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BACKGROUND OF THE INVENTION
[0001] Field of Invention
[0002] The present invention relates to a fluid control device, and in particular to a fluid control device with a temperature control function and energy recovery system. Specifically, the present invention relates to a valve assembly with a thermostatic function and a heat energy recovery device including the valve assembly.
[0003] Related Art
[0004] In everyday life, people may use different washing facilities for cleaning and washing.
[0005] These washing facilities include, for example, bathrooms, washing sinks, hair washing sinks, and the like. However, if the washing facilities use hot water as a washing medium, wastewater discharged by the facilities still contains a huge amount of heat energy, resulting in a waste of energy. Therefore, people try to recover and utilize heat energy from the discharged wastewater.
[0006] An invention patent CN201010224654.4 filed on Jul. 7, 2010 and entitled “valve assembly and heat energy recovery device with the valve assembly” discloses a valve assembly. As shown in FIG. 1 , the valve assembly 2 includes a housing 30 , a spool 31 disposed in the housing 30 and a handle 32 for controlling the spool. The housing 30 is provided with a cold water input pipe 24 , a cold water output pipe 25 , a tepid water input pipe 26 , a hot water output pipe 27 , and a hot water input pipe 29 , so as to be in communication with the spool 31 . The heat energy recovery device disclosed in the patent can be directly installed without transforming or changing a building structure, thereby simplifying the installation procedure and reducing the installation cost. Moreover, as shown in FIG. 2 , in the heat energy recovery device, a cold water source is not directly communicated with a heat exchange device, but is communicated with the valve assembly and provides cold water for the heat exchange device by means of the valve assembly. The cold water is heated into tepid water by the heat exchange device, and the tepid water is returned to the valve assembly to be mixed with hot water supplied by a hot water source, to generate tepid water at a suitable temperature, and the tepid water is input, by means of the valve assembly, into a washing facility to be utilized. Therefore, water pressure borne by the heat exchange device can be effectively reduced, to prevent seepage of clean water caused by damage to the heat exchange device. However, in the heat energy recovery device, because the cold water enters the valve assembly after heat exchange is performed in a heat exchanger, and the temperature of the cold water rises slowly to achieve stability, in the meantime, a user needs to regulate a handle of the valve assembly constantly to stabilize the water temperature, which is inconvenient.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing problems in the prior art, one objective of the present invention is to provide a fluid control device for stabilizing the temperature of fluid output, such that to output a fluid with desirable temperature. In one of the embodiments, the fluid control device may implement as a valve assembly with a thermostatic function.
[0008] According to a first aspect of the present invention, there is provided a fluid control device, comprising: a housing including a first inlet for receiving a fluid having a first temperature, a second inlet for receiving a fluid having a second temperature, and first outlet through which a fluid of a third temperature flows; a fluid temperature control assembly disposed in the housing, and including a mixing cavity defined therein, wherein the fluid temperature control assembly comprises: a first group of one or more apertures of the mixing cavity configured for regulating fluid communication between the mixing cavity and the first inlet of the housing; a second group of one or more apertures of the mixing cavity for regulating fluid communication between the second inlet of the housing and the mixing cavity; a third group of one or more apertures of the mixing cavity in fluid communication with the first outlet; wherein the fluid temperature control assembly modifies properties of at least one or more of the first group of apertures or the second group of apertures for regulating the amount of fluid having a first temperature relative to the amount of fluid having a second temperature received within the mixing cavity, thereby maintaining the fluid discharged from the first outlet at a predetermined temperature.
[0009] The fluid temperature control assembly may further comprises: a sensor for detecting the temperature of the mixed fluid within the mixing cavity and modifying the at least one or more of the first group of apertures or one or more of the second group of apertures of the fluid temperature control assembly according to the detected temperature of the mixed fluid within the mixing cavity.
[0010] The fluid control device may further includes a third inlet and a third outlet for receiving and discharging fluid of a fourth temperature, wherein the fluid of a fourth temperature may be thermally isolated from the fluid within the fluid control device other than the fluid of a third temperature.
[0011] The fluid control device may further includes a flow regulating valve disposed within the housing, the flow regulating valve comprising: a first plate having a first hole and a second hole therethrough, the first and second holes being spaced apart from each other, a second plate moveable relative to the first plate and including a first slot formed therein, wherein changing the alignment of the first slot of the second plate relative to the holes of the first plate may regulates the amount of fluid flow through a passageway from the third inlet to the third outlet.
[0012] The first plate may further includes at least a further hole in fluid communication with the first inlet and a fourth hole in fluid communication with first group of one or more apertures of the fluid temperature control assembly; the second plate may further includes a second slot, wherein by changing the alignment of the first and second slots of the second plate relative to the holes of the first plate may control the fluid communication between the third inlet and the third outlet and the fluid communication between the first inlet and the first group of one or more apertures of the fluid temperature control assembly.
[0013] The flow regulating valve may further includes a third plate, arranged such that the second plate may be disposed between the first plate and the third plate, wherein each of the first plate, second plate and third plate further includes at least a further hole therein, and said at least one further hole of the third plate and the fluid temperature control assembly being in fluid communication; and the second plate may be configured such that movement of the second plate relative to the first and third plates and the first slot and at least one further hole therein simultaneously regulates flow between the third inlet and the third outlet and flow between the first inlet and fluid temperature control assembly.
[0014] The fluid control device may further includes: a flow regulating knob disposed on the housing for adjusting via a connecting rod the flow regulating valve so as to modify the alignment of the second plate relative to the holes of the other plates; a temperature regulating knob disposed on the housing, for regulating the predetermined temperature of the mixed fluid within the mixing cavity by adjusting the regulating knob or connecting rod thereof; wherein the flow regulating knob or the connecting rod thereof may be axially coincident.
[0015] The fluid control device may further includes: a flow regulating knob disposed on the housing for adjusting via a connecting rod a flow regulating valve so as to modify the alignment of the second plate relative to the holes of the other plates; wherein the connector of the second plate and the flow regulating knob may extend through the interior of the fluid temperature control assembly.
[0016] The third group of one of more apertures of the mixing cavity of the fluid temperature control assembly may be connected to the first outlet of the housing via one of the first plate or the second plate or the third plate.
[0017] The second inlet of the housing may be connected to the second group of one or more apertures of the fluid temperature control assembly through at least one of the first plate, second plate or third plate.
[0018] The fluid control device may further includes: a heat exchanger thermally isolated from the housing; a fluid passageway for conveying fluid with a fourth temperature from the third outlet of the housing to the heat exchanger; wherein the fluid of fourth temperature may undergoes heat exchange with the mixed fluid with third temperature from the first outlet within the heat exchanger, such that the temperature of the fluid with fourth temperature may approach the second temperature, wherein at least a portion of the fluid with a second temperature after heat exchange may be conveyed via the second inlet.
[0019] The fluid control device may further includes a heater, wherein at least a portion of the fluid having a second temperature following heat exchange may be conveyed to the heater for heating to a first temperature and re-introduction into the first inlet.
[0020] Another objective of the present invention is to provide a heat energy recovery device including the aforementioned valve assembly with thermostatic function, where the heat energy recovery device can simplify the installation procedure and reduce the installation cost, effectively reduce water pressure borne by a heat exchange device, to prevent leakage of clean water, and can stably provide the temperature of hot water output.
[0021] According to the present invention, a valve assembly with a thermostatic function is provided, including: a housing with a cavity formed therein, the housing being provided with a cold water inlet, a cold water outlet, a hot water inlet, a tepid water inlet, and a tepid water outlet that are in communication with the cavity, where the cold water inlet is used for communicating with a cold water source, and the hot water inlet is used for communicating with a hot water source; a flow regulating knob; a flow regulating valve disposed in the cavity and connected with the flow regulating knob, used for communicating with the cold water inlet and the cold water outlet of the housing in different degrees; a water-temperature regulating knob; and a thermostat disposed in the cavity and connected with the water-temperature regulating knob, the thermostat having a tepid water inlet, a hot water inlet and a mixing chamber, where the tepid water inlet is in communication with the tepid water inlet of the housing to receive tepid water input externally, the hot water inlet is directly or indirectly in communication with the hot water inlet of the housing, the mixing chamber is in communication with the tepid water outlet of the housing to provide tepid water to the mixing chamber, and the thermostat can automatically regulate the amount of tepid water and hot water that enter the mixing chamber so as to stabilize the water temperature in the mixing chamber to be a temperature preset by the water-temperature regulating knob.
[0022] In the valve assembly, the flow regulating valve includes a first fixed plate and a moveable plate, where a cold water inlet aperture and a cold water outlet aperture are disposed as spaced apart on the fixed plate, and are in communication with the cold water inlet and the cold water outlet of the housing respectively, the moveable plate is relatively rotatably disposed on the fixed plate, and a surface of the fixed plate to which the moveable plate faces is provided with a first groove, where the groove is disposed to be capable of communicating with the cold water inlet and the cold water outlet in different degrees with rotation of the moveable plate so as to control cold water flow.
[0023] In the valve assembly, a contact surface between the fixed plate and the moveable plate is a plane.
[0024] In the valve assembly, the flow regulating knob and the water-temperature regulating knob are located on two ends of the housing separately.
[0025] In the valve assembly, a hot water inlet aperture and a hot water outlet aperture are further disposed as spaced apart on the first fixed plate, and are in communication with the hot water inlet of the housing and the hot water inlet of the thermostat respectively; and the surface of the fixed plate to which the moveable plate faces is further disposed with a second groove, where the first groove and the second groove are disposed to be capable of synchronously communicating the cold water inlet of the housing with the cold water outlet of the housing and communicating the hot water inlet of the housing with the hot water inlet of the thermostat simultaneously in different degrees with rotation of the moveable plate.
[0026] In the valve assembly, the flow regulating knob and the water-temperature regulating knob are located on two ends of the housing separately.
[0027] In the valve assembly, the flow regulating valve further includes a second fixed plate, where the first fixed plate is further provided with a hot water inlet aperture, and the second fixed plate is also provided with a hot water inlet aperture; the moveable plate is disposed between the first fixed plate and the second fixed plate, and is further provided with a hot water aperture; the hot water inlet aperture of the first fixed plate is in communication with the hot water inlet of the housing, and the hot water inlet aperture of the second fixed plate is in communication with the hot water inlet of the thermostat; and the groove and the hot water aperture of the moveable plate are disposed to be capable of synchronously communicating the cold water inlet of the housing with the cold water outlet of the housing and communicating the hot water inlet of the housing with the hot water inlet of the thermostat with different degrees depending on the rotation of the moveable plate.
[0028] In the valve assembly, a contact surface between the moveable plate and the first fixed plate or the second fixed plate is a plane.
[0029] In the valve assembly, the flow regulating knob and the water-temperature regulating knob are located on the same end of the housing.
[0030] In the valve assembly, the flow regulating knob or a connecting rod thereof and the water-temperature regulating knob or a connecting rod thereof are disposed to be capable of rotating coaxially.
[0031] In the valve assembly, the valve assembly further includes a connector connecting the moveable plate and the flow regulating knob, and passing through the interior of the thermostat.
[0032] In the valve assembly, the mixing chamber of the thermostat is communicated with the tepid water inlet of the housing through the first fixed plate, the second fixed plate, or the moveable plate.
[0033] In the valve assembly, the tepid water inlet of the housing is communicated with the tepid water outlet of the thermostat through the first fixed plate, the second fixed plate, or the moveable plate.
[0034] In the valve assembly, the fixed plate and the moveable plate are made of metal or ceramics.
[0035] According to another aspect, the present invention further provides a heat energy recovery device including the aforementioned valve assembly, which further includes a heat exchanger, the heat exchanger receiving hot wastewater from an application device and cold water output by the cold water outlet of the housing, to enable the hot wastewater to exchange heat with the cold water to heat the cold water into tepid water, where at least part of the tepid water is input into the valve assembly through the tepid water inlet of the housing so as to be mixed with external hot water inputted through the hot water inlet of the housing into lukewarm water and provided to the application device through the tepid water outlet.
[0036] The valve assembly with a thermostatic function and the heat energy recovery device including the aforementioned valve assembly with thermostatic function according to the present invention can be directly installed without transforming or changing a building structure, so as to simplify the installation procedure and reduce the installation cost, can effectively reduce water pressure borne by the heat exchange device, so as to effectively prevent leakage of clean water caused by damage to the heat exchange device, and can stably provide the temperature of hot water output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The basic structure of the device of the present invention is illustrated below with reference to the accompanying drawings, where:
[0038] FIG. 1 is a schematic structural view of a valve assembly in the prior art;
[0039] FIG. 2 is a structural block diagram of a heat energy recovery device in the prior art;
[0040] FIG. 3 is an exploded perspective view of a first embodiment of a fluid control device with a temperature control function according to the present invention;
[0041] FIG. 4 is an assembling perspective view of the fluid control device shown in FIG. 3 ;
[0042] FIG. 5 is an assembling sectional view of a temperature control device in the fluid control device shown in FIG. 4 ;
[0043] FIG. 6 is an exploded perspective view of the temperature control device shown in FIG. 5 ;
[0044] FIG. 7 is an exploded perspective view of a flow regulating valve in the fluid control device with a temperature control function shown in FIG. 4 ;
[0045] FIG. 8 is a schematic view of a state change of rotation of a moveable plate in the flow regulating valve shown in FIG. 7 relative to a fixed plate, illustrating that the flow regulating valve is in an off state;
[0046] FIG. 9 is a schematic view of a state change of rotation of the moveable plate in the flow regulating valve shown in FIG. 7 relative to a fixed plate, illustrating that the flow regulating valve is in an on state;
[0047] FIG. 10 is a structural block diagram of a heat energy recovery device including the said fluid control device with a temperature control function shown in FIG. 3 ;
[0048] FIG. 11 is an exploded perspective view of a second embodiment of a fluid control device with a temperature control function according to the present invention;
[0049] FIG. 12 is an assembling perspective view of the fluid control device shown in FIG. 11 ;
[0050] FIG. 13 is an exploded perspective view of a flow regulating valve in the fluid control device shown in FIG. 12 ;
[0051] FIG. 14 is a schematic view of a state change of rotation of a moveable plate in the flow regulating valve shown in FIG. 13 relative to a fixed plate, illustrating that the flow regulating valve is in an off state;
[0052] FIG. 15 is a schematic view of a state change of rotation of the moveable plate in the flow regulating valve shown in FIG. 13 relative to a fixed plate illustrating that the flow regulating valve is in an on state;
[0053] FIG. 16 is a structural block diagram of a heat energy recovery device including the fluid control device with a temperature control function shown in FIG. 11 ;
[0054] FIG. 17 is a perspective view of a third embodiment of a fluid control device with a temperature control function according to the present invention;
[0055] FIG. 18 is an exploded perspective view of the fluid control device with a temperature control function shown in FIG. 17 ;
[0056] FIG. 19 is an exploded perspective view of a flow regulating valve in the fluid control device with a temperature control function shown in FIG. 18 ;
[0057] FIG. 20 is an exploded perspective view of a thermostat in the fluid control device with a temperature control function shown in FIG. 18 ;
[0058] FIG. 21 is an assembling sectional view of the temperature control device shown in FIG. 20 ;
[0059] FIG. 22 is a schematic view of a state change of rotation of a moveable plate in the flow regulating valve shown in FIG. 18 relative to a fixed plate, illustrating that the flow regulating valve is in an off state;
[0060] FIG. 23 is a schematic view of a state change of rotation of the moveable plate in the flow regulating valve shown in FIG. 18 relative to a fixed plate, illustrating that the flow regulating valve is in an on state;
[0061] FIG. 24 is a sectional perspective view of the fluid control device with a temperature control function shown in FIG. 17 ; and
[0062] FIG. 25 is a structural block diagram of a heat energy recovery device including the fluid control device with a temperature control function shown in FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
[0063] Various embodiments in which the valve assembly with a thermostatic function and the heat energy recovery device including the valve assembly according to the present invention are described below only by way of examples with reference to the accompanying drawings. It should be understood that the present invention is not limited thereto. Throughout accompanying drawings, same accompanying drawing reference signs are used for same components.
[0064] In the embodiments as mentioned below, the fluid control device with temperature control function are implemented as valve assembly with thermostat function. One would be appreciated that the fluid control device with temperature control function is not only limited to valve assembly, while temperature control function and temperature control device are not only limited to thermostat functions and thermostat devices. Any devices comprising fluid control functions and devices with temperature control function fall within the scope of the present invention.
[0065] Meanwhile, in the embodiments as mentioned below, the movable plate within the fluid control device are implemented as a rotatable plate for regulating the fluid communication flowing therein. It should be understood that such movable plate is not limited to rotatable plate where any devices comprising fluid flow regulating functions such as linear movable plate fall within the scope of the present invention.
[0066] FIG. 3 to FIG. 9 illustrate a structure of a first embodiment of a valve assembly with a thermostatic function according to the present invention, and FIG. 10 is a structural block diagram of a heat energy recovery device including the aforementioned valve assembly with thermostatic function according to the present invention.
[0067] As shown in FIG. 3 and FIG. 4 , the valve assembly 4 includes a housing 41 , a flow regulating knob 45 , a water-temperature regulating knob 46 , a thermostat 42 disposed in the housing 41 , a flow regulating valve 43 , and a connector 44 that is in communication with the flow regulating valve 43 and the housing 41 . The housing 41 is internally formed with a cavity 418 , and is externally formed with a cold water inlet 414 , a cold water outlet 415 , a hot water inlet 419 , a tepid water inlet 416 , and a tepid water outlet 417 that are in communication with the cavity 418 . In particular, the distance between the center of the cold water inlet 414 and hot water inlet 419 is approximately 150 mm, which is the same distance between the centers of the cold and water inlet of the cold hot water mixing valve utilized in the general bathroom in the market. Users only need to remove the existing mixing valve of the bathroom and replace with the valve assembly of the present invention without replacing the existing conduit of the building.
[0068] As shown in FIG. 5 and FIG. 6 , the thermostat 42 has a hot water inlet 429 in communication with the hot water inlet 419 of the housing 41 , a tepid water inlet 426 in communication with the tepid water inlet 416 of the housing 41 , a mixing chamber 428 in communication with the tepid water outlet 417 of the housing 41 , and a control rod 424 connected with the water-temperature regulating knob 46 . The mixing chamber 428 of the thermostat 42 is provided with a thermostatic element 423 and a slider 425 therein. Substance in the thermostatic element 423 can automatically change the length of a tail 422 of the thermostatic element 423 based on the water temperature in the mixing chamber 428 through the principle of thermal expansion and contraction. When the water temperature in the mixing chamber 428 is higher than a temperature preset by the water-temperature regulating knob 46 by means of the control rod 424 , the tail 422 of the thermostatic element 423 may lengthen to press the slider 425 downwards so as to reduce the degree of communication between the hot water inlet 429 and the mixing chamber 428 and increase the degree of communication between the tepid water inlet 426 and the mixing chamber 428 , to increase the amount of tepid water in the mixing chamber 428 and decrease the amount of hot water, thereby lowering the water temperature in the mixing chamber 428 . However, when the water temperature in the mixing chamber 428 is lower than the temperature preset by the water-temperature regulating knob 46 by means of the control rod 424 , the tail 422 of the thermostatic element 423 may shorten, a spring 427 pushes the slider 425 upwards so as to increase the degree of communication between the hot water inlet 429 and the mixing chamber 428 and reduce the degree of communication between the tepid water inlet 426 and the mixing chamber 428 , to increase the amount of hot water in the mixing chamber 428 and decrease the amount of tepid water, thereby raising the water temperature in the mixing chamber 428 .
[0069] As shown in FIG. 3 and FIG. 4 , the flow regulating valve 43 is disposed in the cavity 418 of the housing 41 , and by means of a control rod 431 through which the flow regulating valve 43 is connected with the flow regulating knob 45 , the flow regulating valve 43 can communicate with the cold water inlet 414 and the cold water outlet 415 of the housing 41 in different degrees to regulate water output of the cold water outlet 415 .
[0070] FIG. 7 is an exploded perspective view of the flow regulating valve 43 . The flow regulating valve 43 includes a housing 53 with a cavity formed therein, a bottom cover 54 snapped to the housing 53 in a sealing manner, a fixed plate 55 fixedly disposed on the bottom cover 54 in the cavity of the housing 53 , a rotatable plate 56 relatively rotatably disposed on the fixed plate 55 , and a control rod 431 passing through the housing 53 and connecting to the rotatable plate 56 , where the control rod 431 can drive the rotatable plate 56 to rotate on the fixed plate 55 . The bottom cover 54 is provided with a cold water inlet 541 and a cold water outlet 542 , which are in communication with the cold water inlet 414 and the cold water outlet 415 of the housing 41 respectively through the connector 44 (see FIG. 3 and FIG. 4 ). A cold water inlet hole 551 and a cold water outlet hole 552 are disposed as spaced apart on the fixed plate 55 , and are in communication with the cold water inlet 541 and the cold water outlet 542 on the bottom cover 54 respectively. A surface (plane) of the fixed plate 55 to which the rotatable plate 56 faces is formed with a groove 561 , which is disposed to selectively communicate with the cold water inlet 414 and the cold water outlet 415 with different degrees depending on the rotation of the rotatable plate 56 so as to control the amount of cold water of the cold water outlet 415 of the housing 41 .
[0071] FIG. 8 and FIG. 9 illustrate state changes generated by rotation of the rotatable plate 56 relative to the fixed plate 55 . In an initial state shown in FIG. 8 , that is, when the flow regulating valve 43 is in an off state, the groove 561 does not cover the cold water inlet hole 551 or the cold water outlet hole 552 , so that the cold water inlet hole 551 and the cold water outlet hole 552 are spaced apart from each other but are not in communication.
[0072] When the flow regulating knob 45 is used to rotate the control rod 431 to drive the rotatable plate 56 to rotate on the fixed plate 55 , the flow regulating valve 43 enters a on state shown in FIG. 9 . In this case, as shown in FIG. 10 , cold water supplied by a cold water source enters the cold water outlet hole 552 through the cold water inlet hole 551 and the groove 561 , that is, the cold water is output to the cold water outlet 415 of the housing 41 through the cold water inlet 414 of the housing 41 and further supplied to a heat exchanger 3 . The cold water exchanges heat with hot water from an application device (for example, a washing facility) within the heat exchanger 3 to become tepid water, and part of the tepid water is directly communicated with the tepid water inlet 416 of the valve assembly 4 through a pipeline, part of the tepid water is communicated with a heater and is heated into a hot water source to be communicated with the hot water inlet 419 of the valve assembly 4 , and provides hot water with a stable water temperature at the temperature preset by the temperature regulating knob 46 by means of the control rod 424 for the tepid water outlet 417 through the thermostat 42 so as to be supplied to the application device.
[0073] The fixed plate 55 and the rotatable plate 56 in the valve assembly of the present invention may be made of metal or ceramics.
[0074] FIG. 10 illustrates a structural block diagram of a heat energy recovery device including the said fluid control device according to the present invention. As shown in the figure, said heat energy recovery device comprises valve assembly 4 and heat exchanger. As shown in the figure, the water from the cold water source enters the heat exchanger through valve assembly 4 . One skilled in the art would understand that water from the cold water may also enter heat exchange directly without passing through valve assembly 4 . Upon passing through the heat exchanger to absorb the heat energy of waste water, the water reaches a higher temperature and becomes tepid water. Tepid water may enter valve assembly 4 through tepid water inlet and mix with the hot water entering valve assembly 4 from hot water inlet within the mixing cavity. For detailed description please refer to the aforementioned disclosure and it would not be reiterated here. It should be explained here that the hot water from the heat exchanger may also be heated to become hot water by a heater, and introduced into valve assembly through hot water inlet 419 .
[0075] When valve assembly 4 is in off state, it separates the clean water within heat exchanger 3 and water heater from the cold water source of the building, such that heat exchanger 3 is not borne with any pressure from the cold water source under circumstances of no water usage, and even if there may exists any water leakage with heat exchanger 3 , precious drinking water would not endlessly leak into waster water conduit and causes waste;
[0076] When valve assembly 4 is in on state, cold water enters heat exchanger 3 through valve assembly 4 upon entering cold water conduit, and further enters valve assembly 4 through hot water inlet 419 and warm water inlet 416 and finally out from warm water outlet 417 . During water usage, the pressure of the cold water source is released through the warm water out from the warm water outlet 417 . Thus, the conduit between the valve assembly 4 and the heat exchanger 3 , the conduit between heat exchanger 3 and heater, the conduit between cold outlet 415 and heat exchanger, and the conduit between heat exchanger 3 and warm water inlet 416 would not subject to excessive pressure under on or off circumstances, and such that it may utilize soft plastic conduit instead of metal tube to reduce material and installation cost. Meanwhile, as heat exchanger 3 bears a lower water pressure, it may be made of thinner material to enhance heat exchange efficiency. FIG. 11 to FIG. 15 illustrate a structure of a second embodiment of a valve assembly with a thermostatic function according to the present invention, and FIG. 16 is a structural block diagram of a heat energy recovery device including the valve assembly with a thermostatic function according to the present invention. The structure of the valve assembly 6 with a thermostatic function in the second embodiment is roughly identical with that of the valve assembly 4 with a thermostatic function in the first embodiment, and the only different exist within the structures of a flow regulating valve 63 . Detailed description about the same components is omitted herein.
[0077] As shown in FIG. 11 and FIG. 12 , the valve assembly 6 includes a housing 41 , a flow regulating knob 45 , a water-temperature regulating knob 46 , a thermostat 42 disposed in the housing 41 , a flow regulating valve 63 , and a connector 64 and connecting pipes 67 , 68 for communicating with the flow regulating valve 63 and the housing 41 . The housing 41 is formed with a cavity 418 therein and is externally formed with a cold water inlet 414 , a cold water outlet 415 , a hot water inlet 419 , a tepid water inlet 416 , and a tepid water outlet 417 that are in communication with the cavity 418 .
[0078] As shown in FIG. 11 and FIG. 12 , the flow regulating valve 63 is disposed within the cavity 418 of the housing 41 , and by means of a control rod 631 through which the flow regulating valve 63 is connected with the flow regulating knob 45 , the flow regulating valve 63 can regulate water quantity.
[0079] FIG. 13 is an exploded perspective view of the flow regulating valve 63 . The flow regulating valve 63 includes a housing 73 with a cavity formed therein, a bottom cover 74 snapped to the housing 73 in a sealing manner, a fixed plate 75 fixedly disposed on the bottom cover 74 in the cavity of the housing 73 , a rotatable plate 76 relatively rotatably disposed on the fixed plate 75 , and a control rod 631 passing through the housing 73 and connecting to the rotatable plate 76 , where the control rod 631 can drive the rotatable plate 76 to rotate on the fixed plate 75 . In addition to being provided with a cold water inlet 741 and a cold water outlet 742 , the bottom cover 74 is further provided with a hot water inlet 743 and a hot water outlet 744 , which, by means of the connector 64 and the connecting pipe 67 (see FIG. 12 ), such that the cold water inlet 741 communicate with the cold water inlet 414 of the housing 41 , the cold water outlet 742 communicate with the cold water outlet 415 of the housing 41 , the hot water inlet 743 communicate with the hot water inlet 419 of the housing 41 , and the hot water outlet 744 communicate with the hot water inlet 429 of the thermostat 42 .
[0080] In addition to a cold water inlet hole 751 and a cold water outlet hole 752 as provided in a spaced manner on the fixed plate 75 , the fixed plate 75 is further provided with a hot water inlet hole 753 and a hot water outlet hole 754 , which are in communication with the cold water inlet 741 , the cold water outlet 742 , the hot water inlet 743 and the hot water outlet 744 on the bottom cover 74 respectively.
[0081] A surface (plane) on the fixed plate 75 to which the rotatable plate 76 faces is formed with two grooves, a first groove 761 and a second groove 762 , which are disposed to selectively synchronously communicate the cold water inlet 741 with the cold water outlet 742 and communicate the hot water inlet 743 with the hot water outlet 744 with different degrees depending on the rotation of the rotatable plate 76 .
[0082] FIG. 14 and FIG. 15 illustrate state changes generated by rotation of the rotatable plate 76 relative to the fixed plate 75 . In an initial state shown in FIG. 14 , that is, when the flow regulating valve 63 is in an off state, the first groove 761 does not cover the cold water inlet hole 751 or the cold water outlet hole 752 , and the second groove 762 does not cover the hot water inlet hole 753 and the hot water outlet hole 754 , so that the cold water inlet hole 751 and the cold water outlet hole 752 are spaced apart from each other but are not in communication, and the hot water inlet hole 753 and the hot water outlet hole 754 are spaced apart from each other but are not in communication.
[0083] When the flow regulating knob 45 is used to rotate the control rod 631 to drive the rotatable plate 76 to rotate on the fixed plate 75 , the flow regulating valve 63 gradually enters a full-on state shown in FIG. 15 . In this case, as shown in FIG. 16 , cold water supplied by a cold water source enters the cold water outlet hole 752 through the cold water inlet hole 751 and the first groove 761 , that is, the cold water is output to the cold water outlet 415 of the housing 41 through the cold water inlet 414 of the housing 41 and to be further supplied to a heat exchanger 3 . The cold water exchanges heat with hot water from an application device (for example, a washing facility) in the heat exchanger 3 to become tepid water, and is then communicated with the tepid water inlet 416 of the housing 41 ; meanwhile, hot water supplied by a hot water source enters the hot water outlet hole 754 through the hot water inlet hole 753 and the second groove 762 , that is, the hot water is communicated with the hot water inlet 429 of the thermostat 42 through the hot water inlet 419 of the housing 41 . The tepid water and the hot water, by means of the thermostat 42 , provide hot water with a stable water temperature at the temperature preset by the temperature regulating knob 46 by means of the control rod 424 for the tepid water outlet 416 , so as to be supplied to the application device.
[0084] FIG. 16 illustrates a structural block diagram of a heat energy recovery device including the fluid control device of a second embodiment according to the present invention. As FIG. 16 is substantially similar to FIG. 10 , the description is omitted herein.
[0085] FIG. 17 to FIG. 24 illustrate a structure of a third embodiment of a valve assembly with a thermostatic function according to the present invention, and FIG. 25 is a structural block diagram of a heat energy recovery device including the valve assembly with a thermostatic function according to the present invention. As shown in FIG. 17 , the valve assembly 8 is fastened onto a table surface 21 by means of fasteners 22 and 23 .
[0086] As shown in FIG. 17 and FIG. 18 , the valve assembly 8 includes a housing 81 which consists of a top shell 811 , a bottom shell 812 , and a screw cap 813 , which form a cavity 818 therein, where the cavity 818 is in communication with a cold water inlet 814 , a cold water outlet 815 , a hot water inlet 819 , a tepid water inlet 816 , and a tepid water outlet 817 on the bottom cover 812 . The valve assembly 8 further includes a thermostat 82 disposed within the cavity 818 , a flow regulating valve 83 , a flow regulating knob 85 , and a water-temperature regulating knob 84 . The water-temperature regulating knob 84 and the flow regulating knob 85 are located on the same end of the housing 81 .
[0087] FIG. 19 is an exploded perspective view of the flow regulating valve 83 . The flow regulating valve 83 includes a housing 831 with a cavity formed therein, a bottom cover 832 sealingly engaged to the housing 831 , a first fixed plate 833 and a second fixed plate 835 fixedly disposed in the cavity 818 of the housing 831 , and a rotatable plate 834 relatively rotatably disposed between the first fixed plate 833 and the second fixed plate 835 . In particular, a contact surface between the first fixed plate 833 and the rotatable plate 834 , and a contact surface between the second fixed plate 835 and the rotatable plate 834 are planes. The bottom cover 832 is provided with a cold water inlet 8321 , a cold water outlet 8322 , a tepid water inlet 8323 , a hot water inlet 8325 , and a tepid water outlet 8324 , which are in communication with the cold water inlet 814 , the cold water outlet 815 , the hot water inlet 819 , the tepid water inlet 816 , and the tepid water outlet 817 of the housing 81 respectively.
[0088] In addition to the cold water inlet hole 8331 and a cold water outlet hole 8332 that are in communication with the cold water inlet 8321 and the cold water outlet 8322 respectively as provided on the bottom cover 832 , the first fixed plate 833 is further provided with a hot water inlet hole 8333 that is in communication with the hot water inlet 8325 on the bottom cover 832 , and a tepid water input hole 8335 and a tepid water output hole 8334 that are in communication with the tepid water inlet 8323 and the tepid water outlet 8324 respectively.
[0089] The second fixed plate 835 is provided with a hot water inlet hole 8353 , a tepid water input hole 8355 , and a tepid water output hole 8354 that are aligned with the hot water inlet hole 8333 , the tepid water input hole 8335 , and the tepid water output hole 8334 of the first fixed plate respectively.
[0090] In addition to a groove 8341 is provided to the rotatable plate 834 , the rotatable plate 834 is further provided with a hot water hole 8343 , a tepid water input hole 8345 , and a tepid water output hole 8344 , which are disposed to be as follows: rotatable plate not only the groove 8341 can communicate with the cold water inlet hole 8331 and the cold water outlet hole 8332 of the first fixed plate 833 in different degrees, the hot water hole 8343 also synchronously communicates with the hot water inlet hole 8333 of the first fixed plate 833 and the hot water inlet hole 8353 of the second fixed plate 835 in different degrees depending on the rotation of the rotatable plate 834 .
[0091] As shown in FIG. 20 to FIG. 21 , the thermostat 82 has a tepid water inlet 821 , a hot water inlet 822 , and a mixing chamber 828 . The mixing chamber 828 of the thermostat 82 is provided with a thermostatic element 823 and a slider 825 therein. Substance in the thermostatic element 823 can automatically change the length of a tail 8231 of the thermostatic element 823 based on the water temperature in the mixing chamber 828 according to the principle of thermal expansion and contraction. When the water temperature in the mixing chamber 828 is higher than a temperature preset by the water-temperature regulating knob 85 by means of a control rod 824 , the tail 8231 of the thermostatic element 823 may lengthen to press the slider 825 downwards so as to narrow a hot water channel 8221 between the hot water inlet 822 and the mixing chamber 828 and widen a tepid water channel 8211 between the cold water inlet 821 and the mixing chamber 828 to increase the amount of tepid water in the mixing chamber 828 and decrease the amount of hot water, thereby lowering the water temperature in the mixing chamber 828 . However, when the water temperature in the mixing chamber 828 is lower than the temperature preset by the water-temperature regulating knob 85 by means of the control rod 824 , the tail 8231 of the thermostatic element 823 may shorten, a spring 827 may push the slider 825 upwards so as to widen the hot water channel 8221 and narrow the tepid water channel 8211 , to increase the amount of hot water in the mixing chamber 828 and decrease the amount of tepid water, thereby raising the water temperature in the mixing chamber 828 . The thermostat 82 is further internally provided with a flow regulating rod 836 , which is connected to a connector 837 and a connector 838 , to enable the connector 838 to synchronously rotate with the flow regulating knob 86 . The flow regulating rod 836 , the connector 837 , and the connector 838 pass through the interior of the thermostat 82 , and one end 8381 of the connector 838 protrudes from the thermostat 82 , and is inserted into a tepid water output hole 8344 in the center of the rotatable plate 834 of the flow regulating valve 83 so as to drive the rotatable plate 834 to synchronously rotate with the flow regulating knob 86 .
[0092] FIG. 22 and FIG. 23 illustrate state changes generated by rotation of the rotatable plate 834 relative to the first fixed plate 833 and the second fixed plate 835 . In an initial state shown in FIG. 22 , that is, when the flow regulating valve 83 is in an off state, the groove 8341 of the rotatable plate 834 does not cover the cold water inlet 8331 and the cold water outlet 8332 of the first fixed plate 833 , and the hot water hole 8343 of the rotatable plate 834 does not cover the hot water inlet hole 8333 of the first fixed plate 833 , so that the cold water inlet hole 8331 and the cold water outlet hole 8332 are spaced apart from each other but are not in communication, and the hot water inlet hole 8333 of the first fixed plate 833 and the hot water inlet hole 8353 of the second fixed plate 835 are also spaced apart from each other but are not in communication.
[0093] When the flow regulating knob 85 is used to rotate the rotatable plate 834 , the rotatable plate 834 gradually enters a full-on state as shown in FIG. 23 . In this case, as shown in FIG. 23 to FIG. 25 , the groove 8341 of the rotatable plate 834 completely covers the cold water inlet 8331 and the cold water outlet 8332 , and the hot water hole 8343 of the rotatable plate 834 completely covers the hot water inlet hole 8333 of the first fixed plate 833 , so as to be completely communicated with the hot water inlet hole 8353 of the second fixed plate 835 . Cold water supplied by a cold water source enters the cold water outlet hole 8332 through the cold water inlet hole 8331 and the groove 8341 , that is, the cold water is output to the cold water outlet 815 of the housing 81 through the cold water inlet 814 of the housing 81 to be supplied to a heat exchanger 3 . The cold water exchanges heat with hot wastewater from an application device (for example, a washing facility) in the heat exchanger 3 , so that the cold water becomes tepid water and is then communicated with the tepid water inlet 816 of the housing 81 ; meanwhile, hot water supplied by a hot water source is communicated with the hot water inlet 822 of the thermostat 82 through the hot water inlet aperture 819 , and the hot water inlet holes 8333 , 8343 and 8353 of the first fixed plate 833 , the rotatable plate 834 and the second fixed plate 835 . The tepid water and the hot water enter an hole 8371 of the connector 837 and a central hole 8381 of the connector 838 through the cavity 828 by means of the thermostat 82 , and then provide hot water with a stable water temperature at the temperature preset by the temperature regulating knob 86 by means of the control rod 824 for the tepid water outlet 817 of the housing 81 through tepid water output holes 8354 , 8344 and 8334 in the center of the second fixed plate 835 , the rotatable plate 834 and the first fixed plate 833 so as to be supplied to the application device.
