballast water 100 in the pressure tank is within the range of only 1 to 5 minutes.
Measures is preferably taken to prevent shortcutting of the ballast water 100 yet to be rid of residual ozone in the pressure tank 1 in order to allow continuous removal of residual ozone in the pressure tank 1 and continuous transfer of the ballast water 100 rid of residual ozone to the ballast tank.
A device of preventing the shortcutting can be constituted by a partition plate 19 which stands from the bottom of the pressure tank 1 , as shown in FIG. 3 . The inside of the pressure tank 1 is divided into two chambers. The two chambers join each other above the partition plate 19 . The ballast water 100 is rid of residual ozone by the high-pressure air sent from the aeration pipe 7 in the one chamber, then transferred to the other chamber over the partition plate 19 . The transfer pipe 14 transfers the ballast water 100 rid of the residual ozone in the latter chamber to the ballast tank.
Furthermore, in the present invention, it is possible to adopt a discrete treatment (batch-type treatment), if necessary.
Then, another embodiment for mixing ozone in the ballast water 100 in the pipe 3 is described as follows:
FIG. 4 shows an apparatus which mixes ozone into ballast water and FIG. 5 is a cross-sectional view along line X-X in FIG. 4 .
In this embodiment, the tip of the ozone injection tube 6 is inserted into the pipe 3 . The ozone injection tube 6 jets ozone into the ballast water 100 in the pipe 3 from a nozzle 61 mounted on an U-shaped tip.
A screw-propeller 20 is installed on the upstream side of the ozone injection tube 6 in the pipe 3 for generating whirlpools. The screw-propeller 20 rotates at high rates of 3000-6000 rpm, for example, to generate high-speed whirlpools 400 in the ballast water 100 flowing in the pipe 3 .
The drive shaft 21 of the screw-propeller 20 passes through the pipe wall of the pipe 3 which bends in the shape of L. The drive shaft 21 rotates by means of a motor or an engine (not shown).
A turbulent flow generating device is installed on the downstream side of the ozone injection tube 6 in the pipe 3 . This turbulent flow generating device can be represented by the static mixer, etc. An example of it is shown in FIG. 5 . The turbulent flow generating device is constituted by a plurality of plates (six plates are shown in FIG. 5 ) or rod-shaped bodies 22 ( 22 a , 22 b , 22 c , 22 d , 22 e and 22 f ) which are arranged spaced at predetermined intervals on an imaginary spiral line 23 drawn on the inner surface of the pipe 3 .
The space L in the direction of the shaft line O of two plates or rod-shaped bodies 22 adjoining each other is related to the inside diameter D of the pipe 3 or the velocity of the ballast water 100 , etc. and is preferably within the range of 10-50 mm and more preferably 20-30 mm. The space L being beyond the said range, the turbulent flow will not occur easily.
The plates or rod-shaped bodies 22 are slightly shorter than the radius of the pipe 3 and stand upright toward the shaft line O of the pipe 3 on the inside wall surface of the pipe 3 .
The plates or rod-shaped bodies 22 are formed to have an oval cross section. The plates or rod-shaped bodies 22 are so mounted on the inside wall surface of the pipe 3 that the direction of the long axis of the oval may face to the circumference of the pipe 3 . The oval cross section of the plates or rod-shaped bodies 22 promotes shearing whirlpools 400 which rotate spirally.
Ozone jetted out from the nozzle 61 of the ozone injection tube 6 forms small bubbles and gets caught in the spiral whirlpools 400 .
The spiral whirlpools 400 involving ozone crash against the plurality of plates or rod-shaped bodies 22 and are agitated violently. As a result small bubbly ozone turns to micro bubbles and are mixed evenly in the ballast water 100 .
The plates or rod-shaped bodies 22 may be so arranged as to traverse the inside of the pipe 3 .
In addition, the plates or rod-shaped bodies 22 may be provided with a convex and a concave at their rear end for reducing resistance so that friction resistance may be reduced greatly. This will result in reducing required motor power.
In the present invention, a device for reducing ozone to be mixed in the ballast water 100 is preferably provided.
FIG. 6 shows an example of the device. Numeral 24 is a compressor which is used as an example of an air supply device. The air supplied from the compressor 24 is mixed in the ballast water flowing in the pipe 3 on the downstream side of the location where ozone is fed from the ozonizer 5 through the ozone injection tube 6 .
Numeral 25 is a micro-bubble generator. The micro-bubble generator 25 feeds ballast water mixed with air and ozone and generates micro bubbles.
The micro-bubble generating mechanism being observed, focusing only on the air out of the air and ozone fed to the ballast water, OH − on the interface with bubbles increases and charges the interface negatively. This OH − is free radical species of active oxygen and has oxidative and microbicidal functions. In this way microorganisms in the ballast water are killed. OH − is generated in large quantity when the micro-bubbles crush.
That is, in this embodiment, generated micro-bubbles show sterilization effect through interaction between electrifiability of micro-bubbles and crush of micro-bubbles. This allows reduction of the quantity of ozone to be mixed. The quantity of ozone to be mixed can be within the range of 1-20 ppm for the ballast water.
The micro-bubble generator 25 is preferably represented by a static mixer, which does not require power source.
The pressure loss of the micro-bubble generator 25 is preferably within the range of 0.2-0.3 MPa (2-3 kgf/cm 2 ).
FIG. 7 shows another example of devices which reduce the quantity of ozone to be mixed in the ballast water 100 .
In FIG. 7 , numeral 26 is a jet generating device, which is installed on the pipe 3 between the static mixer 4 and the pressure tank 1 .
The jet generating device 26 consists of a water jet nozzle 27 and an impact plate 28 , as shown in FIG. 8 .
The jet nozzle 27 has preferably a shape of having a squeezing part 271 and an expanding part 272 . The ballast water flowing in the pipe 3 with ozone injected therein is once squeezed in the squeezing part 271 and then jetted in the expanding part 272 . The jet generating device 26 generates jet in this way. The squeezing part 271 is the origin of the jet.
The impact plate 28 is formed in a smaller shape than the inside diameter of the pipe 3 , for example in quadrangle and arranged in the pipe 3 at a position where the water which has passed the expansion part 272 can crash against the impact plate 28 . A clearance 281 is formed around or above or below (or on the right or left of) the impact plate 28 to allow water to pass between the inside wall of the pipe 3 and the impact plate 28 . Numeral 29 is a reducer.
The distance between the squeezing part 271 and the impact plate 28 is set as appropriate so that eradication can be realized effectively by means of cavitation and impact.
This jet generating device 26 generates jet by means of the water jet nozzle 27 and gives a sharp pressure change to the ballast water flowing in the pipe 3 . Thus, this jet generating device 26 ensures that cavitation generates in the ballast water and, therefore, microorganisms such as plankton are destroyed and eradicated.
The ballast water is transferred from the pipe 3 to the water jet nozzle 27 by the pump 2 at the rate of 20-30 m/sec and crashes against the impact plate 28 . High pressure generated by the jet, sharp pressure change generated by negative pressure and impactive force and frictional force generated by crash against the impact plate 28 destroy pneumatophores or cell walls of microorganisms such as plankton contained in the ballast water and eradicate them. Required quantity of ozone can be decreased in this way.
The jet generating device 26 is not limited to the embodiment. For example, a plurality of water jet nozzles may be arranged face to face or at an angle to increase the cavitation effect. Besides, the surface shape of the impact plate 28 may be convex or concave to increase the cavitation effect as well.
In the present embodiment, ozone from the ozonizer 5 can be inserted into the ballast water flowing in the pipe 3 before or after it passes through the jet generating device 26 . Therefore, the jet generating device 26 may be installed between the pump 3 and the static mixer 4 in the pipe 3 .
While the present invention has been described based on the embodiment applicable to the removal of ozone remaining in the ballast water as aforementioned, the present invention is applicable to any water containing residual ozone.
It may be emphasized that the above-described embodiments, particularly any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.
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The present invention provides a method of removing ozone remaining in water by separating residual ozone which remains in water after ozone is mixed in the water and kills microorganisms in the water including the steps of storing water containing the residual ozone in a pressure tank, supplying the pressure tank with compressed air, generating coarse bubbles larger than the residual ozone existing in water in the form of micro bubbles in pressurized condition, making the residual ozone in the form of micro bubbles adhere to the coarse bubbles, separating the residual ozone from water as the coarse bubbles go up, and discharging the micro bubbles from the pressure tank.
Accordingly, the present invention provides a method of removing ozone remaining in water to remove ozone remaining in water inexpensively and efficiently.
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[0001] This invention claims benefit and priority to U.S. patent application Ser. No. 13/948,460 filed Jul. 23, 2013, which claims priority to U.S. Provisional Application No. 61/790,107 filed Mar. 15, 2013 under 35 U.S.C. 119. All benefit to the priority is claimed and is incorporated by reference.
BACKGROUND
Field of Invention
[0002] The present invention relates to a method of consuming a universal potent healing tonic. When consumed according to the method, the arthritic user will experience a large reduction in symptoms, and possible elimination of symptoms altogether, and may also alleviate general pain in the user.
[0003] Home remedies have been used for hundreds of years to alleviate the many ailments of the human body. Sometimes the best solution can be found right in your kitchen. With the elevated, and sometimes unattainable, cost of traditional health care, many people are turning to home remedies for relief. Moreover, many people prefer to use natural products to synthetic pharmaceuticals traditionally offered by physicians.
[0004] Since ancient time natural sugars such as honey, molasses, and maple syrup have been cited as a remedy for a host of ailments. Either alone, or in combination, these products have been linked to curing cancer, heart disease, arthritis, bladder infections, cholesterol, toothaches, colds, upset stomach, gas, influenza, skin infections, indigestions, enhancement of immune system, fatigue, halitosis, assist in weight loss, as well as others. Sodium bicarbonate, otherwise commonly known as baking soda, is similarly extolled for its healing properties.
[0005] Mainstream science has confirmed that tumor cells can be killed by increasing the pH in their environment. (Dr. Robert Gillies; Wayne State University School of Medicine: “Acidity generated by the tumor microenvironment drives local invasion”: Veronica Estrella, Tingan Chen, Mark Lloyd et al. Cancer Research, Published Online First Jan. 3, 2012; doi: 10.1158/008-5472. CAN-12-2796.) Grants have been given to universities and research institutions to study the effects of pH, including raising pH through sodium bicarbonate, on cancers and arthritis. Still, others believe that raising pH through the use of sodium bicarbonate can eradicate cancer due to the theory that cancer is caused by yeast infection, and the bicarbonate/honey or molasses or syrup combination works to eradicate yeast levels. (Dr. Tullio Simoncini, author of “Cancer is a Fungus”).
[0006] In combination, sodium bicarbonate and molasses, or maple syrup (hereinafter “natural sugars”) have been touted as a cure for many ailments including arthritis, cancer, indigestion, insomnia and many others. Methods and regimens for consuming this combination, however, is something of a mystery. A review of anecdotes and home remedy literature shows a large disparity in recommendations for creating a potent tonic that is safe and effective.
[0007] To treat arthritis, physicians like Dr. Parhatsthid Nabadalung from Thailand recommend taking sodium bicarbonate when the urinary pH is below 5.6. Treatment for arthritis, in one person's opinion, is one teaspoon of sodium bicarbonate in 8 ounces of water twice daily.
[0008] The average consumer is apt to be confused by the multitude of ingredient combinations, amounts to be used, and frequency of use offered by the present literature. The present method seeks to overcome these hurdles by providing and easy to use system that has resulted in the alleviation of arthritis.
[0009] Moreover, the measurement of the correct amounts of the universal potent healing tonic can be viewed as cumbersome. A commercial, user-friendly product could be available to assist the user in consuming the appropriate amount of tonic and is described herein as part of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0010] According to one aspect of the invention, the method of consuming the universal potent healing tonic consists of a regimen of consuming sodium bicarbonate and molasses in water over the course of approximately 45 days.
[0011] According to another aspect of the present invention, sodium bicarbonate is mixed with approximately 6 ounces of boiling water, then one teaspoon of molasses is immediately added and the mixture is stirred for approximately 30 seconds. The water/bicarbonate mixture is cooled to lukewarm temperature with ice cubes of standard size, and the mixture is consumed.
[0012] According to one aspect of the present invention, the method includes consumption of a multivitamin daily, one hour before breakfast.
[0013] According to yet another aspect of the present invention, the tonic is prepared and consumed twice daily. The tonic is consumed once before breakfast and one after the final evening meal. This daily rate of consumption is maintained for 15 days (days 1- 15).