[0094] The working principle of the heat energy recycle device of FIG. 25 is substantially similar to that of the heat energy recycle device shown in FIG. 10 and thus omitted herein.
[0095] In the above examples, the rotatable plates 56 , 76 and 834 regulate the fluid flow passing through the fluid control device of the present invention by means of rotation. It should be understood by one skilled in the art that this could be achieved by other means of movement such as linear movement etc to regulate the fluid flow control. Such variations fall within the spirit and scope of the present invention.
[0096] Although various embodiments of the present invention have been described above in detail, variations and improvements to the present invention may be further made by a person skilled in the art. It should be understood that such variations and improvements shall fall within the spirit and scope of the present invention. It should be noted that although the aforementioned embodiments have exemplified with water as an example of fluids to illustrate the structure and operation of the present invention, one person skilled in the art should appreciate that the embodiments of the present invention is not limited to the usage of water, but also fit for all other suitable fluids. | A fluid control device includes a housing and a fluid temperature control assembly. The housing includes a first inlet, a second inlet for receiving a fluid, and a first outlet through which a fluid of a third temperature flows. The fluid temperature control assembly is in the housing, with apertures for regulating fluid communication between a mixing cavity and the first inlet of the housing, apertures communicating with the first outlet. The fluid temperature control assembly modifies properties of the apertures for regulating the amount of fluid having a first temperature relative to the amount of fluid having a second temperature with the mixing cavity, thereby maintaining the fluid discharged from the first outlet at a predetermined temperature. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording tape cartridge which rotatably accommodates a single reel onto which a recording tape, such as a magnetic tape or the like, which is used as a recording/playback medium of a computer or the like, is wound.
2. Description of the Related Art
Conventionally, magnetic tape cartridges have been known in which a magnetic tape, which is used as a data recording/playback medium of a computer or the like, is wound on a single reel and the reel is accommodated within a plastic case. A leader member, such as a leader block or a leader pin, for example, is provided at a distal end (free end) of the magnetic tape. A drawing-out means, which is provided at a drive device, pulls out the leader member from the magnetic tape cartridge, so that the magnetic tape fixed to the leader member is wound onto a take-up reel of the drive device.
A reel gear is carved in an annular shape at a center of a bottom surface of the reel which emerges from an opening formed in a bottom surface of the magnetic tape cartridge. Due to a driving gear, which is provided at a rotating shaft of the drive device, meshing with the reel gear, the reel is driven to rotate. Further, due to the reel of the magnetic tape cartridge and the take-up reel of the drive device being rotated synchronously, writing and reading of information on the magnetic tape can be carried out.
Such magnetic tape cartridges have leader members provided at the distal ends of the magnetic tapes, as described above. In the case of a leader block 70 , as shown in FIG. 5 , an opening 76 of the magnetic tape cartridge can be closed off by the leader block. The leader block 70 has an outer wall surface 72 which is outwardly exposed from the opening 76 and provided with a rear end portion 72 B. The leader block also has a front end portion 72 A and a concave portion 74 which is next to the front end portion and with which a drawing-out member 60 of a tape drive comes into engagement. By the rear end portion 72 B being hooked at a front end portion 82 B of a right wall of a case 80 and by the front end portion 72 A being hooked at a right end portion 82 A of a front wall of the case 80 , the leader block 70 can be retained so as to close off the opening 76 .
More specifically, the front wall right end portion 82 A of the case 80 has a slit 78 formed at an interior thereof by which the right end portion 82 A is elastically deformable in a front-back direction of the case 80 . Due to such an elastically deformable means formed on the case side, the leader block 70 can be detachably hooked and retained with respect to the case 80 . A force of the case 80 for holding the leader block 70 is sufficient to prevent the leader block 70 from easily falling from the case 80 even with the application of shocks due to dropping and the like.
Further, when the opening 76 is closed of by the leader block 70 , the magnetic tape T is pulled and held by a predetermined tension in a winding direction of a reel (not shown in the drawings) so as to prevent slack and the like which may occur within the case 80 . Therefore, when the leader block 70 is drawn out from the case 80 by the drawing-out member 60 of the tape drive side, some load is applied to the magnetic tape T, even though the reel is driven to rotate. Consequently, it is necessary that a force of the drawing-out member for drawing out the leader block 70 surpasses the load applied to the magnetic tape T and the holding force of the case 80 without the risk of elongation or breakage of the magnetic tape T.
Namely, it is necessary that the leader block 70 is suitably retained by the case 80 when the magnetic tape cartridge is not in use and that the leader block 70 is easily detachable from the case 80 when the magnetic cartridge is in use. Therefore, force-balancing between the drawing-out force exerted by the drawing-out member 60 and the holding force exerted by the case 80 must be appropriately maintained through delicate adjustment. Until now, such an adjustment has been effected by adjusting an elastically deformable means that is formed on the case side or by adjusting an elastic force of the front wall right end portion 82 A that is formed with the slit 78 .
Generally, cases of magnetic tape cartridges have a variety of mechanisms formed on outer surface portions thereof and are often subjected to modification and the like. If such a means for holding a leader block to a case is provided at the case side in this typical way, a degree of freedom of design of the case is adversely affected such that there are many more constraints on the case structure. Further, since the above-described force-balancing must be realized at the case side, the cost of manufacturing the cases is inevitably increased.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a recording tape cartridge that can eliminate the aforementioned problems of the prior art.
In order to achieve the object described above, according to a first aspect of the present invention, there is provided a tape cartridge which is insertable at a tape drive, the drive being provided with a drawing-out member which is operably engageable with the tape cartridge at a time of insertion of the tape cartridge and carrying out at least one of reading and writing of data, the tape cartridge comprising: a reel on which a recording tape is wound; a leader block attached to an end of the recording tape; a case for accommodating the reel; and a leader block receiving portion which is provided in the case and in which the leader block is received; wherein the leader block is elastically deformable and is capable of being held at the leader block receiving portion by an elastic restoring force of the leader block itself.
According to a second aspect of the present invention, there is provided a tape drive into which a tape cartridge is removably inserted and which can carry out at least one of reading and writing of data at a time of insertion of the tape cartridge, the tape drive comprising a drawing-out member for drawing-out a recording tape, the drawing-out member being operably engageable with the tape cartridge, wherein the tape cartridge comprises a reel on which the recording tape is wound, a leader block attached to an end of the recording tape, a case for accommodating the reel, and a leader block receiving portion which is provided in the case and in which the leader block is received, and wherein the leader block is elastically deformable and is capable of being held at the leader block receiving portion by an elastic restoring force of the leader block itself.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded schematic perspective view of a magnetic tape cartridge as seen obliquely from above.
FIG. 2 is a schematic perspective view showing a leader block according to the present invention.
FIGS. 3A , 3 B, and 3 C are explanatory diagrams of a detaching operation of the leader block according to the present invention.
FIGS. 4A and 4B are explanatory diagrams of an attaching operation of the leader block according to the present invention.
FIG. 5 is a schematic perspective view showing a conventional leader block and a drawing-out member of a drive device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described in detail below on the basis of the drawings. For the sake of convenience of explanation, a direction of loading a recording tape cartridge into a drive device (the direction of arrow P in FIG. 1 ) is referred to as a front direction, and other directions of back, left, right, top, and bottom will be specified on the basis of the front direction. Further, a magnetic tape is used as a recording tape, and hereinafter, explanation will be given with regard to a magnetic tape cartridge.
As shown in FIG. 1 , a magnetic tape cartridge 10 is formed in the shape of a substantially rectangular box by an upper case 20 and a lower case 30 , which are each formed from a synthetic resin, being joined together by ultrasonic welding such that peripheral walls 22 and 32 thereof abut one another. A single reel 12 , on which a magnetic tape T serving as an information recording/playback medium is wound, is rotatably accommodated within the magnetic tape cartridge. Specifically, free play-restricting walls 24 and 34 , each being semi-cylindrical, are provided protruding at interior surfaces of the upper case 20 and the lower case 30 . The reel is accommodated inside the free play-restricting walls 24 and 34 .
A circular aperture 36 is formed at a center of the lower case 30 . A reel gear (not shown in the drawings), which is formed on a bottom surface of the reel 12 and has an annular shape, is exposed from the circular aperture 36 . The reel 12 is structured such that a cylindrical reel hub 14 and a bottom flange portion 18 radially projecting from a periphery of a bottom end of the reel hub 14 are integrally formed from a synthetic resin, and a top flange portion 16 having the same shape as the bottom flange portion 18 is joined by ultrasonic welding or the like to a top end of the reel hub 14 . Then, the magnetic tape T is wound around a peripheral surface of the reel hub 14 .
An opening 26 is formed at a front-right corner portion of the magnetic tape cartridge 10 by partially cutting away peripheral walls 22 and 32 . The opening 26 is for drawing out to an exterior of the magnetic tape cartridge 10 the magnetic tape T wound on the reel 12 . When the magnetic tape cartridge 10 is not in use, a leader block 40 , which is secured to a distal end of the magnetic tape T, is held at the front-right corner portion, thereby closing off the opening 26 .
A curved recess portion 48 , which is substantially semi-cylindrical in plan view, is formed at a front end of the leader block 40 . Recess portions 28 and 38 , which have substantially the same curvature as the curved recess portion 48 , are formed at locations of the upper case 20 and the lower case 30 in a vicinity of the opening 26 , which correspond to a location of the curved recess portion 48 of the leader block 40 when the opening 26 is closed off by the leader block 40 . As a result, a drawing-out member 60 (see FIG. 5 ) of the drive device for drawing out the leader block 40 is easily insertable into the curved recess portion 48 .
That is, the leader block 40 is drawn out from the magnetic tape cartridge 10 by moving the drawing-out member 60 , which has been inserted and held in the curved recess portion 48 , to a take-up reel (not illustrated) of the drive device. Thereafter, the leader block is fitted into a fit-in portion (not illustrated) that is provided on a reel hub of the take-up reel of the drive device, so that the magnetic tape can be wound around the take-up reel of the drive device.
Next, detailed explanation will be given with regard to the leader block 40 and holding portions for holding thereof, of the upper case 20 and the lower case 30 in the magnetic tape cartridge described above. As shown in FIGS. 1 through 4B , the leader block 40 is formed by deforming a plastic or metal, flat plate to the general shape of a “7”, as viewed from below. A longer first arm 42 and a shorter second arm 44 thereof are connected by a connection arm 46 . Due to elasticity of the connection arm 46 , the first arm 42 and the second arm 44 are elastically deformable in directions along which they move toward and away from one another (the directions being orthogonal to a heightwise direction of the magnetic tape cartridge 10 ).
That is, the leader block 40 comprises the first arm 42 having an outer wall surface 42 A which is exposed from the opening 26 when the leader block 40 is held by the upper case 20 and the lower case 30 so as to close the opening 26 , the second arm 44 which is disposed substantially parallel to the first arm 42 and has a length that is shorter than the first arm 42 , and the connection arm 46 which connects the first arm 42 and the second arm 44 and is formed in a circular-arc shape as seen in plan view. An outer wall portion 46 A of the connection arm 46 constitutes part of an outer peripheral surface of the reel hub of the take-up reel.
Further, the curved recess portion 48 is formed at a front end of the first arm 42 , is substantially semi-cylindrical in plan view, and engages the drawing-out member 60 of the drive device. The second arm 44 is provided with a recess portion 49 for securing the magnetic tape T, which recess portion 49 is formed in a circular-arc shape as seen in plan view. Specifically, a substantially columnar pin 50 , which is made of elastic material and has a diameter that is equal to or somewhat larger than a diameter of the recess portion 49 , is inserted into the recess portion 49 with the magnetic tape T tucked therein such that the leader block 40 is secured to the distal end (free end) of the magnetic tape T.
On the other hand, right wall portions of mutually joined peripheral walls 22 , 32 of the upper case 20 and the lower case 30 , are integrally formed at front ends thereof with first holding portions 52 for holding a portion of the first arm 42 in the vicinity of a boundary of the connection arm 46 . Further, second holding portions 54 for holding a portion of the second arm 44 in the vicinity of another boundary of the connection arm 46 are integrally formed in a projecting manner, having a height less than or equal to a thickness of the bottom flange portion 18 , at predetermined positions on inside surfaces of the right wall portions of the upper case 20 and the lower case 30 . Side surfaces of the first and second holding portions 52 and 54 serve as abutment surfaces to the first and second arms 42 and 44 , respectively. Further, it is preferable to provide the second holding portions 54 continuously with an inner surface of the right wall, as illustrated, in consideration of the strength.
In plan view as shown in FIGS. 3A-3C and 4 A and 4 B, a distance (spacing) between the first holding portion 52 and the second holding portion 54 is somewhat shorter than a width of the connection arm 46 of the leader block 40 (i.e., the distance between an outer wall of the first arm 42 and an outer wall of the second arm 44 ). Accordingly, when the leader block 40 is inserted between the first holding portion 52 and the second holding portion 54 while being slightly pressed so as to oppose an elastic force of the connection arm 46 , in a direction in which the first arm 42 and the second arm 44 move toward one another, the leader block 40 is secured and held therebetween by the first arm 42 and the second arm 44 respectively pressing on the first holding portion 52 and the second holding portion 54 under a predetermined pressure based on restoring force of the connection arm 46 .
As described above, the height of each of the second holding portions 54 is less than or equal to a thickness of each of the flange portions 16 and 18 of the reel 12 , and a height of the leader block 40 is greater than a width of the magnetic tape T (see FIG. 2 ). As a result, there is no problem in that the magnetic tape would interfere with the second holding portions 54 . The leader block 40 is structured such that when the drawing-out member 60 of the drive device elastically deforms the connection arm 46 by pressing the first arm 42 toward the second arm 44 via the curved recess portion 48 to separate the first arm 42 from the first holding portion 52 , the leader block 40 can be detached from between the first holding portion 52 and the second holding portion 54 .
Load-balance between a holding force exerted by the upper case 20 and the lower case 30 and a pulling-out force exerted by the drawing-out member 60 can be maintained by adjusting an elastic force exerted by the connection arm 46 . More specifically, by appropriately establishing a (bending) force to be required at a time when the first arm 42 and the second arm 44 are bent toward one another, a holding force exerted by the upper case 20 and the lower case 30 can be adjusted, and, by appropriately establishing a (bending) force to be generated at a time when the first arm 42 and the second arm 44 are bent so as to move away from one another, a pulling-out force exerted by the drawing-out member 60 can be adjusted.
Detaching and attaching operations of the leader block will now be described. When the magnetic tape cartridge 10 is inserted into the drive device, the drawing-out member 60 of the drive device is firstly moved to engage the curved recess portion 48 of the leader block 40 which is hooked and held between the first holding portion 52 and the second holding portion 54 so as to close the opening 26 (see FIG. 3 A). Next, as shown in FIG. 3B , the drawing-out member 60 presses and moves the curved recess portion 48 toward the second arm 44 , so that the first arm 42 moves toward the second arm 44 , while opposing an elastic (restoring) force of the connection arm 46 .
At that moment, the first arm 42 separates from the holding portion 52 . By maintaining this separated state and by moving the drawing-out member 60 toward the outside (in a direction in which the drawing-out member 60 departs from the opening 26 ), the second arm 44 can be separated from the second holding portion 54 , so that the leader block 40 is detached from between the first holding portion 52 and the second holding portion 54 (see FIG. 3 C). As described above, because the force to be required for detaching the leader block from the first and second holding portions via the drawing-out member 60 is appropriately adjusted by establishing an elastic force due to the connection arm 46 , problems such as tape breakage or the like can be prevented.
The leader block 40 , which has been drawn out through the opening 26 in the manner described above, is then mounted on the take-up reel of the tape drive. The drive device rotates the reel 12 and the take-up reel simultaneously and carries out recording of information onto the magnetic tape T and/or replaying of information that has been recorded on the magnetic tape T.
When the magnetic tape T has been wound back to the reel 12 , the leader block 40 is detached from the take-up reel and then disposed so as to again close off the opening 26 . Specifically, the leader block 40 is inserted through the opening 26 by the drawing-out member 60 which engages the curved recess portion 48 , so that the second arm 44 abuts the second holding portion 54 . Then, the first arm 42 is further pressed and moved toward the second arm by the drawing-out member 60 such that the connection arm 46 is bent and deformed (see FIG. 4 A).
Thereafter, as shown in FIG. 4B , when the drawing-out member 60 is moved in the return direction and detached from the curved recess portion 48 , the first arm 42 is moved by a restoring force of the connection arm 46 in a direction in which it moves away from the second arm 44 , so that the first arm 42 abuts and presses the first holding portion 52 with a predetermined pressure. In other words, due to an elastic force (a restoring force) of the connection arm 46 , the first arm 42 and the second arm 44 press against the first holding portion 52 and the second holding portion 54 , respectively, with a predetermined pressure.
Consequently, the leader block 40 is again hooked and held between the first holding portion 52 and the second holding portion 54 such that the leader block 40 closes off the opening 26 . Because the holding force (i.e., the predetermined pressure mentioned above) for holding the leader block 40 to the upper case 20 and the lower case 30 is effectively ensured due to the elastic force of the connection arm 46 , the leader block 40 does not easily come apart from the opening 26 even with the application of shocks due to dropping and the like.
As described above, in the magnetic tape cartridge according to the present invention, an elastic, deformable means for holding and anchoring the leader block 40 is formed at the leader block rather than at the case. In other words, the leader block 40 has elasticity that allows deformation in a direction orthogonal to the heightwise direction of the magnetic tape cartridge 10 . Accordingly, if it is not possible to form such means at a case due to frequent design changes or the like, setting or adjustment of forces for holding and pulling-out the leader block 40 can be easily carried out on the leader block side.
Thus, for example, when the magnetic tape cartridge 10 is not in use, the leader block 40 is not easily and improperly removed from the opening 26 , whereas, when the magnetic tape cartridge is in use, there is no difficulty in removing the leader block 40 from the opening 26 .
In accordance with the present invention, even when case portions in the vicinity of the opening are subjected to improvements and the like, load-balance between a holding force and a pulling-out force with respect to the leader block can be easily maintained by simply adjusting the elastic force of the leader block itself. | The instant invention provides a recording tape cartridge in which there is no need for adjustment on the case side with respect to forces for holding and drawing-out a leader block. The tape cartridge comprises: a reel on which a recording tape is wound; a leader block attached to an end of the recording tape; a case for accommodating the reel; and a leader block receiving portion which is provided in the case and in which the leader block is received; wherein the leader block is elastically deformable and is capable of being held at the leader block receiving portion by an elastic restoring force of the leader block itself. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for computing vehicle speed from a signal provided by a vehicle speed sensor. More particularly, the invention presents such a method which provides a stabilized or optimized vehicle speed value for use by vehicle speed control systems.
Many modern vehicles include a variety of electronic controls, particularly an electronic engine control system for the internal combustion engine. Most such electronic engine control systems provide cruise control or vehicle speed governing capabilities. Such systems and algorithms for cruise control or closed loop vehicle speed are well known in the art.
All such systems require as input some value indicative of the actual vehicle road speed which is derived from a speed sensor. Many types of sensors are available for generating a signal indicative of the vehicle speed, most of which are of the pulse generator type. One such pulse generator is a variable reluctance device in which a magnetic pickup located adjacent a rotating component of the drive train produces a pulse with every rotation of the drive train component. In another similar sensor, known as the MINIGEN™ sold by Synchrastart Co., a mechanical cable is driven by the drive train and the cable rotation is sensed. The timing of the sensor pulses is typically determined by counting the time for a given number of pulses to pass. This timing value is then used to calculate the actual vehicle speed by application of a number of conversion factors.
One difficulty with speed sensors of this type is that the pulse signals have a wide output tolerance and are often subject to errors and inaccuracies. Such errors include a wide variation in time between pulses which can lead to erroneous vehicle speed calculations. Most cruise control systems require a relatively higher accuracy vehicle speed value. Inaccurate or widely varying vehicle speed values can cause a cruise control to oscillate about the vehicle speed set point as it governs the vehicle speed. Some sensors are available that can generate a clean narrow tolerance pulse train, but these sensors are more expensive than the less accurate V/R type sensors. Moreover, many of the more sophisticated sensors are not readily adapted to the harsh environment of the vehicle drive train as the V/R speed pickup sensors. Vibration, dirt and electrical or magnetic interference can render the more sophisticated sensor impractical for use in an automotive setting.
There is a need for a method for processing the pulse train from a relatively low accuracy vehicle speed sensor and generating a higher quality accurate vehicle speed value for use by the cruise control or vehicle speed governing routines of an electronic engine control.
SUMMARY OF THE INVENTION
In view of this need, a primary object of this invention is to provide a method for performing vehicle speed calculations using a low quality, wide tolerance vehicle speed signal. The method contemplates using the more accurate engine crankshaft speed measurement provided by the electronic engine control system to compute a gear ratio, which is simply the ratio of engine speed to the vehicle road speed in normalized units. In a first subroutine, this calculated gear ratio is passed through a single pole digital filter to produce a filtered gear ratio.
A number of tests are applied to determine if this filtered gear ratio has stabilized about a certain value. If not, a usable filtered gear ratio is continuously modified over a settling time. The usable filtered gear ratio is passed to a subsequent second subroutine which computes a predicted vehicle road speed. This predicted vehicle road speed is in a proper form to be supplied to the cruise control or closed loop speed control system of the electronic engine control.
In an important aspect of the method of the invention, once a stabilized usable filtered gear ratio has been obtained in the first subroutine, this stabilized value remains unchanged in spite of minor deviations in the sensed vehicle speed signal. A new usable filtered gear ratio is passed on to the second subroutine only when the sensed vehicle speed signal falls outside predetermined tolerance limits. Such a deviation can be attributable to a change in driving gear (such as through shifting gears) or to gear lash or other variations in the transmission and drive train.
In another aspect of the invention, the second subroutine includes a slew rate limit feature to further "smooth" the vehicle speed value sent to the engine control system. Changes in predicted vehicle speed that exceed a maximum slew rate are modified to produce smoother predicted vehicle speed transitions between successive vehicle speed calculations.
One significant feature of the invention is that the method utilizes the more accurate engine speed information to predict the vehicle road speed. The method produces a gear ratio value by which the engine speed may be multiplied to obtain the vehicle speed. Steps of the method generate an optimized or stabilized gear ratio value for this calculation.
It is one object of the present invention to provide a method for determining a vehicle speed value usable by electronic engine control systems for cruise control or closed loop vehicle speed control. A more specific object is to provide such a speed value that is less susceptible to the frailties and wide tolerances of some vehicle speed sensors.
A further object of the method of the invention is to provide a vehicle speed value that remains at a stabilized value in spite of minor fluctuations in the sensed vehicle speed signal, but that can be modified when a change in vehicle driving gear or an actual vehicle speed change occurs. Other objects, and certain benefits, of the present invention can be discerned from the following description of the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart showing the steps of the method for computing a stabilized vehicle speed value from a pulse signal.
FIG. 2 is a flowchart of the detailed steps of a first subroutine from the flowchart of FIG. 1.
FIG. 3 is a flowchart of the detailed steps of a second subroutine from the flowchart of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
FIG. 1 shows a flowchart of one embodiment of the method and algorithm for computing a stabilized vehicle speed value according to the present invention. In this algorithm, the vehicle speed is calculated in a continuously executed Loop A beginning at entry point A, Step 12 in the flowchart. Each of the subsequent steps is executed sequentially from Step 12 and to the return Step 55. The entire loop and all the calculations performed in the loop are executed over a predetermined time period. In one specific embodiment, the loop time is 0.1 seconds, which permits adequate sampling of the vehicle and engine speeds while allowing time for all the computations to be performed.
At initial startup of the algorithm, that is prior to the beginning of the Loop A, certain variables used by the algorithm are initialized or preset in Step 10. The manner in which the variables are preset depends upon the variable. Since many of the calculations performed in the loop are recursive in nature, most of the algorithm variables are preset to a non-zero value in the range of an expected value for that variable.
With the commencement of the algorithm loop at Step 12, the vehicle speed sensor pulses are read in Step 14 and used to obtain a time interval value Δt 1 , which is indicative of the vehicle road speed. In the preferred embodiment, this Δt 1 corresponds to the amount of time required for sixteen vehicle speed sensor pulses to pass. Most V/R type sensors generate a signal having 15,000 to 48,000 pulses per mile driven by the vehicle. Vehicle rear end ratio, tire size and pulses per tailshaft revolution determine the pulses per mile value. Although the time interval for the passage of sixteen pulses is measured in the preferred embodiment, fewer or greater numbers of pulses may be sensed to derive a Δt 1 value. In the next Step 16, a sampled road speed SRS is calculated using the measured Δt 1 , by dividing this time value into a conversion constant C 1 . This conversion constant C 1 has the units mph*seconds to convert the sampled signal time to miles per hour.
In Step 18, a second conversion factor C 2 is applied to the calculated sample speed SRS to convert this mph road speed to a tailshaft rpm value, RPM t . It is understood that the tailshaft is the rotating shaft output from the vehicle transmission after the engine rotational speed has been geared up or down. This value RPM t for the tailshaft rpm is based upon the loosely toleranced signal from the vehicle speed sensor, so that the value itself may vary widely between consecutive passes through the Loop A.
In the next two steps of the algorithm, Steps 20 and 22, the engine speed is determined. The nature of the Steps 20 and 22 will depend upon the engine speed data available from the electronic engine control system. In one specific embodiment, actual engine crankshaft speed values can be obtained from memory locations within the electronic control system. Thus, in Step 20, the last six stored engine crankshaft speed values are read. For clarity, the engine speed values are designated RPM(n), where n=1 to 6. In another specific embodiment, a delta time measurement is made from top dead center (TDC) of one cylinder to TDC of the next cylinder as determined from the rotating camshaft gear. It is understood that the top dead center positions on the camshaft gear for a six-cylinder diesel engine occur every sixty degrees of camshaft rotation. Thus, determining the delta time value from top dead center to top dead center produces six engine crankshaft speed values in one rotation of the camshaft.
These six speed values are then entered into the variable RPM(n). An average engine rpm over the most recent full camshaft rotation is calculated using these six rpm values, as indicated in Step 22. A straight arithmetic average is determined by summing each of the RPM(n) values and dividing by six. This averaging calculation eliminates the manufacturing errors associated with locating the top dead center targets on the camshaft gear. A new variable RPM ave obtained in Step 22 is the computed average engine crankshaft rpm over the last camshaft rotation. This value is based upon the relatively more sensitive and accurate sensors used by the electronic engine control system to determine engine speed.
The tailshaft rpm value RPM t and the engine rpm value RPM ave are then passed to Step 24 in which a gear ratio is calculated. The gear ratio is the ratio of the average engine rpm to the tailshaft rpm, as shown in the equation in Step 24. This gear ratio variable GR is simply a measure of the step up or down in speed provided by the vehicle transmission and associated gearing. This calculated gear ratio value GR is based in part upon the low integrity vehicle speed sensor signal. Consequently, the variable GR is passed through a Subroutine 30 which filters the gear ratio and generates an optimized gear ratio value to be passed down the loop. A principal object of the Subroutine 30 is to generate a filtered gear ratio value that does not vary unnecessarily with each pass through the Loop A. Thus, the subroutine, produces a usable filtered gear ratio that does not change with every minor variation in sensed vehicle speed. In addition, the Subroutine 30 provides means for computing a new usable filtered gear ratio when a change in vehicle gearing or an actual change in vehicle speed occurs.
This usable gear ratio, designated as variable UGR, is passed to a subsequent Subroutine 40 which determines a slew rate limited predicted vehicle road speed. The function of this Subroutine 40 is to limit the rate of change of the predicted vehicle road speed provided to the engine control system. In one specific embodiment, the Subroutine 40 limits changes in predicted vehicle speed to a slew rate of 2.0 mph per second. In other words, the predicted vehicle road speed is not permitted to change faster than two mph per second on each pass through algorithm Loop A. The slew rate limited predicted vehicle road speed generated by Subroutine 40 is designated as variable PMPH. This variable PMPH is stored in Step 50 within an internal memory of the engine control system for use by the vehicle speed control routines. After the storage Step 50, the control is passed in the return Step 55 to the beginning of the Loop A at Step 12. The calculations in Loop A are constantly repeated and the SLEW RATE LIMITED predicted vehicle road speed PMPH is constantly updated as required by the circumstances.
The details of the Subroutine 30 are shown in the flowchart of FIG. 2. In the first step of this subroutine, Step 31, the gear ratio GR is passed through a single pole digital filter to generate a filtered value GR F . The single pole digital filter is a unity gain first order filter implemented by the following equation GR F =GR*G m +GR F *G n where G m and G n are gain values for a known single pole filter. In the preferred embodiment, the single pole digital filter has a time constant τ of approximately seven seconds. The time constant τ is adapted to achieve a filtered gear ratio that settles to a state in which the value does not vary outside predetermined limits so long as the vehicle transmission remains in the same driving gear. According to standard digital filtering techniques, G n is equal to e -T/ τ, and G m is 1.0-G n . Thus, for the specific illustrated embodiment the filtered gear ratio equation reduces to GR F =0.02*GR+0.98*GR F . It should be clear that this single pole filter gives predominant consideration to the last calculated gear ratio GR F . The filter thus automatically minimizes changes in the unfiltered GR between loop passes.
Since Step 31 represents a recursive equation in which the current filtered gear ratio GR F is a function of the last calculated value for the filtered gear ratio, a preset value for GR F is provided in Step 10 prior to entering the algorithm Loop A. Regardless of the preset value for GR F , the Subroutine 30 will rapidly bring the newly calculated gear ratio GR F to a value appropriate for the current vehicle speed and engine rpm.
It should be apparent from the digital filter equation in Step 31 that changes in the filtered gear ratio GR F will occur more slowly than changes in the gear ratio GR calculated in prior Step 24, specifically since the gain factor G m applied to the gear ratio GR is considerably less than the gain factor G n applied to the previous filtered gear ratio value.
After the filtered gear ratio GR F is determined, a test is made in Step 32 to ascertain whether a vehicle driving gear change has occurred. As is well known, when the vehicle transmission gear changes the ratio between the engine speed and the vehicle speed also changes. According to the present invention, the test compares the unfiltered gear ratio GR with the filtered gear ratio GR F . If the absolute value of the difference between these two variables is greater than a predetermined limit parameter D 1 , then it is determined that a gear shift has occurred. The limit parameter D 1 is set to a value greater than the smallest step in gear ratios between one driving gear to the next. In the specific embodiment, the limit value D 1 is set so that a difference of 10% between the unfiltered and filtered gear ratios will cause recognition of a gear shift. The limit parameter D 1 can be unitless based simply upon the arithmetic difference between the filtered gear ratio GR F and the unfiltered gear ratio GR. Alternatively, the limit parameter D 1 can be a percentage value, such as 10%, in which case the test equation would be modified to 100*(GR-GR F )/GR F .
If the test in Step 32 is passed, that is if a gear shift is recognized, control in the algorithm passes to Step 33. In this step, the filtered gear ratio GR F is set equal to the unfiltered value GR since the calculated GR more accurately reflects the true gear ratio after the shift. This revised filtered gear ratio value of GR F is applied on the right hand side of the filter equation in Step 31 in the next following loop through the algorithm. In addition, in Step 33, a background timer is loaded with a time value T set , which corresponds to a settling time increment. This programmable settling time T set fixes an amount of time over which the filtered gear ratio GR F must remain relatively constant in order to be regarded as stabilized. In the preferred embodiment, this settling time T set is equal to six times the time constant of the digital filter. In the specific embodiment in which the time constant is seven seconds, the value T set is equal to forty-two seconds. That is, the filtered gear ratio GR F is given forty-two seconds to settle on a relatively stable value before that filtered gear ratio is regarded as stabilized and therefore not changed in subsequent steps of the algorithm.
The timer referred to in Step 33 can be a background count-down timer which can be loaded with new values. Alternatively, the timer can be a software timer within the algorithm Loop A in which the timer is decremented with each pass through the loop. Implementation of the timer can be left to a person of ordinary skill, provided that the timer can be loaded with the settling time value T set as required by the Subroutine 30.
If no gear shift is detected by the test of Step 32, control passes to another test in Step 35. The limit parameter D 1 is set so that the expected variations in gear ratio due to normal drive train variations or loosely tolerances vehicle speed sensing will not trigger the Step 32 test. In addition, after Step 33 has been executed when a gear shift is recognized, control also returns to the same Step 35 following setting the new GR F value and loading the settling time T set into the background timer. In Step 35, the filtered gear ratio is tested to determine whether it has stabilized about a relatively constant value. In the preferred embodiment, the filtered gear ratio GR F is determined to be stabilized if its current calculated value is within about one percent (1%) of the filtered gear ratio calculated in the last pass through the algorithm Loop A. Thus, the test in Step 35 is whether the absolute value of the difference between GR F and a new variable UGR is greater than a limit parameter D 2 . The limit parameter D 2 represents a tolerance band within which the gear ratio will be regarded as relatively constant or fixed, even though the measured vehicle speed may vary slightly.
The limit parameter D 2 can be unitless for direct comparison between the non-dimensional gear ratio values and can have a value of 0.0118 in one specific embodiment. Alternatively, the limit parameter D 2 can be a percentage, in which case the inequality expressed in Step 35 must be divided by the filtered gear ratio GR F and multiplied times one hundred. The specific values for D 2 and the digital filter time constant translate to a tolerance band of about 2.5 mph for variations in the measured vehicle speed value SRS.
The value UGR corresponds to a usable gear ratio, by which is meant a gear ratio value that is ready for use in calculating a vehicle speed to be passed on to the engine control system. As with GR F , UGR must be preset in Step 10 at least for the initial start up of the algorithm Loop A. However, the value UGR will be reset within Subroutine 30 depending upon whether GR F has stabilized. If the filtered gear ratio has not stabilized about a value, the test in Step 35 is passed and control in the algorithm flows to Step 36. In this step the usable gear ratio UGR is set equal to the current filtered gear ratio GR F . It should be noted that this value GR F may have been recomputed in Step 33 if a gear shift has occurred. It is clear that a change in vehicle driving gear will also result in a rapid change in gear ratio, thus in a gear shift situation, the inequality test of Step 35 will also be satisfied.
Returning to Step 36, if the filtered gear ratio has not yet stabilized, the background timer is again loaded with the settling time T set . This step may be redundant in the event of a gear shift, since the background timer is also loaded in Step 33. However, the timer load is required in Step 36 when Step 33 is avoided because a gear shift has not occurred, since the filtered gear ratio may not be stabilized. The settling time is necessary to validate that the filtered gear ratio GR F has moved to a relatively fixed value.
If the filtered gear ratio is stabilized, that is if the difference between the last calculated filtered gear ratio and the current calculated filtered gear ratio is less than the limit parameter D 2 , the test in Step 35 fails and control passes to another test in Step 38. In this step, the background timer is interrogated to determine whether the settling time T set has expired. In other words, for a count-down background timer, the test in Step 38 is whether the timer value is equal to zero. If not, then it is determined that the filtered gear ratio has not yet demonstrated that it is stabilized by remaining relatively unchanged for the entire settling time. In other words, the stabilization test of Step 35 requires the difference between current and last filtered gear ratios to remain within the limit parameter D 2 a sufficient number of times though the Loop A for the settling timer to expire.
The philosophy behind Subroutine 30 is that the gear ratio is still varying too much to be locked in at one fixed value. Thus, in Step 39, the usable gear ratio UGR is set equal to the newly calculated filtered gear ratio GR F and control passes outside the Subroutine 30. If the settling time has expired, the test of Step 38 is passed, which means that the usable gear ratio UGR is not reset, but left at the value that it was on the prior pass through the algorithm Loop A. The value for the usable gear ratio UGR then passes from the Subroutine 30 into the Subroutine 40.
A principal function of the Subroutine 30 is to only change the usable gear ratio UGR when required. Changes in UGR are required when a gear shift has occurred or when the sensed vehicle speed, or more specifically the calculated gear ratio GR, varies or changes too much to be assessed as stabilized about a fixed value. In this instance, the usable gear ratio will change with each pass through the algorithm Loop A. However, if the gear ratio is determined to be stabilized by the various tests in Steps 32, 35 and 38, no change in the usable gear ratio UGR is required. This means that even though the calculated gear ratio GR and the calculated filtered gear ratio GR F may change, no similar change will be made to the gear ratio value UGR used by the later Subroutine 40. Minor variations in the gear ratio between successive passes through the Loop A less than the limit parameter D 2 will not require changes in the usable gear ratio UGR. This limit value D 2 can be changed depending upon the degree of accuracy required in the usable gear ratio UGR. In addition, the limit parameter D 2 can be changed if the sensed vehicle speed signal is itself more accurate for a "fine tuned" vehicle speed control.
In FIG. 3, the various steps of the Subroutine 40 are depicted. In this Subroutine 40, the vehicle road speed is predicted and limited by a programmable slew rate. In the first Step 42 of the Subroutine 40, a predicted road speed PRS is calculated according to the equation shown. This predicted road speed is a function of the average engine crankshaft rotational speed RPM ave and the usable gear ratio UGR. Various multipliers are applied to these two variables, including the conversion factor constant C 2 , which was used in Step 18 to convert sampled vehicle speed to tailshaft rpm. The units of this conversion factor constant C 2 are rpm over miles per hour. The usable gear ratio UGR is unitless, so that the units of the predicted road speed value PRS are in miles per hour.
In order to prevent rapid swings in predicted road speed between successive passes through the algorithm Loop A, the road speed passed on to the engine control system routines is limited by a programmable slew rate, D 3 . In Step 44, the current calculated predicted road speed PRS is compared with the road speed calculated in the last pass through the loop, designated as PRS' in FIG. 3. If the difference between these two values is greater than the limit parameter D 3 , slew rate limiting is required. In the preferred embodiment the limit parameter D 3 is based upon a slew rate limit of 2 mph/second. That is, the vehicle speed value sent to the engine control system is only permitted to vary over time at a rate less than two mph per second. The limit parameter D 3 is based upon this 2 mph/second slew rate and upon the time over which all of the calculations occur in the algorithm Loop A. As previously indicated, all the calculations are made every 0.1 seconds, so that D 3 is simply 0.1 seconds times 2 mph/second, or 0.2 mph.
If the difference between the current predicted road speed PRS and the last predicted road speed PRS' is greater than 0.2 miles per hour, slew rate limiting is required. In this instance, algorithm flow passes to Step 46. In this step, a new predicted miles per hour PMPH is computed. This value for PMPH is based upon the last PMPH that was sent to the engine control system, increased or decreased by the slew rate limit parameter D 3 . Whether the predicted miles per hour PMPH is reduced or increased depends upon the sign of the difference between the last predicted road speed PRS' and the current predicted road speed PRS. In other words, if the current predicted road speed is greater than the last predicted road speed PRS', the output speed in PMPH is increased from its last computed value by the value of D 3 .
If the test of Step 34 fails, that is if no slew limiting is required, the output variable PMPH is simply set equal to the predicted road speed PRS. Additional tests may be added to determine whether slew rate limiting should be overridden in order to track rapid changes in vehicle speed. Following the completion of either Step 46 or 48, the program flow passes to Step 50 in which the value for PMPH is stored in a memory within the engine control system for use by the vehicle speed control or cruise control routines.
The method and algorithm of the present invention can be implemented within the electronic engine control system. The continuous algorithm Loop A can be readily translated to program code for the microprocessor of the electronic engine control system, which translation is application specific but within the ordinary skill of persons in the relevant field. The microprocessor code can permit user entry of the various limit parameters and conversion constants. The algorithm accepts as inputs the pulse signals from the vehicle speed sensor and the engine rpm values, and produces as an output a predicted vehicle road speed PMPH.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A method is provided for computing a stabilized vehicle speed value from a detected vehicle speed pulse signal and a detected engine speed signal, the vehicle speed value being for use by a vehicle speed control system. The method comprises several continuous cyclic steps commncing with generating a measured vehicle speed value from the detected vehicle speed pulse signal and generating a measured engine speed value from the detected engine speed signal. A current gear ratio is calculated from the measured vehicle speed value and the measured engine speed value. This current gear ratio is then passed through a single pole digital filter to filter changes in the gear ratio between consecutive cycles as a function of the current gear ratio and the gear ratio computed in the last preceding cycle of the computation. A current usable gear ratio is generated which is changed from the most recently generated usable gear ratio only if changes in the gear ratio exceed predetermined limit values. Otherwise the current usable gear ratio is unchanged from its most recently generated value. A stabilized predicted vehicle speed value is then computed from the measured engine speed and the current usable gear ratio for use by the vehicle speed control system. Slew rate limiting of the predicted vehicle speed is also provided by the method. | 1 |
This is a continuation-in-part of U.S. Ser. No. 07/384,647 filed Jul. 24, 1989, and now U.S. Pat. No. 5,017,735.
FIELD OF THE INVENTION
The invention relates to a process for the separation of various dialkyl multinuclear aromatic compounds from a feed stream of mixed isomers of those compounds. A shape selective adsorbent is employed resulting in a process that is more efficient than processes based upon prior separation techniques. Of special interest are combination processes involving synthesis steps followed by sorption steps using the same shape selective materials.
BACKGROUND OF THE INVENTION
The present invention relates to a process for separating various dialkyl multinuclear aromatic compounds from streams containing their isomers. These isomers are of interest for the production of certain di-substituted aromatics which in turn are employed in the synthesis of liquid crystal polymers and specially polyesters.
The p,p'-dialkyl multinuclear aromatic products most suitable for this process, their respective stream, and shape selective catalysts are outlined in the table below:
______________________________________ Shape SelectiveProduct Stream Material______________________________________2,6-diisopropylbiphenyl Mixed DIPN's Mordenite(DIPN)4,4'-diisopropylbiphenyl Mixed DIBP's ZSM-12,(DIPBP) mordenite2,6-dimethylnaphthalene Mixed DMN's ZSM-5(DMN)4,4-diethylbiphenyl Mixed DEBP's ZSM-122-methyl-6-isopropyl Mixed MIPN's Mordenitenaphthalene (MIPN)______________________________________
Those liquid crystal polymers and specially polyesters would likely be commercially attractive if either dihydroxy or dicarboxy forms of the dialkyl multinuclear aromatic compounds were readily available. Unfortunately, they are not. Viable feedstocks which are convertible into either the dihydroxy or dicarboxy monomers based upon known technology are the compounds listed above.
In manufacturing these dialkyl multinuclear aromatics it is clear that some monoalkyl and trialkyl products and a mix of dialkyl isomers will also be produced. In any crude diethyl multinuclear aromatic product stream, separation of these isomers by thermal distillation is difficult because the boiling points of the respective isomers are very close. Similarly, isomer separation by fractional crystallization using melting points is inefficient and suffers from yield problems because of the loss of the desired product in the mother liquor and because of large recycle streams.
It is taught in U.K. Patent Application No. 2,199,590 filed Nov. 27, 1987, that a specific isomer of dimethylnaphthalene can be separated from other isomers when a zeolite Y containing specific metallic ions is used as an adsorbent in combination with a specific desorbent.
Similarly, the separation 4,4'-dialkylbiphenyls in using mordenites is suggested in Japanese Kokai 89/249,729 (assigned to Nippon Steel Chemical Co.).
The references do not suggest combination processes in which the shape selective material used to synthesize the desired p,p'-dialkyl multinuclear aromatic product in a first step is also -used to separate that product from its accompanying isomers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a simulated moving bed column which can be employed in practicing the separation step of the present invention.
FIG. 2 is a graph demonstrating the efficacy of the present invention by comparing ratios of 2,6-diisopropylnaphthalene adsorbed with the volume of desorbent employed.
SUMMARY OF THE INVENTION
This invention is to an adsorbent process for the separation of p,p'-dialkyl multinuclear aromatic compounds from their isomers and, optionally, containing a synthesis step for producing those compounds using materials comprising the same shape selective materials.
Generically, the combination process entails synthesizing the p,p'-dialkyl multinuclear aromatic product compounds using feedstocks and acidic shape selective materials listed in the table below and then adsorbing those product compounds using the same shape selective materials.
______________________________________ Shape SelectiveProducts Alkylating Agents Aromatic Substrate Material______________________________________2,6-DIPN Propylene, pro- Naphthalene, Mordenite panol, propyl 2-isopropyl- chloride naphthalene2,6-DEN Ethylene, ethanol, Naphthalene, ZSM-12 ethyl chloride 2-ethylnaphthalene4,4'-DIPBP Propylene, pro- 4-isopropylbiphenyl, ZSM-12, panol, propyl biphenyl mordenite chloride2,6-DMN Methanol, methyl Naphthalene, ZSM-5 chloride 2-ethylnaphthalene4,4'-DEBP Ethylene, ethanol, 4-ethyl biphenyl, ZSM-12 ethyl chloride biphenylMIPN Propylene, pro- Naphthalene, Mordenite panol, propyl methyl naphthalene chloride______________________________________
Particularly desirable is a process for the selective adsorption of 2,6-DIPN from a stream of DIPN's. The optimum shape selective adsorbent for DIPN separation is a class of crystalline molecular sieves all of which are characterized as having 12 member oxygen rings and pore aperture dimensions between approximately 5.5 Å and 7.0 Å, preferably mordenite.
Following the synthesis step (where used) and the adsorption step, the material held up in the interstices is removed. At this point, the bed of shape selective adsorbent contains sorbed material that is rich in p,p'-dialkyl multinuclear aromatic product. The product sorbed by the bed is then displaced from the bed with a suitable desorbent. The desorbent can then be separated from the desorbed product and recycled. If desired, this enriched material can be further purified by any of several means including, for example, distillation, crystallization, or a second absorption step.
DETAILED DESCRIPTION OF THE INVENTION
This invention is a process for, optionally, synthesizing p,p'-dialkyl multinuclear aromatic compounds and separating those compounds from other materials in the product stream. The catalyst used in the synthesis step and the adsorbent used in the separation step comprise, for a particular dialkyl multinuclear product, the same shape selective material.
The synthesis step generally takes place in the liquid phase in a convenient reactor. The reactor may be batch but preferable is continuous in nature. The alkylating agent is contacted with the polynuclear aromatic feedstock in the presence of the shape selective material. The reaction is conducted at an alkylating agent/aromatic feedstock ratio between 0.1 and 10, preferably between 1.0 and 2.0 and at elevated temperatures and pressures, generally between 100° C. and 400° C., preferably between 250° C. and 350° C., and between 1 and 100 atmospheres, preferably 1 to 10 atmospheres. Under appropriate operating conditions, a larger amount of the noted p,p'-dialkyl multinuclear aromatic product will be produced than would be made using a non-selective acid catalyst such as silica-alumina. The products, alkylating agents, aromatic substrates and appropriate catalytic shape selective materials are specified in the table below:
______________________________________ Shape SelectiveProducts Alkylating Agents Aromatic Substrate Material______________________________________2,6-DIPN Propylene, pro- Naphthalene, Mordenite panol, propyl 2-isopropyl- chloride naphthalene2,6-DEN Ethylene, ethanol, Naphthalene, ZSM-12 ethyl chloride 2-ethylnaphthalene4,4'-DIPBP Propylene, prop- 4,-isopropyl- ZSM-12, panol, propyl biphenyl, mordenite chloride biphenyl2,6-DMN Methanol, methyl Naphthalene, ZSM-5 chloride 2-ethylnaphthalene4,4'-DEBP Ethylene, ethanol, 4-ethyl biphenyl, ZSM-12 ethyl chloride biphenylMIPN Propylene, pro- Naphthalene, Mordenite panol, propyl methyl naphthalene chloride______________________________________
The product stream, preferably containing enhanced or more than equilibrium amounts of the dialkylated aromatic product, may then be passed to a separation step. The separation step is typically performed in the liquid phase in a batch or simulated batch mode. The product stream containing dialkylates which are not p,p', and other alkylates such as monoalkylates and trialkylates, is contacted with an amount of the appropriate shape selective material. A minimal amount of experimentation to optimize the ratio of feedstock to shape selective material and similar operating conditions may be desirable. The mass of shape selective material is removed from contact with the stream and placed in contact with a desorbent stream. The p,p-dialkyl multinuclear aromatic compound which has been adsorbed into the pores of the shape selective material is desorbed by contact with an appropriate desorbent. That material comprises the same shape selective material as was used to synthesize the dialkyl aromatic product. The cation found in the shape selective material used in the separation step may be the same or different from that found in the synthesis step's material. The desorbents act with various levels of efficacy in removing the p,p'-dialkyl aromatic from the shape selective materials. Suitable desorbents should be easily separable (by distillation or otherwise) from the dialkyl aromatic and include C.sub. 1 -C 4 ethers, single ring alkyl aromatics, and benzene. Particularly preferred desorbents are m-xylene, toluene, ethylbenzene, n-propylbenzene, isopropylbenzene, 4-ethyl toluene, and p-diethylbenzene.
The desorbent and p,p'-dialkyl multinuclear aromatic product are then separated as was noted above.
A particularly desirable aspect of the invention is the isolated step for the selective adsorption of 2,6-diisopropylnaphthalene from a feed stream of mixed diisopropylnaphthalenes as well as to a process for separating the 2,6-diisopropyl isomer from a mixture of isomers of diisopropylnaphthalenes. This may be done as a batch process while establishing a unit operation by moving the feed stream of mixed isomers over a bed of suitable adsorbent.
The present process can be carried out employing, for example, chemical processing equipment used for liquid bulk separations. For example, FIG. 1 illustrates a schematic representation of such bulk separation equipment as employed by UOP for the adsorptive separation of p-dialkylbenzene from other dialkylbenzene isomers. See D. B. Broughton, "Bulk Separations Via Adsorptions", Chemical Engineering Progress, pp. 49-51 (October, 1977). However, it must be emphasized that virtually any well known packed column can be employed insuring a flow of liquid feed stock and desorbent over a fixed bed of adsorbent which can be employed as a powder, pellet, or extrudate.
Referring to FIG. 1, the preferred process utilizes a column 2 filled with a fixed bed of adsorbent. The column has numerous ports 4 for feeding dialkylnaphthalene feed and desorbent as well as removing raffinate and extract. These ports are all piped to a rotary valve 8 which controls where in the adsorption column materials are fed and withdrawn. For a period of time, dialkylnaphthalene feed is provided to a section of the adsorption column wherein the adsorbent selectively adsorbs the desired 2,6-diisopropylnaphthalene isomer. The raffinate now depleted in the desired 2,6-diisopropylnaphthalene isomer is either recycled by pump 6 or withdrawn and sent to a column 10 where any desorbent it picks up is separated and returned. At a later period in time, the rotary valve 8 redirects the stream and now desorbent is fed over the portion of the packed bed which had previously adsorbed the desired 2,6-diisopropylnaphthalene isomer. The desorbent releases the desired isomer (the extract) from the adsorbent and passes through the rotary valve to a column 12 in which 2,6-diisopropylnaphthalene is separated from the desorbent.
Such a process may also be used to separate the other dialkyl aromatic products from their isomers.
If the 2,6-diisopropylnaphthalene enriched product does not contain sufficient purity of the desired isomer, it clan be further purified by another adsorption step, fractional crystallization, or other conventional separation means.
The adsorbents employed for the preferential removal of the 2,6-diisopropyl isomer from a feed stock of mixed dialkylated naphthalenes are one or more crystalline molecular sieves such as those taught in applicants' copending U.S. application Ser. No. 254,284, filed on Oct. 5, 1988, entitled SELECTIVE ISOPROPYLATION OF NAPHTHALENES TO 2,6-DIISOPROPYLNAPHTHALENE, the disclosure of which is hereby incorporated by reference. Broadly, the adsorbents of the present invention for the selective adsorption of 2,6-diisopropylnaphthalene from other diisopropylnaphthalene isomers are crystalline molecular sieves containing 12 membered oxygen rings and pore aperture dimensions between approximately 5.5 Å and 7.0 Å.
Shape selective adsorption occurs when the zeolite framework and its pore structure allow molecules of a given size and shape to preferentially diffuse into and adsorb within the intracrystalline free space. It is therefore important to characterize accurately the pore structure that is encountered in the various crystalline molecular sieve frameworks. Pore structure (dimensions and network) varies greatly among zeolites. Without modifications of the zeolite structure, the lowest pore aperture dimension is about 2.6 Å and the highest is 7.4 Å. Maximum values for the four-, six-, eight-, ten-, and twelve-membered oxygen rings have been calculated to be 2.6 Å, 3.6 Å, 4.2 Å, 6.3 Å, and 7.4 Å, respectively. Pores may lead to linear, parallel, or interconnected channels or may give access to larger intracrystalline cavities, sometimes referred to as cages. For all zeolites, the pore opening is determined by the free aperture of the oxygen ring that limits the pore aperture.
The free diameter values given in the channel description and on the ring drawings (not shown here) are based upon the atomic coordinates of the type species in the hydrated state and an oxygen radius of 1.35 Å, as determined from x-ray crystallographic data. Both minimum and maximum values are given for noncircular apertures. In some instances, the corresponding interatomic distance vectors are only approximately coplanar; in other cases the plane of the ring is not normal to the direction of the channel. Close inspection of the framework and ring drawings should provide qualitative evidence of these factors. Some ring openings are defined by a very complex arrangement of oxygen atoms. Included are references to publications which contain extensive drawings and characterization data. The relevant portions of those references are incorporated herein. It should be noted that crystallographic free diameters may depend upon the hydration state of the zeolite particularly for the more flexible frameworks. It should also be borne in mind that effective free diameters can be temperature dependent.
As used throughout the instant specification, the term "pore aperture" is intended to refer to both the pore mouth at the external surface of the crystalline structure, and to the intracrystalline channel, exclusive of cages. When a crystalline molecular sieve is hereinafter characterized by a "pore aperture dimension," adopted is the geometric dimensional analysis defined as "crystallographic free diameter of channels" in Meier, W. M., Olson, D. H., Atlas of Zeolite Structure Types, (Butterworth's, 1987, 2d Rev. Ed.). The term "dimension" is preferred over "diameter" because the latter term implies a circular opening, which is not always accurate in crystalline molecular sieves.
Crystalline molecular sieves which are useful in practicing the present process include MeAPSO-46, offretite, ZSM-12 and synthetic mordenite. Preferred adsorbents are synthetic mordenite, with pore aperture dimensions of 6.5 Å and 7.0 Å and ZSM-12 with pore aperture dimensions of 6.2 Å, 5.7 Å and 5.5 Å. These preferred adsorbents can be used in the adsorption process without any pretreatment to modify their pore aperture dimensions. Synthetic mordenite is particularly preferred while other useful adsorbents ,nay be obtained by treatment of a crystalline molecular sieve having pore aperture dimensions greater than 7.0 Å selected from the group consisting of zeolite L, zeolite Beta, faujasite and SAPO-5 to reduce the dimensions of the pore apertures. Mordenite, ZSM-12, off retite and MeASPO-46 fall into the first class of adsorbents whose pore aperture dimensions are between 5.5 Å and 7.0 Å, prior to any modification to their pores.
The preferred adsorbents, mordenite and ZSM-12, as well as other suitable sieves, can be optimized to greater selective adsorption of the desired 2,6-diisopropylnaphthalene without substantially altering their pore dimensions by modifying the hydrophobic character of the molecular sieves. One such modification to the preferred adsorbents is to dealuminate. Dealumination of acidic crystalline molecular sieve materials can be achieved by exposing the molecular sieve to mineral acids such as HCl. The desired degree of dealumination will dictate the strength of acid used and the time during which the crystalline structure is exposed to the acid. It is also common to use a steam treatment in combination with the acid leach to dealuminate the zeolite materials. For additional methods of preparing aluminum-deficient zeolites, see J. Scherzer, "The Preparation and Characterization of Aluminum-Deficient Zeolites", Thaddeus E. Whyte et al., "Catalytic Materials: Relationship Between Structure and Reactivity", ACS Symposium Series 248, pp. 156-60 (American Chemical Society, 1984). Dealumination according to the instant invention is intended to achieve a Si:Al ratio above 3 and preferably above 15. Dealumination can also be applied to the second class of molecular sieve materials whose pore aperture dimensions exceed 7.0 Å.
A dealuminated crystalline molecular sieve can be calcined at temperatures between 400° C. and 1000° C., preferably between 400° C. and 600° C. Calcination serves to dehydrate or "heal" Si--OH bonds or "nests" after dealumination. Healing these nests provides for a more uniform pore structure within the crystalline material, leading to structural stability and ultimately resulting in improved adsorption. For a zeolite like hydrogen mordenite, the optimal temperature range was found experimentally to lie between 400° C. and 600° C., but preferentially at 500° C. See Mathur, Kuldeep, Narain, Ph.D. Thesis, University of Pittsburgh, 1977. In the case of H-mordenite, removal of extra and intra crystalline water can be accomplished effectively in the presence of an atmosphere of oxygen or nitrogen. As previously noted, other adsorbents may also be considered which have aperture dimensions in excess of 7.0 Å. These other adsorbents are obtained by a combination of modifications of commercially available, acidic crystalline molecular sieve products. Examples of such sieves include zeolite L, zeolite Beta, faujasite and SAPO-5, which have 12 membered oxygen rings whose pore aperture dimensions typically exceed 7.0 Å. SAPO is an acronym for silicoaluminophosphate molecular sieves, first reported in 1984. See B. M. Lok et al U.S. Pat. No. 4,440,871. MeAPO is an acronym for metalaluminophosphate molecular sieves reported in S. T. Wilson et al U.S. Pat. No. 4,567,029. For more complete characterizations of each of the catalyst members discussed above, see Flanigen, E. M., et al., Stud. Surf. Sci. Cat., 28, pp. 103-12. Also, see E. G. Derouane, "Diffusion and Shape-Selective Catalysis in Zeolites", Intercalation Chemistry, pp. 112-14, Ed. by M. Stanley Whittingham (Academy Press, 1982). Also, see S. Ernst, Zeolites, Vol. VII, p. 458 (1987), for a good discussion of ZSM-12.
When using adsorbents obtained by the treatment of crystalline molecular sieves whose pore aperture dimensions are initially above 7.0 Å, internal acid site modification can be used to reduce the pore aperture dimensions to an extent which show an enhanced 2,6-diisopropylnaphthalene selectivity. Molecular sieves with reduced pore aperture dimensions are best described with reference to their performance in the adsorption under consideration. Those crystalline molecular sieves which have been adequately modified by internal acid site treatment will perform the selective adsorption of 2,6-diisopropylnaphthalene.
Ion exchange can be used to treat crystalline molecular sieves whose pore aperture dimensions are initially above 7.0 Å and reduce the pore aperture to the desired range. Elements suitable for ion exchange include alkali metals and alkali earth metals.
Crystalline molecular sieves may be treated to modify internal acid sites by contact with reagents selected from the group consisting of halogen, hydridic and organic derivatives of group 3A, 4A, 4B and 5A. Preferred embodiments of the internal acid site reagents include B 2 H 6 , SiH 4 and PH 3 . For a more complete discussion of the internal acid site modification techniques contemplated herein, see A. Thijs et al., J. Chem. Soc. Faraday Trans., 79, 2821 (1983). See also J. Philippaerts et al., "The Implantation of Boron-Nitrogen Compounds in Mordenite LP and Their Influence on the Adsorption Properties", Stud. Surf. Sci. Catal., 28, pp. 305-10 (1986). The relevant portions of each of these citations are incorporated herein by reference.
In addition to the use of the above described reagents which tend to be nonspecific, there is an intermediate level of crystalline molecular sieve modification which can be used to perform "pore mouth engineering". These reagents provide an intermediate level since they are not specific for external acid site, but are not entirely nonspecific, leading to substantial internal acid site modification. In selecting an intermediate reagent, the characteristics and pore aperture dimensions of the starting crystalline molecular sieve must be matched against the molecular dimensions of the reagent.
It has been shown that chemical vapor deposition of Si(OCH 3 ) 4 on H-mordenite can be successfully used to control the intracrystalline pore aperture without substantially affecting the adsorbent's internal surface acid properties. Si(OCH 3 ) 4 can be deposited irreversibly on zeolite without entering the intracrystalline pores. See Niwa, M. et al., J. Chem. Soc., Faraday Trans., 1, 1984, 80, pp. 3135-45; Niwa, M. et al., "Modification of H-Mordenite by Vapor-Phase Deposition Method", J. Chem. Soc. Commun., p. 819-20 (1982).
Similarly, chemical vapor deposition of metal chlorides such as SiCl 4 , GeCl 4 , TiCl 4 , and SnCl 4 can be effective to modify pore mouth structures. These metal molecules with a range of molecular dimensions can be selected to be larger than the adsorbent pore aperture, thereby preventing substantial diffusion into the internal pore. See Hidalgo, T. V. et al., Zeolites, 4, pp. 175-80 (April, 1984).
The pore-modifying agents can be contacted with the molecular sieves in either solution or in vapor phase.
As noted previously, the crystalline molecular sieve adsorbent can be supplied as a powder, pellet or extrudate. Pellets and extrudates can be made according to known techniques for binding powder. Pellets can be formed by applying pressure to powder. Pellets and extrudates can be formed by using binders such as alumina, clays, silica, or can be silica-alumina as well known in the art. In one embodiment of the process, the adsorbent is packed in a column and a stream of mixed diisopropyinaphthenes pass through the column. After a suitable contact time with the adsorbent bed, the depleted dialkylnaphthalene stream is purged from the packed bed. In a second step, a desorbent is fed to the column to remove the adsorbed isomers. The stream containing the desorbent and the adsorbed isomers is collected. The dialkylate fraction of this stream which is enriched in 2,6-diisopropylnaphthalene, can be separated from the desorbent by any conventional separation means such as by crystallization, thermal distillation or chromatographic adsorption. It is also contemplated that a series of adsorption/desorption cycles can be employed.
The desorbent is a liquid chosen to desorb selectively the isomers absorbed by the adsorbent. The desorbent is also chosen as a material which is easily and efficiently separated from the desired 2,6-diisopropyl isomer. In this regard, it was found that various alcohols, ethers, single ring alkyl aromatics such as p-xylene and o-xylene are particularly preferred while other desorbents contemplated for use herein include m-xylene, toluene, ethylbenzene, n-propylbenzene, isopropylbenzene, 4-ethyltoluene, 1,2,4-trimethylbenzene, p-diethylbenzene, p-cymene, 1,2,3,4-tetrahydronaphthalene and mixtures thereof.
The temperature and pressure conditions for the adsorption process also affect the diffusion rate. The temperature must be between ambient and 300° C., preferably between 100° C. and 200° C. The pressure in the packed column must be between 0 psia and 5000 psia, preferably about atmospheric pressure but in any case higher than the vapor pressure of the alkylnaphthalene feed at the temperature of the adsorption step.
EXAMPLES
Example 1
A 1/4 inch O.D. stainless steel tube 12 inches long was packed with a steam de-aluminated, acid washed and calcined mordenite powder (381-10, Si/Al 32 23). The column was heated to a temperature of 104°-119° C. and a sample of a dialkylnaphthalene stream was pumped over the bed at a rate of 0.25 ml/min. Analysis of the initial liquid exiting the column showed a depletion of 2,6-diisopropylnaphthalene isomer over that contained in the feed stream (Table 1).
TABLE 1______________________________________Total Initial Ratio Final RatioIsomer/DIPN's (% by Wt.) (% by Wt.)______________________________________2,6 18.8 4.92,7 15.8 10.71,3 20.6 30.11,5 4.0 3.81,4 8.1 11.31,6 17.0 24.31,7 14.2 12.8Total 98.5 97.92,6/2,7-DIPN 1.2 0.5______________________________________
These data show that the 2,6-diisopropylnaphthalene isomer was preferentially removed from the dialkylnaphthalene stream since the 2,6/2,7 ratio dropped from 1.2 to 0.5. Also the percentage of the 2,6-diisopropyl isomer changed from 18.8 to 4.9% further illustrating the selection of this isomer by the adsorbent.
Example 2
The mordenite sieve used in Example 1 was loaded into a 1/4 inch diameter stainless steel tube 12 inches long. A mixture of diisopropylnaphthalenes was pumped over ca. 1.8 gm of the sieve at 157° C. at 0.25 ml/min. Samples of the dialkylnaphthalenes passing over the mordenite bed were collected at 0.5 mi increments. Table 2 shows the mole % composition of the dialkylnaphthalene stream fed to the column. The initial 2,6/2,7 ratio was 1.19. Table 3 shows the 2,6/2,7 ratio for the samples collected after contact with the mordenite. The data shows that the 2,6/2,7 ratio dropped from 1.19 to 0.5 after 4.3 ml were pumped.
TABLE 2______________________________________Mole % Composition of DIPN Isomer mol %______________________________________ 2,6 18.8 2,7 15.8 1,3 20.6 1,5 4.0 1,4 8.1 1,6 17.0 1,7 14.2______________________________________
TABLE 3______________________________________2,6/2,7 Ratio of Adsorbed DIPNvolume pumped (ml) 2,6/2,7______________________________________4.3 0.505.0 1.137.0 1.179.5 1.19______________________________________
After pumping 9.5 ml of dialkylnaphthalene, the 2,6/2,7 ratio finally reached the initial value.
After the 2,6/2,7 ratio was at the initial value of 1.19 the dialkylnaphthalene feed stream was turned off and p-xylene was pumped to flush the adsorbed 2,6-diisopropylnaphthalene from the sieve. FIG. 2 shows the ratio of the 2,6-diisopropyl isomer/total dialkylated naphthalenes as a function of the amount of xylene pumped. From the graph it can be seen that the first material eluted is probably the original dialkylate displaced from the void space between the mordenite particles, since the 2,6/total isomers is 0.2 (or 20%) initially. The maximum in the curve is due to the 2,6-isomer being displaced from the pore of the sieve. The enrichment is significant since the sample taken at 6.8 ml contains 54% 2,6-DIPN as compared to 19% in the initial dialkylate mixture. | The invention relates to a process for the separation cf various dialkyl multinuclear aromatic compounds from a feed stream of mixed isomers of those compounds. A shape selective adsorbent is employed resulting in a process that is more efficient than processes based upon prior separation techniques. Of special interest are combination processes involving synthesis steps followed by sorption steps using the same shape selective materials. | 2 |
BACKGROUND
Portable media players are becoming pervasive, particularly among relatively younger people. An unintended side effect of using such players is the damaging effect on the users' hearing. The damaging effect on the users' hearing may be exacerbated by new manners of use (all day use, versus for limited time periods such as during jogging) and, perhaps, by the configuration of the headphones (in the ear).
Furthermore, since the damaging effect on users' hearing is both gradual and cumulative, even those users who are concerned about hearing loss may not behave with respect to their portable media players in a manner that would limit or minimize such damaging hearing effects.
SUMMARY
A method of operating a media player includes playing back audio media. During the step of playing back audio media, a maximum volume parameter is refined for the playing back of the media by the media player. The refining is based at least in part on the playing back of audio media during a time period prior to executing the maximum volume refining step. After a period of time, the maximum volume refining step is repeated.
The refining is configured to prevent/minimize harm to hearing of the media player user based, for example, on the actual volume of media playback and time/duration profiles provided by occupational safety and/or other organizations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a host application in detachable communication with a portable media player, including communication of an indication of protection parameters from the host application to the portable media player.
FIG. 2 is a flowchart illustrating processing in the portable media player for refining a maximum volume value based on an actual volume of media playback by the portable media player.
FIG. 3 illustrates a table of compensation factors, based on headphone type, employed in refining the maximum volume value.
FIG. 4 illustrates a table of compensation factors, based on song characteristics, employed in refining the maximum volume value.
DETAILED DESCRIPTION
In accordance with a broad aspect, a portable media player processes protection parameters to control the playback of media by the portable media player. During use of the portable media player and based on actual use of the portable media player, the protection parameters are adjusted. Thus, for example, the adjustment of the protection parameters may take into account volume of playback in actual use, including duration of playback.
In one example, a “credit” accounting is maintained for determining the protection parameters, where credits are subtracted based on actual use that has first particular characteristics, whereas credits are added based on actual use that has second particular characteristics. For example, the first particular characteristics may be characteristics for which it has been determined to have a relatively damaging cumulative effect on hearing (e.g., relatively “loud” playback), whereas the second particular characteristics may be characteristics for which it has been determined to not have a relatively damaging cumulative effect on hearing (e.g., relatively “soft” playback, that allows recovery from the relatively damaging cumulative effect on hearing).
FIG. 1 broadly illustrates one example of an architecture that uses protection parameters. As shown in FIG. 1 , a host application 102 executing on a computer interfaces with a portable media player 104 . The host application 102 may be, for example, the iTunes® software provided by Apple Computer, Inc. In one example, a user (e.g., a parent of the user of the portable media player 104 ) interacts with the host application 102 to choose a protection profile. The protection profile may be based, for example, on a desired level of protection (such as “low,” “medium” and “high”) or on an age of the user (e.g., assuming that a younger user requires more constraints).
As also shown in FIG. 1 , an indication of protection parameters is provided from the host application 102 to the portable media player 104 . The protection parameters may be pre-stored on the portable media player 104 , with a signal being provided to from the host application 102 to the portable media player 104 that indicates which protection parameters to use. In other examples, a user of the portable media player 104 interacts directly with the portable media player 104 to cause the protection parameters to be indicated. Indication of the protection parameters may also be a result of interaction with both the host application 102 and the portable media player 104 .
In the portable media player 104 , a controller 106 processes the protection parameters to determine threshold playback characteristics, such as maximum playback volume or characteristics that are an indication of (and/or contribute to) the maximum playback volume. The actual playback by the portable media player, by audio output circuitry 108 , is thus constrained by the determined threshold playback characteristics. Moreover, the threshold playback characteristics are adjusted by the controller based on characteristics of the actual playback operation of the portable media player 104 . In some examples, the threshold playback characteristics are determined on the host, by the host application 102 .
FIG. 2 is a flowchart illustrating an example of processing within the controller 106 of the portable media player 104 ( FIG. 1 ) to accomplish enforcing the protection parameters. The controller may operate, for example, in a programmed manner based on software or firmware instructions. However, the controller is not limited, for example, to being a processor that executes instructions. In the FIG. 2 example, a “credit” scheme is employed. It is noted that this is an example, and other types of schemes may be employed. Turning now specifically to FIG. 2 , at step 202 , an initial number of credits is determined based on the protection parameters indicated or provided by the host application 102 .
At step 204 , a maximum allowed volume parameter, indicative of a maximum volume allowed for the next timer period “x” is determined based on the determined credits. In one particular example, the maximum allowed volume is determined based on the determined credits with reference to a profile such as profiles provided by the California Occupational Safety and Health Administration (Cal-OSHA). See, for example, Cal-OSHA Regulations—Control of Noise Exposures, in the California Code of Regulations, Title 8, Section 5096-5100 Article 105 and, see also, Permissible Noise Exposure—Table N-1 of the just-referenced regulation. It is noted that the profiles promulgated by Cal-OSHA appear to be rudimentary (e.g., do not deal in a sophisticated way with varying exposure over time and do not deal account for “recovery”). Thus, in some examples, more sophisticated profiles are employed.
At step 206 , during the time period “x”, the actual volume is controlled based on the determined maximum volume for the time period “x.” Details according to particular examples are discussed later.
At step 208 , the credits are recalculated based on the actual volume during the timer period “x.” For example, if the user of the portable media player set the desired volume to be less than the determined maximum volume (or, perhaps, less than some other volume that is less than the determined maximum volume), then this may have allowed the user's hearing some “recovery” such that credits can be granted. That is, the credits may be usable to increase the determined maximum volume (as determined at step 204 ) for a future time period “x.” After the credits are recalculated, then processing returns to step 204 for the next time period “x.”
We now discuss, with reference to FIGS. 3 and 4 , how step 204 processing may be affected by factors other than those purely within the profiles. FIG. 3 is an example of compensation factors that are utilized for various types of headphones. That is, the compensation factors may be factors that indicate (and, thus, are used as parameters to the formulas) how the formula may be modified for a particular headphone such that the formula more accurately reflects reality. For example, for a particular volume of sound output, one headphone may have characteristics versus characteristics of another headphone such that the first headphone does not have as deleterious effect on hearing as does the second headphone, even at the same particular volume of sound output. In various examples, compensation factors are provided for general types of headphones (e.g., earbud, over the ear, etc.) and, in other examples, the compensation factors are more specific, provided for various models of headphones.
FIG. 4 illustrates another example of compensation factor. In particular, FIG. 4 illustrates providing a compensation factor that characterizes the media that is being played. In one example, the characteristic is a characteristic (or is based on a characteristic) that has been determined by a Soundcheck feature of iTunes, indicating an approximate audio level of the song.
We now discuss details of an example of controlling the volume during time period “x” based on the determined maximum volume. In one example, the determined maximum volume is treated as a threshold. Thus, if the user of the portable media player sets the volume to a desired volume that is greater than the determined maximum volume for the time period “x,” then the actual playback volume is set to the determined maximum volume. On the other hand, if the user of the portable media player sets the volume to a desired volume that is less than the determined maximum volume for the timer period “x,” then the actual playback volume is set to the desired volume.
In another example, the indication of the determined maximum volume parameter is used in step 206 as a scale factor, such that the actual volume of audio output is the desired volume, scaled down by the scale factor.
In addition to lowering of the volume in step 206 leading to additional credits in step 208 , a complete cessation of playing the media player should also lead to additional credits upon restarting of playing. Thus, in one example, when audio output is stopped, the time of cessation is stored such that, upon restarting of playing, the time between cessation and restarting can be treated as a “quiet” time during which recovery has taken place and for which credits should be added.
In other examples, at step 204 , the determined maximum volume may be either zero or “indeterminate” (i.e., whatever volume the user desires). In these examples, then, the processing at step 206 operates to control the volume only when the determine maximum volume is zero—shutting down the audio output of the media player. At step 208 , as part of the recalculating step, a user interface function may be provided to give the user of the portable media player an indication of how many credits remain. This indication may be, for example, an indication of how long output will be allowed at the current actual volume, based on the remaining credits. The indication may be a simple binary indication (such as flashing when only a threshold amount of time remains).
In some examples, causing the indication of the protection parameters is secure such that, for example, a parent could securely set the protection parameters for a child user of the portable media player. In one example, the host software 102 is used to create a tamperproof (or tamper-resistant) configuration file as described, for example, in U.S. patent application Ser. No. 11/191,133, entitled CONFIGURATION OF A COMPUTING DEVICE IN A SECURE MANNER, filed on Jul. 26, 2005 (the disclosure of which is incorporated herein in its entirety).