[0014] According to yet another aspect of the present invention, the tonic is then prepared and consumed every evening for 15 more days (days 16 through 30).
[0015] According to another aspect of the present invention, the tonic is modified by reducing the sugar and is prepared and consumed once every other day after the evening meal for 15 additional days (days 31-45).
[0016] According to another aspect of the present invention, a supplemental preventative dosage may be taken by repeating the dosage of days 31-45.
[0017] According to yet another aspect of the invention, the method should be carried out in conjunction with the consumption of at least three 8 oz. glasses of water per day and not exceeding 16, 8 oz. glasses of water.
[0018] According to yet another aspect of the invention, a laxative may be taken while performing the method to avoid or alleviate any constipation.
[0019] According to yet another aspect of the invention, daily sugar intake should be reduced to not more than approximately 200 grams.
[0020] According to one aspect of the present invention, the method should be performed in conjunction with a healthy diet including fruits and vegetables where possible.
[0021] According to yet another aspect of the present invention, the method should be performed where the user has a daily intake of sugar not more than approximately 200 grams per day.
[0022] According to another aspect of the invention, to assist the user in performing the method, a kit containing 8 ounces of water in a microwave or heat- able material, as well as a pouch containing the appropriate amount of sodium bicarbonate and the appropriate amount of molasses could be packaged and purchased for use by the consumer.
[0023] According to yet another aspect of the invention, separate pouches of sodium bicarbonate and molasses in conjunction with a heat-able container containing 8 ounces of water could be packaged for use by a consumer.
[0024] According to one aspect of the invention, a container having markings as to the appropriate amount of sodium bicarbonate, molasses and water could be packaged for use by a consumer.
[0025] According to yet another aspect of the invention, a container having markings as to the appropriate amount of water as well as a pouch, either separate or together, with the appropriate amount of sodium bicarbonate and molasses could be packaged and provided for use by the consumer.
DETAILED DESCRIPTION
[0026] The invention described in detail herein generally relates to a system for producing and consuming a universal potent healing tonic.
[0027] A full course of using this healing tonic consists of 45 days. During this time, the user will be taking a multivitamin, such as GERITOL® as in the preferred embodiment, before breakfast. As is apparent to those in the art, other multivitamins can be used. Additionally, the user will consume at least three 8 oz. glasses of water per day, and not exceeding sixteen 8 oz. glasses of water. The user's diet should be considered healthy and include 5 servings per day of fruits and vegetables where possible. A laxative may be taken as needed by the user to avoid or alleviate constipation while executing the course. Moreover, sugar consumption should be limited to not more than 200 grams per day.
[0028] Consumption of the healing tonic occurs either before breakfast or in the evening, after the final meal of the day. The tonic is made by preparing 8 ounces of boiling water in one container. In another container, place approximately one tablespoon of sodium bicarbonate, and one teaspoon of GRANDMA′S MOLASSES®. As is apparent, other types of molasses may be substituted. Moreover, other natural sugars may be substituted without departing from the scope of the invention. Next, approximately 6 ounces of boiling water is poured into the container with sodium bicarbonate and stirred to dissolve, then molasses is added, and the mixture is gently stirred for approximately 30 seconds or until the contents are in solution.
[0029] Alternatively, 6 ounces of boiling water may be mixed with one tablespoon of sodium bicarbonate and the molasses is added immediately thereafter. The mixture is then gently stirred for approximately 30 seconds.
[0030] The mixture is then cooled to lukewarm temperature, approximately 90-100° Fahrenheit. This can be accomplished with the addition of ice (approximately two standard ice cubes having the dimensions of approximately one inch in height, 1 and 2/8 inches in width, and 1 and ¾ inches in length). Once the mixture is lukewarm, it is consumed.
[0031] The mixture is prepared and consumed twice daily, in the morning before breakfast, and in the evening after the last meal, for fifteen consecutive days (days 1-15). Then, the mixture is prepared and consumed every day, in the evening, for the next fifteen days (days 16-30).
[0032] Next, the tonic is made by preparing 8 ounces of boiling water in one container. In another container, place approximately one tablespoon of sodium bicarbonate, and one half teaspoon of GRANDMA′S MOLASSES®. As is apparent, other types of molasses may be substituted.. Next, approximately 6 ounces of boiling water is poured into the container with sodium bicarbonate, which is dissolved, and then molasses is added, and the mixture is gently stirred for approximately 30 seconds or until the contents are in solution.
[0033] Alternatively, 6 ounces of boiling water may be mixed with one tablespoon of sodium bicarbonate and the molasses is added immediately thereafter. The mixture is then gently stirred for approximately 30 seconds.
[0034] The mixture is then cooled to lukewarm temperature, approximately 90-100° Fahrenheit. This can be accomplished with the addition of ice (approximately two standard ice cubes). Once the mixture is lukewarm, it is consumed. The mixture is prepared and consumed once every other day, in the evening, for fifteen days (days 31-45). A supplemental preventative sustaining dosage may be taken by repeating the regimen for days 31-45 and consuming the dosage at least once every six months.
[0035] Additionally, the mixture may be purchased by the consumer as a kit as is part of the present invention. This kit would include a sealed container of 8 ounces of water. The container is capable of being heated to the boiling temperature of water without degradation. The kit also includes packets of one tablespoon of sodium bicarbonate, one teaspoon, and one half teaspoon of GRANDMA′S MOLASSES®, or other natural sugars, and in sufficient quantities to complete all aspects of the 45 day course of treatment. The packets may be singular (i.e., only sodium bicarbonate), or may have the capability of housing both ingredients without mixing.
[0036] Moreover, another embodiment of the kit consisting of a container with markings as to the appropriate amount of water to boil as well as a packets of one tablespoon of sodium bicarbonate, one teaspoon, or one half teaspoon of molasses. The packets may be singular (i.e., only sodium bicarbonate), or may have the capability of housing both ingredients without mixing.
[0037] While the invention has been shown and described herein with reference to particular embodiments, it is to be understood that the various additions, substitutions, or modifications of form, structure, arrangement, proportions, materials, and components and otherwise, used in the practice and which are particularly adapted to specific environments and operative requirements, may be made to the described embodiments without departing from the spirit and scope of the present invention. Accordingly, it should be understood that the embodiments disclosed herein are merely illustrative of the principles of the invention. Various other modifications may be made by those skilled in the art, which will embody the principles of the invention and fall within the spirit and the scope thereof.
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The present invention relates to a method of consuming a universal potent healing tonic. When consumed according to the method, the arthritic user will experience a large reduction in symptoms, and possible elimination of symptoms altogether, and may also alleviate general pain in the user.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 60/680,194, filed May 12, 2005, and which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to magneto-rheological couplings.
BACKGROUND OF THE INVENTION
[0003] It is known to provide a power steering system for a vehicle such as a motor vehicle to assist a driver in steering the motor vehicle. Typically, the power steering system is of a hydraulic type. The hydraulic power steering system employs an engine driven hydraulic power steering pump for generating pressurized fluid, which is subsequently communicated to a hydraulic steering gear of the motor vehicle. Since the power steering pump is driven directly by the engine using a belt or other method, its rotational speed is determined by that of the engine and it operates continuously as long as the engine is running, resulting in continuous circulation of the hydraulic fluid through the steering gear. In addition, the power steering pump must provide the required flow and pressure for the worst case engine speed, which is typically near idle engine speed, under static steering conditions.
[0004] More recently, electro-hydraulic power steering systems have been used to provide an on-demand hydraulic pressure using an electric motor to drive the hydraulic power steering pump. An example of such an electro-hydraulic power steering system incorporates a hydraulic power steering pump driven by a brushless direct current electric motor controlled by a pulse width modulated inverter. Also in use are electrically driven steering systems, which are operable to assist in steering the vehicle using purely electro-mechanical system components.
[0005] Other devices, such as the one described in commonly assigned U.S. Pat. No. 6,920,753, provide a means to directly control the speed of the power steering pump by using a magneto-rheological clutch or coupling (MRC) disposed between the accessory drive belt and the power steering pump. The MRC provides a continuously variable speed by controlling the torque transmitted to the power steering pump. The MRC can be part of the pump assembly, a separate unit, an integral part of the pump pulley, etc. The viscosity of the magneto-rheological fluid, or MRF, contained within the MRC can be controlled by exposing the MRF to a magnetic flux field. As the viscosity of the MRF is increased, the torque transfer properties of the fluid are increased. Since a conventional electronic control unit (ECU) can control the intensity of the magnetic field, the duty cycle of the power steering pump may be varied independent of engine speed.
[0006] The MRF contained within the MRC includes magnetically permeable particles, which tend to be highly abrasive and harmful to bearings. Although bearings within the MRC are typically sealed units, it is preferred that the MRF fluid should not be allowed to contact these seals.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention provides a magneto-rheological clutch or coupling (MRC) having improved sealing provisions such that the magneto-rheological fluid, or MRF, is substantially precluded from contacting bearings within the MRC.
[0008] A magneto-rheological coupling, or MRC, is provided having an input assembly coaxially disposed and spaced from an output member such that a working gap is defined between the input assembly and the output member. A magneto-rheological fluid is at least partially disposed within the working gap. The magneto-rheological fluid exhibits a variable viscosity characteristic in the presence of a variable magnetic field. Also provided is at least one bearing operable to rotatably mount the input assembly with respect to the output member. Additionally, at least one annular lip is provided with respect to at least one of the input assembly and the output member. The annular lip is operable to direct the flow of the magneto-rheological fluid away from the bearing.
[0009] At least one labyrinth seal may be provided that is operable to substantially restrict the flow of the magneto-rheological fluid from contacting the bearing. Additionally, an annular bushing may be disposed within the labyrinth seal. The annular bushing is operable to reduce the clearances of the at least one labyrinth seal by providing a predetermined amount of sacrificial material which is removed through wear during the operation of the MRC.
[0010] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0011] FIG. 1 is a cross sectional side elevational view of a magneto-rheological fluid clutch or coupling (MRC) of the present invention, shown at rest and adapted to operate a vehicular power steering pump.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring now to FIG. 1 , there is shown a magneto-rheological fluid clutch or coupling (MRC), generally indicated at 10 , having an input assembly 12 rotatably mounted with respect to a drive shaft 14 of a hydraulic power steering pump 16 and adapted to be driven by an engine accessory drive belt 18 . Those skilled in the art will recognize additional methods of providing drive to the input assembly 12 , such as a gear drive. The MRC 10 is adapted to provide variable rotational speed to the drive shaft 14 of the power steering pump 16 . The rotational speed of the drive shaft 14 may be varied from a zero rotational speed condition to a maximum of the rotational speed of the input assembly 12 . The input assembly 12 includes a generally cylindrical magnetically permeable ring 20 coaxially located with respect to, and radially spaced from, the drive shaft 14 . Secured to the magnetically permeable ring 20 is a non-magnetic first cover member 22 that extends radially inward toward a central axis of the driveshaft 14 . The magnetically permeable ring 20 pilots a non-magnetic second cover member 24 , having a generally L-shaped partial cross section, to the first cover member 22 . The axially extending portion of the second cover member 24 is secured to the first cover member 22 via a plurality of fasteners 26 . A pulley member 28 is secured to the second cover member 24 via a plurality of fasteners 30 . The outer circumferential surface of the pulley member 28 has a plurality of radially extending ribs 32 defined thereon. The ribs 32 are operable to provide a surface upon which the accessory drive belt 18 may frictionally engage.
[0013] The second cover member 24 is secured, via a plurality of fasteners 34 , to a magnetically permeable core 36 disposed coaxially with respect to, and spaced from, the drive shaft 14 . The core 36 has an annular channel 38 with a wire coil 40 disposed therein. An outer surface 42 of the core 36 forms an inner boundary, while an inner surface 44 of the magnetically permeable ring 20 forms an outer boundary of a working gap 46 . The wire coil 40 is operable to provide a magnetic flux field 48 when energized with electrical current. The core 36 has a low magnetically permeable portion 50 formed centrally thereon. The portion 50 is filled with a high-temperature resistant epoxy or other suitable non-magnetic material, and operates to shape the magnetic flux field 48 of the core 36 and ensures proper distribution through the working gap 46 . Additionally, the interstices of the wire coil 40 within the channel 38 may be filled with a high-temperature resistant epoxy similar to that of the portion 50 . A seal 52 , such as an elastomeric o-ring, is disposed between the second cover member 24 and the core 36 . Likewise, a seal 54 , such as an elastomeric o-ring, is disposed between the second cover member 24 and the first cover member 22 . The seals 52 and 54 operate to prevent leakage of magneto-rheological fluid (MRF) 56 from the MRC 10 .