Furthermore, the discussion thus far has been in the context of a portable media player. However, in some examples, the concepts discussed herein are also applicable to audio devices such as, for example, cellular phones. With some audio devices, the audio playback characteristics can not (or, at least, cannot primarily) be determined in advance. For example, while playback characteristics of a song can be determined in advance (as illustrated by FIG. 4 , for example), the levels of a voice speaking over a cellular phone connection typically cannot be determined in advance. Thus, in such situations, recalculating the credits (or otherwise adjusting how volume is to be controlled) may be more complicated, since more sophisticated monitoring of actual volume may be required.
While this invention has been described in terms of several embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. | A method of operating a media player includes playing back audio media. During the step of playing back audio media, a maximum volume parameter is refined for the playing back of the media by the media player. The refining is based at least in part on the playing back of audio media during a time period prior to executing the maximum volume refining step. After a period of time, the maximum volume refining step is repeated. The refining is configured to prevent/minimize harm to hearing of the media player user based, for example, on the actual volume of media playback and time/duration profiles provided by occupational safety and/or other organizations. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to products to freshen laundry.
BACKGROUND OF THE INVENTION
[0002] There is a segment of consumers that prefer a strong perfume scent to their laundry. These so called “scent seekers” will often over dose laundry products such as laundry detergent and fabric softener to provide the desired freshness to their laundry. There is a need to provide a perfume scent additive product to consumer that will provide freshness to laundry. Such scent additive needs to be able to be applied by the consumer, independent of other laundry products, to achieve the desired scent level in a cost effective manner.
SUMMARY OF THE INVENTION
[0003] An embodiment of the invention can be a composition consisting essentially of: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g.
[0004] An additional embodiment of the invention can be a unit dose of a fabric treatment composition comprising a plurality of pastilles, wherein each pastille comprises: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein each pastille has a mass from about 0.95 mg to about 2 g; and wherein the plurality of pastilles has a mass from about 13 g to about 27 g to comprise the unit dose.
[0005] An additional embodiment of the invention can be a composition consisting essentially of:
[0000] (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; and
(b) from about 9% to about 20 wt% of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein the composition is essentially free of free perfume; and wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g.
[0006] An additional embodiment of the invention can be a composition consisting essentially of: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; and (b) from about 9% to about 20% by weight of the composition free perfume; wherein the composition is essentially free of a perfume carrier; and wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g.
[0007] An additional embodiment of the invention can be a method of making a composition comprising the steps of: providing a viscous material having a glass transition temperature, the viscous material comprising: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; providing the viscous material at a processing temperature less than about 20 degrees Celsius higher than the glass transition temperature; and passing the viscous material through small openings and onto a moving conveyor surface upon which the viscous material is cooled below the glass transition temperature to form a plurality of pastilles.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a schematic of a pastillation apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The compositions of the present invention may comprise: polyethylene glycol; free perfume and/or perfume microcapsules; and optionally a dye. In one embodiment, the composition is essentially free of detergent surfactants and/or fabric softening actives.
Polyethylene Glycol (PEG)
[0010] Polyethylene glycol (PEG) has a relatively low cost, may be formed into many different shapes and sizes, minimizes free perfume diffusion, and dissolves well in water. PEG comes in various molecular weights. A suitable molecular weight range of PEG for the purposes of freshening laundry includes from about 3,000 to about 13,000, from about 4,000 to about 12,000, alternatively from about 5,000 to about 11,000, alternatively from about 6,000 to about 10,000, alternatively from about 6,000 to about 10,000, alternatively from about 7,000 to about 9,000, alternatively combinations thereof. PEG is available from BASF, for example PLURIOL E 8000.
[0011] The compositions of the present invention may comprise from about 65% to about 99% by weight of the composition of PEG. Alternatively, the composition can comprise from about 80% to about 91%, alternatively from about 85% to about 91%, more than about 75%, alternatively from about 70% to about 98%, alternatively from about 80% to about 95%, alternatively combinations thereof, of PEG by weight of the composition.
Free Perfume
[0012] The compositions of the present invention may comprise a free perfume and/or a perfume microcapsule. Perfumes are generally described in U.S. Pat. No. 7,186,680 at column 10, line 56, to column 25, line 22. In one embodiment, the composition comprises free perfume and is essentially free of perfume carriers, such as a perfume microcapsule. In yet another embodiment, the composition comprises perfume carrier materials (and perfume contained therein). Examples of perfume carrier materials are described in U.S. Pat. No. 7,186,680, column 25, line 23, to column 31, line 7. Specific examples of perfume carrier materials may include cyclodextrin and zeolites.
[0013] In one embodiment, the composition comprises free (neat) perfume but is free or essentially free of a perfume carrier. In such an embodiment, the composition may comprise less than about 20%, alternatively less than about 25%, alternatively from about 9% to about 20%, alternatively from about 10% to about 18%, alternatively from about 11% to about 13%, alternatively combinations thereof, of free perfume by weight of the composition.
[0014] In one embodiment, the composition consists essentially of: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; and (b) from about 9% to about 20% by weight of the composition free perfume; wherein the composition is essentially free of a perfume carrier; and wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g. In an alternative embodiment, the composition consists essentially of: (a) more than about 75% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; and (b) less than about 25% by weight of the composition free perfume; wherein the composition is essentially free of a perfume carrier; and wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g.
[0015] In another embodiment, the composition comprises free perfume and perfume microcapsules. In this embodiment, the composition may comprise from about 2% to about 12%, alternatively from about 1% to about 10%, alternatively from about 3% to about 8%, alternatively from about 4% to about 7%, alternatively from about 5% to about 7%, alternatively combinations thereof, of the free perfume by weight of the composition.
[0016] In yet another embodiment, the composition comprises free (neat) perfume and a perfume microcapsule but is free or essentially free of other perfume carriers.
Perfume Microcapsules
[0017] The compositions of the present invention can comprise perfume oil encapsulated in a perfume microcapsule (PMC). The PMC can be a friable PMC. The term “PMC” and “perfume microcapsule” are used interchangeably and refers to a plurality of perfume microcapsules. Suitable perfume microcapsules and perfume nanocapsules can include: U.S. Patent Publication Nos. 2003215417 A1; 2003216488 A1; 2003158344 A1; 2003165692 A1; 2004071742 A1; 2004071746 A1; 2004072719 A1; 2004072720 A1; 2003203829 A1; 2003195133 A1; 2004087477 A1; and 20040106536 A1; U.S. Pat. Nos. 6,645,479; 6,200,949; 4,882,220; 4,917,920; 4,514,461; and 4,234,627; and U.S. Re. 32,713, and European Patent Publication EP 1393706 A1.
[0018] For purposes of the present invention, the term “perfume microcapsules” or “PMC” describes both perfume microcapsules and perfume nanocapsules. The PMCs can be friable (verses, for example, moisture activated PMCs). The PMCs can be moisture activated.
[0019] In one embodiment, the PMC comprises a melamine/formaldehyde shell. Encapsulated perfume and/or PMC may be obtained from Appleton, Quest International, or International Flavor & Fragrances, or other suitable source. In one embodiment, the PMC shell is coated with polymer to enhance the ability of the PMCs to adhere to fabric, as describe in U.S. Pat. Nos. 7,125,835; 7,196,049; and 7,119,057.
[0020] In one embodiment, the composition comprises a PMC but is free or essentially free or free of (neat) perfume. In such an embodiment, the composition may comprise less than about 20%, alternatively less than about 25%, alternatively from about 9% to about 20%, alternatively from about 9% to about 15%, alternatively from about 10% to about 14%, alternatively from about 11% to about 13%, alternatively combinations thereof, of PMC (including the encapsulated perfume) by weight of the composition. In such an embodiment, the perfume encapsulated by the PMC may comprise from about 0.6% to about 4% of perfume by weight of the composition.
[0021] In one embodiment, the composition consists essentially of: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; and (b) from about 9% to about 20% by weight of the composition of a friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein the composition is essentially free of free perfume; and wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g. In such an embodiment, the perfume encapsulated by the PMC may comprise from about 0.6% to about 4% of perfume by weight of the composition.
[0022] In another embodiment, the composition comprises PMC and free perfume. In such an embodiment, the composition may comprise from about 1% to about 10%, alternatively from about 2% to about 12%, alternatively from about 2% to about 8%, alternatively from about 3% to about 8%, alternatively from about 4% to about 7%, alternatively from about 5% to about 7%, alternatively combinations thereof, of PMC (including the encapsulated perfume) by weight of the composition. In this embodiment, the perfume encapsulated by the PMC may comprise from about 0.6% to about 4% of perfume by weight of the composition.
[0023] In one embodiment, the composition may consist essentially of: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein the composition is shaped in a pastille having a mass from about 0.95 mg to about 2 g. In this embodiment, the perfume encapsulated by the PMC may comprise from about 0.6% to about 4% of perfume by weight of the composition.
[0024] In one embodiment, the composition comprises (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of a friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein the composition is shaped in a pastille, each of the pastilles has a mass from about 0.95 mg to about 2 g. Such a formulation is thought to provide for a balanced scent experience to the user of the composition. With the level of polyethylene glycol between about 80% and about 91% by weight of the composition, the about 2% to about 12% by weight of the composition of free perfume can provide for a pleasant scent experience to the user upon opening of the package containing the composition and as the user pours the composition into a dosing device and transfers the composition to her washing machine. That is the user can experience the scent at an appreciably detectable level but is not overwhelmed by the scent. Similarly, the about 2% to about 12% by weight of the composition of friable perfume microcapsule can provide physical and/or chemical stability of the pastille and for a sufficient quantity of friable perfume microcapsule to deposit on a user's clothing during washing when the pastilles are applied in the wash in a unit dose. Further, it can be beneficial for the composition to consist essentially of the above ingredients at the prescribed levels as additional components might interfere with the physical and/or chemical stability of the pastilles and recognizing that other components, such as surfactants, fabric softeners, or other such ingredients, might be delivered by other mechanisms, such as the detergent or dryer added product, and there would be the potential that the user might over apply such ingredients during washing and/or drying.
[0025] In yet another embodiment, the composition can comprise perfume microcapsule but is free or essentially free of other perfume carriers and/or free (neat) perfume. In yet still another embodiment, the composition may comprise a formaldehyde scavenger. In yet still another embodiment, the scent of the present composition is coordinated with scent(s) of other fabric care products (e.g., laundry detergent, fabric softener). This way, consumers who like APRIL FRESH scent, may use a pastille having an APRIL FRESH scent, thereby coordinating the scent experience of washing their laundry with their scent experience from using APRIL FRESH. The pastilles of the present invention may be sold as a product array (with laundry detergent and/or fabric softener) having coordinated scents.
Dye
[0026] The composition may comprise dye. The dye may include those that are typically used in laundry detergent or fabric softeners. The composition may comprises from about 0.001% to about 0.1%, alternatively from about 0.01% to about 0.02%, alternatively combinations thereof, of dye by weight of the composition. An example of a dye includes LIQUITINT BLUE BL from Millikin Chemical.
Free of Laundry Actives and Softeners
[0027] The composition may be free of laundry active and/or fabric softener actives. To reduce costs and avoid formulation capability issues, one aspect of the invention may include compositions that are free or essentially free of laundry actives and/or fabric softener actives. In one embodiment, the composition comprises less than about 3%, alternatively less than about 2% by weight of the composition, alternatively less than about 1% by weight of the composition, alternatively less than about 0.1% by weight of the composition, alternatively are about free, of laundry actives and/or fabric softener actives (or combinations thereof). A laundry active includes: detergent surfactants, detergent builders, bleaching agents, enzymes, mixtures thereof, and the like. It is appreciated that a non-detersive level of surfactant may be used to help solubilize perfume contained in the composition.
Pastilles
[0028] The composition of the present invention may be formed into pastilles by those methods known in the art, including methods disclosed in U.S. Pat. Nos. 5,013,498 and 5,770,235. The composition of the present invention may be prepared in either batch or continuous mode. In batch mode, molten PEG is loaded into a mixing vessel having temperature control. PMC is then added and mixed with PEG until homogeneous. Perfume is then added to the vessel and the components are further mixed for a period of time until the entire mixture is homogeneous. In continuous mode, molten PEG is mixed with perfume and PMC in an in-line mixer such as a static mixer or a high shear mixer and the resulting homogeneous mixture is then used for pastillation. PMC and perfume can be added to PEG in any order or simultaneously and dye can be added at a step prior to pastillation.
[0029] The pastilles may be formed into different shapes include tablets, pills, spheres, and the like. A pastille can have a shape selected from the group consisting of spherical, hemispherical, compressed hemispherical, lentil shaped, and oblong. Lentil shaped refers to the shape of a lentil bean. Compressed hemispherical refers to a shape corresponding to a hemisphere that is at least partially flattened such that the curvature of the curved surface is less, on average, than the curvature of a hemisphere having the same radius. A compressed hemispherical pastille can have a ratio of height to diameter of from about 0.01 to about 0.4, alternatively from about 0.1 to about 0.4, alternatively from about 0.2 to about 0.3. Oblong shaped refers to a shape having a maximum dimension and a maximum secondary dimension orthogonal to the maximum dimension, wherein the ratio of maximum dimension to the maximum secondary dimension is greater than about 1.2. An oblong shape can have a ratio of maximum dimension to maximum secondary dimension greater than about 1.5. An oblong shape can have a ratio of maximum dimension to maximum secondary dimension greater than about 2. Oblong shaped particles can have a maximum dimension from about 2 mm to about 6 mm, a maximum secondary dimension of from about 2 mm to about 4 mm.
[0030] In alternative embodiments of any of the formulations disclosed herein, each individual pastille can have a mass from about 0.95 mg to about 2 g, alternatively from about 10 mg to about 1 g, alternatively from about 10 mg to about 500 mg, alternatively from about 10 mg to about 250 mg, alternatively from about 0.95 mg to about 125 mg, alternatively combinations thereof. In a plurality of pastilles, individual pastilles can have a shape selected from the group consisting of spherical, hemispherical, compressed hemispherical, lentil shaped, and oblong.
[0031] An individual pastille may have a volume from about 0.003 cm 3 to about 0.15 cm 3 . A plurality of pastilles may collectively comprise a unit dose for dosing to a laundry washing machine or laundry was basin. A single unit dose of the pastilles may comprise from about 13 g to about 27 g, alternatively from about 14 g to about 20 g, alternatively from about 15 g to about 19 g, alternatively from about 16 g to about 18 g, alternatively combinations thereof. The individual pastilles forming the plurality of pastilles that make up the unit dose can each have a mass from about 0.95 mg to about 2 g. The plurality of pastilles can be made up of pastilles of different size, shape, and/or mass. The pastilles in a unit dose can have a maximum dimension less than about 1 centimeter.
[0032] The composition may be manufactured by a pastillation process. A schematic of a pastillation apparatus 100 is illustrated in FIG. 1 . The steps of manufacturing according to such process can comprise providing the desired formulation as a viscous material 50. The viscous material 50 can comprise or consists of any of the possible formulations disclosed herein. In one embodiment, the viscous material 50 comprises: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume. The viscous material 50 can be provided at a processing temperature less than about 20 degrees Celsius above the onset of solidification temperature as determined by differential scanning calorimetry.
[0033] In one embodiment, the PMC can be added as a slurry to the polyethylene glycol and free perfume to form the viscous material 50 . The PMC can be added as a powder to the polyethylene glycol and free perfume to form the viscous material 50 . The viscous material 50 is passed through small openings 10 and onto a moving conveyor surface 20 upon which the viscous material 50 is cooled below the glass transition temperature to form a plurality of pastilles 30 . As illustrated in FIG. 1 , the small openings 10 can be on a rotatable pastillation roll 5 . Viscous material 50 can be distributed to the small openings 10 by a viscous material distributor 40 . Pastilles can be formed on a ROTOFORMER, available from Sandvik Materials Technology.
Package
[0034] A unit dose or a plurality of unit doses may be contained in a package. The package may be a bottle, bag, or other container. In one embodiment, the package is a bottle, preferably a PET bottle comprising a translucent portion to showcase the pastilles to a viewing consumer. In one embodiment, the package comprises a single unit dose (e.g., trial size sachet); or multiple unit doses (e.g., from about 15 unit doses to about 30 unit doses).
Dosing
[0035] The aforementioned package may comprise a dosing means for dispensing the pastilles from the package to a laundry washing machine (or laundry wash basin in hand washing applications). The user may use the dosing means to meter the recommended unit dose amount or simply use the dosing means to meter the pastilles according to the user's own scent preference. Examples of a dosing means may be a dispensing cap, dome, or the like, that is functionally attached to the package. The dosing means can be releasably detachable from the package and re-attachable to the package, such as for example, a cup mountable on the package. The dosing means may be tethered (e.g., by hinge or string) to the rest of the package (or alternatively un-tethered). The dosing means may have one or more demarcations (e.g., fill-line) to indicate a recommend unit dose amount. The packaging may include instructions instructing the user to open the removable opening of the package, and dispense (e.g., pour) the pastilles contained in the package into the dosing means. Thereafter, the user may be instructed to dose the pastilles contained in the dosing means to a laundry washing machine or laundry wash basin. The pastille of the present invention may be used to add freshness to laundry. The package including the dosing means may be made of plastic.
[0036] One embodiment can be a unit dose of a fabric treatment composition comprising a plurality of pastilles, wherein each pastille comprises: (a) from about 80% to about 91% by weight of the composition of polyethylene glycol, wherein the polyethylene glycol has a molecular weight from about 5,000 to about 11,000; (b) from about 2% to about 12% by weight of the composition free perfume; and (c) from about 2% to about 12% by weight of the composition of friable perfume microcapsule, wherein the perfume microcapsule comprises encapsulated perfume; wherein each pastille has a mass from about 0.95 mg to about 2 g; and wherein the plurality of pastilles has a mass from about 13 g to about 27 g to comprise the unit dose.
[0037] In one embodiment, the pastilles of the present invention can be administered to a laundry machine as used during the “wash cycle” of the washing machine (but a “rinse cycle” may also be used). In another embodiment, the pastilles of the present invention are administered in a laundry wash basin—during washing and/or rinsing laundry. In a laundry hand rinsing application, the pastille may further comprise an “antifoam agent” such as those available from Wacker. Antifoam agents (suds suppressing systems) are described in U.S. Patent Publication No. 20030060389 at 65-77.
[0000]
EXAMPLE
Grams in a 17 g
% Weight of
Ingredient:
unit Dose
Composition
PEG 8000
15
88.24%
Free (neat) Perfume
1
5.88%
Perfume Microcapsule 1
1
5.88%
(Encapsulated
(0.32)
(1.88%)
perfume) 2
Dye
0.0025
0.015%
1 PMC is a friable PMC with a urea-formaldehyde shell from Appleton. About 50% water by weight of the PMC (including encapsulated perfume) is assumed.
2 Encapsulated perfume (within PMC) assumes about 32% active.
[0038] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0039] Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0040] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | A laundry scent additive having polyethylene glycol and perfume. The laundry scent additive enables consumers to control the amount of scent imparted to their laundry. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 73,176 filed Sept. 7, 1979, and now abandoned, all the teachings of which application are incorporated herein by specific reference thereto.
BACKGROUND OF THE INVENTION
Crude petroleum oil, and the heavier hydrocarbon fractions and/or distillates obtained therefrom, generally contain nitrogenous and sulfurous compounds in large quantities. In addition, crude oil, and the heavier hydrocarbon fractions contain quantities of metallic contaminants which exert detrimental effects upon the catalyst utilized in various processes to which the crude oil or heavy hydrocarbon fraction is ultimately subjected. The most common metallic contaminants are nickel and vanadium, although other metals including iron, copper, etc., are often present. These metals may occur in a variety of forms; they may exist as metal oxides or as sulfides, introduced into the crude oil as metallic scale or particles; in the form of soluble salts of such metals; usually, however, they exist in the form of organo-metallic compounds such as metal porphyrins and the derivatives thereof.
Although the metallic contaminants existing as oxide or sulfide scale may be removed, at least in part, by a relatively simple filtering technique, and the water-soluble salts are at least in part removable by washing and subsequent dehydration, a much more severe treatment is generally required to remove the organometallic compounds to the degree required in order that the resulting crude oil or heavy hydrocarbon fraction is suitable for further processing. In addition to the organometallic compounds, including metal porphyrins, crude oils contain greater quantities of sulfurous and nitrogenous compounds that are found in light hydrocarbon fractions such as gasoline, kerosene, light gas oil, etc. For example, a Wyoming sour crude, having a gravity of 23.2° API at 60° F., contains about 2.8% by weight of sulfur and about 2700 ppm of total nitrogen. The nitrogenous and sulfurous compounds are converted, upon being subjected to a treating process, into hydrocarbons, ammonia, and hydrogen sulfide, the latter being readily removed from the system in a gaseous phase. Reduction in the concentration of the metallic contaminants is not as easily achieved to the extent that the crude oil or heavy hydrocarbon charge stock becomes suitable for further processing. Notwithstanding that the concentration of these compounds, such as metal porphyrins, is relatively small, for example, less than about 10 ppm, calculated as the elemental metal, subsequent processing techniques will be adversely affected thereby. For example, when a hydrocarbon charge stock containing metals in excess of about 3.0 ppm, is subjected to a cracking process for the purpose of producing lower-boiling components, the metals become deposited upon the catalyst employed, steadily increasing in quantity until such time as the composition of the catalytic composite is changed to the extent that undesirable results are obtained. That is to say, the composition of the catalytic composite, which is closely controlled with respect to the nature of the charge stock being processed and to the desired product quality and quantity, is changed considerably as the result of the deposition of the metallic contaminants onto the catalyst. This change in the catalyst results in a change in the characteristics of the catalyst. Such an effect is undesirable with respect to the cracking process, since the deposition of metallic contaminants upon the catalyst tends to result in a lesser quantity of valuable liquid product, and a larger amount of hydrogen and coke, the latter producing relatively rapid catalyst deactivation. The presence of organic metal compounds, including metal porphyrins, affects deleteriously other processes including catalytically reforming, isomerization, hydrodealkylation, etc.
In addition to the foregoing described contaminating influences, crude oils and other heavier hydrocarbon fractions, generally contain large quantities of pentane-insoluble material. For example, the Wyoming sour crude consists of about 8.37% by weight of pentane-insoluble asphaltenes which are hydrocarbonaceous compounds considered as coke-precursors having the tendency to become immediately deposited within the reaction zone and onto the catalytic composite employed in the form of a gummy hydrocarbonaceous residue. This constitutes a large loss of charge stock; it is economically desirable to convert such asphaltenes into useful hydrocarbon oil fractions.
The use of a slurry catalyst system for the conversion of hydrocarbon feedstock containing asphaltenes and organometallic compounds is well-known. For example, U.S. Pat. No. 3,161,585 describes such a process. The first preferred method of the above-mentioned patent for catalyst preparation comprises thermally decomposing an organometallic complex in admixture with the petroleum hydrocarbon charge stock to be treated. The second preferred method indicates that molybdenum metal may be dissolved in a suitable solvent, which is taught as comprising water, an alcohol or an ether. The '585 patent teaches that in both preferred methods some contact is necessitated with the petroleum charge stock to be treated.
Another U.S. Pat. No. 4,134,825 teaches that insoluble molybdenum oxide powder is not a feasible starting material to prepare an unsupported molybdenum sulfide catalyst.
OBJECTS AND EMBODIMENTS
The object of the present invention is to provide a novel method of preparing a molybdenum sulfide catalyst utilized in the processing of hydrocarbon feedstocks containing asphaltenes and organometallic compounds.
The present invention teaches the preparation of a finely divided, unsupported catalyst useful in a slurry process, and which will not effect extensive erosion of the reaction system. A slurry process yields a liquid hydrocarbon product which is more suitable for further processing without experiencing the difficulties otherwise resulting from the presence of the hereinabove described contaminants. A slurry process is particularly advantageous in effecting the removal of the organic metal compounds without significant product yield loss, while simultaneously converting pentane-insoluble material into pentane-soluble liquid hydrocarbons.
In a broad embodiment, the present invention involves a method of preparing an unsupported molybdenum sulfide catalyst utilized in hydrorefining a hydrocarbon charge stock.
A more limited embodiment of the present invention affords a method of preparing an unsupported molybdenum sulfide catalyst which comprises reacting molybdenum oxide with ammmonium sulfide at a temperature and pressure selected to produce an ammonium salt of molybdenum sulfide and thereafter thermally decomposing said ammonium salt of molybdenum sulfide in a non-oxidative atmosphere to form said unsupported molybdenum sulfide catalyst.
DETAILED DESCRIPTION OF THE INVENTION
From the foregoing embodiments, it is readily ascertained that the method of the present invention involves the preparation of an unsupported molybdenum sulfide catalyst. The catalyst prepared in accordance with the method of the present invention comprises molybdenum which is derived from molybdenum oxide. A suitable molybdenum oxide which may be used as the molybdenum catalyst precursor is MoO 3 . The catalyst is prepared by initially contacting the molybdenum oxide with ammonium sulfide to form an ammonium salt of the molybdenum sulfide. The resulting ammonium salt of the molybdenum sulfide is thermally decomposed in a non-oxidative atmosphere and molybdenum sulfide catalyst is recovered. Any suitable non-oxidative atmosphere may be used but preferred atmospheres include hydrogen and nitrogen.
In order to ensure complete conversion of the molybdenum oxide it is preferable to add from about 110% to about 200% of the stoichiometric requirement of ammonium sulfide.
The reaction of the molybdenum oxide and the ammonium sulfide may suitably be performed at a temperature in the range of about 100° C. to about 225° C. and at a pressure from about 100 psig to about 700 psig. Preferred reaction conditions are a temperature of 200° C. and a pressure of 500 psig. The resulting ammonium salt of the molybdenum sulfide is then thermally decomposed in a non-oxidative atmosphere to yield a molybdenum sulfide catalyst. The thermal decomposition may be suitably performed at a temperature of from about 200° C. to about 300° C. and at ambient pressure. Preferred decomposition conditions are at a temperature of 250° C. and ambient pressure. Any suitable non-oxidative atmosphere may be used but preferred atmospheres include hydrogen and nitrogen.
The following example is given to illustrate the method of the present invention and is not intended as an undue limitation on the generally broad scope of the invention as set out in the appended claims.
EXAMPLE
This example describes a preferred embodiment of the present invention. About 30 grams of MoO 3 is contacted with 125% of the stoichiometric amount of ammonium sulfide to form an ammonium salt of the molybdenum sulfide at a temperature of about 150° C. and a pressure of 500 psig. The resulting ammonium salt of molybdenum sulfide is then thermally decomposed at a temperature of 260° C. under a hydrogen blanket and about 15 grams of molybdenum sulfide catalyst is recovered.
The foregoing specification and example clearly illustrate the method of the present invention for the preparation of an unsupported molybdenum sulfide catalyst and the advantages derived therefrom. | A novel method of preparing an unsupported molybdenum sulfide catalyst utilized in the processing of hydrocarbon feedstocks containing asphaltenes and organometallic compounds. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 14/568,604 filed on Dec. 12, 2014, which was a continuation of U.S. patent application Ser. No. 13/202,447 filed on Aug. 19, 2011 (now Abandoned), which was based upon and claimed the benefit of priority from the prior PCT/JP2009/052901 filed on Feb. 19, 2009, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a paper-sheet counting machine adapted for counting paper sheets, such as banknotes, checks and the like.
BACKGROUND ART
[0003] In the past, various types of machines have been known as the paper-sheet counting machine adapted for counting the paper sheets, such as the banknotes, checks and the like. For instance, a banknote counting machine disclosed in JP2600100Y2 is provided for setting a plurality of banknotes in a stacked condition on a placing unit (e.g., a hopper), then feeding and inserting each banknote located at the lowest position of the banknotes into a space between a pair of gate units, one by one, by using a feeding unit, such as a feed roller or the like, provided at a bottom part of the placing unit, thereby separating such banknotes, one by one, and feeding each separated banknote downward, via a passage, and further feeding it into a space between two vanes of a stacking wheel located in the middle of the passage. Thereafter, each banknote received between the two vanes is thrown off therefrom, downward onto a stacking unit, while being turned round with rotation of the stacking wheel, and then arranged in the stacking unit. Further, in the banknote counting machine disclosed in JP2600100Y2, a sensor is provided for counting the number of the banknotes passing through this sensor, before such banknotes reach the stacking wheel.
[0004] Further, in JP3537697B and JP3741893B, a banknote processing machine provided for recognizing each banknote and then sorting the recognized banknote, based on each recognition result thereof, is disclosed. In such a banknote processing machine, a plurality of stacking units (or stackers) are provided for respectively receiving the banknotes that have been respectively sorted for each corresponding denomination of money and then fed to the stacking units. In this case, a shutter is provided to each stacker. This shutter serves to selectively close an opening of each stacking unit, in order to prevent access of an operator to the stacking unit.
DISCLOSURE OF THE INVENTION
[0005] However, in the conventional banknote counting machine as disclosed in the above JP2600100Y2, each banknote is stacked, with the rotation of the stacking wheel, while falling down forward from the back. Therefore, dust accumulated on the transport path and/or dust attached to each banknote tends to be blown out toward the operator. In addition, in this banknote counting machine, the sound generated in the interior of the machine during its operation tends to leak to the outside, thus making a considerable noise.
[0006] Further, in the above JP3537697B and JP3741893B, the shutter is provided to each stacking unit in the banknote processing machine. However, in this banknote processing machine, the opening is provided at an upper part of each stacking unit, and the shutter is designed for opening and closing such an opening provided at the upper part of each stacking unit. Therefore, this shutter is not directly intended for a dustproof application. More specifically, when in an opening position, the shutter provided to each stacking unit serves to allow the banknotes stacked in this stacking unit to be respectively taken out therefrom. Meanwhile, when in a closing position, this shutter serves to prevent any banknote from being taken out from the corresponding stacking unit. Namely, this shutter is intended only for providing the so-called locking function.
[0007] The present invention was made in view of the above problems. Therefore, it is an object of this invention to provide the paper-sheet counting machine that can prevent the dust accumulated in a casing of the machine and/or dust attached to each paper-sheet from being blown out toward the operator, as well as can successfully prevent the sound generated in the interior of the machine from leaking to the outside during the operation of the machine.
[0008] A paper-sheet counting machine of the present invention includes: a counting unit configured to count paper sheets; a stacking unit configured to stack therein the paper sheets that have been counted by the counting unit, an opening being provided in a front face of the stacking unit; a rotary guide unit provided to the stacking unit and configured to allow the paper sheets that have been counted by the counting unit to be stacked in the stacking unit; a shutter configured to close the opening provided in the front face of the stacking unit; a shutter drive unit configured to drive the shutter to open and close the opening provided in the front face of the stacking unit; and a control unit configured to control the shutter drive unit.
[0009] According to the aforementioned paper-sheet counting machine, the opening and closing operation for the opening provided in the front face of the stacking unit can be performed by the shutter driven by the shutter drive unit controlled by the control unit. Therefore, the opening provided in the front face of the stacking unit can be selectively closed by the shutter. Thus, when this shutter closes the opening, the blowing out of the dust accumulated in the casing of the paper-sheet counting machine and/or dust attached to each paper sheet, toward the operator, can be successfully prevented. Further, when the shutter closes the opening in the front face of the stacking unit, the unwanted leakage of the sound generated in the interior of the paper-sheet counting machine to the outside can be effectively prevented during the operation of the machine.
[0010] In the paper-sheet counting machine of the present invention, it is preferred that the rotary guide unit includes a stacking wheel configured to be rotated about a shaft extending in a substantially horizontal direction, the stacking wheel having a plurality of vanes respectively extending from the outer circumferential face of the stacking wheel, outward in a direction reverse to the rotation direction of the rotary guide unit, and the stacking wheel is configured to receive each paper sheet counted by the counting unit, between the vanes thereof, and then feed the paper sheet received between the vanes into the stacking unit.
[0011] In the paper-sheet counting machine of the present invention, it is preferred that the control unit controls the shutter drive unit to drive the shutter to close the opening provided in the front face of the stacking unit, before the counting process for the paper sheets is started by the counting unit.
[0012] Alternatively, the control unit may control the shutter drive unit to drive the shutter to start closing the opening provided in the front face of the stacking unit, at the same time as starting of the counting process for the paper sheets by the counting unit, thereby allowing the paper sheets to be counted, while the opening is closed.
[0013] In the aforementioned paper-sheet counting machine, it is further preferred that the paper-sheet counting machine further includes a placing unit configured to place thereon the paper sheets to be respectively counted by the counting unit, for allowing such paper sheets, respectively placed on the placing unit, to be fed, one by one, to the counting unit, and a first paper-sheet detection unit configured to detect whether or not the paper sheets are placed on the placing unit, and when the first paper-sheet detection unit detects that all of the paper sheets respectively placed on the placing unit are fed to the counting unit and thus there is no paper sheet remaining on the placing unit, the control unit controls the shutter drive unit to retreat the shutter from the opening provided in the front face of the stacking unit to open the opening.
[0014] In this case, it is further preferred that interval of time between the time the first paper-sheet detection unit detects that there is no paper sheet remaining on the placing unit and the time the control unit controls the shutter drive unit to retreat the shutter from the opening, is capable of being altered by settings.
[0015] It is further preferred that the counting unit is configured to recognize the paper sheets, and the paper-sheet counting machine further comprises a reject unit configured to receive the paper sheets respectively recognized as reject paper sheets by the counting unit and fed thereto from the counting unit, and a second paper-sheet detection unit configured to detect whether or not the paper sheets are stacked in the reject unit, and when the first paper-sheet detection unit detects that there is no paper sheet remaining on the placing unit and when the second paper-sheet detection unit detects that there is a paper sheet or sheets in the reject unit, the control unit serves to drive the shutter to keep closing the opening provided in the front face of the stacking unit.
[0016] It is further preferred that the control unit serves to selectively perform a batch process mode, in which the counting unit counts paper sheets by the batch number, the batch number being instructed to the control unit, and when the first paper-sheet detection unit detects that there is no paper sheet remaining on the placing unit and when the number of the paper sheets fed to the stacking unit does not reach the batch number, during the process for the paper sheets in the batch process mode performed by the control unit, the control unit serves to drive the shutter to keep closing the opening provided in the front face of the stacking unit.
[0017] In the paper-sheet counting machine of the present invention, it is preferred that the control unit serves to selectively perform a batch process mode, in which the counting unit counts paper sheets by the batch number, the batch number being instructed to the control unit, and when the batch number inputted to the control unit is smaller than a preset number, during the process for the paper sheets in the batch process mode performed by the control unit, the control unit serves to retreat the shutter from the opening provided in the front face of the stacking unit to keep the opening opened.
[0018] In the paper-sheet counting machine of the present invention, it is preferred that the paper-sheet counting machine further comprises a placing unit configured to place thereon the paper sheets to be respectively counted by the counting unit, for allowing such paper sheets, respectively placed on the placing unit, to be fed, one by one, to the counting unit, and a third paper-sheet detection unit provided between the placing unit and the stacking unit and configured to detect each paper sheet when the paper sheet fed to the stacking unit from the placing unit passes through the third paper-sheet detection unit, and the control unit serves to selectively perform a batch process mode, in which the counting unit counts paper sheets by the batch number, the batch number being instructed to the control unit, and when the batch number inputted to the control unit is equal to or greater than the preset number, during the process for the paper sheets in the batch process mode performed by the control unit, the control unit controls the shutter drive unit to drive the shutter to close the opening provided in the front face of the stacking unit, before the counting process for the paper sheets is started by the counting unit, and when the third paper-sheet detection unit detects the last paper sheet of the batch number, the control unit controls the shutter drive unit to retreat the shutter from the opening provided in the front face of the stacking unit to open the opening.
[0019] In this case, it is further preferred that interval of time between the time the third paper-sheet detection unit detects the last paper sheet of the batch number and the time the control unit controls the shutter drive unit to retreat the shutter from the opening, is capable of being altered by settings.
[0020] In the paper-sheet counting machine of the present invention, it is preferred that the paper-sheet counting machine further comprises a placing unit configured to place thereon the paper sheets to be respectively counted by the counting unit, for allowing such paper sheets, respectively placed on the placing unit, to be fed, one by one, to the counting unit, and a third paper-sheet detection unit provided between the placing unit and the stacking unit and configured to detect each paper sheet when the paper sheet fed to the stacking unit from the placing unit passes through the third paper-sheet detection unit, and the control unit controls the shutter drive unit to drive the shutter to close the opening provided in the front face of the stacking unit, before the counting process for the paper sheets is started by the counting unit, and when the third paper-sheet detection unit detects a certain paper sheet, with which the stacking unit will be full up upon receiving thereof, the control unit controls the shutter drive unit to retreat the shutter from the opening provided in the front face of the stacking unit to open the opening.
[0021] In this case, it is further preferred that interval of time between the time the third paper-sheet detection unit detects the paper sheet, with which the stacking unit will be full up upon receiving thereof, and the time the control unit controls the shutter drive unit to retreat the shutter from the opening, is capable of being altered by settings.
[0022] It is further preferred that the third paper-sheet detection unit is provided in such a position that interval of time between the time the paper sheet is detected by the third paper-sheet detection unit and the time this paper sheet is fed to the stacking unit is substantially matched with the time required for the shutter to be moved from the position for closing the opening provided in the front face of the stacking unit to the position for opening the same opening.