[0014] The MRF 56 contains magnetizable particles such as carbonyl iron spheroids of about half (½) to twenty five (25) microns in diameter dispersed in a viscous fluid such as silicon oil or synthetic hydrocarbon oil. The MRF 56 may also contain surfactants, flow modifiers, lubricants, viscosity enhancers, and other additives.
[0015] A slip ring assembly 58 is mounted with respect to the MRC 10 . The slip ring assembly 58 includes spring-biased brushes 59 and 60 , which are operable to communicate electrical current to and from a first ring 62 and a second ring 64 , respectively. The first and second rings 62 and 64 are secured to the core 36 and are in electrical communication with the coil 30 though conductors 66 and 66 ′, respectively. A carrier assembly 68 is provided to secure the brushes 59 and 60 with respect to a power steering pump housing 70 . The brushes 59 and 60 are in electrical communication with the electrical system of the vehicle and are provided with operating signals from a conventional electronic control module (ECU), not shown. The ECU preferably includes a programmable digital computer that contains stored data for establishing the operational criteria of the MRC 10 during operation of the vehicle.
[0016] An inner rotor or output member 72 includes a non-magnetic drive portion 74 secured to the drive shaft 14 through an interference fit or other method. A conventional fastener 76 , such as a hex head bolt, is employed to fixedly retain the output member 72 in relation to the drive shaft 14 . A non-magnetic hub portion 78 extends generally radially from the drive portion 74 , while a substantially cylindrical magnetically permeable drum portion 80 extends generally axially from the hub portion 78 . The magnetically permeable drum portion 80 bisects the working gap 46 , thereby creating a first working gap 46 A and a second working gap 46 B. The drum portion 80 has a first surface 82 and a second surface 84 in contact with MRF 56 contained within the working gaps 46 A and 46 B, respectively. The drum portion 80 has a low magnetic permeability portion 86 to ensure that the magnetic flux field 48 of the core 36 is properly distributed through the working gaps 46 A and 46 B. The core 36 , the magnetically permeable ring 20 , the drum portion 80 , and the MRF 56 disposed within the working gaps 46 A and 46 B form the magnetic circuitry of the MRC 10 . The dual working gap geometry of the MRC 10 is suited to reduce the axial length of the MRC 10 , thereby minimizing the cantilevered loading on the driveshaft 14 . The first surface 82 and second surface 84 may have a roughness to reduce the surface sliding friction of the MRF 56 , thereby increasing the shear forces of the MRF 56 on the drum portion 80 .
[0017] The first cover member 22 and the core 36 cooperate to form a storage cavity 88 for the MRF 56 that recedes from the working gap 46 when the MRC 10 is idle. The first cover member 22 has an inner cavity 90 that is a portion of the storage cavity 88 . The inner cavity 90 has a wall 92 that diverges toward the working gap 46 . Centrifugal forces acting on the MRF 56 in the inner cavity 90 promote the return of the MRF 56 to the working gap 46 during operation of the MRC 10 .
[0018] The first cover member 22 and the core 66 are rotatably supported on the output member 74 by bearings 94 and 96 , respectively. The bearings 94 and 96 are preferably ball-type or roller-type bearings. Labyrinth seals 98 and 100 have tight radial clearances that cooperate with the high viscosity of the MRF 56 to substantially prevent the MRF 56 from reaching the roller bearings 94 and 96 , respectively. Disposed within the labyrinth seals 98 and 100 are annular bushings 102 and 104 , respectively. The bushings 102 and 104 have a generally C-shaped cross section that closely matches the dimensions of the labyrinth seals 98 and 100 , respectively. The bushings 102 and 104 are preferably made from a low friction material such as a carbon based material, or may be made from polytetrafluoroethylene (PTFE) or other suitable polymer. The bushings 102 and 104 operate to reduce the need for precise machining and assembly tolerances of the labyrinth seals 98 and 100 by providing a predetermined amount of sacrificial material, which will be removed through wear during the operation of the MRC 10 .
[0019] A generally radially extending annular lip 106 is provided on the first cover member 22 and a partially radially and partially axially extending annular lip 108 is provided on the hub portion 78 forming pockets 110 and 112 , respectively. The pocket 110 is formed at the inner radial boundary of the storage cavity 88 . The pockets 110 and 112 operate to capture and redirect MRF 56 that may recede from the working gap 46 B; thereby, preventing MRF 56 from migrating to the labyrinth seal 98 when the MRC 10 is at rest or idle. By redirecting the MRF 56 away from the labyrinth seal 98 , the likelihood of exposing the bearing 94 to MRF 56 is minimized. Additionally, a generally radially extending annular lip 114 is provided on the hub portion 78 forming a pocket 116 thereon. The pocket 116 is operable to capture MRF 56 that may recede from the working gap 46 A to prevent MRF 56 from migrating to the labyrinth seal 100 and possibly the bearing 96 when the MRC 10 is idle. The pockets 110 and 112 operate to extend the life of the MRC 10 by preventing incursion of MRF 56 within the bearings 94 . Likewise, pocket 116 operates to extend the life of the MRC 10 by preventing incursion of MRF 56 within the bearings 96 . While the bearings 94 and 96 are sealed units, it is preferred to maintain the MRF 56 out of contact with the bearing seals. Those skilled in the art will recognize that the annular lip 106 may be separate piece attached to the first cover member and may be formed from various non-magnetic materials such as rubbers or polymers. Likewise, the annular lips 108 and 114 may be separate pieces attached to the first cover member and may be formed from various non-magnetic materials such as rubbers or polymers.
[0020] A toothed wheel 118 is secured to the drive shaft 14 and cooperates with a sensor 120 to provide the ECU, not shown, with a rotational speed value of the power steering pump 16 . The preferred sensor 120 is a Hall Effect sensor; however, those skilled in the art will recognize that other types of sensors may be employed.
[0021] During operation, the coil 40 is selectively and variably energized with electrical current, thereby creating the magnetic flux field 48 that passes through the MRF 56 contained within the working gap 46 . As is well known, when the MRF 56 is exposed to the magnetic flux field 48 , the magnetizable particles therein will align with the magnetic flux field 48 and increase the viscosity of the MRF 56 . The increased viscosity will therefore increase the shear strength of the MRF 56 resulting in torque transfer from the input assembly 12 to the output member 72 causing rotation of the drive shaft 14 , which operates the power steering pump 16 . The torque transfer ability or characteristic of the MRF 56 varies with the intensity of the magnetic flux field 48 .
[0022] Although the description has detailed the MRC 10 application within a power steering system, those skilled in the art will recognize that the present invention may be incorporated into other clutches employing MRF, such as fan clutches. Additionally, while the foregoing description describes an MRC 10 with a rotating coil 40 , the invention herein described may be used in a stationary coil-type MRC. While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A magneto-rheological coupling (MRC) is provided having an input assembly operable to receive a torque input and an output member operable to selectively transmit torque to a driveshaft. A magneto-rheological fluid, or MRF, having a variable viscosity in response to a magnetic flux field is operable to vary the torque transmitted from the input assembly to the output member. At least one annular lip forming a magneto-rheological fluid retention pocket is provided on at least one of the input assembly and the output member of the MRC. The annular lip is operable to direct MRF away from a roller bearing, thereby reducing the likelihood of MRF fluid incursion within the roller bearing. Additionally, a labyrinth seal may be employed to provide additional protection to the bearing. The labyrinth seal may have an annular bushing disposed therein to reduce the clearances of the labyrinth seal.
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BACKGROUND OF THE INVENTION
The present invention relates to a case for a portable equipment such as transmitter for key-less entry system of a vehicle.
There has been known a key-less entry system as a remotely controllable auxiliary means for a vehicle, which is provided with a portable equipment such as transmitter. The portable equipment is accommodated in a case having a case body generally colored with black. Further, in an event where color changing is effected to the case entirely or partially, the coloring is effected with resin or two-color formation. This coloring method has been considered to be undesirable in an impact in design, and especially, in the case of two-color formation, a fusing (fused) portion, at which the colors are different, provides a weak strength, thus being inconvenient.
Moreover, although as is well seen in a portable phone, for example, a UV coating of metallic color to a surface of the case has been considered, a portable equipment such as for keyless entry system is often engaged with a key holder or key ring together with keys formed of metal. In such case, there is a fear that the surface of the portable equipment may be injured by such metal keys and the durability of the portable equipment may be made worse.
Furthermore, in a case of a portable equipment of a type using an electric wave transmission, if the case body is coated with metallic material, the metallic coat film formed on the surface of the case body provides a considerably large thickness, and because of the metal contained in this coat film, permeability or transmission of the electric wave may be deteriorated thereby.
Furthermore, there is known a printing technology, in which a printing of an opaque, not transparent, ink is made on t transparent resin sheet. In such technology, when a light is projected, a pattern of the printing is made visible through the transparent sheet. There is known a coaster to which such printing technology is applied.
SUMMARY OF THE INVENTION
The present invention was conceived in consideration of the defects or inconveniences encountered in the prior art mentioned above and an object of the present is therefore to provide a case of a portable equipment having a surface capable of being decorated and being hard to be injured or damaged.
Another object of the present invention is to provide a case for a portable equipment having a surface coated with metallic color film having a high electric wave permeability.
These and other objects can be achieved according to the present invention by providing, in one aspect, a case of a portable equipment for communication to an external system comprising:
a body portion; and
an operation portion acting as a function member,
wherein at least a portion of the body portion and the operation portion is provided with: a decorative film having a resin film having transparency and a print layer printed on a back surf ace of the resin film in a predetermined pattern; and a base member resin portion formed on a back surface of the decorative film so as to contact the print layer, and the decorative layer has a front surface exposed as a most outside surface of the case.
According to the invention of this aspect, the decorative film having a transparent base film, to the back surface of which a printed layer having a predetermined print pattern is formed, is disposed to at least a portion of the case so that the front surface of the decorative film is disposed to the most outside surface portion of the case. According to this structure, the printed layer can be protected between the transparent film and the resin base member, so that the predetermined printed pattern of the printed layer can be free from external damage by, for example, a metallic key.
In addition, the case is applicable to another portable equipment having different function only by changing the pattern to be printed on the print layer.
In preferred embodiments of the above aspect, there are some advantageous features will be provided.
That is, a transparent protection film may be formed to the front surface of the resin film. In an arrangement in which this transparent protection film is disposed most outside the case, the transparency of the resin film can be preferably maintained.
The print layer may be formed of a material containing a metallic component to thereby provide a metallic feeling to the outside surface of the case through the transparent resin film.
The case body has an inner hollow structure in which an antenna element for transmission may be disposed. Since, in the present invention, the print layer has a thin thickness, the electric wave transmission is less reduced even though the print layer contains the metallic component, and thus, the lowering of the transmitting ability can be minimally suppressed.
The operation portion includes knob pieces for inputting operation modes and the knob pieces have front surfaces covered by the decorative film, thus being capable of protecting the knob member by the decorative film.
The print layer of the decorative film has a portion which covers the knob pieces and to which patterns representing contents of functions are printed. Therefore, the functions of the knob pieces can be easily recognized by a user.
The front surface of the decorative film may be provided with a marked or stamped portion formed as a protruded or recessed portion, which can enhance the touch feeling of a user.
The body portion and the operation portion may be covered integrally by the decorative film. According to this structure, the intrusion of water component or dust and the like into the case body can be prevented. The integral formation of the body portion and the operation portion of the case can contribute to cost reduction.
On the other hand, the body portion and the operation portion may be covered by independent decorative films, respectively. According to this structure, the decorative film may be formed for each of the operation portions having different functions.
The decorative film has an end portion intruding into the base member resin portion to thereby prevent the decorative film from being peeled off from the base member of the case.
The body portion may be formed from two half portions so as to have an inner hollow portion when assembled and the operation portion is formed to one of the two half portions. According to this structure, the case can be easily manufactured with a simple forming device.
In another aspect, the present invention provides a case of a portable equipment for communication to an external system comprising:
a body portion having an inner hollow structure in which an antenna element is disposed for communication to the external system; and
an operation portion acting as a function member having a surface on which knob pieces for inputting operation modes are formed,
wherein at least a portion of the body portion and the operation portion is provided with: a decorative film having a resin film having a front surface on which a transparent protection film is formed and a print layer printed on a back surface of the resin film in a predetermined pattern, the print layer containing a metallic component; and a base member resin portion formed on a back surface of the decorative film so as to contact the print layer, and the transparent protection film is disposed as a most outside surface of the case.