[0023] In the paper-sheet counting machine of the present invention, it is preferred that the control unit performs selectively either one of a with-shutter-operation mode, in which the control unit controls the shutter drive unit to drive the shutter to open and close the opening provided in the front face of the stacking unit, and a without-shutter-operation mode, in which the shutter drive unit is not controlled by the control unit, and thus the opening and closing operation for the opening provided in the front face of the stacking unit is not performed by the shutter.
[0024] In the paper-sheet counting machine of the present invention, it is preferred that the shutter is configured to be retreated from the opening provided in the front face of the stacking unit, by hand, even during the counting process for the paper sheets by the counting unit.
[0025] In the paper-sheet counting machine of the present invention, it is preferred that the shutter is composed of a transparent material.
[0026] In the paper-sheet counting machine of the present invention, it is preferred that the shutter is capable of being reciprocated, about a shaft, between a closing position for closing the opening provided in the front face of the stacking unit and an opening position retreated from the opening to open the opening, the opening position being located below the rotary guide unit.
[0027] In the paper-sheet counting machine of the present invention, it is preferred that an elastic member is provided to the shutter, and a cam configured to be engaged with the shutter is provided to the shutter drive unit, and the shutter is biased toward the closing position for closing the opening provided in the front face of the stacking unit, by contraction force of the elastic member, and is adapted to be retreated from the opening, toward the opening position for opening the opening, by the cam provided to the shutter drive unit.
[0028] Alternatively, a gear and a torque limiter may be respectively provided between the shutter and the shutter drive unit, and the driving force applied from the shutter drive unit is transmitted to the shutter, via the gear and torque limiter, and when force greater than a preset torque is applied to the torque limiter, the torque limiter may serve to block the driving force transmitted from the shutter drive unit to the shutter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a drawing for schematically illustrating the internal construction of a paper-sheet counting machine related to one embodiment of the present invention, when a shutter closes an opening provided in the front face of a stacking unit.
[0030] FIG. 2 is a drawing for schematically illustrating the internal construction of the paper-sheet counting machine shown in FIG. 1 , when the shutter is retreated from the opening provided in the front face of the stacking unit to open the opening.
[0031] FIG. 3 is a drawing for illustrating details of the construction of the shutter, a shutter support unit for supporting the shutter, a shutter drive unit and the like, respectively provided in the paper-sheet counting machine shown in FIG. 1 and the like, when the shutter closes the opening provided in the front face of the stacking unit.
[0032] FIG. 4 is another drawing for illustrating the details of the construction of the shutter, shutter support unit for supporting the shutter, shutter drive unit and the like, respectively provided in the paper-sheet counting machine shown in FIG. 1 and the like, when the shutter is retreated from the opening provided in the front face of the stacking unit to open the opening.
[0033] FIG. 5 is a block diagram for illustrating a control system of the paper-sheet counting machine shown in FIG. 1 and the like.
[0034] FIG. 6 is a flow chart showing a series of operations, respectively performed by the paper-sheet counting machine shown in FIG. 1 and the like.
[0035] FIG. 7 is another flow chart further showing the series of operations, respectively performed by the paper-sheet counting machine shown in FIG. 1 and the like.
[0036] FIG. 8 is still another flow chart further showing the series of operations, respectively performed by the paper-sheet counting machine shown in FIG. 1 and the like.
[0037] FIG. 9 is a side view for illustrating the construction of the shutter, shutter support unit for supporting the shutter, shutter drive unit, a plurality of gears, a torque limiter and the like, respectively provided in the paper-sheet counting machine related to one variation of the present invention.
[0038] FIG. 10 is a top view for illustrating the shutter, shutter support unit for supporting the shutter, shutter drive unit, plurality of gears, torque limiter and the like, respectively shown in FIG. 9 , when such units or parts are respectively seen from above.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Hereinafter, one embodiment of the present invention will be described, with reference to the drawings. Of these drawings, FIGS. 1 through 8 are respectively provided for illustrating the paper-sheet counting machine related to the embodiment. More specifically, FIGS. 1 and 2 are respectively provided for schematically illustrating the internal construction of the paper-sheet counting machine related to the embodiment. FIGS. 3 and 4 are respectively provided for illustrating the details of the construction of the shutter, shutter support unit for supporting the shutter, shutter drive unit and the like, respectively provided in the paper-sheet counting machine shown in FIG. 1 and the like. The block diagram of FIG. 5 is provided for illustrating one exemplary control system of the paper-sheet counting machine shown in FIG. 1 and the like. Each flow chart of FIGS. 6 through 8 illustrates the series of operations, respectively performed by the paper-sheet counting machine shown in FIG. 1 and the like. It is noted that the paper-sheet counting machine related to this embodiment is intended for counting the number of the paper sheets, such as the banknotes, checks and the like.
[0040] As illustrated in FIGS. 1 and 2 , a paper-sheet counting machine 10 includes a casing 12 and a placing unit 14 adapted for placing thereon a plurality of paper sheets P to be respectively counted, in a stacked condition. Further, this paper-sheet counting machine 10 includes a feeding unit 16 adapted for feeding each paper sheet P located at the lowermost layer of the paper sheets P placed on the placing unit 14 in the stacked condition, one by one, into the casing 12 , and a transport unit 22 adapted for transporting the paper sheets P, respectively fed into the casing 12 by the feeding unit 16 , one by one. In FIGS. 1 and 2 , the right side face of the casing 12 is depicted as the front face thereof, while the left side face of the casing 12 shows the back face thereof. In addition, a recognition and counting unit 24 adapted for recognizing and counting the paper sheets P respectively fed into the casing 12 from the placing unit 14 is provided to the transport unit 22 . For instance, the recognition and counting unit 24 is composed of a line sensor.
[0041] The feeding unit 16 includes a kicker roller 16 a provided to be in contact with the surface of one paper sheet P located at the lowermost layer of the paper sheets P placed on the placing unit 14 in the stacked condition, and a feed roller 16 b located on the downstream side, in the feeding direction of the paper sheets P, relative to the kicker roller 16 a and adapted for feeding the paper sheets P, respectively kicked out by the kicker roller 16 a, into the casing 12 . Further, a gate roller (or reverse rotation roller) 16 c is provided to be opposed to the feed roller 16 b, with a gate part provided between the feed roller 16 b and the gate roller 16 c. Thus, each paper sheet P kicked out by the kicker roller 16 a is passed through the gate part and then fed out, one by one, toward the transport unit 22 in the casing 12 .
[0042] The transport unit 22 is bifurcated into two transport paths at a point located on the downstream side relative to the recognition and counting unit 24 , and one of the two bifurcated transport paths is connected with a stacking unit 26 , while the other transport path is connected with a reject unit 30 . To the stacking unit 26 , each paper sheet P that has been recognized as a normal paper sheet by the recognition and counting unit 24 is fed. An opening is provided in the front face of the stacking unit 26 (i.e., the face of the stacking unit 26 depicted on the right side in FIGS. 1 and 2 ), such that the operator can take out the paper sheets P respectively stacked in the stacking unit 26 , via this opening.
[0043] Meanwhile, each paper sheet that is not recognized as the normal paper sheet by the recognition and counting unit 24 and each paper sheet that cannot be recognized by the recognition and counting unit 24 are respectively fed to a reject unit 30 , as reject paper sheets P′, by the transport unit 22 . Similarly, one opening is provided in the front face of the reject unit 30 , such that the operator can take out the reject paper sheets P′ respectively stacked in the reject unit 30 , via this opening.
[0044] As shown in FIGS. 1 and 2 , a diverter 32 is provided at the same point where the transport unit 22 is bifurcated into the two transport paths. Due to this diverter 32 , each paper sheet that has been fed from the upstream side of the diverter 32 can be selectively fed to either one of the two bifurcated transport paths.
[0045] A stacking wheel 28 is provided on the back face side (i.e., in a position located on the left side shown in FIGS. 1 and 2 ) of the stacking unit 26 in the casing 12 . This stacking wheel 28 is configured to be rotated in a clockwise direction in FIG. 1 and the like (i.e., the direction indicated by an arrow depicted in FIGS. 1 and 2 ) about a shaft extending in a substantially horizontal direction orthogonal to the sheet of FIG. 1 and the like. The rotational operation of the stacking wheel 28 is performed by a stacking-wheel drive unit 29 (not shown in FIGS. 1 and 2 ) that will be described later. In this stacking wheel 28 , a plurality of vanes 28 a are provided to extend outward, from an outer circumferential face of the wheel 28 , in a direction reverse to the rotation direction of the wheel 28 (i.e., the anticlockwise direction in FIG. 1 and the like). More specifically, such vanes 28 a are provided to the outer circumferential face of the stacking wheel 28 , at an equal interval, as shown in FIG. 1 and the like.
[0046] The stacking wheel 28 is configured to be constantly rotated in the clockwise direction in FIG. 1 and the like, by the stacking-wheel drive unit 29 , during the operation of the paper-sheet counting machine 10 , thereby to receive the paper sheets P, respectively fed from the transport unit 22 , one by one. Then, the stacking wheel 28 receives each paper sheet P fed from the transport unit 22 , between the two vanes 28 a thereof, and then feeds the paper sheet P received between the two vanes 28 a into the stacking unit 26 . In this way, the paper sheets P can be fed to the stacking unit 26 , one by one, from the stacking wheel 28 , as such the plurality of paper sheets P can be stacked in the stacking unit 26 .
[0047] In the paper-sheet counting machine 10 of this embodiment, a shutter 40 is provided to close the opening provided in the front face of the stacking unit 26 . Thus, the opening in the front face of the stacking unit 26 can be selectively closed by the shutter 40 . By a shutter drive unit 50 (not shown in FIGS. 1 and 2 ) that will be described later and is composed of, for example, a motor, the shutter 40 is moved, between the closing position, as depicted in FIG. 1 , in which the opening in the front face of the stacking unit 26 is closed, and the opening position, as depicted in FIG. 2 , in which the shutter 40 is retreated from the opening in the front face of the stacking unit 26 to open the opening. Namely, when the shutter 40 is located in the closing position as depicted in FIG. 1 , the opening in the front face of the stacking unit 26 is closed, thus preventing the operator from accessing the paper sheets P respectively stacked in the stacking unit 26 . Meanwhile, when the shutter 40 is located in the opening position as depicted in FIG. 2 , this shutter 40 is retreated from the opening in the front face of the stacking unit 26 , and thus the opening is opened, thereby allowing the operator to access the paper sheets P respectively stacked in the stacking unit 26 .
[0048] Now, the reason why the shutter 40 is provided will be described below. In the paper-sheet counting machine 10 including the stacking wheel 28 provided to the stacking unit 26 , each paper sheet P is stacked in the stacking unit 26 , while falling down forward from the back (or rightward from the left as shown in FIG. 1 and the like). Therefore, there is a risk that the dust accumulated in the stacking unit 26 and the like and/or dust attached to each paper sheet P may be blown out toward the operator, via the opening in the front face of the stacking unit 26 . However, when the shutter 40 is moved to the closing position, as depicted in FIG. 1 , to close the opening in the front face of the stacking unit 26 , this shutter 40 can serve to suppress the blowing out of the dust toward the operator with rotation of the stacking wheel 28 . Further, when the shutter 40 is located in the closing position to close the opening in the front face of the stacking unit 26 , the unwanted leakage of the sound generated in the paper-sheet counting machine 10 , to the outside, can be prevented during the operation of the machine 10 .
[0049] The shutter 40 may be composed of a transparent material, such as a plastic material or the like. In this case, even in the case the shutter 40 is located in the closing position in which the opening in the front face of the stacking unit 26 is closed as depicted in FIG. 1 , the operator can confirm, with eyes, the stacked condition of the paper sheets P in the stacking unit 26 , via the shutter 40 formed of a proper transparent material.
[0050] Next, the operation of the shutter 40 driven by the shutter drive unit 50 will be described in more detail, with reference to FIGS. 3 and 4 . FIGS. 3 and 4 are respectively provided for illustrating the details of the construction of the shutter 40 , shutter support unit 42 for supporting the shutter 40 , shutter drive unit 50 and the like, respectively provided in the paper-sheet counting machine 10 shown in FIG. 1 and the like. More specifically, FIG. 3 is provided for illustrating one operational state corresponding to FIG. 1 , in which the shutter 40 closes the opening provided in the front face of the stacking unit 26 . Meanwhile, FIG. 4 is provide for illustrating another operational state corresponding to FIG. 2 , in which the shutter 40 is retreated from the opening provided in the front face of the stacking unit 26 to open the opening.
[0051] As shown in FIG. 3 and the like, the shutter 40 is supported by the shutter support unit 42 , and a substantially rectangular plate member 44 is attached to the shutter support unit 42 . A shaft 44 a is provided to a central part of the plate member 44 , such that the plate member 44 is reciprocated about this shaft 44 a. As such, the shutter 40 supported by the shutter support unit 42 is also reciprocated about the shaft 44 a. Further, a circular linking member 44 b is attached to one end of the plate member 44 on the opposite side of the shutter 40 , such that this linking member 44 b can be optionally rotated relative to the plate member 44 .
[0052] Further, an elastic member, more specifically, one end 46 b of a spring 46 , is attached to the end of the plate member 44 opposite to the end thereof to which the linking member 44 b is provided. In this case, the other end 46 a of the spring 46 opposite to the one end 46 b thereof attached to the plate member 44 is fixed to an inner face of the casing 12 . Namely, the other end 46 a of the spring 46 is fixed in position, while the position of the one end 46 b of the spring 46 attached to the end of the plate member 44 is changed, with the reciprocation movement of the plate member 44 about the shaft 44 a. With such configuration, due to contraction force of the spring 46 , the shutter 40 is constantly biased from the opening position thereof as depicted in FIG. 4 toward the closing position thereof as depicted in FIG. 3 .
[0053] Further, a cam 52 is provided to be in contact with the outer circumferential face of the circular linking member 44 b rotatably provided relative to the plate member 44 . This cam 52 has a rotation shaft 51 attached thereto and located in a point eccentric to the central part of the cam 52 . This rotation shaft 51 is rotated in the anticlockwise direction in FIG. 3 and the like (as indicated by an arrow), by the shutter drive unit 50 composed of, for example, the motor or the like. Thus, the cam 52 is also rotated in the anticlockwise direction in FIG. 3 and the like (as indicated by the arrow), about the rotation shaft 51 . With this rotation of the cam 52 about the rotation shaft 51 , the linking member 44 b that is in contact with an edge portion of the cam 52 is pressed and pushed upward in FIG. 3 (as indicated by another arrow), from the state shown in FIG. 3 . Thus, the plate member 44 is rotated in the clockwise direction about the shaft 44 a. As such, the shutter support unit 42 attached to the plate member 44 is also rotated in the clockwise direction about the shaft 44 a from the state shown in FIG. 3 , thus allowing the shutter support unit 42 to be moved to the position shown in FIG. 4 from the position shown in FIG. 3 . In this way, the shutter 40 is moved to the opening position as depicted in FIG. 2 , from the closing position as depicted in FIG. 1 . During this operation, the spring 46 is expanded from the state shown in FIG. 3 to the state shown in FIG. 4 .
[0054] However, when the cam 52 is further rotated about the rotation shaft 51 , in the anticlockwise direction in FIG. 4 (as indicated by an arrow) from the state as shown in FIG. 4 , the circular linking member 44 b provided to the plate member 44 is no longer pressed upward in FIG. 4 by the cam 52 . As such, due to the contraction force of the spring 46 , the plate member 44 is rotated in the anticlockwise direction in FIG. 4 , about the shaft 44 a, from the state shown in FIG. 4 . Thus, the shutter support unit 42 attached to the plate member 44 is also rotated in the anticlockwise direction, about the shaft 44 a, from the state shown in FIG. 4 , and hence returned to the position shown in FIG. 3 from the position shown in FIG. 4 . In this way, the shutter 40 is returned to the closing position as shown in FIG. 1 , from the opening position as shown in FIG. 2 . During this operation, the spring 46 is contracted into the state shown in FIG. 3 , from the state shown in FIG. 4 .
[0055] In this way, the shutter 40 is reciprocated about the shaft 44 a by the shutter drive unit 50 , between the closing position (see FIGS. 1 and 3 ), in which the opening in the front face of the stacking unit 26 is closed, and the opening position (see FIGS. 2 and 4 ), in which the shutter 40 is retreated from the opening to open this opening. In the opening position, as shown in FIG. 2 and the like, the shutter 40 is located below the stacking wheel 28 . Thus, when the shutter 40 is located in the opening position, the dust generated from the stacking wheel 28 and the like can be received by this shutter 40 , thereby preventing such dust being accumulated on an inner bottom face of the casing 12 .
[0056] For instance, the time required for the shutter 40 to be moved from the closing position shown in FIG. 1 to the opening position shown in FIG. 2 and the time required for the shutter 40 to be moved from the opening position shown in FIG. 2 to the closing position shown in FIG. 1 are set at 0.5 seconds, respectively.
[0057] Further, since the shutter 40 is biased, toward the closing position as depicted in FIG. 3 from the opening position as depicted in FIG. 4 , by the contraction force of the spring 46 , this shutter 46 can be moved downward, by hand, from the closing position shown in FIG. 3 , against the contraction force of the spring 40 . Therefore, the shutter 40 can be retreated, as needed, by hand, from the opening in the front face of the stacking unit 26 , even in a period of time during which the shutter 40 is located in the closing position shown in FIG. 3 and the paper sheets P are counted by the recognition and counting unit 24 . In this way, the paper sheets P can be taken out from the stacking unit 26 .
[0058] Further, as described above, the spring 46 is provided to the shutter 40 , and the cam 52 is provided to the shutter drive unit 50 , while being engaged with the linking member 44 b of the plate member 44 . In addition, the shutter 40 can be biased toward the closing position (as shown in FIG. 3 ) in which the opening in the front face of the stacking unit 26 is closed, by the contraction force of the spring 46 , as well as can be retreated from the opening in the front face of the stacking unit 26 toward the opening position (as shown in FIG. 4 ) to open the opening, by the cam 52 provided to the shutter drive unit 50 . Therefore, this configuration can successfully prevent the finger or the like of the operator from being accidentally nipped and injured by the shutter 40 , during the period of time in which the shutter 40 is moved from the opening position shown in FIG. 2 to the closing position shown in FIG. 1 . This is because, the force used for pressing and moving the shutter 40 toward the closing position is not the driving force exerted from the shutter drive unit 50 , but the contraction force of the spring 46 .
[0059] As shown in FIGS. 3 and 4 , a shutter-closing detection sensor 54 a and a shutter-opening detection sensor 54 b are respectively fixed in position in the vicinity of the cam 52 . Each of the shutter-closing detection sensor 54 a and shutter-opening detection sensor 54 b is composed of an optical sensor. Further, a detection target member 53 to be detected by each of the shutter-opening detection sensor 54 a and shutter-opening detection sensor 54 b is provided to one side face of the cam 52 . In this case, as shown in FIG. 3 , when the shutter-closing detection sensor 54 a detects the detection target member 53 , the shutter 40 is detected to be in the closing position. Meanwhile, when the cam 52 is rotated in the anticlockwise direction about the rotation shaft 51 , from the state shown in FIG. 3 to the state shown in FIG. 4 , the shutter-opening detection sensor 54 b detects the detection target member 53 . As a result, the shutter 40 is detected to be in the opening position.
[0060] In addition, as shown in FIG. 1 and the like, various sensors are provided to the paper-sheet counting machine 10 . Specifically, to the placing unit 14 , a placing-unit-residue detection sensor (or first paper-sheet detection unit) 60 is provided for detecting whether or not there are some paper sheets P remaining on the placing unit 14 . Further, to the reject unit 30 , a reject-unit paper-sheet detection sensor (or second paper-sheet detection unit) 62 is provided for detecting whether or not there are some reject paper sheets P′ remaining in the reject unit 30 . Additionally, to the transport unit 22 located on the upstream side relative to the recognition and counting unit 24 , a paper-sheet tracking detection sensor (or third paper-sheet detection unit) 64 is provided for detecting each paper sheet P when the paper sheet P transported by the transport unit 22 passes through this paper-sheet tracking detection sensor 64 . In FIGS. 1 and 2 , while the paper-sheet tracking detection sensor 64 is located on the upstream side relative to the recognition and counting unit 24 in the transport unit 22 , this paper-sheet tracking detection sensor 64 may be located on the downstream side relative to the recognition and counting unit 24 .
[0061] Now, the position in which the paper-sheet tracking detection sensor 64 is located will be described more specifically. Namely, this paper-sheet tracking detection sensor 64 is provided to the transport unit 22 , in such a position that interval of time between the time one paper sheet P is detected by the paper-sheet tracking detection sensor 64 and the time this paper sheet P is fed to the stacking unit 26 , is substantially matched with the time required for the shutter 40 to be moved from the closing position (see FIG. 1 ) in which the opening in the front face of the stacking unit 26 is closed to the opening position (see FIG. 2 ) in which the opening is opened (e.g., 0.5 seconds). With such provision of the paper-sheet tracking detection sensor 64 in the position as described above in the transport unit 22 , if the shutter 40 starts to move from its closing position shown in FIG. 1 when one paper sheet P is detected by the paper-sheet tracking detection sensor 64 , this paper sheet P reaches the stacking unit 26 at the same time the shutter 40 reaches the opening position shown in FIG. 2 . Thus, the operator can take out each paper sheet P from the stacking unit 26 , immediately after the paper sheet P reaches the stacking unit 26 .
[0062] Additionally, a diversion timing sensor 66 is provided on the upstream side relative to the diverter 32 in the transport unit 22 . The diverter 32 is optionally moved to either one of a first position for feeding each paper sheet P to the stacking unit 26 and a second position for feeding the paper sheet P to the reject unit 30 , at each timing on which the paper sheet P is detected by the diversion timing sensor 66 (e.g., in FIGS. 1 and 2 , the diverter 32 is shown to be located in the position for feeding the paper sheet P to the stacking unit 26 ). With this configuration, each paper sheet P that has been transported by the transport unit 22 and detected by the diversion timing sensor 66 is selectively fed, by the diverter 32 , to either one of the two transport paths.
[0063] Further, a stacking-unit paper-sheet detection sensor 68 is provided on a downstream-side end of the transport unit 22 extending toward the stacking unit 26 . This stacking-unit paper-sheet detection sensor 68 serves to detect each paper sheet P when the paper sheet P is fed to the stacking wheel 28 from the transport unit 22 . With the provision of this stacking-unit paper-sheet detection sensor 68 , the number of the paper sheets P respectively fed to the stacking unit 26 can be counted.
[0064] As shown in FIG. 5 and the like, the paper-sheet counting machine 10 includes a control unit 70 . This control unit 70 serves to control each component of the paper-sheet counting machine 10 . More specifically, this control unit 70 is connected with each of the feeding unit 16 , transport unit 22 , recognition and counting unit 24 , stacking-wheel drive unit 29 for driving the stacking wheel 28 , diverter 32 and shutter drive unit 50 for driving the shutter 40 . In this case, the recognition and counting result on each paper sheet P recognized by the recognition and counting unit 24 is sent to the control unit 70 , while the control unit 70 sends a command signal to each of the feeding unit 16 , transport unit 22 , stacking-wheel drive unit 29 , diverter 32 , shutter drive unit 50 and the like, in order to control such components. Further, the control unit 70 is connected with each of the placing-unit-residue detection sensor 60 , reject-unit paper-sheet detection sensor 62 , paper-sheet tracking detection sensor 64 , diversion timing sensor 66 and stacking-unit paper-sheet detection sensor 68 , in order to receive each detection result from such sensors.
[0065] In addition, the control unit 70 is connected with the shutter-closing detection sensor 54 a and shutter-opening detection sensor 54 b. Thus, the control unit 70 receives information that the shutter 40 is located in the closing position shown in FIG. 3 or information that the shutter 40 is located in the opening position shown in FIG. 4 , from the shutter-closing detection sensor 54 a or shutter-opening detection sensor 54 b. Furthermore, the control unit 70 is connected with a display unit 72 and an operation unit 74 . The display unit 72 and operation unit 74 are respectively provided to a front face of the casing 12 . In this case, the condition under which the paper sheets P are handled by the paper-sheet counting machine 10 , more specifically the information on the number or the like of the paper sheets P counted by the recognition and counting unit 24 , is displayed on the display unit 72 . Further, the operator can input various commands to the control unit 70 via the operation unit 74 .
[0066] Next, referring to the flow charts of FIGS. 6 through 8 , the operation of the paper-sheet counting machine 10 constructed as described above will be discussed. It is noted that the operation of the paper-sheet counting machine 10 is performed by controlling each component of the paper-sheet counting machine 10 , under control of the control unit 70 .
[0067] First of all, the operator places the paper sheets P to be counted, on the placing unit 14 , in the stacked condition.
[0068] In this case, two operational modes, i.e., a with-shutter-operation mode and a without-shutter-operation mode, are provided to the control unit 70 . The with-shutter-operation mode means a mode in which the control unit 70 controls the shutter drive unit 50 , in order to open and close the opening in the front face of the stacking unit 26 by using the shutter 40 . Meanwhile, the without-shutter-operation mode means a mode in which the control unit 70 does not control the shutter drive unit 50 and thus the opening and closing operation for the opening in the front face of the stacking unit 26 is not performed by the shutter 40 . When the paper-sheet counting machine 10 is operated, the operator selects either one of the with-shutter-operation mode and without-shutter-operation mode, via the operation unit 74 .
[0069] In the case the without-shutter-operation mode is selected by the operator, via the operation unit 74 , the paper sheets P placed on the placing unit 14 are counted and the so-counted paper sheets P are fed to the stacking unit 26 , in a state in which the shutter 40 is kept located in the opening position shown in FIG. 2 , or in a state in which the opening in the front face of the stacking unit 26 is kept opened.
[0070] Meanwhile, in the case the with-shutter-operation mode is selected by the operator, via the operation unit 74 , the operation shown in the flow charts of FIGS. 6 through 8 is performed. Namely, in an initial state of this operation, the shutter 40 is retreated from the opening in the front face of the stacking unit 26 (i.e., the shutter 40 is located in the opening position shown in FIG. 2 ), and thus the opening in the front face of the stacking unit 26 is opened (STEP 1 of FIG. 6 ).
[0071] In this case, the control unit 70 serves to selectively perform a batch process mode, in which the counting unit 24 counts paper sheets P by the batch number, the batch number being instructed to the control unit 70 via the operation unit 74 . Then, as shown in STEP 2 of FIG. 6 , whether or not the batch process mode is performed is selected by the operator via the operation unit 74 . If the batch process mode is selected to be performed by the operator, the operation, as is shown in the flow charts of FIGS. 7 and 8 described later, is performed. The operation of the paper-sheet counting machine 10 associated with this batch process mode will be described later. Meanwhile, if the batch process mode is not selected to be performed, the counting process for the paper sheets P, as will be described below, is performed in accordance with the flow chart of FIG. 6 .
[0072] Namely, before the counting process for the paper sheets P by the recognition and counting unit 24 is started, the control unit 70 controls the shutter drive unit 50 to drive the shutter 40 to close the opening in the front face of the stacking unit 26 (STEP 3 of FIG. 6 ). More specifically, the shutter drive unit 50 rotates the rotation shaft 51 in the anticlockwise direction in FIG. 4 (i.e., in the direction indicated by the arrow), from the state shown in FIG. 4 . As a result, the circular linking member 44 b provided to the plate member 44 is no longer pressed upward in FIG. 4 by the cam 52 . Thus, the plate member 44 is rotated, by the contraction force of the spring 46 , in the anticlockwise direction in FIG. 4 , about the shaft 44 a, from the state shown in FIG. 4 . Therefore, the shutter support unit 42 attached to the plate member 44 is also rotated in the anticlockwise direction in FIG. 4 , about the shaft 44 a, from the state shown in FIG. 4 . Eventually, the shutter support unit 42 is moved from the position shown in FIG. 4 to the position shown in FIG. 3 . In this way, the shutter 40 is moved from the opening position as shown in FIG. 2 to the closing position as shown in FIG. 1 , thus closing the opening in the front face of the stacking unit 26 .
[0073] The timing on which the opening in the front face of the stacking unit 26 is closed by the shutter 40 is set, as the timing before the counting process for the paper sheets P by the recognition and counting unit 24 is started, i.e., the timing before the counting process for the paper sheets P is started or timing substantially the same as the start of the counting process for the paper sheets P. If the opening in the front face of the stacking unit 26 is closed by the shutter 40 at substantially the same timing as the start of the counting process for the paper sheets P, the time required for the entire process for the paper sheets P in the paper-sheet counting machine 10 can be reduced.
[0074] The control unit 70 may control the shutter drive unit 50 to drive the shutter 40 to start closing the opening in the front face of the stacking unit 26 , at the same time as the start of the counting process for the paper sheets P by the recognition and counting unit 24 , thereby to close the opening in the front face of the stacking unit 26 , while counting the paper sheets P. In this case, the opening in the front face of the stacking unit 26 is closed, in a period of time during which the paper sheets P are counted. Therefore, the time required for the entire process for the paper sheets P in the paper-sheet counting machine 10 can be reduced, as compared with the case in which the paper sheets P are counted after the opening in the front face of the stacking unit 26 is closed.
[0075] Thereafter, the paper sheets P, respectively placed in the stacked condition on the placing unit 14 , are fed to the transport unit 22 in the casing 12 , one by one, by the feeding unit 16 , successively, from the paper sheet P located at the lowermost layer, and then transported by the transport unit 22 . At this time, the recognition and counting process for the paper sheets P is performed by the recognition and counting unit 24 . In this case, each paper sheet P recognized, as the normal paper sheet, by the recognition and counting unit 24 is fed to the stacking unit 26 via the diverter 32 . More specifically, the paper sheets P are fed, one by one, from the transport unit 22 to the stacking wheel 28 . Then, the stacking wheel 28 receives each paper sheet P fed from the transport unit 22 , between the two vanes 28 a thereof. Thereafter, each paper sheet P received between the two vanes 28 a is fed into the stacking unit 26 . In this way, the paper sheets P can be arranged in the stacking unit 26 , by the stacking wheel 28 . At this time, since the opening in the front face of the stacking unit 26 is closed by the shutter 40 , the operator cannot take out the paper sheets P stacked in the stacking unit 26 .
[0076] Meanwhile, each paper sheet that is not recognized as the normal paper sheet by the recognition and counting unit 24 and each paper sheet that cannot be recognized by the recognition and counting unit 24 are respectively fed, as the reject paper sheets P′, to the reject unit 30 , by the diverter 32 . Since the opening is provided in the front face of the reject unit 30 , the operator can take out the reject paper sheets P′ stacked in the reject unit 30 , via this opening.
[0077] When a maximum number of the reject paper sheets P′ that can be stored in the reject unit 30 is set in advance, and when the number of the reject paper sheets P′ fed to the reject unit 30 reaches this preset maximum number or when the reject unit 30 is full up with the reject paper sheets P′, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 4 of FIG. 6 ), this condition of the reject unit 30 is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is once stopped. Thereafter, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 5 of FIG. 6 ), sets again such reject paper sheets P′ on the placing unit 14 , and starts again the counting process for the paper sheet P, via the operation unit 74 (STEP 6 of FIG. 6 ). In this way, the counting process for the paper sheets P is started again in the paper-sheet counting machine 10 . In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0078] Further, when a maximum number of the paper sheets P that can be stored in the stacking unit 26 is set in advance, and when the number of the paper sheets P fed to the stacking unit 26 reaches this preset maximum number or when the stacking unit 26 is full up with the paper sheets P, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 7 of FIG. 6 ), this condition of the stacking unit 26 is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is once stopped. Then, the control unit 70 controls the shutter drive unit 50 to move the shutter 40 to the opening position shown in FIG. 2 from the closing position shown in FIG. 1 . As a result, the opening in the front face of the stacking unit 26 is opened (STEP 8 of FIG. 6 ). Thereafter, the operator takes out the paper sheets P stacked in the stacking unit 26 via the opening in the front face of the stacking unit 26 (STEP 9 of FIG. 6 ), and then starts again the counting process for the paper sheet P, via the operation unit 74 (STEP 10 of FIG. 6 ). In this way, the counting process for the paper sheets P in the paper-sheet counting machine 10 is started again. Also in this case, in place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator takes out the paper sheets P form the stacking unit 26 . In this case, before the counting process for the paper sheets P is started again by the recognition and counting unit 24 , the control unit 70 controls the shutter drive unit 50 to drive the shutter 40 to close the opening in the front face of the stacking unit 26 (STEP 3 of FIG. 6 ).
[0079] In this manner, the counting process for the paper sheets P in the paper-sheet counting machine 10 is continued, until no paper sheet P remains on the placing unit 14 . During this counting process, the placing-unit-residue detection sensor 60 detects whether or not there are some paper sheets P remaining on the placing unit 14 (STEP 11 of FIG. 6 ). When the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , this detection result is displayed on the display unit 72 . Thereafter, the reject-unit paper-sheet detection sensor 62 detects whether or not there are some reject paper sheets P′ remaining in the reject unit 30 (STEP 12 of FIG. 6 ). When the reject-unit paper-sheet detection sensor 62 detects that there are some reject paper sheets P′ remaining in the reject unit 30 , this detection result is displayed on the display unit 72 . Thereafter, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 15 of FIG. 6 ), sets again such paper sheets P′ on the placing unit 14 , and then starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 16 of FIG. 6 ). In this way, the counting process for the paper sheets P in the paper-sheet counting machine 10 is started again. In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0080] Meanwhile, when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , and when the reject-unit paper-sheet detection sensor 62 detects that there is no reject paper sheet P′ remaining in the reject unit 30 , the counting process for the paper sheets P in the paper-sheet counting machine 10 is ended (STEP 13 of FIG. 6 ). Thereafter, the control unit 70 controls the shutter drive unit 50 to move the shutter 40 to the opening position shown in FIG. 2 from the closing position shown in FIG. 1 . Thus, the opening in the front face of the stacking unit 26 is opened (STEP 14 of FIG. 6 ). Then, the operator takes out the paper sheets P stacked in the stacking unit 26 , via the opening in the front face of the stacking unit 26 . In this way, the operation of the paper-sheet counting machine 10 , in the case of not performing the batch process mode, is completed.
[0081] According to the operation of the paper-sheet counting machine 10 as shown in the flow chart of FIG. 6 , as shown in the operation in the STEP 3 of FIG. 6 , the control unit 70 controls the shutter drive unit 50 to drive the shutter 40 to close the opening provided in the front face of the stacking unit 26 , before the counting process for the paper sheets P is started by the recognition and counting unit 24 . Therefore, the opening in the front face of the stacking unit 26 is closed by the shutter 40 , during the period of time in which the counting process for the paper sheets P is performed by the recognition and counting unit 24 , thereby preventing the dust accumulated in the casing 12 of the paper-sheet counting machine 10 and/or dust attached to each paper sheet from being blown out toward the operator.
[0082] Further, as shown in the STEP 11 and STEP 13 of FIG. 6 , when the paper sheets P placed on the placing unit 14 are all fed to the recognition and counting unit 24 and thus the placing-unit-residue detection sensor 60 detects that there is no paper sheet remaining on the placing unit 14 , the control unit 70 controls the shutter drive unit 50 to retreat the shutter 40 from the opening provided in the front face of the stacking unit 26 to open the opening. Alternatively, skipping the operation in the STEP 12 of FIG. 6 , or the control unit 70 may serve to open the opening in the front face of the stacking unit 26 , once the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , irrespectively of whether or not there are some reject paper sheets P′ remaining in the reject unit 30 . In addition, interval of time between the time the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 and the time the control unit 70 controls the shutter drive unit 50 to retreat the shutter 40 from the opening in the front face of the stacking unit 26 , may be optionally altered, by the operator, with appropriate settings via the operation unit 74 . In this case, the operator can optionally select the order of priority, between the dustproof and/or soundproofing in the paper-sheet counting machine 10 and the reduction of the time required for handling the paper sheets P.
[0083] Further, as shown in the STEP 11 and STEP 12 of FIG. 6 , when the reject-unit paper-sheet detection sensor 62 detects that there are some reject paper sheets P′ remaining in the reject unit 30 even though the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , the control unit 70 serves to drive the shutter 40 to keep closing the opening provided in the front face of the stacking unit 26 . This is because, when there are some reject paper sheets P′ remaining in the reject unit 30 even though there is no paper sheet P remaining on the placing unit 14 , it is necessary for the operator to take out such reject paper sheets P′ from the reject unit 30 , and set again the reject paper sheets P′ on the placing unit 14 , and then start again the counting process for the paper sheets P in the paper-sheet counting machine 10 .
[0084] In the operation of the paper-sheet counting machine 10 as shown in the flow chart of FIG. 6 , as shown in the operation in the STEP 7 of FIG. 6 , when the paper-sheet tracking detection sensor 64 provided to the transport unit 22 detects a certain paper sheet, with which the stacking unit 26 will be full up upon receiving thereof, the control unit 70 may control the shutter drive unit 50 to retreat the shutter 40 from the opening in the front face of the stacking unit 26 to open the opening. Due to this operation, as compared with the case in which the shutter drive unit 50 starts to move the shutter 40 once the number of the paper sheets P fed to the stacking unit 26 reaches the preset maximum number of the paper sheets P that can be stored in the stacking unit 26 or once the stacking unit 26 is full up with the paper sheets P, the opening in the front face of the stacking unit 26 can be opened more rapidly, thereby to substantially reduce the time required for the entire process for the paper sheets P. It is noted that interval of time between the time the paper-sheet tracking detection sensor 64 detects the paper sheet P, with which the stacking unit 26 will be full up upon receiving thereof, and the time the control unit 70 controls the shutter drive unit 50 to retreat the shutter 40 from the opening in the front face of the stacking unit 26 , may be optionally altered, by the operator, with proper settings via the operation unit 74 . In this case, the operator can optionally select the order of priority, between the dustproof or soundproofing in the paper-sheet counting machine 10 and the reduction of the time required for handling the paper sheets P.