The nature and further characteristic features of the present invention will be made more clear from the following descriptions with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a longitudinal sectional view of a portable equipment as a key-less entry system according to one embodiment of the present invention;
FIG. 2 is a developed perspective view of the portable equipment of FIG. 1 ;
FIG. 3 includes FIG. 3A being a plan view showing a decoration film effected to an upper cover of the portable equipment of FIG. 1 , FIG. 3B being a side or sectional view of FIG. 1 and FIG. 3C being an enlarged sectional view of a portion of FIG. 3B ;
FIG. 4 includes FIG. 4A being a plan view showing a decorative film applied to an upper cover of the portable equipment of FIG. 3 after the forming working and FIG. 4B being a sectional view taken along the line IVB—IVB in FIG. 4A ;
FIG. 5 includes FIG. 5A being a plan view showing an upper cover of the portable equipment of FIG. 1 after the film in-mold formation, FIG. 5B being a sectional view taken along the line VB—VB in FIG. 5A and FIG. 5C being an enlarged sectional view of an end portion of the upper cover of FIG. 5B ;
FIG. 6 is a plan view of a decorative film of a lower cover of the case of the portable equipment of FIG. 1 ;
FIG. 7 includes FIG. 7A being a plan view showing a decorative film applied to the lower cover of the portable equipment of FIG. 6 after the forming working and FIG. 7B being a sectional view taken along the line VIIB—VIIB in FIG. 7A ;
FIG. 8 includes FIG. 8A being a plan view showing the lower cover of the portable equipment of FIG. 1 after the film in-mold formation, and FIG. 8B being a sectional view taken along the line VIIIB—VIIIB in FIG. 8A ;
FIG. 9 includes FIGS. 9A and 9B both showing a plan view of a decorative film of a knob member after the forming working of the embodiment of FIG. 1 ;
FIG. 10 is a plan view of a decorative film of an upper cover of a case of a portable equipment according to another embodiment of the present invention;
FIG. 11 includes FIG. 11A being a plan view showing a decorative film effected to the upper cover of the portable equipment of according to the embodiment of FIG. 10 after the forming working and FIG. 11B being a sectional view taken along the line XIB—XIB in FIG. 11A ; and
FIG. 12 includes FIG. 12A being a plan view showing the upper cover of the portable equipment of FIG. 10 after the film in-mold formation, FIG. 12B being a sectional view taken along the line XIIB—XIIB in FIG. 12A and FIG. 12C being a sectional view taken along the line XIIB—XIIB in FIG. 12A in which a knob printing portion is flexed in shape of recess.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Preferred embodiments of the present invention will be described hereunder with reference to the accompanying drawings. It is to be noted that, in the following descriptions, terms of “upper”, “lower” and the like are used with reference to the illustrated state.
First Embodiment
The first embodiment of the present invention will be first described with reference to FIGS. 1 and 2 .
A portable equipment 1 comprises upper and lower case covers 2 and 9 which constitute an outer case and elements disposed in an inner space defined by the upper and lower case covers 8 and 9 when assembled into the case. As best illustrated in FIG. 2 , the elements include: a knob member 3 ; a water-proof cover 4 ; a circuit board 5 provided with switching elements 51 a to 51 c on its upper surface and an antenna element 6 on its lower surface; a cushion member 7 disposed between the antenna element 6 and the lower case cover 9 for damping a shock to the antenna element 6 ; a cell terminal 81 ; a cell case 82 ; a button cell 83 ; and a spacer 80 supporting the circuit board 5 from the lower case cover 9 , in substantially the described order. Further, other circuit elements disposed on the lower surface of the circuit board are omitted from the illustration in FIG. 1 .
Referring to FIG. 2 , the knob member 3 includes knob pieces 31 a , 31 b and 31 c each formed in shape of protrusion from a decorative film 100 , which will be mentioned hereinlater in detail, and the switching elements 51 a , 51 b and 51 c formed on the upper surface of the circuit board 5 are arranged below the respective knob pieces 31 a , 31 b and 31 c through the water-proof cover 4 made of silicone resin. Further., the knob piece 31 c is provided, at its upper surface, with a projection piece 32 so as to be easily distinctive from the other knob pieces 31 a and 31 b.
Hereunder, with reference to FIGS. 1 to 9 , the formation method of the upper case cover 2 , the lower case cover 9 and the knob member 3 with the decorative film 100 will be described.
As shown in FIG. 3 ( FIGS. 3A to 3C ), the decorative film 100 is made of polycarbonate PC, having light transmittancy, and has thickness t of 0.3 mm (t=0.03 mm). More specifically, the front surface of the transparent resin film 101 (corresponding to the most outside surface of the portable equipment 1 ) is entirely coated with a transparent protective film 102 of hard-coat agent, and a print (printed or printing) layer 103 is formed on the rear (back) surface of the resin film 101 (corresponding to a surface of the upper case cover 2 contacting a base member BP formed of resin for the upper case cover 2 ).
The print layer 103 comprises two-color printing portions including a metallic printing portion 110 formed of an ink containing metallic component such as aluminium powder and a body color printing portion 120 formed of an ink having a body case color (black in this embodiment). These metallic printing portion 110 and body color portion 120 constitute a body portion of the upper case cover 2 .
The metallic printing portion 110 is formed with an LED (light emitting diode) portion 111 on which any printing is not applied in order to transmit the emitting light of the LED, not shown, indicating an operation mode of the portable equipment 1 . On the other hand, the body color printing portion 120 is formed with holes 21 a to 21 c , for the knob member 3 as function (operation) member, corresponding to non-printed portions 121 a to 121 c and a non-printed portion 121 d corresponding to a keeling hole 20 .
Incidentally, in order to provide a metallic feeling to the case body, it is generally required to apply the coating so that the coated film provides a thickness of about 30 μm, and in such coated film, the metallic component is contained, which adversely affects on the transmission performance of the electric wave, thus being inconvenient.
On the contrary, in the printed layer 103 of the described embodiment of the present invention, the metallic color printing portion 110 and the body color printing portion 120 each merely has a thickness of about 3 μm. Accordingly, the metallic feeling can be provided by the less amount of the metallic component of the metallic printing portion 110 and, in addition, an adverse influence on the electric wave transmission performance of the antenna element 6 in the portable equipment 1 can be minimally suppressed.
In the next step, the decorative film 100 shown in FIG. 3A is subjected to a forming working by using a die, not shown. Further, FIG. 4A shows a plan view of the decorative film 100 after the forming working.
In the forming working, an end portion of the decorative film 100 is cut, and a three-dimensional formation along the surface shape of the upper case cover 2 is performed. The forming of the knob holes 21 a to 21 c and the keeling hole 20 are also performed. In the three-dimensional formation of the decorative film 100 , the projection 32 to the knob piece 31 c will be also formed.
The decorative film 100 subjected to the forming working is set to a molding machine, not shown. Then, the resin base member formed of polycarbonate (PC) is injected on the side of the printing layer 103 by the film in-mold method to thereby form the upper case cover 2 .
FIG. 5A shows a plan view of the upper cover 2 formed by this film in-mold method, FIG. 5B is a sectional view taken along the line VB—VB in FIG. 5A and FIG. 5C is an enlarged sectional view showing an end portion M of the decorative film 100 .
At the time of the in-mold formation, the resin material for the base member BP moves and turns so as to catch the end portion M of the decorative film 100 in a manner that this end portion M enters into the base member BP. Hence, the end portion M of the decorative film 100 is not exposed externally, so that the decorative film 100 can be prevented from being peeled off from the resin base member BP.
Furthermore, the material of the resin film 100 of the decorative film 100 is the same as the material of the resin base member BP, that is, both being formed of PC (polycarbonate). Accordingly, both the materials have the same linear expansion coefficient, so that both the resin film 101 of the decorative film 100 is not peeled off from the resin base member BP after the in-mold formation.
The lower case cover 9 of the portable equipment 1 according to the described first embodiment will be manufactured substantially the same manner or steps as those mentioned above with reference to the upper case cover 2 .
Referring to FIGS. 6 to 8 , reference numeral 200 denotes a decorative film of the lower case cover 9 . A resin film 201 is formed of a polycarbonate resin and has a front surface on which a transparent protective film 102 of hard-coat agent is formed and a back (rear) surface on which a black body color printing portion 220 is formed. The resin film 201 is then subjected to the forming working for cutting the end portion, forming the keeling hole and carrying the three-dimensional molding. The formed decorative film 210 is molded through the in-mold process with the polycarbonate resin base member BP to thereby form the lower case cover 9 .
Further, a mark, not shown, showing a maker, a kind of car, or like may be formed on the surface of the lower case cover 9 of the portable equipment 1 by forming, through for example stamping process, protrusion or recess on the surface of the decorative film 210 at the time of forming working.
On the other hand, as to the knob member 3 , decorative films 310 , 320 decorated for the knob member (knob pieces) is formed through the forming working substantially identical to that for the decorative film 100 or 200 .
With reference to FIG. 9 , FIG. 9A shows one example of the knob member of a portable equipment for a one-box car, in which patterns respectively showing the knob piece 31 c for a door-lock switch, the knob piece 31 b for a door-unlock switch and the knob piece 31 a for a slide-door opening switch are multi-color printed, as switch pattern print portions, on the back surface of the decorative film 310 .
On the other hand, FIG. 9B shows one example of the knob member of a portable equipment for a sedan-type vehicle, in which a pattern showing a knob piece 311 a for a trunk-unlock switch is multi-color printed on the back surface of a decorative film 320 in place of the slide-door opening switch.
Thus, according to the first embodiment of the present invention, it is possible to manufacture or provide a case of the potable equipment capable of being utilized for cars of different types or kinds, or different functions merely by changing the print (printing or printed) pattern.
Further, since the back surface of the knob member 3 contacts the switches 51 a to 51 c through the water-proof cover 4 at the switching time, it may be desired to apply the hard-coat agent on the surface of the printed layer 103 of the knob member 3 so as to protect the layer 103 .
As mentioned hereinabove, according to the first embodiment of the present invention, the upper case cover 2 , the lower case cover 9 and the knob member 3 can be formed by utilizing or using the decorative films 100 , 200 , 310 , 320 , which are subjected to the three-dimensional molding. Each of these decorative films is formed from the transparent polycarbonate resin film 101 which has the front surface on which the transparent protective film of the hard-coat agent is formed and has the back surface on which the printed layer 103 provided with the metallic print portion 110 ( 210 ) and the body color print portion 120 ( 220 ) or switch pattern printed portion 31 a ( 31 b , 31 c , 311 a ) are formed. Thereafter, the upper and lower case covers 2 and 9 are formed by the film in-mold method, i.e., injection-molding the resin BP for the base member on the printed layer side of the back (rear) surface of the decorative film 100 ( 200 ) which has been subjected to the forming working.
Accordingly, the transparent protective film 102 as the surface of the decorative film 100 ( 200 ) is exposed on the most outside surface of the portable equipment. Moreover, since the printed layer 103 is sandwiched between the resin film 101 and the resin base member BP on the back surface of the decorative film 100 ( 200 ), it becomes possible to prevent the printed layer 103 from being damaged by a metallic member such as key of an automobile, and in addition, the printed layer 103 can be seen from the outside of the portable equipment case through the transparent protective film 102 and the transparent resin film 101 .
Still furthermore, it is possible to make thin the thickness of the printed layer 103 containing the metallic component of an amount leas than the coat film thickness, so that the metallic feeling can be given to the case of the portable equipment 1 by the formation of the metallic printed portion 110 ( 210 ), and in addition, an adverse influence to the electric wave transmission performance of the antenna element 6 disposed inside the portable equipment 1 can be made minimal.
Thus, according to the first embodiment of the present invention, there can be provided a portable equipment case decorated by the metallic color coat and body color coat having good durability and having less influence to the electric wave transmission performance of the integrated antenna element.
Second Embodiment
In the first embodiment mentioned above, the upper case cover 2 and the lower case cover 9 are formed as independent members, whereas in this second embodiment, both the case covers are formed integrally, and this second embodiment differs from the first embodiment in a structure that two switch knobs are integrally formed to the upper case cover 2 . According to this viewpoint, only the upper case cover 2 is explained hereunder through its manufacturing process with reference to FIGS. 10 to 12 .
FIG. 10 is a plan view of a decorative film 400 according to this second embodiment, in which the resin film 101 made of polycarbonate (PC) and having a thickness t=0.3 mm and the transparent protection film 102 made of UV hard coat agent are the same as those in the first embodiment.