[0085] As described above, the paper-sheet tracking detection sensor 64 is provided in such a position that interval of time between the time one paper sheet P is detected by the paper-sheet tracking detection sensor 64 and the time this paper sheet P is fed to the stacking unit 26 , is substantially matched with the time required for the shutter 40 to be moved from the closing position (see FIG. 1 ) in which the opening in the front face of the stacking unit 26 is closed to the opening position (see FIG. 2 ) in which the opening is opened. Therefore, when the paper-sheet tracking detection sensor 64 detects a certain paper sheet, with which the stacking unit 26 will be full up upon receiving this paper sheet P fed thereto, and then this paper sheet P actually reaches the stacking unit 26 , the opening in the front face of the stacking unit 26 is just opened. Thus, the operator can take out a batch of the paper sheets P stacked in the stacking unit 26 , just after the certain paper sheet P reaches the stacking unit 26 .
[0086] Now, referring to the flow charts of FIGS. 7 and 8 , the operation of the paper-sheet counting machine 10 , in the case the batch process mode is selected by the operator, will be described.
[0087] First, the operator designates the batch number of the paper sheets, via the operation unit 74 . Then, the control unit 70 compares the batch number inputted to the control 70 via the operation unit 74 with a preset number (e.g., ten) of the paper sheets (STEP 21 of FIG. 7 ). If the batch number inputted to the control unit 70 is equal to or greater than the preset number, the operation, shown in the flow chart of FIG. 8 described later, is performed. The operation of the paper-sheet counting machine 10 in the batch process mode will be described later. Meanwhile, in the case the batch number inputted to the control unit 70 via the operation unit 74 is smaller than the preset number, the control unit 70 serves to keep the shutter 40 retreated from the opening in the front face of the stacking unit 26 , thereby to keep this opening opened. Thereafter, the counting process for the paper sheets P is performed, as will be described below.
[0088] Namely, the paper sheets P respectively placed, in the stacked condition, on the placing unit 14 are fed, one by one, to the transport unit 22 in the casing 12 , by the feeding unit 16 , successively, from the paper sheet P located at the lowermost layer, and then transported by the transport unit 22 . During this operation, the paper sheets P are recognized and counted by the recognition and counting unit 24 . In this case, each paper sheet P recognized as the normal paper sheet by the recognition and counting unit 24 is fed to the stacking unit 26 by the diverter 32 . At this time, the paper sheets P are arranged in the stacking unit 26 by the stacking wheel 28 .
[0089] Meanwhile, each paper sheet that is not recognized as the normal paper sheet by the recognition and counting unit 24 and each paper sheet that cannot be recognized by the recognition and counting unit 24 are respectively fed, as the reject paper sheets P′, to the reject unit 30 , by the diverter 32 . Since the opening is provided in the front face of the reject unit 30 , the operator can take out such reject paper sheets P′ stacked in the reject unit 30 , via this opening.
[0090] As described above, the maximum number of the reject paper sheets P′ that can be stored in the reject unit 30 is set, in advance. In this case, when the number of the reject paper sheets P′ fed to the reject unit 30 reaches the preset maximum number of the reject paper sheets P′ that can be stored therein, or when the reject unit 30 is full up with the reject paper sheets P′, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 22 of FIG. 7 ), this condition of the reject unit 30 is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is once stopped. Thereafter, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 23 of FIG. 7 ), sets again such reject paper sheets P′ on the placing unit 14 , and starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 24 of FIG. 7 ). In this way, the counting process for the paper sheets P is started again in the paper-sheet counting machine 10 . In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0091] Further, when the number of the paper sheets P respectively fed to the stacking unit 26 reaches the batch number inputted to the control unit 70 , or when one batch process is completed, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 25 of FIG. 7 ), this condition or state is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is ended (STEP 26 of FIG. 7 ). At this time, since the opening in the front face of the stacking unit 26 is kept opened, the operator can take out the paper sheets P stacked in the stacking unit 26 , via the opening in the front face of the stacking unit 26 . In this way, the operation of the paper-sheet counting machine 10 for one batch process is completed. Thereafter, when the operator starts again the counting process for the paper sheets P, via the operation unit 74 , the next batch process is performed as shown in the flow chart of FIG. 7 .
[0092] Meanwhile, when the number of the paper sheets P fed to the stacking unit 26 does not reach the batch number inputted to the control unit 70 , and when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 (STEP 27 of FIG. 7 ), this condition is displayed on the display unit 72 . Then, the reject-unit paper-sheet detection sensor 62 detects whether or not there are some reject paper sheets P′ remaining in the reject unit 30 (STEP 28 of FIG. 7 ). As a result, when the reject-unit paper-sheet detection sensor 62 detects the reject paper sheets P′ remaining in the reject unit 30 , this condition is further displayed on the display unit 72 . Then, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 29 of FIG. 7 ), sets again such reject paper sheets P′ on the placing unit 14 , and then starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 30 of FIG. 7 ). In this way, the counting process for the paper sheets P in the paper-sheet counting machine 10 is started again. In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0093] Meanwhile, when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , and when the reject-unit paper-sheet detection sensor 62 detects that there is no reject paper sheet P′ remaining in the reject unit 30 , if the operator inputs a command for terminating the counting process for the paper sheets P, to the control unit 70 , via the operation unit 74 (STEP 31 of FIG. 7 ), the counting process for the paper sheets P in the paper-sheet counting machine 10 is ended (STEP 26 of FIG. 7 ). At this time, since the opening in the front face of the stacking unit 26 is kept opened, the operator can take out the paper sheets P stacked in the stacking unit 26 , via the opening in the front face of the stacking unit 26 .
[0094] Further, when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , and when the reject-unit paper-sheet detection sensor 62 detects that there is no reject paper sheet P′ remaining in the reject unit 30 , if the operator places additional paper sheets P on the placing unit 14 (STEP 32 of FIG. 7 ), and then starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 33 of FIG. 7 ), the counting process for the paper sheets P in the paper-sheet counting machine 10 is restarted. In place of the operator starting again the counting process for the paper sheets, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the additional paper sheets P on the placing unit 14 .
[0095] In the operation of the paper-sheet counting machine 10 as shown in the flow chart of FIG. 7 , as shown in the operation in the STEP 21 of FIG. 7 , when the control unit 70 performs the counting process for the paper sheets P in the batch process mode, and when the batch number of the paper sheets P inputted to the control unit 70 is smaller than the preset number, the control unit 70 serves to retreat the shutter 40 from the opening provided in the front face of the stacking unit 26 to open this opening. Namely, in the case the batch number inputted to the control unit 70 is relatively small, if the opening and closing operation of the shutter 40 is performed for each batch process, the time required for the entire process for the paper sheets P becomes considerably long. Therefore, in this case, by keeping the opening opened in the front face of the stacking unit 26 , the time required for the entire process for the paper sheets P can be reduced.
[0096] Next, referring to the flow chart of FIG. 8 , the operation of the paper-sheet counting machine 10 will be further described, when the operator selects the batch process mode, and the batch number of the paper sheets inputted to the control unit 70 is equal to or greater than the preset number.
[0097] Before starting the counting process for the paper sheets P by the recognition and counting unit 24 , the control unit 70 controls the shutter drive unit 50 to drive the shutter 40 to close the opening in the front face of the stacking unit 26 (STEP 41 of FIG. 8 ). Then, the counting process for the paper sheets P is performed, as will be described below.
[0098] Namely, the paper sheets P, respectively placed in the stacked condition on the placing unit 14 , are fed to the transport unit 22 in the casing 12 , one by one, by the feeding unit 16 , successively, from the paper sheet P located at the lowermost layer, and then transported by the transport unit 22 . At this time, the recognition and counting process for the paper sheets P is performed by the recognition and counting unit 24 . In this case, each paper sheet P recognized, as the normal paper sheet, by the recognition and counting unit 24 is fed to the stacking unit 26 via the diverter 32 . Then, the paper sheets P are arranged in the stacking unit 26 , by the stacking wheel 28 . At this time, since the opening in the front face of the stacking unit 26 is closed by the shutter 40 , the operator cannot take out the paper sheets P stacked in the stacking unit 26 .
[0099] Meanwhile, each paper sheet that is not recognized as the normal paper sheet by the recognition and counting unit 24 , and each paper sheet that cannot be recognized by the recognition and counting unit 24 are respectively fed, as the reject paper sheets P′, to the reject unit 30 , via the diverter 32 . In this case, since the opening is provided in the front face of the reject unit 30 , the operator can take out the reject paper sheets P′ stacked in the reject unit 30 , via the opening.
[0100] As described above, when the preset maximum number of the reject paper sheets P′ that can be stored in the reject unit 30 is set, and when the number of the reject paper sheets P′ fed to the reject unit 30 reaches the preset maximum number of the reject paper sheets P′ that can be stored therein or when the reject unit 30 is full up with such reject paper sheets P′, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 42 of FIG. 8 ), this condition of the reject unit 30 is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is once stopped. Thereafter, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 43 of FIG. 8 ), sets again such reject paper sheets P′ on the placing unit 14 , and starts again the counting process for the paper sheet P, via the operation unit 74 (STEP 44 of FIG. 8 ). In this way, the counting process for the paper sheets P is started again in the paper-sheet counting machine 10 . In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0101] Further, when the number of the paper sheets P respectively fed to the stacking unit 26 reaches the batch number inputted to the control unit 70 , or when one batch process is completed, during the counting process for the paper sheets P in the paper-sheet counting machine 10 (STEP 45 of FIG. 8 ), this condition is displayed on the display unit 72 , and the counting process for the paper sheets P in the paper-sheet counting machine 10 is ended (STEP 46 of FIG. 8 ). Thereafter, the control unit 70 controls the shutter drive unit 50 to move the shutter 40 to the opening position shown in FIG. 2 form the closing position shown in FIG. 1 . Thus, the opening in the front face of the stacking unit 26 is opened (STEP 47 of FIG. 8 ), and then the operator takes out the paper sheets P stacked in the stacking unit 26 , via the opening in the front face of the stacking unit 26 . In this way, the operation of the paper-sheet counting machine 10 for one batch process is completed. Thereafter, when the operator starts again the counting process for the paper sheets P, via the operation unit 74 , the next batch process is performed as shown in the flow chart of FIG. 8 .
[0102] Meanwhile, when the number of the paper sheets P fed to the stacking unit 26 does not reach the batch number inputted to the control unit 70 , and when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 (STEP 48 of FIG. 8 ), this condition is displayed on the display unit 72 . Thereafter, the reject-unit paper-sheet detection sensor 62 detects whether or not there are some reject paper sheets P′ remaining in the reject unit 30 (STEP 49 of FIG. 8 ). When the reject-unit paper-sheet detection sensor 62 detects that there are some reject paper sheets P′ remaining in the reject unit 30 , this condition is displayed on the display unit 72 . Thereafter, the operator takes out the reject paper sheets P′ from the reject unit 30 (STEP 50 of FIG. 8 ), sets again such taken-out reject paper sheets P′ on the placing unit 14 , and then starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 51 of FIG. 8 ). In this way, the counting process for the paper sheets P in the paper-sheet counting machine 10 is started again. In place of the operator starting again the counting process for the paper sheets P, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the reject paper sheets P′, respectively taken out form the reject unit 30 , on the placing unit 14 .
[0103] Meanwhile, when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , and when the reject-unit paper-sheet detection sensor 62 detects that there is no reject paper sheet P′ remaining in the reject unit 30 , if the operator inputs a command for ending the counting process for the paper sheets P, to the control unit 70 , via the operation unit 74 (STEP 52 of FIG. 8 ), the counting process for the paper sheets P in the paper-sheet counting machine 10 is ended (STEP 46 of FIG. 8 ). Thereafter, the control unit 70 controls the shutter drive unit 50 to move the shutter 40 to the opening position shown in FIG. 2 from the closing position shown in FIG. 1 . Thus, the opening in the front face of the stacking unit 26 is opened (STEP 47 of FIG. 8 ). Then, the operator takes out the paper sheets P stacked in the stacking unit 26 , via the opening in the front face of the stacking unit 26 .
[0104] Meanwhile, when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , and when the reject-unit paper-sheet detection sensor 62 detects that there is no reject paper sheet P′ remaining in the reject unit 30 , if the operator places the additional paper sheets P on the placing unit 14 (STEP 53 of FIG. 8 ), and starts again the counting process for the paper sheets P, via the operation unit 74 (STEP 54 of FIG. 8 ), the counting process for the paper sheets P in the paper-sheet counting machine 10 is restarted. In place of the operator starting again the counting process for the paper sheets, via the operation unit 74 , the paper-sheet counting machine 10 may be configured to restart the counting process for the paper sheets P, automatically, therein, once the operator places the additional paper sheets P on the placing unit 14 .
[0105] According to the operation of the paper-sheet counting machine 10 as shown in the flow chart of FIG. 8 , as shown in the operation in the STEP 45 and STEP 48 of FIG. 8 , when the control unit 70 performs the counting process for the paper sheets P in the batch process mode, and when the placing-unit-residue detection sensor 60 detects that there is no paper sheet P remaining on the placing unit 14 , if the number of the paper sheets P counted by the recognition and counting unit 24 does not reach the batch number, the control unit 70 controls the shutter drive unit 50 to drive the shutter 40 to keep closing the opening provided in the front face of the stacking unit 26 . Namely, in this case, as shown in the STEP 53 and STEP 54 of FIG. 8 , it is necessary for the operator to place the additional paper sheets P on the placing unit 14 and start again the counting process for the paper sheets P, via the operation unit 74 . Therefore, even in the case the operation of the paper-sheet counting machine 10 is stopped, while the actual number of the paper sheets P fed to the stacking unit 26 is slightly short of the batch number inputted to the control unit 70 , this paper-sheet counting machine 10 can prevent the operator from misunderstanding that the batch process has been properly performed and thus the number of the paper sheets P stacked in the stacking unit 26 , at this point of time, is correctly corresponding to the batch number. Accordingly, this paper-sheet counting machine 10 can securely prevent the operator from mistakenly taking out the paper sheets P from the stacking unit 26 .
[0106] Alternatively, in the operation of the paper-sheet counting machine 10 as shown in the flow chart of FIG. 8 , the control unit 70 may control the shutter drive unit 50 to retreat the shutter 40 from the opening in the front face of the stacking unit 26 to open this opening, at a point of time that the paper-sheet tracking detection sensor 64 provided to the transport unit 22 detects the last paper sheet P of the batch number. With this operation, as compared with the case of starting to move the shutter 40 once the counting process for one batch process is completely finished or once the stacking-unit paper-sheet detection sensor 68 detects that the number of paper sheets P respectively fed to the stacking unit 26 reaches the batch number, the opening in the front face of the stacking unit 26 can be opened more rapidly, thereby to reduce the time required for the entire process for the paper sheets P. It is noted that interval of time between the time the paper-sheet tracking detection sensor 64 detects the last paper sheet P of the batch number and the time the control unit 70 controls the shutter drive unit 50 to retreat the shutter 40 from the opening in the front face of the stacking unit 26 , may be optionally altered, by the operator, with appropriate settings, via the operation unit 74 . In this case, the operator can optionally select the order of priority, between the dustproof or soundproofing in the paper-sheet counting machine 10 and the reduction of the time required for handling the paper sheets P.
[0107] Further, as described above, the paper-sheet tracking detection sensor 64 is provided to the transport unit 22 , in such a position that interval of time between the time one paper sheet P is detected by the paper-sheet tracking detection sensor 64 and the time this paper sheet P is fed to the stacking unit 26 , is substantially matched with the time required for the shutter 40 to be moved from the closing position (see FIG. 1 ) in which the opening in the front face of the stacking unit 26 is closed to the opening position (see FIG. 2 ) in which the opening is opened. With this configuration, the opening in the front face of the stacking unit 26 can be just opened at the time the last paper sheet P of the batch number actually reaches the stacking unit 26 after this paper sheet P is detected by the paper-sheet tracking detection sensor 64 . As such, the operator can take out one batch of the paper sheets P stacked in the stacking unit 26 , just after the last paper sheet P of the batch number reaches the stacking unit 26 .
[0108] As stated above, according to the paper-sheet counting machine 10 of this embodiment, the opening and closing operation for the opening provided in the front face of the stacking unit 26 can be optionally performed by the shutter 40 driven by the shutter drive unit 50 controlled by the control unit 70 . Therefore, the opening provided in the front face of the stacking unit 26 can be selectively closed by the shutter 40 . Thus, when this shutter 40 closes the opening, the blowing out of the dust accumulated in the casing 12 of the paper-sheet counting machine 10 and/or dust attached to each paper sheet, toward the operator, can be successfully prevented. Further, when the shutter 40 closes the opening in the front face of the stacking unit 26 , the unwanted leakage of the sound generated in the interior of the paper-sheet counting machine 10 to the outside can be effectively prevented during the operation of the machine 10 .
[0109] It is noted that the paper-sheet counting machine according to the present invention is not limited to such an aspect as described above. For instance, any suitable variations or modifications can be made to the mechanism for driving the aforementioned shutter of the paper-sheet counting machine shown in FIGS. 3 and 4 .
[0110] FIGS. 9 and 10 respectively show one variation of the driving mechanism for driving the shutter in the paper-sheet counting machine of the present invention. Of these drawings, FIG. 9 shows one side view for illustrating the construction of the shutter, shutter support unit for supporting the shutter, shutter drive unit, a plurality of gears, torque limiter and the like, respectively provided in the paper-sheet counting machine related to one variation of the present invention. FIG. 10 shows one top view for illustrating the shutter, shutter support unit for supporting the shutter, shutter drive unit, a plurality of gears, torque limiter and the like, respectively shown in FIG. 9 , when such units or parts are respectively seen from above. It is noted that FIG. 9 is provided for illustrating the construction of the shutter and the like when the shutter closes the opening provided in the front face of the stacking unit.
[0111] In the shutter drive mechanism of the paper-sheet counting machine in the variation of the present invention as shown in FIGS. 9 and 10 , like parts or units are respectively designated by like reference numerals respectively shown in FIGS. 1 through 5 .
[0112] As shown in FIGS. 9 and 10 , a first gear 80 is attached to the shutter drive unit 50 composed of the motor, such that this first gear 80 is rotated by the shutter drive unit 50 in both of the clockwise and anticlockwise directions in FIG. 9 . Further, a second gear 81 substantially larger, in size, than the first gear 80 is provided in the vicinity of the first gear 80 . The first and second gears 80 and 81 are meshed with each other. Thus, the rotation force is transmitted from the first gear 80 to the second gear 81 .
[0113] On one side face of the second gear 81 (more specifically, on an upper side face of the second gear 81 in FIG. 10 ), a third gear 82 substantially smaller, in size, than the second gear 81 is attached. The second and third gears 81 and 82 respectively have the same rotation shaft extending in one straight line. Thus, when the second gear 81 is rotated, the third gear 82 is rotated in synchronism with the second gear 81 . Further, a fourth gear 83 substantially larger, in size, than the third gear 82 is provided in the vicinity of the third gear 82 . Such third and fourth gears 82 and 83 are meshed with each other. Thus, the rotation force is transmitted from the third gear 82 to the fourth gear 83 .
[0114] On one side face of the fourth gear 83 , a fifth gear 85 substantially smaller, in size, than the fourth gear 83 is attached, via a torque limiter 84 . Such fourth and fifth gears 83 and 85 have the same rotation shaft extending in one straight line. Thus, when the fourth gear 83 is rotated, the fifth gear 85 is rotated in synchronism with the forth gear 83 . In this case, if the rotation force greater than a preset torque is applied to the torque limiter 84 provided between the fourth gear 83 and the fifth gear 85 , the connection between the fourth gear 83 and the fifth gear 85 is released, and then the fifth gear 85 will be rotated freely relative to the fourth gear 83 .
[0115] In addition, a sixth gear 86 substantially larger, in size, than the fifth gear 85 is provided in the vicinity of the fifth gear 85 . Such fifth and sixth gears 85 and 86 are meshed with each other. Thus, the rotation force is transmitted from the fifth gear 85 to the sixth gear 86 . Further, the sixth gear 86 is attached to the shutter support unit 42 for supporting the shutter 40 . Therefore, the sixth gear 86 is rotated integrally with the shutter support unit 42 about a shaft 86 a.
[0116] A first notched portion 86 b and a second notched portion 86 c are respectively provided to the sixth gear 86 . Additionally, the shutter-closing detection sensor 54 a and shutter-opening detection sensor 54 b are respectively fixed in position, in the vicinity of the sixth gear 86 . Each of such shutter-closing detection sensor 54 a and shutter-opening detection sensor 54 b is composed of the optical sensor. In this case, when the shutter 40 is located in the closing position, the position of the first notched portion 86 b of the sixth gear 86 is substantially matched with the position of the shutter-closing detection sensor 54 a. Therefore, the detection of the first notched portion 86 b of the sixth gear 86 by the shutter-closing detection sensor 54 a indicates the detection of the shutter 40 located in the closing position. Meanwhile, when the shutter 40 is located in the opening position, the position of the second notched portion 86 c of the sixth gear 86 is substantially matched with the position of the shutter-opening detection sensor 54 b. Therefore, the detection of the second notched portion 86 c of the sixth gear 86 by the shutter-opening detection sensor 54 b indicates the detection of the shutter 40 located in the opening position.
[0117] Now, the operation of the shutter drive mechanism of the paper-sheet counting machine related to the variation of the present invention, as shown in FIGS. 9 and 10 , will be described.
[0118] In the case of driving the shutter 40 to move to the opening position from the closing position shown in FIG. 9 , the shutter drive unit 50 composed of the motor serves to rotate the first gear 80 in the clockwise direction in FIG. 9 . Thus, the driving force exerted from the shutter drive unit 50 is transmitted, from the first gear 80 , through the second gear 81 , third gear 82 , fourth gear 83 , torque limiter 84 and fifth gear 85 , up to the sixth gear 86 , as such the sixth gear 86 is rotated in the clockwise direction in FIG. 9 about the shaft 86 a. Therefore, the shutter support unit 42 attached to the sixth gear 86 is also rotated in the clockwise direction in FIG. 9 about the shaft 86 a. As a result, the shutter 40 is moved from the closing position as shown in FIG. 1 to the opening position as shown in FIG. 2 .
[0119] Meanwhile, in the case of driving the shutter 40 to move to the closing position from the opening position, the shutter drive unit 50 composed of the motor serves to rotate the first gear 80 in the anticlockwise direction in FIG. 9 . In this way, the driving force exerted from the shutter drive unit 50 is transmitted, from the first gear 80 , through the second gear 81 , third gear 82 , fourth gear 83 , torque limiter 84 and fifth gear 85 , up to the sixth gear 86 , as such the sixth gear 86 is rotated in the anticlockwise direction in FIG. 9 about the shaft 86 a. Thus, the shutter support unit 42 attached to the sixth gear 86 is also rotated in the anticlockwise direction in FIG. 9 about the shaft 86 a. As a result, the shutter 40 is moved from the opening position as shown in FIG. 2 to the closing position as shown in FIG. 1 .
[0120] As described above, the torque limiter 84 is provide between the shutter support unit 42 for supporting the shutter 40 and the shutter drive unit 50 . Therefore, in the case the operator moves the shutter 40 downward, by hand, from the closing position shown in FIG. 1 , when the force applied from the operator to the torque limiter 84 is greater than the preset torque, the torque limiter 84 releases the connection between the fourth gear 83 and the fifth gear 85 . As such, the fifth gear 85 can be rotated freely relative to the fourth gear 83 . Namely, in this case, the torque limiter 84 serves to block the driving force of the shutter drive unit 50 to be transmitted to the shutter 40 . Therefore, even in the period during which the counting process for the paper sheets P is performed by the recognition and counting unit 24 , the operator can move the shutter 40 downward, by hand, from the closing position shown in FIG. 1 , thereby to take out the paper sheets P from the stacking unit 26 .
[0121] Further, even in the case the hand or the like of the operator is placed in the stacking unit 26 in a period during which the shutter 40 is moved from the opening position shown in FIG. 2 to the closing position shown in FIG. 1 , if the force applied to the torque limiter 84 becomes greater than the preset torque once the shutter is in contact with such a hand or the like of the operator, the torque limiter 84 releases the connection between the fourth gear 83 and the fifth gear 85 , thus allowing the fifth gear 85 to be rotated freely relative to the fourth gear 83 . In this way, the torque limiter 84 serves to block the driving force of the shutter drive unit 50 to be transmitted to the shutter 40 . Thus, the shutter 40 is stopped when this shutter 40 is in contact with the hand or the like of the operator, thereby successfully preventing such trouble that the finger or the like of the operator is seriously nipped and injured by the shutter 40 . | A paper-sheet counting machine ( 10 ) includes: a recognition and counting unit ( 24 ) configured to count paper sheets; a stacking unit ( 26 ) configured to stack therein the paper sheets that have been counted by the recognition and counting unit ( 24 ), an opening being provided in a front face of the stacking unit ( 26 ); a rotary guide unit ( 28 ) provided to the stacking unit ( 26 ) and configured to allow the paper sheets that have been counted by the recognition and counting unit ( 24 ) to be stacked in the stacking unit ( 26 ); a shutter ( 40 ) configured to close the opening provided in the front face of the stacking unit ( 26 ); a shutter drive unit ( 50 ) configured to drive the shutter ( 40 ) to open and close the opening provided in the front face of the stacking unit ( 26 ); and a control unit ( 70 ) configured to control the shutter drive unit ( 50 ). | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 14/479,276 filed Sep. 6, 2014 and since issued as U.S. Pat. No. 9,049,406, which is a continuation of U.S. application Ser. No. 13/587,962 filed Aug. 17, 2012 and since issued as U.S. Pat. No. 8,856,824, which is a continuation of U.S. application Ser. No. 11/712,249 filed Feb. 28, 2007 and since issued as U.S. Pat. No. 8,272,008, with all applications incorporated herein by reference in their entireties.
BACKGROUND
Exemplary embodiments generally relate to communications, to interactive video, and to television and, more generally, to selection of multiple sources for audio inputs.
Alternate audio content is desirable. When a user receives audio-visual content (such as a movie, for example), the user may not be satisfied with the audio portion of that content. The audio portion may contain offensive language, undesirable dialog, or an unknown language. A common situation involves televised sporting events. When televised football and baseball are watched, some people prefer to listen to different announcers for the play-by-play action. For whatever reasons, then, a user may prefer to receive and experience an alternate audio source that provides a different language track, sanitized dialog, and/or alternate commentary. What is needed, then, are methods, systems, and products that search and retrieve alternate audio sources for video signals.
SUMMARY
Exemplary embodiments provide methods, systems, and products for searching, retrieving, and synchronizing alternate audio sources. Exemplary embodiments identify alternate audio content that may be separately available from video content. When a user receives and watches a movie, for example, exemplary embodiments permit the user to seek out and retrieve alternate audio content from the Internet, from an AM/FM radio broadcast, or from any other source. When the video content is received, the video content may self-identify one or more alternate audio sources that correspond to the video content. The video content, for example, may be tagged or embedded with websites, server addresses, frequencies, or other information that describe the alternate audio sources. Exemplary embodiments may even automatically query database servers (such as GOOGLE® and YAHOO®) for alternate audio sources that correspond to the video content. Once the user selects an alternate audio source, exemplary embodiments may then synchronize the video content and the separately-available alternate audio content. Because the video content and the alternate audio content may be received as separate streams of data, either of the streams may lead or lag. Exemplary embodiments, then, may also synchronize the separately-received streams of data to ensure a pleasing entertainment experience.
Exemplary embodiments include a method for retrieving an audio signal. A video signal is received that comprises a content identifier and an alternate audio tag. In response to the alternate audio tag, a query is sent for an alternate audio source that corresponds to the content identifier. This query may be automatically generated and sent, or the query may be specifically requested by the viewer. A query result is received that identifies an audio signal that corresponds to the content identifier and that is separately received from the video signal.
More exemplary embodiments include a system for retrieving an audio signal. A video signal is received that comprises a content identifier and an alternate audio tag. In response to the alternate audio tag, a query is sent for an alternate audio source that corresponds to the content identifier. A query result is received that identifies an audio signal that corresponds to the content identifier and that is separately received from the video signal.
Other exemplary embodiments describe a computer program product for retrieving an audio signal. The computer program product has processor-readable instructions for receiving a video signal that comprises a content identifier and an alternate audio tag. In response to the alternate audio tag, a query is sent for an alternate audio source that corresponds to the content identifier. A query result is received that identifies an audio signal that corresponds to the content identifier and that is separately received from the video signal.
Other systems, methods, and/or computer program products according to the exemplary embodiments will be or become apparent to one with ordinary skill in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, and/or computer program products be included within this description, be within the scope of the claims, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
These and other features, aspects, and advantages of the exemplary embodiments are better understood when the following Detailed Description is read with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic illustrating an operating environment in which exemplary embodiments may be implemented;
FIG. 2 is a schematic illustrating a process for retrieving alternate audio sources, according to more exemplary embodiments;
FIG. 3 is a schematic further illustrating a process for retrieving alternate audio, according to more exemplary embodiments;
FIG. 4 is a schematic illustrating additional queries for alternate audio sources, according to more exemplary embodiments;
FIG. 5 is a schematic illustrating a user interface for retrieving alternate audio sources, according to more exemplary embodiments;
FIGS. 6 and 7 are schematics illustrating synchronization of signals, according to more exemplary embodiments;
FIG. 8 is a schematic illustrating an electronic device, according to more exemplary embodiments;
FIGS. 9-14 are schematics illustrating additional operating environments in which exemplary embodiments may be implemented; and
FIG. 15 is a flowchart illustrating a method of retrieving audio signals, according to more exemplary embodiments.
DETAILED DESCRIPTION
The exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings. The exemplary embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the exemplary embodiments to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating the exemplary embodiments. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include wirelessly connected or coupled. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first device could be termed a second device, and, similarly, a second device could be termed a first device without departing from the teachings of the disclosure.
FIG. 1 is a schematic illustrating an environment in which exemplary embodiments may be implemented. A user's electronic device 20 receives a video signal 22 from a communications network 24 . The video signal 22 may be a movie, sporting event, or any other content. The video signal 22 may originate, or be received from, any source, such as a video server 26 . The video signal 22 may have any formatting, and the video signal 22 may be unicast, multicast, or broadcast to the electronic device 20 . The video signal 22 may also originate from a local source, such as a DVD player, a digital or analog recorder, local memory, or other local source that may be accessible without the communications network 24 . Although the electronic device 20 is generically shown, the electronic device 20 , as will be later explained, may be a computer, a radio, a set-top receiver, a personal digital assistant (PDA), a cordless/cellular/IP phone, digital music player, or any other processor-controlled device.
The video signal 22 may include an alternate audio tag 28 . According to exemplary embodiments, the alternate audio tag 28 may be any information that identifies alternate audio sources for the video signal 22 . The video signal 22 may include, or be received with, audio content or portions (such as an audio track to a movie). The user, however, may wish to experience an alternate audio source that is not sent with the video signal 22 . The alternate audio source, for example, may be a different language track, sanitized dialog, an AM or FM radio broadcast, and/or alternate commentary. These alternate audio sources, in general, may be any audio signal that is separately received from the video signal 22 . As FIG. 1 illustrates, the video signal 22 , and/or alternate audio tag 28 , may include a video content identifier 30 . The video content identifier 30 may be any identification number, title, code, or other data that uniquely describes the content associated with the video signal 22 . The alternate audio tag 28 may be embedded within the video signal 22 (or otherwise associated with the video signal 22 ) to alert or notify users of these alternate audio sources.
The user's electronic device 20 receives the video signal 22 . The user's electronic device 20 also receives the alternate audio tag 28 and/or the video content identifier 30 . The user's electronic device 20 comprises a processor 32 (e.g., “μP”), application specific integrated circuit (ASIC), or other similar device that may execute an alternate audio application 34 stored in memory 36 . According to exemplary embodiments, the alternate audio application 34 comprises processor-executable instructions that may inspect the video signal 22 for the alternate audio tag 28 or otherwise identify the associated alternate audio tag 28 . The presence of the alternate audio tag 28 notifies the alternate audio application 34 that alternate audio sources may exist for the video signal 22 . When the alternate audio tag 28 is detected, the alternate audio application 34 may alert the user that alternate audio sources may exist for the video signal 22 . The alternate audio application 34 , for example, may cause the visual and/or audible presentation of a prompt 38 on a display device 40 . The prompt 38 notifies the user that alternate audio sources may exist. When the user wishes to retrieve an alternate audio source, the user may affirmatively select a control 42 , thus authorizing the alternate audio application 34 to query for the alternate audio sources.
FIG. 2 is a schematic illustrating a process for retrieving alternate audio sources, according to more exemplary embodiments. When the user wishes to retrieve an alternate audio source, the user affirmatively responds to the prompt (shown as reference numeral 38 in FIG. 1 ). The alternate audio application 34 may call or invoke a search application 50 to issue or send a query for any alternate audio sources associated with the video content identifier (Step 52 ). The query may communicate (via the communications network 24 illustrated in FIG. 1 ) to a database server 54 (such as a YAHOO® or GOOGLE® server). The query may additionally or alternatively communicate to other devices in the vicinity of the user's electronic device 20 . The query, for example, may be sent via an infrared, BLUETOOTH®, WI-FI®, or other coupling to other devices within the user's social network.
A response is then received (Step 56 ). The response includes a query result that may include or describe a listing 58 of one or more alternate audio sources that may correspond to the video signal 22 . The listing 58 , for example, may describe one or more websites or network addresses that provide an alternate, simulcast or archived audio signal to accompany the video signal 22 . The listing 58 may describe one or more radio stations that broadcast an alternate audio signal (such as alternate announcers for a sporting event). The listing 58 may include real-time or archived podcasts from a member of an audience. The listing 58 may also include alternate audio sources obtainable from members of the user's social network.
The listing 58 is presented to the user (Step 60 ). The search application 50 and/or the alternate audio application 34 may cause the listing 58 to be displayed on the display device (illustrated as reference numeral 40 in FIG. 1 ). The user may then select an alternate audio source from the listing 58 , and that selection is received (Step 62 ). According to exemplary embodiments, the alternate audio application 34 causes an audio query to be sent for the selected alternate audio source (Step 64 ). The audio query communicates (via the communications network 24 illustrated in FIG. 1 ) to a communications address associated with a source of the selected alternate audio source. The audio query, for example, may communicate to an audio server. An audio signal is then received at the user's electronic device 20 (Step 66 ). If the alternate audio source is a terrestrial AM or FM radio station signal, then the user's electronic device 20 may be tuned to the corresponding frequency (as later paragraphs will explain).
The user's electronic device 20 then processes signals. The user's electronic device 20 thus receives the video signal (illustrated as reference numeral 22 in FIG. 1 ) and also receives the separate, audio signal. The video signal and the audio signal may thus be separately received as separate streams of data. The user's electronic device 20 then processes the video signal and the audio signal for visual and audible presentation (Step 68 ).
Exemplary embodiments may be applied regardless of networking environment. The communications network 24 may be a cable network operating in the radio-frequency domain and/or the Internet Protocol (IP) domain. The communications network 24 , however, may also include a distributed computing network, such as the Internet (sometimes alternatively known as the “World Wide Web”), an intranet, a local-area network (LAN), and/or a wide-area network (WAN). The communications network 24 may include coaxial cables, copper wires, fiber optic lines, and/or hybrid-coaxial lines. The communications network 24 may even include wireless portions utilizing any portion of the electromagnetic spectrum, any modulation technique, and/or any signaling standard (such as the I.E.E.E. 802 family of standards, GSM/CDMA/TDMA or any cellular standard, and/or the ISM band). The concepts described herein may be applied to any wireless/wireline communications network, regardless of physical componentry, physical configuration, or communications standard(s).
FIG. 3 is a schematic further illustrating a process for retrieving alternate audio, according to more exemplary embodiments. Here, when the video signal (illustrated as reference numeral 22 in FIG. 1 ) is received (Step 80 ), the video signal may also identify the alternate audio sources. That is, when the alternate audio tag 28 is received, the listing 58 of one or more alternate audio sources may also be embedded or encoded within the video signal and/or the alternate audio tag 28 . Alternatively, the listing 58 may be separately retrieved via a database query using the video content identifier 30 . A content provider of the video signal, for example, may configure the video signal to self-identify the alternate audio sources. The video signal may include information that identifies a website or server address that provides an alternate language track or a different dialog. The content provider may identify radio stations providing different announcers for a football game, political convention, or background music. Again, whatever the alternate audio sources, the listing 58 may be embedded or encoded within the video signal and/or the alternate audio tag 28 .
The user's electronic device 20 receives the alternate audio tag 28 . The presence of the alternate audio tag 28 again notifies the alternate audio application 34 that alternate audio sources may exist for the video signal. The alternate audio application 34 may visually and/or audibly present the listing 58 already received from the video signal (Step 82 ). The user may select an alternate audio source from the listing 58 , and the alternate audio application 34 receives that selection (Step 84 ). The alternate audio application 34 sends the audio query to the source of the selected alternate audio source (e.g., an audio server 86 ) (Step 88 ). The audio server 86 sends the separate audio signal (Step 90 ). The user's electronic device 20 thus receives the video signal and also receives the separate, audio signal. The user's electronic device 20 then processes the video signal and the audio signal for visual and audible presentation (Step 92 ).
FIG. 4 is a schematic illustrating additional queries for alternate audio sources, according to more exemplary embodiments. Because FIG. 4 is similar to FIGS. 2 and 3 , FIG. 4 is only briefly described. When the video signal is received (Step 100 ), the video signal may also include the alternate audio tag and the listing of alternate audio sources. The listing of alternate audio sources is presented to the user (Step 102 ). Here, even though the content provider may embed or provide the listing of alternate audio sources, the user may still wish to query for other alternate audio sources. The alternate audio sources identified in the listing, for example, may not appeal to the user. The user may, instead, wish to conduct a search for additional alternate audio sources not identified in the listing. The alternate audio application 34 , then, may prompt to search for alternate audio sources, despite the listing (Step 104 ). When the user affirmatively responds to the prompt, the alternate audio application 34 is authorized to query for additional alternate audio sources. The alternate audio application 34 calls or invokes the search application 50 and sends the query for any alternate audio sources associated with the video content identifier (Step 106 ). A response to the query is received (Step 108 ), and the query result describes more alternate audio sources that may correspond to the same video content identifier.
The alternate audio sources are then presented (Step 110 ). The user may select any alternate audio source from the listing or from the query result. The user's selection is received (Step 112 ) and the audio query is sent to the source (e.g., the audio server 86 ) (Step 114 ). The separate audio signal is received (Step 116 ) and processed along with the video signal (Step 118 ).
FIG. 5 is a schematic illustrating a user interface for retrieving alternate audio sources, according to more exemplary embodiments. According to exemplary embodiments, the alternate audio application 34 causes the processor 32 to graphically present a user interface 130 on the display device 40 . When the video signal 22 includes the listing 58 , the user interface 130 may present the listing 58 to the user. The user is thus informed of alternate audio sources embedded or encoded within the video signal 22 . The user, however, may wish to search for additional alternate audio sources not identified in the listing 58 . The user interface 130 , then, may include the control 42 to search for additional audio sources. When the user selects the control 42 , the alternate audio application 34 may invoke the search application (illustrated as reference numeral 50 in FIGS. 2-4 ) and query for alternate audio sources associated with the video content identifier 30 . When the search results are received, the user interface 130 may visually present those additional audio sources 134 . The user may then select a desired alternate audio source from the alternate audio sources provided by the listing 58 and/or from the additional alternate audio sources found by invoking the search application 50 . The desired alternate audio source is retrieved and processed.
FIG. 6 is a schematic illustrating synchronization of signals, according to more exemplary embodiments. Now that the user has selected an alternate audio source, the user's electronic device 20 may receive the video signal 22 and the separate audio signal 140 . The video signal 22 may communicate from the video server 26 via the communications network 24 . According to exemplary embodiments, the separate audio signal 140 communicates from a separate source, such as the audio server 86 . The video signal 22 and/or the audio signal 140 may be unicast, multicast, or broadcast to the electronic device 20 . The video signal 22 and the audio signal 140 may thus be separately received as separate streams of data.
The audio signal 140 and the video signal 22 may need synchronization. When the audio signal 140 and the video signal 22 correspond to the same content, propagation delays in the communications network 24 may cause the video signal 22 and/or the audio signal 140 to lead or lag. The video signal 22 , for example, may contain more bits or information than the audio signal 140 , so the video signal 22 may propagate more slowly through the communications network 24 . Whatever the causes, though, the audio signal 140 and the video signal 22 may be unsynchronized. When the audio signal 140 and the video signal 22 correspond to the same content, then the audio portion of the content may be out-of-synchronization with the video portion. The electronic device 20 , then, may synchronize the audio signal 140 and the video signal 22 to help ensure the content is enjoyed as intended.
A synchronizer 142 may be invoked. The synchronizer 142 may be a component of the electronic device 20 that causes synchronization of the audio signal 140 and the video signal 22 . As later paragraphs will explain, the synchronizer 142 may be circuitry, programming, or both. The synchronizer 142 , for example, may compare time stamps and/or markers. As FIG. 6 illustrates, the video signal 22 may include one or more video time stamps 144 . The video time stamps 144 mark or measure an amount of time from a reference point or time. The video time stamps 144 , for example, may signify an offset time from the start of a file, program, or the video signal 22 . Some or all frames in the video signal 22 may have corresponding time stamps that measure when a frame occurs with reference to the start of the file, program, or the video signal 22 .
The electronic device 20 may also receive audio time stamps 146 . When the audio signal 140 is received, the audio time stamps 146 may be encoded within the audio signal 140 . The audio time stamps 146 mark or measure an amount of time from a reference point or time. The audio time stamps 146 may signify an offset time from the start of a file, program, or the audio signal 140 . The audio time stamps 146 mark or measure when portions of the audio signal 140 occur with reference to the start of the file, program, or the audio signal 140 .
The synchronizer 142 may compare the audio time stamps 146 to the video time stamps 144 . When a currently-received audio time stamp 148 exceeds a currently-received video time stamp 150 , then the synchronizer 142 may delay the audio signal 140 . The synchronizer 142 may subtract the currently-received video time stamp 150 from the currently-received audio time stamp 148 . That difference is compared to a threshold time 152 . The threshold time 152 is any configurable time at which timing lag (or lead) in the video signal 22 is unacceptable. When the difference between the currently-received audio time stamp 148 and the currently-received video time stamp 150 equals and/or exceeds the threshold time 152 , then the synchronizer 142 may delay the audio signal 140 . The synchronizer 142 may even compare the absolute value of the difference to the threshold time 152 . The synchronizer 142 continues to compare the successively-received audio time stamps 146 to the successively-received video time stamps 144 until the difference is within the threshold time 152 . The synchronizer 142 then releases a delayed audio signal 154 for subsequent processing. The delayed audio signal 154 , for example, may be processed by processing circuitry 156 for audible presentation. The video signal 22 may also be processed by the processing circuitry 156 for visual presentation. Because the audio signal 140 has been delayed, though, exemplary embodiments synchronize the delayed audio signal 154 and the video signal 22 to help ensure the content is enjoyed.
The synchronizer 142 may additionally or alternatively utilize markers. The video signal 22 and/or the audio signal 140 may include or be associated with markers. These markers may or may not be based on time stamps. These markers represent and/or identify an event within the video signal 22 and/or the audio signal 140 . A marker, for example, may identify a scene, a transition, a beginning of a new segment, and/or some other occurrence in the video signal 22 and/or the audio signal 140 . For example, a marker may identify a kick-off of a football game, a transition from one scene to another in a movie, or some other occurrence. The synchronizer 142 may compare the video signal 22 and/or the audio signal 140 for similar markers. When a lead condition is detected, the leading signal may be delayed for synchronization.
Some aspects of synchronization are known, so this disclosure will not greatly explain the known details. If the reader desires more details, the reader is invited to consult the following sources, all incorporated herein by reference in their entirety: U.S. Pat. No. 4,313,135 to Cooper; U.S. Pat. No. 4,839,733 to Karamon, et al.; U.S. Pat. No. 5,055,939 to Karamon, et al.; U.S. Pat. No. 5,202,761 to Cooper; U.S. Pat. No. 5,387,943 to Silver; U.S. Pat. No. 5,440,351 to Ichino; U.S. Pat. No. 5,577,042 to McGraw, Sr., et al.; U.S. Pat. No. 5,917,557 to Toyoda; U.S. Pat. No. 6,263,505 to Walker, et al.; U.S. Pat. No. 6,502,142 to Rapaich; U.S. Pat. No. 6,630,963 to Billmaier; U.S. Pat. No. 6,710,815 to Billmaier; U.S. Patent Application Publication 2002/0101442 to Costanzo, et al.; U.S. Patent Application Publication 2003/0086015 to Korhonen, et al.; U.S. Patent Application Publication 2004/0117825 to Watkins; and U.S. Patent Application Publication 2005/0027715 to Casey, et al.
FIG. 7 is a schematic illustrating a delay of the video signal 22 , according to more exemplary embodiments. Here, for whatever reason, the video signal 22 may lead the audio signal 140 . That is, when the audio signal 140 lags the video signal 22 , exemplary embodiments may delay the video signal 22 . The synchronizer 142 may again compare the audio time stamps 146 to the video time stamps 144 . When the currently-received video time stamp 150 exceeds the currently-received audio time stamp 148 , then the synchronizer 142 may delay the video signal 22 . The synchronizer 142 may subtract the currently-received audio time stamp 148 from the currently-received video time stamp 150 and compare that difference to the threshold time 152 . When the difference equals and/or exceeds the threshold time 152 , then the synchronizer 142 may delay the video signal 22 . The synchronizer 142 continues to compare the successively-received video time stamps 144 to the successively-received audio time stamps 146 until the difference is within the threshold time 152 . The synchronizer 142 then releases a delayed video signal 160 for subsequent processing. The processing circuitry 156 processes the audio signal 140 and/or the delayed video signal 160 for audible/visual presentation. The audio signal 140 and the delayed video signal 160 are thus synchronized to help ensure the content is enjoyed.
FIG. 8 is a schematic further illustrating the electronic device 20 , according to more exemplary embodiments. Here the synchronizer 142 comprises the processor 32 , and the processor 32 executes a synchronization application 170 . The synchronization application 170 is illustrated as a module or sub-component of the alternate audio application 34 . The synchronization application 170 , however, may be a separate application that stores in the memory 36 and cooperates with the alternate audio application 34 . The synchronization application 170 may even be remotely stored and accessed at some location within the communications network (illustrated as reference numeral 24 in FIG. 1 ). Regardless, the synchronization application 170 comprises processor-executable instructions that determine when synchronization is needed between the received audio signal 140 and the received video signal 22 , according to exemplary embodiments. When synchronization is needed, the synchronization application 170 synchronizes the video signal 22 and the separately-received audio signal 140 .
The synchronization application 170 may first determine when synchronization is desired. When the audio signal 140 and the video signal 22 correspond to the same content, synchronization may be desired. If, however, the audio signal 140 and the video signal 22 are unrelated, then perhaps synchronization is unnecessary. The synchronization application 170 , then, may inspect for content identifiers. As FIG. 8 illustrates, when the audio signal 140 is received, the audio signal 140 may include an audio content identifier 172 . The audio content identifier 172 may be any information that describes the audio signal 140 . The audio content identifier 172 , for example, may be any identification number, title, code, or other alphanumeric string that uniquely describes the audio signal 140 . Likewise, when the video signal 22 is received, the synchronization application 170 may inspect the video signal 22 for the video content identifier 30 . The video content identifier 30 may be any identification number, title, code, information, or alphanumeric string that uniquely describes the video signal 22 .
The synchronization application 170 may then compare the audio content identifier 172 to the video content identifier 30 . If the audio content identifier 172 matches the video content identifier 30 , then the audio signal 140 and the video signal 22 likely correspond to the same content. If even some portion of the audio content identifier 172 matches the video content identifier 30 (or vice versa), then the audio signal 140 and the video signal 22 may still correspond to the same content. The synchronization application 170 may thus confirm that the audio signal 140 and the video signal 22 should be synchronized. If the synchronization application 170 observes no similarity, or an insubstantial amount of similarity, in the audio content identifier 172 and the video content identifier 30 , then synchronization application 170 may decline to synchronize. Regardless, a user may configure the synchronization application 170 to start, or to stop, synchronization as needed, despite dissimilar content identifiers.
Once synchronization is determined to be needed and/or desired, the synchronization application 170 may ensure the content remains pleasing and enjoyable. The synchronization application 170 reads, extracts, or otherwise obtains the audio time stamps 146 and the video time stamps 144 and makes a comparison. Whenever a lead or a lag condition is detected, the synchronization application 170 may instruct the processor 32 to divert the leading signal to a buffer memory 174 . The buffer memory 174 may store the leading signal in a first in, first out (FIFO) fashion. As the leading signal accumulates in the buffer memory 174 , the leading signal is delayed in comparison to a lagging signal 176 . A delayed signal 178 may then be retrieved from the buffer memory 174 and processed by the processing circuitry 156 . So, regardless of whether the video signal 22 or the audio signal 140 leads, the buffer memory 174 may cause a delay, thus synchronizing the audio and video portions.
FIG. 8 also illustrates user-configuration of the threshold time 152 , according to more exemplary embodiments. Because the threshold time 152 is configurable, the threshold time 152 may be specified by a user of the electronic device 20 , according to exemplary embodiments. The user interface 130 , for example, may permit changing or entering the threshold time 152 . The user interface 130 allows the user to alter the threshold time 152 and, thus, manually set or establish any delay caused by the synchronizer 142 . The user interface 130 , for example, may have a data field 180 into which the user enters the threshold time 152 . The threshold time 152 may be expressed in any measurement and/or in any increment of time, from zero delay to seconds, minutes, or even hours of delay. The user interface 130 may additionally or alternatively include a first timing control 182 for increasing the threshold time 152 . A second timing control 184 may be used to decrease the threshold time 152 . The user interface 130 may additionally or alternatively include a graphical or physical rotary knob, slider, button, or any other means of changing the threshold time 152 .
The threshold time 152 may be specified by a content provider. A provider of the video signal 22 , for example, may include threshold information 186 within the video signal 22 . The threshold information 186 is then used to define, derive, or specify the threshold time 152 . The threshold information 186 , for example, may be embedded or encoded within the video signal 22 . When the video signal 22 is received, exemplary embodiments may then obtain, read, and/or extract the threshold information 186 . The provider of the video signal 22 may thus specify the threshold time 152 and determine how much asynchronism is tolerable between the video signal 22 and the corresponding (but separately received) audio signal 140 . A content provider, for example, may encode 500 millisecond as the threshold information 186 within the video signal 22 . When a lead or lag condition exceeds 500 milliseconds, then the synchronization application 170 instructs the processor 32 to delay the audio signal 140 , the video signal 22 , or both. Similarly, the threshold information 186 may be embedded or encoded within, or modulated onto, the audio signal 140 , and the synchronization application 170 causes a delay when needed. If the audio signal 140 and the video signal 22 both include the threshold information 186 , then the synchronization application 170 may have authority to choose one or the other. When the audio signal 140 specifies a first threshold information, while the video signal 22 specifies another, second threshold information, then the synchronization application 170 may choose the smaller value to minimize asynchronous conditions.
FIG. 9 is a schematic illustrating another operating environment in which exemplary embodiments may be implemented. The electronic device 20 again receives the video signal 22 and the separate audio signal 140 . Here, however, the video signal 22 and/or the audio signal 140 are terrestrially broadcast at some frequency of any portion of the electromagnetic spectrum. The audio signal 140 , for example, may be wirelessly broadcast from an antenna coupled to the communications network 24 . The audio signal 140 may be wirelessly transmitted using any signaling standard (such as the I.E.E.E. 802 family of standards, GSM/CDMA/TDMA or any cellular standard, WI-FI®, and/or the ISM band). The video signal 22 , too, may be received via wireless or wired communication. Regardless, the video signal 22 and the audio signal 140 may be separately received as separate streams of data.
According to exemplary embodiments, the electronic device 20 includes at least one wireless receiver. A wireless video receiver 200 , for example, couples to an antenna 202 and wirelessly receives the video signal 22 at some frequency of any portion of the electromagnetic spectrum. A wireless audio receiver 204 may couple to another antenna 206 and wirelessly receives the audio signal 140 at some frequency of any portion of the electromagnetic spectrum. If the audio signal 140 and/or the video signal 22 is/are modulated, the electronic device 20 may include one or more demodulators 208 . If analog or digital conversion is needed, the electronic device 20 may include an A/D or D/A converter 210 . If synchronization is needed, the synchronizer 142 delays the leading video signal 22 and/or the audio signal 140 . Analog and/or digital broadcasting techniques and circuitry are well known, so no further discussion is made. If, however, the reader desires a further explanation, the reader is invited to consult the following sources, with each incorporated herein by reference in its entirety: F ERRILL L OSEE , RF S YSTEMS , C OMPONENTS, AND C IRCUITS H ANDBOOK (1997); L EENAERTS ET AL ., C IRCUIT D ESIGN FOR RF T RANSCEIVERS (2001); J OE C ARR, RF C OMPONENTS AND C IRCUITS (2002); W OLFGANG H OEG AND T HOMAS L AUTERBACH , D IGITAL A UDIO B ROADCASTING (2003); and A NNA R UDIAKOVA AND V LADIMIR K RIZHANOVSKI , A DVANCED D ESIGN T ECHNIQUES FOR RF P OWER A MPLIFIERS (2006).
Exemplary embodiments, as earlier explained, may determine whether synchronization is desired. For example, the audio content identifier 172 is compared to the video content identifier 30 . If a partial or full match is found, then a determination may be made that the audio signal 140 and the separately-received video signal 22 likely correspond to the same content. Exemplary embodiments thus confirm that the audio signal 140 and the video signal 22 should be synchronized.
Once synchronization is desired, exemplary embodiments may compare time stamps. The audio time stamps 146 are compared to the video time stamps 144 , as explained above. Whenever a lead or a lag condition is detected, exemplary embodiments implement a delay in the audio signal 140 , the video signal 22 , or both. When, for example, the audio signal 140 is digital, exemplary embodiments may divert the audio signal 140 to the buffer memory (shown as reference numeral 174 in FIG. 8 ). As the digital audio signal 140 accumulates in the buffer memory, the audio signal 140 is delayed in comparison to the video signal 22 . The video signal 22 , alternatively or additionally, may similarly be stored in the buffer memory when the video content leads the audio content. Exemplary embodiments then release the buffered audio signal 140 and/or video signal 22 when synchronization is achieved.
FIG. 10 is a schematic illustrating yet another operating environment in which exemplary embodiments may be implemented. Here the electronic device 20 is illustrated as a television or set-top receiver 220 that receives the video signal 22 and the separate audio signal 140 . The video signal may be broadcast along a wireline, cable, and/or satellite portion of the communications network 24 , while the audio signal 140 is separately and wirelessly received at an RF receiver 222 as a terrestrial broadcast. While the television or set-top receiver 220 may receive the audio signal 140 at any frequency of any portion of the electromagnetic spectrum, here the audio signal 140 is wirelessly received at the radio-frequency portion of the spectrum. The audio signal 140 may or may not be modulated onto a carrier signal 224 . The audio signal 140 , for example, may be amplitude modulated or frequency modulated (e.g., AM or FM) onto the carrier signal 224 . The audio signal 140 may additionally or alternatively be broadcast from a satellite using any frequency of any portion of the electromagnetic spectrum, and the satellite broadcast may or may not be modulated onto the carrier signal 224 . Here, then, the electronic device 20 may be an AM-FM real time television-capable device with broadband capability to wirelessly receive television signals and/or RF audio signals. Regardless, the electronic device 20 may also receive time stamps and content identifiers. The electronic device 20 may receive the video time stamps 144 and the video content identifier 30 encoded within the video signal 22 . The electronic device 20 may also receive the audio time stamps 146 and the audio content identifier 172 . The audio time stamps 146 and the audio content identifier 172 may be encoded within the audio signal 140 and, if desired, modulated onto the carrier signal 224 .
Exemplary embodiments may then proceed as discussed above. The demodulator 208 may demodulate the audio signal 140 , the audio time stamps 146 , and/or the audio content identifier 172 , from the carrier signal 224 . Exemplary embodiments may compare the audio content identifier 172 to the video content identifier 30 . If a partial or full match is found, then the audio signal 140 and the separately-received video signal 22 may correspond to the same content and may be synchronized. The audio time stamps 146 may be compared to the video time stamps 144 , as explained above. When a lead or a lag condition is detected, exemplary embodiments may implement a delay in the audio signal 140 , the video signal 22 , or both to synchronize the audio signal 140 and the separately-received video signal 22 .
FIG. 11 is a schematic illustrating still another operating environment in which exemplary embodiments may be implemented. Here the video signal 22 is received, processed, and presented by a television or computer 240 , while the audio signal 140 is separately received by an AM/FM radio 242 . The AM/FM radio 242 includes the RF receiver 222 that wirelessly receives the audio signal 140 as a terrestrial broadcast. The user, for example, may be watching a football game on the television or computer 240 , yet the user prefers to listen to play-by-play action from radio announcers. Unfortunately, though, the separately-received audio signal 140 may lead the video signal 22 by several seconds. The radio announcer's commentary, then, is out-of-synchronization with the television video signal 22 .
Exemplary embodiments, then, may delay the audio signal 140 . The user interface 130 may be used to establish an amount of delay introduced by the synchronizer 142 . The user interface 130 , for example, may be graphical (as illustrated and explained with reference to FIGS. 1 , 5 , and 8 ), or the user interface 130 may be a physical knob, slider, or other means for adjusting delay. When the user notices that the audio signal 140 leads the video signal 22 , the user may adjust the user interface 130 to introduce a delay into the leading audio signal 140 . The user refines the delay until the audio signal 140 is synchronized to the video signal 22 .
FIG. 12 is a schematic illustrating another operating environment in which exemplary embodiments may be implemented. Here the user has multiple electronic devices 20 operating in the user's residence, business, building, or other premise. Some of the electronic devices 20 may receive analog signals and some of the electronic devices 20 may receive digital signals. Some of the electronic devices 20 may receive audio signals and some of the electronic devises 20 may receive video signals. When all the electronic devices 20 receive signals that correspond to the same content, the user may need to synchronize one or more of the electronic devices 20 . When, for example, all the electronic devices 20 receive the same football game, any leading or lagging audio/video signal may be annoying. Exemplary embodiments, then, allow the user to individually synchronize any of the electronic devices 20 for an enjoyable entertainment experience.
As FIG. 12 illustrates, exemplary embodiments may operate in one or more of the electronic devices 20 . An instance of the alternate audio application 34 , for example, may operate in a computer 260 . The computer 260 may receive the video signal 22 and the separate audio signal 140 from the communications network 24 . Another instance of the alternate audio application 34 may operate in a set-top receiver 262 that also receives the video signal 22 and the separate audio signal 140 from the communications network 24 . Yet another instance of the alternate audio application 34 may operate in an analog television 264 that receives a terrestrially-broadcast analog version 266 of the video signal 22 . Another instance of the alternate audio application 34 may operate in a digital television 268 that receives a terrestrially-broadcast standard definition or high-definition digital version 270 of the video signal 22 . More instances of the alternate audio application 34 may even operate in a wireless phone 272 and an AM/FM radio 274 .
Exemplary embodiments permit synchronization of all these electronic devices 20 . When all the electronic devices 20 receive signals that correspond to the same content, some of the electronic devices 20 may lead or lag, thus producing an unpleasant entertainment experience. Exemplary embodiments, however, allow the user to delay the audio and/or video signals received at any of the electronic devices 20 . The user may thus synchronize audio and video outputs to ensure the content remains pleasing.
FIG. 13 is a block diagram further illustrating the electronic device 20 , according to even more exemplary embodiments. When either the audio signal 140 or the video signal 22 lags, here the synchronizer 142 may divert a leading signal 300 to a first delay circuit 302 . The first delay circuit 302 may comprise clocked and/or unclocked circuits or components. If clocked, a reference or clock signal 304 may be received at the first delay circuit 302 . The leading signal 300 propagates through the first delay circuit 302 . As the leading signal 300 propagates, delays may be introduced by the first delay circuit 302 . The amount of delay may be determined according to the complexity and/or the number of components within the first delay circuit 302 . When a delayed signal 306 emerges from the first delay circuit 302 , the delayed signal 306 may be synchronized with a lagging signal 308 . The delayed signal 306 may then be diverted through, or “peeled off” by, a first gate circuit 310 and sent to the processing circuitry 156 for audible presentation.
More delay may be needed. The first delay circuit 302 may introduce a predetermined amount of delay. Suppose, for example, that the first circuit introduces twenty milliseconds (20 msec.) of delay in the audio signal 140 . If twenty milliseconds of delay does not satisfy the threshold time 152 , then more delay may be needed. The first gate circuit 310 , then, may feed, or cascade, the delayed signal 306 to a second delay circuit 312 . The second delay circuit 312 introduces additional delay, depending on its complexity and/or number of components. If this additional delay is sufficient, then a second gate circuit 314 diverts an additionally delayed signal 316 to the processing circuitry 156 . If more delay is again needed, the second gate circuit 314 may feed or cascade the additionally delayed signal 316 back to the first delay circuit 302 for additional delay. According to exemplary embodiments, the leading signal 300 , then, may cascade or race through the first delay circuit 302 and through the second delay circuit 312 until synchronization is achieved.
FIG. 14 depicts other possible operating environments for additional aspects of the exemplary embodiments. FIG. 14 illustrates that the alternate audio application 34 and/or the synchronizer 142 may alternatively or additionally operate within various other devices 400 . FIG. 14 , for example, illustrates that the alternate audio application 34 and/or the synchronizer 142 may entirely or partially operate within a personal/digital video recorder (PVR/DVR) 402 , personal digital assistant (PDA) 404 , a Global Positioning System (GPS) device 406 , an interactive television 408 , an Internet Protocol (IP) phone 410 , a pager 412 , or any computer system and/or communications device utilizing a digital processor and/or digital signal processor (DP/DSP) 414 . The device 400 may also include watches, radios, vehicle electronics, clocks, printers, gateways, and other apparatuses and systems. Because the architecture and operating principles of the various devices 400 are well known, the hardware and software componentry of the various devices 400 are not further shown and described. If, however, the reader desires more details, the reader is invited to consult the following sources, all incorporated herein by reference in their entirety: A NDREW T ANENBAUM , C OMPUTER N ETWORKS (4 th edition 2003); W ILLIAM S TALLINGS , C OMPUTER O RGANIZATION AND A RCHITECTURE : D ESIGNING FOR P ERFORMANCE (7 th Ed., 2005); and D AVID A. P ATTERSON & J OHN L. H ENNESSY , C OMPUTER O RGANIZATION AND D ESIGN : T HE H ARDWARE /S OFTWARE I NTERFACE (3 rd . Edition 2004); L AWRENCE H ARTE et al., GSM S UPERPHONES (1999); S IEGMUND R EDL et al., GSM AND P ERSONAL C OMMUNICATIONS H ANDBOOK (1998); and J OACHIM T ISAL , GSM C ELLULAR R ADIO T ELEPHONY (1997); the GSM Standard 2.17, formally known Subscriber Identity Modules, Functional Characteristics (GSM 02.17 V3.2.0 (1995-01))”; the GSM Standard 11.11, formally known as Specification of the Subscriber Identity Module—Mobile Equipment ( Subscriber Identity Module—ME ) interface (GSM 11.11 V5.3.0 (1996-07))”; M ICHEAL R OBIN & M ICHEL P OULIN , D IGITAL T ELEVISION F UNDAMENTALS (2000); J ERRY W HITAKER AND B LAIR B ENSON , V IDEO AND T ELEVISION E NGINEERING (2003); J ERRY W HITAKER , DTV H ANDBOOK (2001); J ERRY W HITAKER , DTV: T HE R EVOLUTION IN E LECTRONIC I MAGING (1998); and E DWARD M. S CHWALB, I TV H ANDBOOK : T ECHNOLOGIES AND S TANDARDS (2004).
FIG. 15 is a flowchart illustrating a method of retrieving audio signals, according to more exemplary embodiments. A video signal is received (Block 500 ). The video signal may comprise the alternate audio tag 28 , the video content identifier 30 , the video time stamps 144 , the threshold information 186 , and/or the listing 58 of alternate audio sources that correspond to the video signal. In response to the alternate audio tag 28 , a query is sent for an alternate audio source that corresponds to the video content identifier (Block 502 ). A query result is received that identifies an audio signal that corresponds to the video content identifier and that is separately received from the video signal (Block 504 ). A selection is received that selects an alternate audio source from the listing and/or from the query result (Block 506 ). Another query is sent for the alternate audio source (Block 508 ), and a separate audio signal is received (Block 510 ). The separate audio signal may comprise the audio content identifier 172 , the audio time stamps 146 , and the threshold information 186 . The audio time stamps are compared to the video time stamps (Block 512 ). When an audio time stamp exceeds a corresponding video time stamp by a threshold time, then the audio signal is delayed until the audio time stamps are within the threshold time of the video time stamps (Block 514 ). When a video time stamp exceeds a corresponding audio time stamp by the threshold time, then the video signal is delayed until the video time stamps are within the threshold time of the audio time stamps (Block 516 ).
Exemplary embodiments may be physically embodied on or in a computer-readable medium. This computer-readable medium may include CD-ROM, DVD, tape, cassette, floppy disk, memory card, and large-capacity disk (such as IOMEGA®, ZIP®, JAZZ®, and other large-capacity memory products (IOMEGA®, ZIP®, and JAZZ® are registered trademarks of Iomega Corporation, 1821 W. Iomega Way, Roy, Utah 84067, www.iomega.com). This computer-readable medium, or media, could be distributed to end-subscribers, licensees, and assignees. These types of computer-readable media, and other types not mention here but considered within the scope of the exemplary embodiments. A computer program product comprises processor-executable instructions for synchronizing audio and video content.
While the exemplary embodiments have been described with respect to various features, aspects, and embodiments, those skilled and unskilled in the art will recognize the exemplary embodiments are not so limited. Other variations, modifications, and alternative embodiments may be made without departing from the spirit and scope of the exemplary embodiments. | Audio and video signals are synchronized for pleasing presentation of content. As content is streamed to a device, an audio portion may lag or lead a video portion. Spoken words, for example, are out of synch with the lip movements. Video content is thus synchronized to audio content to ensure streaming content is pleasing. | 7 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not applicable.
CROSS-REFERENCE TO RELATED APPLICATION
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to flush valves that control the flow of water from toilet tanks to toilet bowls, and in particular, to flush valves providing improved protection against overflows from toilet bowls.
A variety of systems are known for controlling the flush of toilet tank water to a toilet bowl. See e.g. U.S. Pat. Nos. 3,072,919, 3,988,785, 4,365,365, 5,794,279 and 5,848,422. Most of these systems include an outlet near the bottom of the toilet tank with a trip-activated flapper valve positioned adjacent the outlet. There is also an inlet valve for the tank that is typically controlled by a float that senses tank water level.
Depressing a trip lever raises the flapper, thereby unsealing the outlet so that water can empty from the tank into the bowl. As the tank water drains, the inlet valve float drops with the water level in the tank, thereby triggering inlet water flow. However, normally the water level drops faster than the inlet water enters. The flapper then can drop down to reseal the outlet, and the water level in the tank can be re-established. As the tank refills, the inlet valve float rises with the water and eventually closes the inlet valve to shut off the incoming water.
However, if the bowl trap were to be become obstructed, water from the tank would flood into the bowl through the rim openings and fill the bowl. The obstruction would prevent the bowl from emptying, and the water in the bowl would rise to the rim level.
If the outlet opening were positioned sufficiently high above the rim level, this would not interfere with the tendency of the flapper to reseal. However, if the outlet opening were positioned at or below the rim level, as might be desired in the design of an extremely low profile toilet to preserve tank water capacity, this might prevent the flapper from resealing. This could lead to an overflow condition (as in the absence of the flapper closing the outlet, the inlet water valve will not shut off).
Thus, a need exists for improved overflow protection in connection with flapper valves used for low profile toilets.
SUMMARY OF THE INVENTION
In one form, the invention provides a flapper valve assembly for regulating the passage of water out from a toilet water tank. The tank is of the type having a lower outlet opening. There is a flapper seal for seating against a seal surface of the outlet opening, and an attachment site for attaching a trip connector adjacent the flapper seal. There is also a yoke supporting the flapper seal adjacent an outer end of the yoke, and having a pivot axis adjacent an inward end of the yoke. A flapper arm has a first segment connected to the yoke adjacent the pivot axis, and a second segment extending at least partially in an outward direction.
In preferred forms the second segment of the flapper arm has a U-bend in it, or is otherwise provided with extra weight. When the flapper seal is horizontal, the second segment preferably extends at between 30 degrees and 60 degrees from vertical. The above assembly is particularly well suited for use when the flapper seal has an inner cavity and is supported by a yoke having a pair of legs (each having an opening defining the pivot axis).
In another aspect the invention provides a toilet tank. There is a tank housing with a lower outlet and a flapper seal pivotably positioned adjacent the outlet to control flow out the outlet. There is also a flapper arm coupled to the seal. The flapper arm is configured such that it delays seating of the flapper seal against the outlet when the water in the water tank is above a first specified level and assists seating of the flapper seal against the outlet when the water is either below that first specified level, or a second lower level.
The invention provides a flapper valve assembly that can be retrofit onto existing toilets to reduce the incidence of overflow. The flapper valve assembly can also be incorporated into newly designed toilets that have lower drain outlets.
As will be appreciated from the following, a primary aspect of the invention is the provision of a weighted element that is above the flapper when the flapper is horizontal or near horizontal. It can therefore help drive the flapper down even when there is some residual water in the tank (e.g. due to a bowl overflow condition). However, when the flapper is angled upward to a sufficient extent, the primary arm weight is shifted to an opposite side of a pivot axis. In this position, the arm retards flapper closure, thereby avoiding premature closure of the valve when the toilet tank hasn't completely emptied (during normal operation).
Advantages of the present invention therefore include:
(a) reducing the risk of an overflow from toilets;
(b) permitting toilets to be designed with lower profiles while retaining adequate water capacity for proper cleaning cycles; and
(c) providing flapper assemblies of the above kind which can be retrofit into existing toilets. These and other advantages of the invention will be apparent from the detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing a flapper assembly of the present invention mounted in a low profile, one-piece type toilet;
FIG. 2 is a view similar to a part of FIG. 1, albeit with the flapper assembly shown seated;
FIG. 3 is a rear perspective view of the flapper assembly, with a flapper arm shown disassembled;
FIG. 4 is a front perspective view of the flapper assembly, with a trip lever chain attached thereto shown in phantom; and
FIG. 5 is a top view of the flapper assembly with the flapper seal shown in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a “one-piece” type low profile toilet 10 includes a water tank 12 and a bowl section 14 . The tank 12 has a lower vertical wall 16 with an outlet opening 18 leading to a channel 20 in an upper rim 22 of the bowl 14 .
The flush valve assembly 24 has an overflow tube 26 disposed vertically upright in the tank 12 . It is connected to a horizontal extension tube 28 that is suitably coupled to the vertical wall 16 at the outlet opening 18 . See e.g. U.S. Pat. No. 5,848,442 for an example of a preferred coupling technique.
The horizontal section 28 has a cylindrical flush opening 30 , the upper edge of which provides a seal surface 32 . The seal surface 32 is preferably located near, at or even below the height of the bowl rim 22 .
Back wall 36 of the overflow tube 26 includes a plurality of vertically spaced clip members 34 for attaching the flapper valve assembly 38 of the present invention. The multiple clip members 34 allow the flapper valve assembly 38 to be attached at different heights, depending on the design of the toilet tank. Again, see generally U.S. Pat. No. 5,848,442 for a discussion of the design and function of such clips.
As best shown in FIGS. 3-5, the flapper valve assembly 38 includes a flapper seal generally 40 supported by a yoke 42 , to which is attached a unique flapper arm 44 . The seal 40 is preferably made of an elastomeric material (e.g. rubber) defining a generally conical body with a hollow interior cavity open to the atmosphere through an opening (not shown) in a cap 46 at the bottom of the flapper seal 40 . At its top, the flapper seal 40 has a ring 48 for sealing with the seal surface 32 of the flush opening 30 , and a tapered boss 49 for snap connecting the flapper seal 40 to the yoke 42 . A preferred flapper seal 40 is commercially available from Fluidmaster, Inc. of San Juan Capistrano, Calif. See also the flapper seal of U.S. Pat. No. 3,988,785.
The yoke 42 is preferably made of 20% talc-filled polypropylene and has a pair of parallel legs 50 and 52 interconnected at one end by a somewhat triangular section 54 having an opening 56 there through. There are flexible inwardly extending fingers 58 for snapping onto a boss 49 on the flapper seal 40 .
At the tip of the triangular section 54 is a recessed projection or attachment site 60 for attaching a chain 61 . The chain is coupled at its opposite end to the flush trip lever (not shown), with the lever being accessible in the usual manner from outside of the tank 12 . At the end of the legs 50 and 52 opposite the triangular section 54 are openings 62 and 64 , respectively, and a vertical clip member 66 (at the end of leg 50 only) for connecting the flapper arm 44 .
The flapper arm 44 is preferably a 0.188 diameter 300 series stainless steel rod bent into two segments, 68 and 70 . The first segment 68 is straight and attaches the flapper valve assembly 38 to the flush assembly 24 by fitting the yoke legs 50 and 52 around the front of the overflow tube 26 and inserting the first segment 68 of the flapper arm 44 through the openings 62 and 64 and into a selected clip member 34 at the back wall 36 of the overflow tube 24 .
The second segment 70 bends in a first direction and then angles away at approximately 45 degrees. The outer portion of the segment 70 is bent in a hairpin so that there two generally parallel runs of the rod. The purpose of this is to skew the weight of the arm towards this portion of the arm.