The print (printed or printing) layer 103 includes, as like as in the first embodiment, an metallic printed portion 410 , as a body portion, of ink including metallic component and a body color print portion 420 printed with black color and also is provided with knob printed portions 421 b , 421 c printed with brown as a control (function or operation) portion. As like as the first embodiment, the metallic printed portion 410 includes an LED portion 411 , at which no printing is made, and the body color printed portion 420 is formed with a non-printed portion 421 d for a keeling hole.
The thus formed decorative film 400 is subjected to a forming working by means of die, not shown, as like as the first embodiment. FIG. 11A is a plan view of the decorative film 400 after the forming working and FIG. 11B is a sectional view thereof taken along the line XIB—XIB.
As shown in FIG. 11B , in the forming working in this second embodiment, the keeling hole 20 is formed and the knob printed portions 421 b , 421 c are formed in shape of protrusion without being formed as a hole or like. Moreover, a projection 432 is formed to the surface of the knob printed portion 421 c for knob discrimination.
The decorative film 400 after the forming working is set to a molding machine, not shown, as like as the first embodiment, and subjected to the injection molding by the film in-mold method so as to inject the base material resin (i.e. resin base member) BP of polycarbonate to the side of the printed layer 103 . Further, FIG. 12A is a plan view of the upper case cover 2 formed by the film in-mold method, and with reference to FIG. 12C , it will be seen that the knob printed portions 421 b and 421 c are deformable in a concave shape (recess) by a force of operating the knobs.
According to the portable equipment case according to the second embodiment of the present invention, as like as the first embodiment, the transparent protection film 102 as the front surface of the protective film 400 is exposed to the most outside surface of the case of the portable equipment 1 , and the printed layer 103 is sandwiched, on the rear surface of the decorative film 400 , between the resin film 101 and the base material resin BP. Accordingly, the surface of the printed layer 103 can be prevented from being damaged by a metallic article, and on the other hand, the printed layer 103 can be observed from the outside thereof through the transparent protection film 102 and the transparent resin film 101 .
In addition, the thickness of the metallic layer 103 containing the metallic component can be made thin even in comparison with a coat film. Therefore, the metallic feeling can be given to the case of the portable equipment 1 by the metallic printed portions 410 and 210 , and moreover, an adverse influence to be given to the electric wave performance of the antenna element 6 disposed inside the portable equipment 1 can be made minimal.
Still furthermore, in the second embodiment of the present invention, the knob printed portions 421 b and 421 c as function portions covering the switches 51 b and 51 c of the circuit board 5 are formed integrally with the decorative film 400 forming the body color printed portion 420 and the metallic printed portion 410 . Accordingly, there exists substantially no gap between the function portion and the body portion of the case surface, thus improving the water-proof ability, dust-proof ability and the like to the case of the portable equipment.
Other Embodiments
Further, it is to be noted that the present invention is not limited to the described embodiments and many other changes and modifications may be made without departing from the scopes of the appended claims.
For example, in the described embodiments, the transparent polycarbonate (PC) film is utilized for the resin film 101 as the base of the decorative film. In an alternation, however, a transparent polyetylenetelephthalate (PET) may be used. Further, the resin film thickness may be selected in a range of 0.18 to 0.5 mm to thereby easily form or mold the decorative film at the forming working.
In addition, there is also used, for the resin film 101 , a translucent film other than the transparent one to obtain mette metallic feeling.
As the resin base member or base material resin BP, there may be utilized, other than the PC, a mixture resin of the PC and ABS resin. In such case, it is desired, in order to enhance the moldability in the film in-mold process, that the linear expansion coefficients of the resin film and the base material resin BP of the decorative film accord or substantially accord with each other.
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A case of a portable equipment for communication to an external system comprises a body portion and an operation portion acting as a function member. At least a portion of the case is provided with a decorative film having a resin film having transparency and a print layer printed on a back surface of the resin film in a predetermined pattern, and a resin base member formed on a back surface of the decorative film so as to contact the print layer. The front surface of the decorative layer is exposed as a most outside surface of the case.
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CROSS REFERENCES
This application relates to and claims priority from Japanese Patent Application No. 2009-245915, filed on Oct. 26, 2009, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
The present invention relates to a power factor correction device and its control method and, for example, can be suitably applied to a switching power supply unit of an AC/DC converter or the like.
Conventionally, as a power supply unit, broadly used is a type with a power factor collection circuit (hereinafter referred to as the “PFC (Power Factor Correction) circuit”) configured from a choke coil, a switching element and a capacitor disposed at the subsequent stage of a full wave rectification circuit for outputting an absolute value of a commercial AC (refer to Japanese Patent Application Publication No. 2007-288892).
This type of PFC circuit generates a triangle wavelike coil current in the choke coil by subjecting the switching element to ON/OFF operation at a high frequency, performs rectification smoothing to the coil current with a capacitor, corrects the input current to a sine wave of the same phase as the input voltage, and thereby outputs the same.
SUMMARY
Meanwhile, as an operation mode of the foregoing PFC circuit, there is a critical mode of controlling the ON/OFF of the switching element so that the coil current becomes “0” ampere for each repetition period of the ON/OFF operation of the switching element (this is hereinafter referred to as the “switching cycle”).
When the PFC circuit is operated in the critical mode, since a zero current detection circuit for detecting the timing that the coil current becomes “0” ampere is required, the circuit size must be enlarged by just that much, and there were problems in terms of high cost.
Moreover, the precision of the zero current detection circuit differs based on each product, and it is difficult to accurately detecting the timing that the coil current becomes “0” ampere. If it is not possible to perform control so that the coil current accurately becomes “0” ampere for each switching cycle; the operation of the PFC circuit becomes unstable, and, consequently, there is a problem in that the output of the power supply unit becomes unstable.
The present invention was devised in view of the foregoing points. Thus, an object of this invention is to propose a power factor correction device and its control method capable of obtaining a stable output as the output of a power supply unit while simplifying and miniaturizing the configuration.
In order to achieve the foregoing object, the present invention provides a power factor correction device including a coil and a switching element, and a control unit for controlling ON/OFF of the switching element. This power factor correction device comprises an input voltage detection unit for detecting an input voltage of the power factor correction device, an output voltage detection unit for detecting an output voltage, and a coil current detection unit for detecting a coil current that is generated in the coil pursuant to the ON/OFF operation of the switching element. The control unit predicts an OFF time of the switching element of each switching cycle for controlling the switching element in a critical mode based on a voltage value of the input voltage detected with the input voltage detection unit, a voltage value of the output voltage detected with the output voltage detection unit, and a current value of the coil current detected with the coil current detection unit, and controls the ON/OFF of the switching element based on the prediction result.
Moreover, the present invention additionally provides a control method of a power factor correction device including a coil and a switching element, and a control unit for controlling ON/OFF of the switching element. The power factor correction device comprises an input voltage detection unit for detecting an input voltage of the power factor correction device, an output voltage detection unit for detecting an output voltage, and a coil current detection unit for detecting a coil current that is generated in the coil pursuant to the ON/OFF operation of the switching element. The control method comprises a first step of the control unit predicting an OFF time of the switching element of each switching cycle for controlling the switching element in a critical mode based on a voltage value of the input voltage detected with the input voltage detection unit, a voltage value of the output voltage detected with the output voltage detection unit, and a current value of the coil current detected with the coil current detection unit, and a second step of the control unit controlling the ON/OFF of the switching element based on the prediction result.
According to the present invention, since it is possible to perform power factor correction control with a critical mode without requiring a zero current detection circuit for detecting the zero point of the coil current during the switching, the power factor correction device can be downsized and, consequently, the configuration of the overall power supply unit using the power factor correction device can be simplified and miniaturized.
Moreover, according to the present invention, since the power factor correction device can be operated stably, a stable output can be obtained since the oscillation of the output voltage of the power factor correction device can be suppressed.
Consequently, the present invention is able to realize a power factor correction device and its control method capable of obtaining a stable output as the output of a power supply unit while simplifying and miniaturizing the configuration.
DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing a schematic configuration of the power supply unit according to an embodiment of the present invention;
FIG. 2 is a waveform diagram showing the voltage waveform and current waveform in the power supply unit according to an embodiment of the present invention;
FIG. 3 is a circuit diagram showing a configuration of the PFC circuit according to the first embodiment;
FIG. 4 is a waveform diagram explaining the principle of the PFC control according to the first embodiment;
FIG. 5 is a block diagram showing a configuration of the control unit according to the first embodiment;
FIG. 6 is a block diagram showing a configuration of the PMW generation unit according to the first embodiment;
FIG. 7 is a waveform diagram explaining the operation of the PFC circuit according to the first embodiment;
FIG. 8 is a circuit diagram showing a configuration of the PFC circuit according to the second embodiment;
FIG. 9 is a waveform diagram explaining the operation of the PFC circuit according to the second embodiment;
FIG. 10 is a waveform diagram explaining the principle of the PFC control according to the second embodiment;
FIG. 11 is a waveform diagram explaining the principle of the PFC control according to the second embodiment;
FIG. 12 is a block diagram showing a configuration of the control unit according to the second embodiment;
FIG. 13 is a block diagram showing a configuration of the PMW generation unit according to the second embodiment; and
FIG. 14 is a circuit diagram explaining another embodiment.
DETAILED DESCRIPTION
An embodiment of the present invention is now explained with reference to the attached drawings.
(1) First Embodiment
(1-1) Configuration of Power Supply Unit of Present Embodiment
FIG. 1 shows the overall power supply unit 1 according to this embodiment. The power supply unit 1 comprises an EMI (ElectroMagnetic Interference) filter unit 3 , a full wave rectification unit 4 , a PFC unit 5 , and a DC/DC conversion unit 6 .
The EMI filter unit 3 eliminates noise from the AC source voltage V 1 and AC source current I 1 as shown in FIG. 2(A) which are provided from a commercial AC source 2 . Moreover, the full wave rectification unit 4 is configured, for example, from a diode bridge, performs full wave rectification to the AC source voltage V 1 and AC source current I 1 , from which noise has been eliminated, which are provided from the EMI filter unit 3 , and outputs the thus obtained input voltage V 2 and input current I 2 as shown in FIG. 2(B) to the PFC unit 5 .
The PFC unit 5 controls the input cycle of the input current I 2 throughout the entire interval so that the average value I LAVE of the input current I 2 provided from the full wave rectification unit 4 becomes a sine wave as shown in FIG. 2(C) , and corrects the phase shifting between the input voltage V 2 and the input current I 2 . Moreover, the PFC unit 5 smoothes the input voltage V 2 and input current I 2 in which the phase shifting has been corrected, and outputs the thus obtained output voltage V 4 and output current I 4 as shown in FIG. 2(D) to the DC/DC conversion unit 6 .
The DC/DC conversion unit 6 converts the output voltage V 4 provided from the PFC unit 5 into an intended DC voltage, and outputs the thus obtained DC voltage of a predetermined level to the power supply destination (load).
(1-2) Configuration of PFC Unit
Here, the PFC unit 5 is configured from a PFC circuit 10 and a control unit 11 as shown in FIG. 3 .
The PFC circuit 10 comprises a choke coil L 1 and a reflux output diode D 1 which are connected serially between a positive-side output terminal of the full wave rectification unit 4 and a positive-side input terminal of the DC/DC conversion unit 6 , and a switching element Q 1 is connected between a connection midpoint of the choke coil L 1 and the reflux output diode D 1 , and a ground line 15 for connecting a negative-side output terminal of the full wave rectification unit 4 and a negative-side input terminal of the DC/DC conversion unit 6 .
The switching element Q 1 is configured, for example, from a MOS-FET (Metal-Oxide-Semiconductor Field-Effect Transistor), a drain is connected to the connection midpoint of the choke coil L 1 and the reflux output diode D 1 , and a source is connected to the ground line 15 . Moreover, a gate of the switching element Q 1 is connected to the control unit 11 .
Moreover, an output smoothing capacitor C 1 is connected between the connection midpoint of the reflux output diode D 1 and the positive-side input terminal of the DC/DC conversion unit 6 , and the ground line 15 .
In addition, a current detector 12 for detecting the coil current I L that is generated in the choke coil L 1 based on the ON/OFF operation of the switching element Q 1 is provided between the positive-side output terminal of the full wave rectification unit 4 and the choke coil L 1 . The current detector 12 sends the detected coil current I L as a coil current detection signal S 1 to the control unit 11 . As the current detector, for example, used may be a shunt resistor, a hall element or the like.
In addition, a first partial pressure resistor 13 configured from first and second partial pressure resistors R 1 , R 2 is connected between the positive-side output terminal and the negative-side output terminal of the full wave rectification unit 4 . The first partial pressure resistor 13 divides the pulsating voltage V 2 output from the full wave rectification unit 4 at a ratio according to the respective resistance values of the first and second partial pressure resistors R 1 , R 2 , and outputs the thus obtained first partial pressure voltage V 10 to the control unit 11 .
Meanwhile, a second partial pressure resistor 14 configured from third and fourth partial pressure resistors R 3 , R 4 is connected between the connection midpoint of the reflux output diode D 1 and the output smoothing capacitor C 1 , and the ground line 15 . The second partial pressure resistor 14 divides the output voltage V 4 output from the PFC unit 5 to the DC/DC conversion unit 6 according to a ratio of the respective resistance values of the third and fourth partial pressure resistors R 3 , R 4 , and outputs the thus obtained second partial pressure voltage V 11 to the control unit 11 .
The control unit 11 generates a PWM (Pulse Width Modulation) signal S 2 as shown in FIG. 7(B) as a drive signal of the switching element Q 1 based on the coil current detection signal S 1 provided from the current detector 12 , the first partial pressure voltage V 10 provided from the first partial pressure resistor 13 , and the second partial pressure voltage V 11 provided from the second partial pressure resistor 14 , and applies the generated PWM signal S 2 to the gate of the switching element Q 1 .
In the foregoing configuration, in the PFC unit 5 , the input voltage V 2 provided from the full wave rectification unit 4 is applied to the choke coil L 1 of the PFC circuit 10 , and, here, in the PFC circuit 10 , the switching element Q 1 is subject to the ON/OFF operation based on the PWM signal S 2 provided from the control unit 11 , and the choke coil L 1 is generated in the coil current I L in a critical mode as shown in FIG. 2(C) pursuant to the ON/OFF operation of the switching element Q 1 .
Subsequently, the coil current I L and the choke coil terminal voltage (drain-source voltage of Q 1 ) are subject to smoothing processing in the reflux output diode D 1 and the output smoothing capacitor C 1 , and thereafter output to the DC/DC conversion unit 6 .
(1-3) Configuration of Control Unit
The configuration of the control unit 11 of the PFC unit 5 is now explained. Prior to such explanation, the principle of the PFC control that is executed by the control unit 11 is foremost explained.
(1-3-1) Principle of PFC Control of Present Embodiment
In FIG. 4 , FIG. 4(A) shows the coil current I L that is generated in the choke coil L 1 , and FIG. 4(B) shows the sampling timing in the sampling processing to be executed by the control unit 11 for performing digital control. Specifically, FIG. 4(B) illustrates a case of sampling the coil current I L at a timing in which half of the ON time of the switching element Q 1 has elapsed for each sampling period.
Here, if the PFC control is stable (steady), the (n+1)-th ON time T on [n+1] of the switching element Q 1 can be assumed to be approximately the same as the ON time T on [n] of the previous sampling, and the following formula is realized.
[Formula 1]
T on [n+ 1]= T on [n] (1)
Moreover, since the switching frequency for the PFC control is extremely high in comparison to the frequency of the commercial AC, the following formula is realized between the n-th switching cycle T S [n] of the switching element Q 1 and the (n+1)-th switching cycle T S [n+1].
[Formula 2]
T S [n+ 1 ]≅T S [n] (2)
Accordingly, based on Formula (1) and Formula (2) above, the following formula is realized between the n-th OFF time T off [n] of the switching element Q 1 and the (n+1)-th OFF time T off [n+1].
[Formula 3]
T off [n+ 1 ]≅T off [n] (3)
Moreover, in a state where the PFC unit 5 is operating stably in the critical mode, as also evident from FIG. 4 , the following formula is realized.
[
Formula
4
]
I
L
[
n
]
+
m
1
T
on
[
n
]
2
-
m
2
T
off
[
n
]
=
0
(
4
)
Note that, in Formula (4) above, m 1 represents rate of increase (inclination at the ON time T on [n] of the waveform of FIG. 4 ) of the coil current I L at the n-th ON time T on [n], and m 2 represents the rate of decrease (portion in which “−” is excluded from the inclination at the OFF time T off [n] of the waveform of FIG. 4 ) of the coil current I L at the operation time (this is hereinafter referred to as the “OFF time”) T off [n] of the n-th OFF operation. Moreover, I L [n] represents the actual value of the coil current I L at the n-th sampling timing.
If Formula (4) is solved regarding T off [n], the following formula is obtained.
[
Formula
5
]
T
off
[
n
]
=
1
m
2
I
L
[
n
]
+
m
1
2
m
2
T
on
[
n
]
(
5
)
In addition, as described above with reference to Formula (3), the n-th OFF time T off [n] and the (n+1)-th OFF time T off [n+1] are considered to be approximately the same. Thus, the (n+1)-th OFF time T off [n+1] can be represented with the following formula by using Formula (5).
[
Formula
6
]
T
off
[
n
+
1
]
=
1
m
2
I
L
[
n
]
+
m
1
2
m
2
T
on
[
n
]
(
6
)
Accordingly, since the (n+1)-th switching cycle T S [n+1] is obtained by adding the n-th ON time T on [n] to Formula (6) above, it can be represented with the following formula.
[
Formula
7
]
T
s
[
n
+
1
]
≅
1
m
2
I
L
[
n
]
+
(
1
+
m
1
2
m
2
)
T
on
[
n
]
(
7
)
Meanwhile, the rate of increase m 1 of the coil current I L at the n-th ON time T on [n] described above can be represented with the following formula.
[
Formula
8
]
m
1
=
V
^
in
sin
ω
t
L
=
V
in
[
n
]
L
(
8
)
Moreover, the rate of decrease m 2 of the coil current I L at the n-th OFF time T off [n] can be represented with the following formula.
[
Formula
9
]
m
2
=
V
out
-
V
^
in
sin
ω
t
L
=
V
out
[
n
]
-
V
in
[
n
]
L
(
9
)
However, in Formula (8) and Formula (9), V in with “^” shows the actual peak value of the input voltage V 2 that is provided from the full wave rectification unit 4 to the PFC unit 5 , V in [n] shows the actual value of the input voltage V 2 at the n-th sampling timing, L shows the inductance value of the choke coil L 1 , and V out [n] shows the actual value at the n-th sampling timing of the output voltage V 4 that is output from the PFC unit 5 to the DC/DC conversion unit 6 , respectively.
Based on Formula (6), Formula (8) and Formula (9) above, the OFF time T off [n+1] during the (n+1)-th OFF operation can be predicted with the following formula.
[
Formula
10
]
T
off
[
n
+
1
]
=
L
V
out
[
n
]
-
V
in
[
n
]
·
I
L
[
n
]
+
V
in
[
n
]
2
(
V
out
[
n
]
-
V
in
[
n
]
)
·
T
on
[
n
]
(
10
)
The (n+1)-th switching cycle T S [n+1] in the foregoing case can be represented with the following formula based on Formula (7) to Formula (9).
[
Formula
11
]
T
s
[
n
+
1
]
=
L
V
out
[
n
]
-
V
in
[
n
]
I
L
[
n
]
+
[
1
+
V
in
[
n
]
2
(
V
out
[
n
]
-
V
in
[
n
]
)
]
·
T
on
[
n
]
(
11
)
Accordingly, by controlling the OFF time of the switching element Q 1 so that the switching cycle satisfies Formula (11) (that is, by controlling the OFF time of the switching element Q 1 to satisfy Formula (10)), the PFC control can be performed in a critical mode without having to use a zero voltage detection circuit.
(1-3-2) Specific Configuration of Control Unit
FIG. 5 shows the specific configuration of the control unit 11 that was created in consideration of the foregoing points. As evident from FIG. 5 , the control unit 11 is configured from an analog/digital conversion unit 20 , an OFF time prediction unit 21 , an ON time control unit 22 , an adding circuit 23 and a PWM generation unit 24 .
The analog/digital conversion unit 20 samples (analog/digital converts) the first partial pressure voltage V 10 provided from the first partial pressure resistor 13 ( FIG. 3 ) and the coil current detection signal S 1 provided from the current detector 12 ( FIG. 3 ), respectively, at a timing in which half of the ON time has elapsed, based on a notification from the carrier generation unit 33 ( FIG. 6 ) of the PWM generation unit 24 as described later.
The analog/digital conversion unit 20 sends the first partial pressure voltage value W 10 as the sampled value of the first partial pressure voltage V 10 and the coil current detection value VS 1 as the sampled value of the coil current detection signal S 1 , which were obtained with the foregoing sampling, to the OFF time prediction unit 21 , respectively.
Moreover, the analog/digital conversion unit 20 samples the second partial pressure voltage V 11 provided from the second partial pressure resistor 14 ( FIG. 3 ) at the same timing as the first partial pressure voltage V 10 and the coil current detection signal S 1 , and sends the thus obtained second partial pressure voltage value W 11 as the sampled value of the second partial pressure voltage V 11 to the OFF time prediction unit 21 and the ON time control unit 22 .
The ON time control unit 22 is configured from a reference value output circuit 30 , a subtraction circuit 31 and a PI control unit 32 , and inputs the second partial pressure voltage value VV 11 provided from the analog/digital conversion unit 20 to the negative-side input port of the subtraction circuit 31 .
Here, the reference voltage value VR to be taken by the second partial pressure voltage value VV 11 when a default voltage is output from the PFC unit 5 is provided from the reference value output circuit 30 to the positive-side input port of the subtraction circuit 31 . Consequently, the subtraction circuit 31 subtracts the second partial pressure voltage value VV 11 from the reference voltage value VR, and sends the obtained value as an error value VE to the PI control unit 32 .
The PI control unit 32 calculates the target value of the ON time in the subsequent sampling period according to the PI control based on the error value VE that is provided from the subtraction circuit 31 , and sends this as the ON time command value T on — com to the OFF time prediction unit 21 , one signal input port of the adding circuit 23 , and the PWM generation unit 24 , respectively.
The OFF time prediction unit 21 predicts, using foregoing Formula (10), the OFF time for the critical mode control in the subsequent sampling period based on the first partial pressure voltage value VV 10 , the coil current detection value VS 1 and the second partial pressure voltage value W 11 provided from the analog/digital conversion unit 20 , and the ON time command value T on — com provided from the ON time control unit 22 .
Specifically, the OFF time prediction unit 21 calculates the voltage value (corresponds to V in [n] of Formula (10)) of the input voltage V 2 that is provided from the full wave rectification unit 4 ( FIG. 1 ) to the PFC unit 5 based on the first partial pressure voltage value W 10 , and additionally calculates the current value (corresponds to I L [n] of Formula (10)) of the coil current I L based on the coil current detection value VS 1 . Moreover, the OFF time prediction unit 21 calculates the voltage value (corresponds to V out [n] of Formula (10)) of the output voltage V 4 that is output from the PFC unit 5 to the DC/DC conversion unit 6 ( FIG. 1 ) based on the second partial pressure voltage value W 11 .
The OFF time prediction unit 21 thereby calculates the OFF time (corresponds to T off [n+1] of Formula (10)) of the subsequent sampling period according to Formula (10) based on the thus obtained voltage value of the input voltage V 2 , the coil current value I L , the voltage value of the output voltage V 4 , and the ON time command value T on — com (corresponds to T on [n] of Formula (10)) provided from the ON time control unit 22 . Note that the inductance L of the choke coil L 1 is provided to the OFF time prediction unit 21 in advance, and the OFF time prediction unit 21 stores and retains the inductance L in an internal memory not shown.
Moreover, the OFF time prediction unit 21 outputs the thus obtained prediction value of the OFF time in the subsequent sampling period as the OFF time command value T off — com to the other signal input port of the adding circuit 23 .
The adding circuit 23 calculates the subsequent sampling period that is provided in foregoing Formula (11) by adding the ON time command value T on — com provided from the ON time control unit 22 and the OFF time command value T off — com provided from the OFF time prediction unit 21 , and sends the calculation result as the sampling period command value V m to the PWM generation unit 24 .
The PWM generation unit 24 is configured from a carrier generation unit 33 , a comparing unit 34 and an output unit 35 as shown in FIG. 6 . The carrier generation unit 33 generates, as shown in FIG. 7(C) , a triangle wavelike carrier wave CA with a peak value V mp according to the sampling period command value V m provided from the adding circuit 23 , and sequentially sends the level value of the carrier wave CA to the comparing unit 34 in the internal clock cycle.
Note that, in the case of this embodiment, the carrier generation unit 33 is configured from a counter. The carrier generation unit 33 starts counting from zero, and, while counting up in the internal clock cycle, sequentially sends the count value to the comparing unit 34 . Moreover, when the count value reaches the peak value V mp , the carrier generation unit 33 thereafter sequentially sends the count value to the comparing unit 34 while counting down. As a result of continuously repeating the foregoing count processing, the carrier generation unit 33 sequentially and continuously generates the carrier wave CA with the peak value V mp according to the sampling period command value V m provided from the adding circuit 23 .
Moreover, the carrier generation unit 33 notifies the timing that the level value (count value) of the carrier wave CA becomes zero (timing of the arrow shown in FIG. 7(D) ) to the analog/digital conversion unit 20 . Consequently, the analog/digital conversion unit 20 samples the first partial pressure voltage V 10 , the coil current detection signal S 1 and the second partial pressure voltage V 11 at the notified timing.
The comparing unit 34 compares the size of the level value of the carrier wave CA provided from the carrier generation unit 33 in the internal clock cycle and the ON time command value T on — com provided from the ON time control unit 22 ( FIG. 5 ), and sends the comparative result to the output unit 35 .
The output unit 35 subsequently generates a PWM signal S 2 as shown in FIG. 7(B) which rises to a high level during the period that the ON time command value T on — com is higher than the level value of the carrier wave CA and which falls to a low level during the period that the ON time command value T on — com is lower than the level value of the carrier wave CA based on the comparative result of the comparing unit 34 , and sends the generated PWM signal S 2 to the gate of the switching element Q 1 .
Consequently, the switching element Q 1 is subject to the ON/OFF operation based on the PWM signal S 2 , and thereby generates the triangle wavelike coil current I L as shown in FIG. 7(A) in the choke coil L 1 .
(1-3-3) Relation of Internal Clock of Control Unit and Peak Value V mp of Carrier Wave
The relation of the internal block of the control unit and the peak value V mp of the carrier wave is now explained.
When considering that the portions of the respective triangle shapes of the carrier wave shown in FIG. 7(C) are all isosceles triangles and that the carrier generation unit 33 ( FIG. 6 ) is a counter which counts up or counts down in the internal clock cycle CLK, the peak value V mp of the carrier wave in the n-th sampling period T S [n] can be represented with the following formula.
[
Formula
12
]
V
mp
[
n
]
=
CLK
·
T
s
[
n
]
2
(
12
)
Note that, in Formula (12), CLK represents the internal clock (for example, 150 MHz) of the control unit.
Moreover, the relation of the ON time command value T on — com [n] at the n-th sampling period that is output from the ON time control unit 22 and the ON time T on [n] at such n-th sampling period can be represented with the following formula upon referring to FIG. 7(C) .
[
Formula
13
]
T
on
_
com
[
n
]
=
CLK
·
T
on
[
n
]
2
(
13
)
Accordingly, in the case of this embodiment, the peak value V mp [n+1] of the carrier wave in the (n+1)-th sampling period T S [n+1] can be represented with the following formula by using Formula (11) to Formula (13).
[
Formula
14
]
V
mp
[
n
+
1
]
=
CLK
·
T
s
[
n
+
1
]
2
=
CLK
·
L
2
(
V
out
[
n
]
-
V
in
[
n
]
)
I
L
[
n
]
+
(
1
+
V
in
[
n
]
2
(
V
out
[
n
]
-
V
in
[
n
]
)
)
·
T
on
_
com
[
n
]
(
14
)
(1-4) Effect of Present Embodiment
As described above, with the power supply unit 1 according to this embodiment, the OFF time of the switching element Q 1 in the subsequently sampling period in the case of performing the PFC control in the critical mode is predicted based on the pulsating voltage (input voltage V 2 ) to the PFC unit 5 in the previous sampling period, the smoothing voltage (output voltage V 4 ) from the PFC unit 5 , the coil current I L , and the ON time of the switching element Q 1 , and the ON/OFF control of the switching element Q 1 is performed based on the prediction result. Thus, the PFC control can be performed in the critical mode without having to use a zero current detection circuit for detecting the zero point of the coil current I L . The circuit size of the PFC unit 5 can thereby be downsized and, consequently, the configuration of the overall power supply unit 1 can be simplified and miniaturized.
Moreover, with the power supply unit 1 according to this embodiment, since the critical mode control can be performed with accuracy based on the foregoing method, the PFC unit 5 can be operated stably. Consequently, the output voltage oscillation or output ripple of the PFC unit 5 can be suppressed, and a stable output can be obtained as the output of the power supply unit 1 .
(2) Second Embodiment
(2-1) Configuration of PFC Circuit of Present Embodiment
FIG. 8 , which uses the same reference numerals for the portions corresponding to FIG. 1 , shows a PFC unit 40 according to the second embodiment that is applied to the power supply unit 1 of FIG. 1 in substitute for the PFC unit 5 according to the first embodiment. The PFC unit 40 differs from the PFC unit 5 according to the first embodiment in that a dual interleave system is adopted as the PFC control system.
Specifically, the PFC unit 40 according to this embodiment is configured from a PFC circuit 41 and a control unit 42 .
The PFC circuit 41 comprises a master-side choke coil L 10M and a master-side reflux output diode D 10M which are connected serially between the positive-side output terminal of the full wave rectification unit 4 and the positive-side input terminal of the DC/DC conversion unit 6 . Moreover, a master-side switching element Q 10M is connected between a connection midpoint of the master-side choke coil L 10M and the master-side reflux output diode D 10M , and the ground line 15 .
The master-side switching element Q 10M is configured, for example, as with the switching element Q 1 of the first embodiment, from a MOS-FET, a drain is connected to the connection midpoint of the master-side choke coil L 10M and the master-side rectification output diode D 10M , and a source is connected to the ground line 15 . Moreover, a gate of the master-side switching element Q 10M is connected to the control unit 42 .
In addition, a master-side current detector 12 M for detecting the coil current I LM that is generated in the master-side choke coil L 10M based on the ON/OFF operation of the master-side switching element Q 10M is provided between the positive-side output terminal of the full wave rectification unit 4 and the master-side choke coil L 10M . The master-side current detector 12 M sends the detected coil current I LM as the master-side coil current detection signal S 10M to the control unit 42 .
Meanwhile, the PFC circuit 41 is provided with a slave-side choke coil L 10S and a slave-side reflux output diode D 10S , which are connected serially, in parallel with the master-side choke coil L 10M and the master-side reflux output diode D 10M , and a slave-side switching element Q 10S is connected between the connection midpoint of the slave-side choke coil L 10S and the slave-side rectification output diode D 10S , and the ground line 15 .
The slave-side switching element Q 10S is configured, for example, as with the master-side switching element Q 10M , from a MOS-FET, a drain is connected to the connection midpoint of the slave-side choke coil L 10S and the slave-side reflux output diode D 10S , and a source is connected to the ground line 15 . Moreover, a gate of the slave-side switching element Q 10S is connected to the control unit 42 .
In addition, a slave-side current detector 12 S for detecting the coil current I LS that is generated in the slave-side choke coil L 10S based on the ON/OFF operation of the slave-side switching element Q 10S is provided between the positive-side output terminal of the full wave rectification unit 4 and the slave-side choke coil L 10S . The slave-side current detector 12 S sends the detected coil current I LS as the slave-side coil current detection signal S 10S to the control unit 42 .
The control unit 42 generates a master-side PWM signal S 11M as shown in FIG. 9(C) and a slave-side PWM signal S 11S as shown in FIG. 9(D) in which the phase has shifted 180 degrees in relation to the master-side PWM signal S 11M based on the master-side coil current detection signal S 10M and the slave-side coil current detection signal S 10S which are respectively provided from the master-side current detector 12 M and the slave-side current detector 12 S, the first partial pressure voltage V 10 provided from the first partial pressure resistor 13 , and the second partial pressure voltage V 11 provided from the second partial pressure resistor 14 , applies the master-side PWM signal S 11M to the gate of the master-side switching element Q 10M , and applies the slave-side PWM signal S 11M to the gate of the slave-side switching element Q 10S .
In the foregoing configuration, in the PFC unit 40 , the input voltage V 2 provided from the full wave rectification unit 4 is applied to the master-side choke coil L 10M and the slave-side choke coil L 10S of the PFC circuit 41 , respectively.
Here, the master-side switching element Q 10M is subject to the ON/OFF operation based on the master-side PWM signal S 11M provided from the control unit 42 , and the master-side coil current I LM of the critical mode as shown in FIG. 9(A) is generated in the master-side choke coil L 10M pursuant to the ON/OFF operation of the master-side switching element Q 10M . Similarly, here, the slave-side switching element Q 10S is subject to the ON/OFF operation based on the slave-side PWM signal S 11S that is provided from the control unit 42 , and the slave-side coil current I LS of the critical mode as shown in FIG. 9(B) is generated in the slave-side choke coil L 10S pursuant to the ON/OFF operation of the slave-side switching element Q 10S .
The master-side coil current I LM and the slave-side coil current I LS are subsequently rectified in the corresponding master-side reflux output diode D 10M or the slave-side reflux output diode D 10S and thereafter synthesized, and the thus obtained rectification coil signal is smoothed in the output smoothing capacitor C 1 and output to the DC/DC conversion unit 6 .
(2-2) Configuration of Control Unit
(2-2-1) Principle of PFC Control of Present Embodiment
Meanwhile, in the PFC control according to the foregoing interleave system, it is necessary to cause the current distribution of the master-side and the slave-side to be equal. In other words, as shown in FIG. 10(A) , the phase difference between the master-side coil current I LM generated in the master-side choke coil L 10M and the slave-side coil current I LS generated in the slave-side choke coil L 10S must be accurately 180 degrees. Note that the arrow of FIG. 10(B) shows the timing of sampling that is executed in the control unit 42 in order to perform digital control.
Nevertheless, due to differences in the characteristics between the respective parts of the master-side (choke coil, switching element and the like) and the corresponding parts of the slave-side, there are cases where the phase difference between the master-side coil current I LM and the slave-side coil current I LS does not accurately become 180 degrees. In the foregoing case, the current ratio of the master-side and the slave-side will collapse and stress of the parts will be applied to either the master-side or the slave-side, and, in a worst case scenario, the control will become unstable.
Here, FIG. 11(A) shows an example where the phase difference between the master-side coil current I LM generated in the master-side choke coil L 10M and the slave-side coil current I LS generated in the slave-side choke coil L 10S deviates from 180 degrees. Moreover, FIG. 11(B) shows the timing of the sampling that is executed in the control unit 42 for performing digital control.
In FIG. 11(A) , the following formula is hypothesized with the rate of increase (inclination of the corresponding straight line of FIG. 11 ) of the master-side coil current I LM in the period that the master-side coil current I LM increases as m 1 — ILM (refer to FIG. 10 ), and the rate of increase (inclination of the corresponding straight line of FIG. 11 ) of the slave-side coil current I LS in the period that the slave-side coil current I LS increases as m 1 — ILS (refer to FIG. 10 ).
[Formula 15]
m 1 — ILM ≅m 1 — ILS =m 1 (15)
Moreover, in FIG. 11(A) , the following formula is hypothesized with the rate of decrease (inclination of the corresponding straight line of FIG. 11 ) of the master-side coil current I LM in the period that the master-side coil current I LM decreases as −m 2 — ILM (refer to FIG. 10 ), and the rate of decrease (inclination of the corresponding straight line of FIG. 11 ) of the slave-side coil current I LS in the period that the slave-side coil current I LS decreases as −m 2 — ILS (refer to FIG. 10 ).
[Formula 16]
m 2 — ILM ≅m 2 — ILS =m 2 (16)
In addition, upon referring to FIG. 11(A) , the following formula is realized.
[Formula 17]
|− m 2 ·ΔT on [n]|+m 1 ·ΔT on [n]=ΔI L [n] (17)
Note that, in Formula (17), ΔT on [n] shows the temporal shift from the correct timing of the ON time T on [n] of the slave-side coil current I LS in the case of FIG. 11(A) . Moreover, ΔI L [n] shows the level difference between the master-side coil current I LM and the slave-side coil current I LS at the n-th sampling timing (arrow of FIG. 11(B) ) in the case of FIG. 11(A) .
Here, upon solving Formula (17) above regarding temporal shift ΔT on [n], the following formula is realized.
[
Formula
18
]
Δ
T
on
[
n
]
=
Δ
I
L
[
n
]
m
2
+
m
1
(
18
)
Formula (18) can be modified as the following formula based on Formula (8) and Formula (9) above.
[
Formula
19
]
Δ
T
on
[
n
]
=
Δ
I
L
[
n
]
m
2
+
m
1
=
L
V
out
·
(
I
LS
[
n
]
-
I
LM
[
n
]
)
(
19
)
In Formula (19), I LM [n] shows the value of the master-side coil current I LM at the n-th sampling timing (arrow of FIG. 11 (B)), and I LS [n] shows the value of the slave-side coil current I LS at the n-th sampling timing.
Accordingly, as a result of adding the temporal shift ΔT on [n] represented with Formula (19) to the slave-side ON time command value, it is possible to obtain the slave-side ON time command value (hereinafter referred to as the “slave-side ON time command value”) T on — com,S in which the phase difference between the master-side coil current I LM and the slave-side coil current I LS has been corrected to be accurately 180 degrees. Note that the slave-side ON time command value T on — com,S can be represented with the following formula with the sampling period designated value as V m , and the master-side ON time command value (hereinafter referred to as the “master-side ON time command value”) as T on — com,M .
[Formula 20]
T on — com,S [n]=V m [n]−T on — com,M [n]+ΔT on [n− 1] (20)
(2-2-2) Configuration of Control Unit
FIG. 12 , which uses the same reference numerals for the portions corresponding to FIG. 5 , shows the configuration of the control unit 42 according to the second embodiment that was configured in consideration of the foregoing points. The control unit 42 comprises, as with the control unit 11 ( FIG. 5 ) according to the first embodiment, an analog/digital conversion unit 20 , an OFF time prediction unit 21 , an ON time control unit 22 , an adding circuit 23 and a PWM generation unit 54 . Moreover, the control unit 42 according to this embodiment comprises, in addition to the foregoing configuration, a slave-side ON time correction unit 51 , a slave-side ON time arithmetic unit 52 and an adding circuit 53 .
The analog/digital conversion unit 20 analog-digital converts the first partial pressure voltage V 10 provided from the first partial pressure resistor 13 ( FIG. 8 ) and the master-side coil current detection signal S 10M provided from the master-side current detector 12 M ( FIG. 8 ), respectively, based on a notification that is provided from the carrier generation unit 33 ( FIG. 13 ) of the PWM generation unit 54 as described later.
The analog/digital conversion unit 20 sends the first partial pressure voltage value VV 10 as the sampled value of the first partial pressure voltage V 10 obtained with the foregoing sampling to the OFF time prediction unit 21 , and sends the master-side coil current detection value VS 10M as the sampled value of the master-side coil current detection signal S 10M to the OFF time prediction unit 21 and the slave-side ON time correction unit 51 .
Moreover, the analog/digital conversion unit 20 samples the second partial pressure voltage V 11 provided from the second partial pressure resistor 14 ( FIG. 8 ) at the same timing as the first partial pressure voltage V 10 and the master-side coil current detection signal S 10M , and sends the thus obtained second partial pressure voltage value VV 11 as the sampled value of the second partial pressure voltage V 11 to the OFF time prediction unit 21 and the ON time control unit 22 .
In addition, the analog/digital conversion unit 20 analog/digital converts the slave-side coil current detection signal S 10S provided from the slave-side current detector 12 S ( FIG. 8 ), and sends the thus obtained slave-side coil current detection value VS 10S to the slave-side ON time correction unit 51 .
The ON time control unit 22 , as with the first embodiment, calculates the target value of the ON time of the master-side in the subsequent sampling period, and outputs this as the master-side ON time command value T on — com,M to the OFF time prediction unit 50 , one signal input port of the adding circuit 23 , the PWM generation unit 54 and the slave-side ON time arithmetic unit 52 , respectively.
The OFF time prediction unit 21 predicts, using foregoing Formula (10), the OFF time of the master-side for performing the critical mode control in the subsequent sampling period based on the first partial pressure voltage value W 10 , the master-side coil current detection value VS 10M and the second partial pressure voltage value VV 11 provided from the analog/digital conversion unit 20 , and the master-side ON time command value T on — com,M provided from the ON time control unit 22 . The OFF time prediction unit 50 thereafter outputs the thus obtained prediction value of the OFF time of the master-side in the subsequent sampling period as the master-side OFF time command value T off — com,M to the other signal input port of the adding circuit 23 .
The adding circuit 23 calculates the sampling period provided in Formula (11) by adding the master-side ON time command value T on — com,M provided from the ON time control unit 22 , and the master-side OFF time command value T off — com,M provided from the OFF time prediction unit, and sends the calculation result as the sampling period command value V m to the PWM generation unit 54 and the slave-side ON time arithmetic unit 52 , respectively.
The slave-side ON time correction unit 51 calculates the foregoing slave-side ON time correction value ΔT on [n] explained with reference to Formula (19) based on the master-side coil current detection value VS 10M and the slave-side coil current detection value VS 10S provided from the analog/digital conversion unit 20 , and sends the obtained slave-side ON time correction value ΔT on [n] to one signal input port of the adding circuit 53 .
Moreover, here, the slave-side ON time arithmetic unit 52 calculates the slave-side ON time command value based on the master-side ON time command value T on — com,M provided from the ON time control unit 22 , and the sampling period command value V m provided from the adding circuit 23 , and sends the ON time command value to the other signal input port of the adding circuit 53 .
The adding circuit 53 generates the slave-side ON time command value T on — com,S provided in Formula (20) above subject to phase compensation by adding the slave-side ON time correction value ΔT on provided from the slave-side ON time correction unit 51 to the ON time command value provided from the slave-side ON time arithmetic unit 52 , and sends this to the PWM generation unit 54 .
The PWM generation unit 54 is configured, as shown in FIG. 13 , from a carrier generation unit 33 , a master-side comparing unit 60 M, a slave-side comparing unit 60 S, a master-side output unit 61 M and a slave-side output unit 61 S.
The carrier generation unit 33 , as shown in FIG. 9(E) and as with the first embodiment, generates a triangle wavelike carrier wave CA with a peak value V mp according to the sampling period command value V m provided from the adding circuit 23 , and sequentially sends the level value of the carrier wave CA to the master-side comparing unit 60 M and the slave-side comparing unit 60 S in the internal clock cycle.
Moreover, the carrier generation unit 33 notifies the timing that the level value (count value) of the carrier wave CA becomes zero (timing of the arrow shown in FIG. 9(F) ) to the analog/digital conversion unit 20 . Consequently, the analog/digital conversion unit 20 samples the first partial pressure voltage V 10 , the second partial pressure voltage V 11 , the master-side coil current detection signal S 10M and the slave-side coil current detection signal S 10S at the notified timing.
The master-side comparing unit 60 M compares the size of the level value of the carrier wave provided from the carrier generation unit 33 and the master-side ON time command value T on — com,M provided from the ON time control unit, and sends the comparative result to the master-side output unit 61 M.
The master-side output unit 61 M subsequently generates a master-side PWM signal S 11M as shown in FIG. 9(C) which rises to a high level during the period that the master-side ON time command value T on — com,M is lower than the level value of the carrier wave and which falls to a low level during the period that the master-side ON time command value T on — com,M is higher than the level value of the carrier wave based on the comparative result of the master-side comparing unit 60 M, and sends the generated master-side PWM signal S 11M to the gate of the master-side switching element Q 11M .
Consequently, the master-side switching element Q 11M is subject to the ON/OFF operation based on the master-side PWM signal S 11M , and the master-side coil current I LM as shown in FIG. 9(A) is generated in the foregoing master-side choke coil L 10M pursuant to the ON/OFF operation of the master-side switching element Q 11M .
Moreover, the slave-side comparing unit 60 S compares the size of the level value of the carrier wave provided from the carrier generation unit 33 and the slave-side ON time command value T on — com,S provided from the slave-side ON time arithmetic unit 52 ( FIG. 12 ), and sends the comparative result to the slave-side output unit 61 S.
The slave-side output unit 61 S subsequently generates a slave-side PWM signal S 11S as shown in FIG. 9(D) which rises to a high level during the period that the slave-side ON time command value T on — com,S is higher than the level value of the carrier wave and which falls to a low level during the period that the slave-side ON time command value T on — com,S is lower than the level value of the carrier wave based on the comparative result of the slave-side comparing unit 60 S, and sends the generated slave-side PWM signal S 11S to the gate of the slave-side switching element Q 10S .
Consequently, the slave-side switching element Q 10S is subject to the ON/OFF operation based on the slave-side PWM signal S 11s , and the slave-side coil current I LS with a phase difference of 180 degrees from the master-side coil current I LM as shown in FIG. 9(B) is generated in the foregoing slave-side choke coil L 10S pursuant to the ON/OFF operation of the slave-side switching element Q 10S .
(2-3) Effect of Present Embodiment
As described above, the PFC unit 40 according to this embodiment, as with the PFC unit 5 according to the first embodiment, predicts the OFF time of the master-side for performing the critical mode control in the subsequent sampling period based on the first partial pressure voltage value VV 10 , the master-side coil current detection value VS 10M and the second partial pressure voltage value VV 11 provided from the analog/digital conversion unit 20 , and the master-side ON time command value T on — com,M provided from the ON time control unit 22 , and additionally corrects the phase of the slave-side PWM signal S S11S in the slave-side ON time correction unit 51 and the slave-side ON time arithmetic unit 52 . Thus, the phase of the slave-side PWM signal S11S can be retained with accuracy as a phase difference of 180 degrees in relation to the master-side PWM signal S11M .
Consequently, the output voltage oscillation or output ripple of the PFC unit 40 can be suppressed, and a stable output can be obtained as the output of the power supply unit 1 .
(2) Other Embodiments
Although the foregoing first embodiment explained a case of detecting the current value of the coil current IL that is generated in the choke coil L 1 with the current detector 12 , and performing the PFC control according to the foregoing embodiment based on the detected current value of the coil current IL, the present invention is not limited thereto, and, for example, as shown in FIG. 14 , it is also possible to connect a resistor R 10 between the source of the switching element Q 1 and the ground line 15 , acquire an inductor current Ids (drain-source current of Q 1 ) flowing in the switching element Q 1 from the connection midpoint of the source of the switching element Q 1 and the resistor R 10 , and perform the PFC control according to the foregoing embodiment based on the inductor current Ids.
This also applied to the second embodiment. However, in the foregoing case, as evident from FIG. 9 , sampling is performed at the wave trough of the carrier wave CA, and, as the master-side coil current I LM , a value at the rise of the coil current (that is, at a timing that is exactly ½ of the ON period of the master-side PWM signal S 11M ) can be acquired. Meanwhile, the slave-side coil current I LS is sampled at the fall of the coil current. This means that, considering that the inductor current Ids will be a sawtooth current waveform, it will not be possible to detect the current at the fall. Thus, in the foregoing case, if a sample value of only the slave-side current detector 12 S is acquired at a timing of a half cycle before (detection of the master-side current is one cycle before) (that is, at the wave crest of the carrier wave CA), the current can be detected at the rise as with the master-side coil current I LM .
Moreover, although the foregoing second embodiment explained a case where, in the control unit 42 , the phase of the slave-side PWM signal S 11S is corrected so that the phase of the slave-side PWM signal S 11S is shifted 180 degrees in relation to the master-side PWM signal S 11M with the master-side as the reference, the present invention is not limited thereto, and, for example, the phase of the master-side PWM signal S 11M may be corrected such as the phase of the slave-side PWM signal S 11M is shifted 180 degrees in relation to the slave-side PWM signal S 11S with the slave-side as the reference.
In addition, although the foregoing first and second embodiments explained a case of configuring the input voltage detection unit for detecting the input voltage from the first and second partial pressure resistors R 1 , R 2 , and configuring the output voltage detection unit for detecting the output voltage from the third and fourth partial pressure resistors R 3 , R 4 , the present invention is not limited thereto, and various types of configurations may be broadly applied as the configuration of the input voltage detection unit and the output voltage detection unit.
In addition, although the foregoing first and second embodiments explained a case of predicting the OFF time in the subsequent period based on Formula (10), the present invention is not limited thereto, and the OFF time in the subsequent sampling period may also be predicted using various other computation methods.
|
Proposed are a power factor correction device and its control method capable of obtaining a stable output as the output of a power supply unit while simplifying and miniaturizing the configuration. In the power factor correction device and the control method thereof including a coil and a switching element, and a control unit for controlling ON/OFF of the switching element, provided are an input voltage detection unit for detecting an input voltage of the power factor correction device, an output voltage detection unit for detecting an output voltage, and a coil current detection unit for detecting a coil current that is generated in the coil pursuant to the ON/OFF operation of the switching element. The control unit predicts an OFF time of the switching element of each switching cycle for controlling the switching element in a critical mode based on a voltage value of the input voltage detected with the input voltage detection unit, a voltage value of the output voltage detected with the output voltage detection unit, and a current value of the coil current detected with the coil current detection unit, and controls the ON/OFF of the switching element based on the prediction result.
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