Prior to performing a flush operation, the flapper valve assembly 38 is in the position shown in FIG. 2, with the flapper seal 40 seated on the seal surface 32 of the flush opening 30 . The water level in the tank 12 at this point is shown in FIG. 1 by upper dotted line 80 . Depressing the trip lever (not shown) causes the chain 61 to become taught and pull the yoke 42 upwardly sufficient to cause it to pivot about pivot axis 74 (see FIG. 3 ), and unseat the flapper seal 40 , as shown in FIG. 1 .
The flapper seal 40 is initially held up by the buoyancy force of the water acting on the flapper valve assembly 38 plus (and importantly) the weight of the flapper arm 44 , which provides a countervailing moment on the flapper seal 40 (via the yoke 42 ) because its center of mass is at this point on the opposite side of the pivot axis 74 . While the flapper valve assembly 38 is in the position shown in FIG. 1, water in the tank 12 can flow through the flush opening 30 , extension tube 28 , outlet opening 18 , rim channel 20 and rim openings (not shown).
When the water drains to water level line 82 of FIG. 1, which in the depicted embodiment is well above the height of the bowl rim 22 , the weight of the flapper arm 44 is still opposing the tendency of the flapper to close. Thus, it still slightly delays closure so that the water can empty from the tank. However, the weight is not sufficient to prevent the flapper from dropping. It is only sufficient to retard the rate. Accordingly, the flapper valve assembly 38 continues to pivot until the weight of the flapper arm is more to the side of the flapper than to the opposite side.
As it pivots, the weight of the bent segment of the flapper arm 44 begins to transfer from behind, to in front of, the pivot axis 74 . This occurs above the top level of the rim, and below level 82 . At this point, the flapper arm goes from opposing the seating of the flapper seal 40 to assisting it.
Thus, the dual action flapper arm 44 first delays and then positively assists seating of the flapper seal 40 . Once seated, the tank 12 and bowl 14 can be refilled by supply water, which is shut off by a suitable valve, such as a float operated inlet valve assembly.
Water and waste in the bowl 14 is evacuated to plumbing waste lines in the usual manner through a trap. If the trap were to become obstructed, the contents of the bowl 14 might not drain. The bowl contents could then rise up to the rim 22 , causing some water to remain in the tank. Such an occurrence might stop the flapper from reseating in certain conventional systems. Because the tank 12 could then not refill, the water level in the tank could not rise, and the inlet valve assembly would not shut off the incoming water supply. This could cause water to continuously pour over the bowl rim 22 and onto the floor until the water is shut off manually.
The flapper valve assembly 38 of the present invention is designed to reduce the risk of such an occurrence. Should some water remain in the tank, the weight of the flapper arm will still be sufficient to drive the flapper into closure, thus permitting water in the tank to rise and the inlet water to be shut off.
The invention therefore provides a toilet with reduced overflow risk for any given tank height. Moreover, the system is designed to be suitable to either retrofit to existing drains, or to be incorporated into new toilets. The feature that provides the protection has very low cost, and is easy to manufacture and assemble.
A preferred embodiment of the invention has been described above. Modifications and variations to the preferred embodiment are within the spirit and scope of the invention. Therefore, the invention is not to be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced. | A flapper valve assembly for regulating the passage of water from a toilet tank is provided with a structure to reduce overflow risk. There is a yoke pivotally disposed in the tank and supporting a flapper seal that can be seated on and unseated from the flush opening. A flapper arm has a first segment coupled to the yoke along a pivot axis and a second segment extending away from the pivot axis toward the flapper seal. The flapper arm is configured such that it delays seating of the flapper seal when the water in the tank is above a predetermined level and assists seating of the flapper seal when the water is below a designated level. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of co-pending application Ser. No. 09/305,504, filed May 5, 1999, and which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to a torque-transmitting apparatus with a fluid-operated torque coupler such as, e.g., a fluid coupling or a hydrodynamic torque converter, with at least one housing that can be connected to a driving shaft of a prime mover. The housing contains at least one impeller pump receiving torque from the housing and a turbine that is connected to the input shaft, such as a transmission shaft, of a power train to be driven. Also, if applicable, the housing contains at least one stator arranged between the pump and the turbine. Further, at least one damper is arranged in the power flow between the turbine and a rotary output element of the device. The damper has an input member constrained to rotate together with the turbine and an output member connected to the rotary output element. The input member and the output member are rotatable relative to each other at least against the opposition of a restoring force furnished by energy-storing devices arranged between them.
Torque-transmitting apparatuses of this kind have been proposed, e.g., in DE-OS 195 14 411. To allow rotational displacement of the input and output members relative to each other, it is customary for torque-transmitting apparatuses of this kind to be equipped with a hub that has a toothed internal profile establishing a positive engagement with the transmission shaft and also a toothed external profile which mates with a further component, normally a further hub that carries the turbine and has a toothed internal profile, with play between the flanks of the mating teeth. When a lockup clutch is added that is activated by an axial control piston, there needs to be a corresponding axial space to allow for the axial travel of the hub containing the two toothed profiles. The manufacture of hubs of this kind is complex and therefore expensive. Furthermore, due to the required axial dimension, longer transmission shafts will be needed. Added to this is the difficulty of connecting bulky hub components with the filigreed construction of the turbine shell. Also, dampers that extend far in the radial direction have a tendency to wobble. If in an attempt to solve these problems, the damper is axially docked to the turbine along two or more perimeters of different radii, this will cause undesirable stresses and frictional losses in the damper.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to improve the design of a torque-transmitting apparatus in a manner that allows a stress-free accommodation of the damper as well as economical and technical improvements in the manufacturing process for torque-transmitting apparatuses of this kind. According to a further object of the invention, the device is to be manufacturable in such a manner that a modular assembly without time-consuming fastening operations can be performed during final assembly. Also required of the torque-transmitting apparatus are the capabilities to transfer torque of high magnitude and to attenuate rotational perturbations over a broad RPM range. Besides, the unit is to meet the objectives that it will minimize wear and prolong the useful life of the overall system of which it is a part.
SUMMARY OF THE INVENTION
The invention is embodied in a torque-transmitting apparatus of the kind that has a fluid-operated torque coupler such as a hydrodynamic torque converter or a similar device comprising
at least one housing that can be connected to a driving shaft of a prime mover,
at least one pump that is arranged inside of and driven by the housing,
a turbine that is connected to and drives the input shaft of a power train such as a transmission shaft and also, if applicable,
at least one stator arranged between the pump and the turbine, and further
at least one damper arranged in the torque-flow path between the turbine and a rotary output element of the apparatus, with an input member of the damper being constrained to rotate together with the turbine and an output member of the damper being connected to the rotary output element, the input member and the output member being at least rotatable relative to each other at least against the opposition of the restoring force exerted by energy-storing devices arranged between them.
In accordance with one presently preferred embodiment of the improved torque-transmitting apparatus, the damper at its outside perimeter is directly or indirectly connected to the turbine through a positive rotational constraint. This connection may be free of play relative to coaxial rotational displacements but may allow an axial displacement of the turbine and the input member of the damper relative to each other. For example, the connection may be axially displaceable by means of an axial plug-in connection with the damper rigidly attached to a hub. The problem can further be solved through a torque-transmitting apparatus with a damper whose connection to the turbine shell or turbine, or to the hub, is rotationally fixed both along an inside and outside perimeter, while in the axial direction the connection is fixed only along one perimeter, either on the hub or on the turbine shell, so that axial stresses are relieved by an axial displacement at the axially non-restrained connection.
In accordance with a further inventive concept, there may also be an axially and rotationally fixed connection at the outside perimeter of the damper in which case, in order to prevent stresses in the damper, the inside perimeter of the damper may be designed to be axially displaceable, e.g., in an arrangement where the damper, by means of a positive circumferential coupling such as a toothed profile, engages a complementary profile on the hub. In addition, the profile on the hub may be axially fixed but rotatable on a complementary profile of the turbine hub on which the turbine is seated, with the amount of rotational play designed to be at least equal to the working range, i.e., the effective angular range, of the damper. The play in the form-fitting engagement between the turbine hub and the hub may also be obtained through additional devices such as window-like openings that are distributed over the circumference of the hub and are engaged with angular play by a corresponding series of axially directed projections on the turbine hub.
With particular advantage, the connection between the turbine and the input member of the damper is accomplished through welding processes such as laser welding, impulse welding, or resistance welding, in which case the damper can be centered on the hub by means of a disk-shaped part that holds the energy-storing devices, or on the turbine shell, e.g., by providing the turbine shell with a series of projections that are distributed over the circumference and that may also serve as locating references for the weld.
It is advantageous for the torque-transmitting apparatus to be provided with a lockup clutch arranged in the torque-flow path between the driving shaft and the damper, in which case it has proved to be beneficial if the lockup clutch, by means of friction linings or laminar disks, establishes a positive engagement with a housing surface and transfers the torque to be transmitted directly to the input member of the damper. Thus, when the lockup clutch is engaged, the torque converter is bypassed and the torque to be transmitted is introduced directly into the damper and from there to the rotary output element and subsequently to the transmission shaft. When the lockup clutch is disengaged, the turbine will impart the torque that has been converted—in most cases amplified through the effect of the stator—to the input member of the damper from where the torque will follow the same path as has been previously described.
The clutch can be engaged and disengaged through an axially moveable control piston that is controlled by an application of pressure. It is advantageous if the control piston defines a plenum chamber which, in the engaged state of the lockup clutch, is essentially sealed tight against the interior space of the housing (except for insignificant flows of pressure medium into the housing that may be provided to cool the friction linings) and is energized by a pressure medium identical to the converter fluid that is admitted through a bore hole, whereby a pressure force is applied to the piston in the axial direction towards the turbine. According to the invention, this axial displacement is compensated by allowing an axial displacement of the axial plug-in connection. Another possibility for controlling the piston is to apply an over pressure to the control piston, in which case the piston will seal off the chamber when the clutch is open; and when the pressure in the chamber is reduced, the piston is pushed to the housing wall by the fluid pressure in the torque converter, thereby causing the lockup clutch to engage.
The control piston can be centered on the transmission shaft, on a hub holding the housing of the torque converter, or on another appropriate part of the apparatus and is preferably provided with sealing means at the interface surfaces to these components for the purpose of sealing the plenum chamber in the same manner as the piston can be sealed at its outside perimeter against the housing.
A further embodiment comprises a form-fitting engagement between the control piston and the housing by means of complementary profiles extending in the axial direction, in which case the axial profile is formed by alternating ridges and grooves in the shape of ring segments that are distributed over a perimeter where, e.g., the ridges of the control piston may engage the grooves in the housing. An advantage of such configuration is the direct engagement of the piston with the housing so that the piston can transmit torque to the friction linings directly and/or through other pressure-transmitting devices, whereby the use of an enlarged friction surface and/or of a larger number of friction surfaces and thus a greater transmission torque is made possible.
For this purpose, there may be one or more carriers of friction linings in the form of annular disks or laminar disks that can carry friction linings in the outer zones of their axially facing surfaces. The friction-lining carriers or laminar disks are axially movable, and the pressure force is applied against a ring-shaped pressure plate that is connected with the housing either directly or indirectly, e.g., welded, riveted or attached to a flange that is, in turn, connected to the housing. For better cooling fluid distribution, the pressure plate can have one or more circles of holes.
It is advantageous to center the friction-lining carrier on the housing. For this purpose, the friction-lining carrier can be provided with lugs that protrude axially towards the housing and are inserted in a shoulder extending in the direction away from the friction-lining carrier.
A further advantageous embodiment renders it possible to configure the piston itself as the lockup clutch or, more precisely, as the friction-lining carrier. For this, the radially outer part of the control piston surface that faces axially towards the housing carries a ring-shaped friction lining that may be provided with an optimized surface finish to achieve better cooling. The piston surface may be bent in the axial direction towards the turbine, so that the piston may rest in form-fitting contact against the housing, which in the respective surface portion is shaped similar to a cone shell.
As already described above, the lockup clutch is connected through one of its components to the input member of the damper. In one embodiment, the connecting part may be the control piston itself in the manner described above, in which case the piston may be connected to lateral parts of the input member by rivets, weld joints or similar means. A further embodiment employs a ring-shaped friction-lining carrier that may form an axial plug-in connection by virtue of an appropriately shaped lateral portion. In case the friction-lining carrier has a form-fitting engagement with the input member of the damper, e.g., by means of internal teeth at its inside perimeter and, e.g., an axially oriented profile on the lateral part of the input member. The advantages of axial plug-in connections in accordance with the invention are that they compensate for axial displacements and facilitate the manufacturing process by virtue of a modular configuration, because systems of this kind can be built by plug-in assembly without further resort to fastening undertakings such as, e.g., welding or riveting, thus allowing the use of work stations that are not equipped with the respective infrastructure.
Further advantageous embodiments of axial plug-in connections between components of the damper and components of the turbine will be described hereinafter. An advantageous configuration has two components of the two units to be connected meeting each other approximately at a right angle, i.e., in the form of a radially and an axially extending flange, respectively, with the two parts in a form-fitting engagement. In this, it may be advantageous to provide the radially extending flange with external teeth and the axially extending flange with axially oriented teeth.
It may also be advantageous if a radially extending flange-like part has closed cutouts, distributed along a circle of smaller radius than the outside perimeter, that are engaged by axially directed extremities of the axially extending flange-like part.
A preferred embodiment may be a radially oriented flange-like part that, starting at its inside perimeter, follows the shape of the turbine shell outwards in the radial direction and is attached in this portion, e.g., welded or riveted. From there, the flange-like part bends into the radial direction and has a toothed profile along its exterior circumference that is engaged by the lateral part of the input member of the damper. For this purpose, the lateral part at its exterior circumference bends into the axial direction and forms the axially directed flange-like part that carries, e.g., the axially oriented toothed profile.
A further advantageous embodiment may include a flange-like part in the shape of an annular disk that adjoins along its inside perimeter the turbine shell and conforms to the shape of the turbine shell towards the inside in the radial direction, is attached to the shape-conforming portion as described above and then curves into the axial direction. The profile facing away from the turbine shell in axial direction, e.g., a toothed profile, engages in closed recesses distributed over the circumference of a radially directed lateral part and in this manner forms an axial plug-in connection. To form this plug-in connection, it may be necessary for the axially directed toothed profile to pass through the output member before engaging the input member of the damper, given that the output member is interposed axially between the turbine and the input member. For this purpose, the output member has a circular arrangement of elongated holes matching the number of teeth. The angular width of the holes corresponds to the maximum angular displacement of the input and output members relative to each other so that at the same time the elongated holes in combination with the axially directed teeth of the axially oriented flange-like part that is connected to the turbine form at least one stop for the angular displacement of the damper.
In an advantageous arrangement, the axially extending flange-like part can itself be in the form of a hub that carries the turbine, the latter being connected to the hub by, e.g., welding or riveting. The hub carrying the turbine, in turn, can be seated on a further hub that performs the function of the rotary output element and is attached to the transmission shaft. The axially extending flange-like part has a profile established, e.g., by axially oriented teeth that extend into enclosed cutouts corresponding to the number of teeth in the flange whereby an axial plug-in connection is formed. Depending on the configuration of the damper, it may be necessary with this embodiment, too (as described above) , to provide in the output member an appropriate arrangement of elongated holes which, in combination with the axially directed profile of the axially oriented flange for the axial plug-in connection, can function as stops for the relative displacement between the input and output members of the damper. The output member, being a radial extension of the hub that is attached to the transmission shaft, may also be configured as a separate flange-like part, in which case the flange needs to be centered on the hub and attached through a rotationally fixed connection.
It can further be advantageous if an annular disk in the form of a radially extending flange-like part with an exterior profile, e.g., an arrangement of external teeth, is centered on the hub that carries the turbine. By attachment means such as, e.g., rivets, the annular disk is rotationally tied to the turbine, and its outward-pointing teeth, mentioned above by way of an example, engage a lateral part that is bent in the axial direction along the interior perimeter and (also by way of example) has a complementary, axially directed toothed profile. In this case, too, a connection is established that constrains rotational but allows translational displacement of the engaged parts relative to each other. The angular displacement of the damper may advantageously be defined by means of a toothed profile with play between the respective tooth flanks of the hub and the annular disk. The outward-facing profile of the hub may also be engaged by the inward-facing profile of the output member, albeit without play at the flanks, in order to secure the output member for rotation with the hub. This has the advantage of saving space in the axial direction of the hub, given that the relative axial displacement occurring between the damper and the turbine as a result of the axial movement of the control piston is already compensated for by the axial plug-in connection.
The axial plug-in connection between the damper and the turbine in different practical variations may be arranged, e.g., at a radial distance beyond the energy-storing devices, at an intermediate radius between the storage devices in the case of at least two damper stages, or inside the radial distance of the storage devices.
Other embodiments of the invention concern the advantageous design of the damper. The damper may be of the single-stage or multi-stage type. A dual-stage damper may be configured in such a way that the damper stages can function in a serial or parallel mode, with the additional possibility of different limits of rotation so that, e.g., in a serial arrangement of the damper stages the relative rotation of one stage is stopped before the other stage, e.g., for the purpose of achieving particular damping characteristics.
In connection with the damper, it is also advantageous to combine different energy-storing devices, e.g., by selecting arc-shaped springs in a radially exterior damper stage, and short, stiff spring elements for use in smaller-diameter areas so that, e.g., a damper characteristic can be achieved that provides a high amount of energy to compensate for both large-amplitude rotational irregularities at low RPM and small-amplitude rotational irregularities at high RPM. In this kind of an arrangement, the arc-shaped springs in the radially exterior area may be pre-bent to their working diameter and are retained radially by a chamber that is formed by at least one lateral part or by other components of the damper or of the torque-transmitting apparatus, e.g., by the wall of the housing. In addition, there may be wear-reducing components such as wear-protection shells interposed between the arc-shaped springs and the chamber, with the characteristic of the arc-shaped spring being determined by all of the aforementioned factors.
It can be advantageous to provide the individual damper stages with displacement properties that depend on the direction from which the torque is introduced. Thus, the damper system may be designed to function in two stages in the “pull” mode and in one stage in the “push” mode. In this manner, the damper characteristic may be adapted to the possibility of hard transient peaks in the torque-flow that are introduced from the “push” side, i.e., from the input shaft of the transmission, in which case, e.g., the soft damper stage is bypassed completely and the firm damper stage is effective instantly. The bypass can be accomplished by means of limit stops that block angular displacement against the drive direction in the input and output members of the damper stage that is inactive in the push mode.
It is advantageous to accommodate the storage devices in disk-shaped parts that have dimensionally matched recesses into which the storage devices are fitted and which may at their ends have force-introduction elements facing against the direction of the restoring force. The force-introduction elements retain and thereby compress the storage devices when the input and output members are displaced in relation to each other. The disk-shaped parts forming the input and output members may be arranged in such a manner that either the input or output member is formed by two mutually connected lateral parts, while the other of the two members is formed by a corresponding disk-shaped, flange-like part arranged between the two lateral parts. A further embodiment that brings cost advantages has two disk-shaped parts, one representing a lateral part serving as input member and the other representing a lateral part serving as output member. In two-stage dampers, it can further be cost-effective to use a common disk-shaped part working with both damper stages.
Further in the interest of optimizing cost, the disk-shaped parts may take or additional functions. For example, as mentioned already, one or more disk-shaped parts may form a chamber for the energy-storing devices, or they may contain the axial plug-in connection between the damper and the turbine, and/or they may perform other functions.
It is further advantageous for cost-optimization if disk-shaped parts and different other components are made of one piece. Thus, e.g., the output member of the damper together with the rotary output element (e.g., the hub that is arranged on the transmission shaft), or the output member together with the hub that carries the turbine, may be made of one piece.
An advantageous and cost-effective embodiment of means for limiting the extent of angular displacement avoids the need for special stops. For this purpose, a circular arrangement of elongated holes may be provided on at least one disk-shaped part, where the fasteners (e.g., rivets) that are in any case already provided pass through the holes and are held on the opposite side by another disk-shaped part and/or by means of a sheet metal holder. The angular width of the elongated holes is preferably selected so that the extent of relative angular displacement between the input member and the output member is limited by the ends of the elongated holes stopping the shafts of the fasteners.
It is advantageous to provide displacement-limiting stops insofar as a damper or either some or all of the damper stages can be bypassed, so that the damper or the damper stages can be protected from wear. This may apply particularly in the case of wear-prone versions with storage devices that, e.g., contain arc-shaped springs, permit large angular displacements, and/or are exposed to strong shock loads. To guard against premature failure, it is advantageous if initially one damper stage is totally bypassed by means of displacement-limiting stops, while the second stage is either not bypassed at all or only at a later point. When a damper or a damper stage reaches its limit stop, the torque that previously entered into the energy-storing device is transmitted through the stop directly to the output member of the bypassed damper or damper stage. It may also be advantageous to provide different angular displacement limits in the damper device and its damper stages depending on the direction off the torque, i.e., whether the torque works in the pull or push direction, respectively. Thus, it may be advantageous, for example, to provide limit stops in such a manner that a damper stage is entirely bypassed in the costing mode. Likewise, there may be advantages to a configuration in which, e.g., one damper stage works only in the coasting direction while the other stage works only in the pull direction.
The novel features that are considered as characteristic of the invention are set forth in particular in the appended claims. The improved apparatus itself, however, both as to its construction and its mode of operation, together with additional features and advantages thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary sectional view of a novel torque-transmitting apparatus with a two-stage damper.
FIG. 2 is a fragmentary sectional view of a further embodiment of a torque-transmitting apparatus with an axial plug-in connection located at a radial position between the energy-storing devices of two damper stages.
FIG. 3 is a fragmentary sectional view of an embodiment of the invention with axially directed projections formed on the hub.
FIG. 4 is a partial view of a disk-shaped part of a damper.
FIG. 5 is a fragmentary sectional view of an embodiment of a damper.
FIG. 6 represents a fragmentary view of another embodiment of a damper.
FIG. 7 is a fragmentary axial sectional view of an embodiment of a torque-transmitting apparatus with a single-stage damper.
FIG. 8 is a fragmentary axial sectional view of an embodiment of a torque-transmitting apparatus with a two-stage damper and a two-part hub.
FIGS. 9-12 are fragmentary sectional views of further embodiments of two-part turbine dampers.
FIG. 13 represents an embodiment with a damper docked fixedly to the turbine shell.
FIG. 14 represents a modified version of the damper of the embodiment of FIG. 13 .
FIG. 15 represents a detail of an embodiment comprising a damper that is docked fixedly to the turbine shell.
FIG. 16 represents an embodiment of a torque-transmitting apparatus comprising a damper that is docked fixedly to the turbine shell.
FIG. 17 represents a hub of the embodiment of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
The torque-transmitting apparatus 1 shown in FIG. 1 has a housing 2 confining a torque converter 3 . The housing 2 is connected to a driving shaft that can constitute the output shaft of a prime mover such as, e.g., the crankshaft of a combustion engine. As is known, the housing 2 is constrained to rotate with the shaft by a sheet metal disk that is connected at an inner radius with the driving shaft and at an outer radius with the housing.
The housing 2 comprises a shell 4 adjoining the driving shaft or the combustion engine and a further shell 5 axially distant from the driving shaft and attached to the housing shell 4 by means of a weld 2 a. The two housing shells 4 and 5 are connected and sealed at their radially outer portions by a welded connection 6 . In the illustrated embodiment, the housing shell 5 simultaneously serves as the outer shell of the pump 7 . This is accomplished by connecting the vane portions 8 to the housing shell 5 in a manner known as per se. A turbine 10 is interposed axially between the pump 7 and the radially extending wall 9 of the housing shell 4 . A stator 11 is provided between the radially interior portions of the pump 7 and the turbine 10 .
Furthermore, the internal space 12 enclosed by the housing shells 4 , 5 contains a torque-elastic damper 13 that establishes torque-elastic connection between the output hub 14 and a driving part. In the illustrated embodiment, the driving part is formed by the housing shell 4 in the case where the lockup clutch 15 is engaged or operates with slip. When the lockup clutch 15 is disengaged or slipping, the driving part is formed by the turbine 10 . The converter lockup clutch 15 is arranged in series with the damper 13 .
The hub 14 representing the rotary output element of the torque-transmitting apparatus 1 can be coupled through an interior toothed profile 16 to an input shaft (not shown) of a transmission. The turbine 10 is rotatable within a limited angular range relative to the rotary output element, i.e., the hub 14 , against the opposition of the damper. In the case of a damper based on the principle of shear flow of a hydraulic medium, while the relative rotation between the turbine 10 and the output element 14 would still be damped, the angle of relative rotation would be unrestricted.
The output hub or rotary output element 14 is non-rotatably connected e.g., welded or caulked, to the flange-like output member 17 of the torque-elastic damper 13 . The input member 18 of the torque-elastic damper 13 is at its outer perimeter bent in the axial direction towards the turbine and forms an axially oriented flange-like part 19 with a rim of axially directed teeth 20 . At its interior perimeter the input member 18 is bent in the axial direction towards the housing shell 4 and has a rim of axially directed teeth 21 so that the input member 18 transmits the torque flow through form-locking connections to the lockup clutch 13 and the turbine 10 by means of the toothed rims 20 , 21 . For this purpose, a radially oriented flange-like part 22 is attached to the turbine 10 by a weld 24 along its inner perimeter to the outside of the turbine shell 23 . The flange-like part 22 along its outside perimeter has a toothed rim 26 and thereby forms an axial plug-in connection 78 to the input member 18 of the damper 13 .
Input member 18 and output member 17 in the axial space between them enclose a flange-like intermediate part 27 which simultaneously constitutes the output member of the first damper stage 28 a and the input member of the second damper stage 28 b. Input member 18 , output member 17 , and intermediate part 27 are equipped in an essentially known manner with windows for holding the energy-storing devices in the form of coil springs 29 , 30 for the two damper stages 28 a, 28 b.
In the axial direction, input member 18 is connected to an intermediate part 27 , and the intermediate part 27 is connected to the output member 17 by means of fasteners, here in the form of rivets 31 , 32 . The given range of play by which the parts can rotate relative to each other is limited by the rivets passing through elongated perforations 33 , 34 that are arranged along a circle on the input member 18 and on the intermediate part 27 , forming stops limiting the extent of travel of the rivets within the holes. As axial retainers for the rivets 31 , 32 , ring-shaped membranes 35 , 36 are provided on the side of the perforations 33 , 34 . The axial spacing of the input member 18 from the intermediate part 27 and of the intermediate part 27 from the output member 17 is provided by energy-storing devices working in the axial direction between the respective parts, represented in this embodiment by plate springs 44 , 45 .
The input member 18 at its interior perimeter has a profile shape designed to accommodate the energy-storing devices 30 so as to make optimum use of the available axial space, then turning into the axial direction to form an axially oriented flange-like part 37 with a rim of axially directed teeth 21 , where the input member 18 meets the exterior toothed rim 39 of a friction-lining carrier 38 in a form-locking engagement. The friction-lining carrier 38 is centered on a shoulder 41 by means of lugs 40 bent into the axial direction towards the control piston 43 and is faced on both sides with friction linings 42 along its outer perimeter. The friction-lining carrier 38 is interposed in the axial direction between the control piston 43 and the annular disk 46 . The latter is attached in a rotation-blocking connection to the housing shell 4 , which in the respective area extends in the radial direction. Fastener means such as the impulse weld 48 of the present example are used for the connection. The annular disk 46 has cut-outs 47 distributed along a circle that serve to promote circulation and cooling of the chamber 49 that is formed between the annular disk 46 , the control piston 43 and the friction-lining carrier 38 . The annular disk is centered on the housing 2 by means of projections 57 arranged in a circle of the housing shell 4 .
The axial displacement of the control piston 43 effects the slipping engagement, full engagement and disengagement of the lockup clutch 15 . The control piston is actuated by the pressure differential in the chamber 50 that is located in the axial direction between the control piston 43 and the housing shell 4 and is supplied from a pressure pump (not shown) with a pressure medium entering through a channel 51 from the radially interior direction. To seal off the chamber 50 , the control piston 43 is equipped along its inner and outer perimeter with sealing means 51 a, 52 . Also, in order to improve guidance and to prevent canting and thereby jamming of the control piston, the latter is bent into the axial direction at one perimeter, such as at the interior perimeter in the present embodiment. To avoid slippage at the sealing means of the piston 43 , the latter has a form-locking engagement with the housing 2 through an axially oriented profile 54 which in the present embodiment consists of alternating ring segment-like recesses 53 and projections 55 that are distributed over the circumference and are engaged by the complementary-shaped profile 56 of the housing shell 4 .
The embodiment of FIG. 1 illustrates the function of the torque-transmitting apparatus 1 as follows: When the lockup clutch is open, the torque is transmitted by the pump 7 driving the turbine 10 , assisted in known manner by the free-wheeling stator 11 , through the converter medium that fills the interior space 12 to the flange-like part 22 from where the torque is introduced through an axial plug-in connection formed by the engagement of toothed rims 20 , 26 into the input member 19 of the damper 13 . When the lockup clutch 15 is closed, the torque-flow path runs through the form-locking engagement of the mutually complementary profiles 54 , 56 as well as through the annular disk 46 that is connected to the housing 2 . Through the friction engagement of the control piston 43 and the annular disk 46 with the friction linings 42 , the torque is introduced into the friction-lining carrier 38 which, by means of the axial plug-in connection with toothed rims 21 , 40 , transmits the torque to the input member 18 . Continuing from the input member 18 , the torque flow is smoothed in the damper 13 by means of energy-storing devices 29 , 30 . The angular displacement of both damper stages 28 a, 28 b is bounded by limit stops 33 , 34 and matched to the characteristics and properties of the energy-storing devices 29 , 30 . If a friction component is needed in the damper 13 , i.e., in the damper stages 28 a, 28 b, the energy-storing devices 44 , 45 are designed independently of each other in such a manner that a frictional engagement occurs for the first damper stage 28 a between the securing membranes 31 , 36 and the input member 17 and/or for the second damper stage 28 b between the securing membranes 35 , 36 and the intermediate part 27 . the output member 17 of the damper 13 transmits the torque to the hub 14 representing the rotary output element of the torque-transmitting apparatus 1 , from where the torque is introduced into the transmission shaft.
FIG. 2 shows an inventive torque-transmitting apparatus 101 of similar configuration as the torque-transmitting apparatus 1 , but with a modified damper 113 . The pump 107 , stator 111 , turbine 110 , the overall construction, function and arrangement of the lockup clutch 115 are provided in similar manner as has been described in connection with FIG. 1 .
The axial plug-in connection 178 in this embodiment is formed by the flange-like part 122 , which is engaged without play in recesses 120 that are distributed over the circumference of the input member 118 . At its interior perimeter, the flange-like part 122 is connected to the shell 123 of the turbine 10 —by a weld 124 in the illustrated example. Subsequently, the flange-like part 122 conforms to the shape of the turbine shell at a radial distance, then turns into the axial direction towards damper 113 , where its rim of axially oriented teeth 126 engages the openings 120 of the input member 118 . The toothed engagement cccurs at a radius inside the first damper stage 128 a and outside the second damper stage 128 b where the flange-like part 122 runs in the axial direction and passes through elongated perforations 133 ) formed along a circle on the intermediate part 117 that is provided as output member of the first damper stage 128 a. Simultaneously, the flange-like part 122 forms the limiting stops for the relative angular displacement between the input member 118 and the intermediate part 117 within the angular range that is delimited by the perforations 133 . Thus, the energy-storing devices 129 are bypassed in the case of large angular displacements and are protected against the possibility of harmful effects from high transient peaks in the torque-flow. In this embodiment, the energy-storing devices of the first, radially exterior damper stage 128 a are formed in a known manner as arc-shaped springs 129 that are accommodated and retained at their outside radius by a chamber 118 b formed by the peripheral portion of the input member 118 that is bent into the axial direction towards the turbine 110 and by an additional lateral part 118 a enclosing the arc-shaped springs on the side facing the turbine 110 . The chamber 118 b has provisions for applying a force in the longitudinal direction of the springs in the shape of protrusions 118 c of the input member 118 and the lateral part 118 a, and wear-protection shells may be interposed between the inside wall at the circumference of the chamber 118 b and the arc-shaped springs 129 . The intermediate part 127 representing the output member of the first damper stage 128 a is arranged between the input member 118 and the lateral part 118 a (relative to the axial direction) and is equipped with a radially arranged extremities 127 a along its outside perimeter. A further radially extending flange-like part 127 b is connected to the intermediate part 127 through fasteners such as the rivets 131 shown in the present embodiment. With openings 130 a formed in a known manner, the flange-like part together with the intermediate part 127 holds the energy-storing devices of the second damper stage 128 b, in this embodiment represented by short, stiff helix springs 130 distributed evenly along a circle. On the output side, the force introduction into the springs is accomplished with the output member 117 that is interposed in the axial direction between the intermediate part 127 and the flange-like part 127 b with openings 117 a corresponding to the dimensions of the helix springs 130 that in the present embodiment consist of sets of helix springs nested inside each other. At its outer perimeter, the output member 117 has extremities 117 b that are directed outwards in the radial direction and engage openings 127 c in the flange-like part 127 b with play, thus allowing the intended range of angular displacement for the second damper stage 128 b and providing limit stops so that the second damper stage 128 b will be bypassed when the angular displacement of the extremities 117 b within the openings 127 c has reached the limit.
By the interposition of energy-storing devices—in this case plate springs 144 , 145 —the respective input and output members 118 , 127 of the first damper stage 128 a and 127 , 117 of the second damper stage 128 b are spaced apart from each other, and through appropriate selection of the spring constants of the plate springs 144 , 145 , it is possible to achieve a desired amount of frictional torque at the friction surfaces 144 a, 145 a.
In the present embodiment, the output member 117 and the output element 114 with the interior toothed profile 116 for the torque-transmitting connection to the transmission shaft (not shown) are formed as one integral part.
FIG. 3 illustrates an embodiment of a similar torque-transmitting apparatus 201 similar to the torque-transmitting apparatuses 1 and 101 with a housing 202 that also contains a torque converter 203 . The pump 208 and the stator 211 are configured and arranged in the same manner as has been described in the context of FIG. 1 .
The turbine 210 is spaced apart from the stator 211 by means of a roller bearing 211 a and is connected to a hub 210 a by means of a weld 210 b made, e.g., by impulse welding. The hub 210 a is centered on a projection 214 b of the hub 214 extending axially towards the stator 211 . The hub 214 represents the output element of the torque-transmitting apparatus 201 and has an interior toothed profile 216 for a form-locking engagement with the outward-facing profile of a transmission shaft 272 . For optimum use of space in the axial dimension, the projection 214 b surrounds the outside of the stationary sleeve 270 that supports the stator 211 through a free-wheeling hub 271 . In the axial direction, the hub 210 a is held in place on the projection 214 b by a retaining ring 214 a. To limit the relative angular displacement between the turbine 210 and the hub 214 , i.e., the working range of the damper 213 , the hub 210 a has axially directed bolts 273 engaged with the required amount of rotational play in openings 274 of the hub 214 , the latter representing at the same time the output member 217 of the damper 213 .
To accommodate the control piston 243 of the lockup clutch 215 , a further hub 275 is slidably supported on the transmission shaft and rotatable relative to the hub 214 by means of a roller bearing 275 a retaining the hub 275 engaged with the housing 202 . In first axially and then radially outwards directed wall portions 202 a, 202 b of the housing 202 , axial and radial toothed profiles are, respectively, arranged for a form-locking engagement with complementary toothed profiles 275 b on the hub 275 . On the axially extending circumference of the hub 275 , a seal 251 is provided for sealing the piston 243 .
Located at a farther radius, the piston 243 has ridges 243 a running in a circle and projecting axially towards the friction-lining carriers 238 . When the piston 243 is displaced in the axial direction, the ridges 243 a bear against the clutch disks 238 a and the friction-lining carriers 238 that are faced on both sides with friction linings 242 , resulting in slipping engagement, full engagement, and disengagement of the lockup clutch 215 . The axial displacement of the piston 243 is energized by the application of pressure differentials of a pressure medium entering through a channel (not shown) into the tightly sealed chamber 250 that is formed by the piston 243 a where the sealing interface between the outer circumference of the piston 243 and the housing 204 is formed by a seal 252 .
The clutch disks 238 a and an additional annular disk 277 that serves as take-up surface against the clutch force are at their exterior circumference engaged by a rotation-blocking toothed profile and secured axially by a retaining ring 276 a in the exterior disk holder 276 that is welded to the housing 204 . The friction-lining carriers 238 are held at their inside perimeter in the interior disk holder 218 e by a rotation-blocking toothed profile. Consequently, when there is friction engagement between the clutch disks 238 a and the friction linings 242 , a torque-locked connection is established between the housing 202 and the interior disk holder 218 e, whereby the latter imparts the applied torque to the input member 218 . For this purpose, the inner disk holder is shaped as a ring of approximately rectangular cross-sectional profile. The portion of the disk holder that is running in the axial direction towards the housing 204 supports the friction-lining carriers 238 , while the second portion, extending outwards in the radial direction, is attached to a radially directed portion of the input member 218 in a non-rotatable connection by means of fasteners such as the rivets 231 that are arranged along a circle in the illustrated example.
As has been described, the input member 218 of the damper 213 takes up the applied torque in the case where the lockup clutch 215 is closed or at least partially engaged. When the lockup clutch 215 is open as well as when it is slipping, the torque (or a portion of the torque when the lockup clutch 215 is slipping) is passed on from the turbine 210 through an axial plug-in connection 278 to the input member 218 in the same manner as was described in the context of FIG. 1, but using the arrangement and functional concept of FIG. 2, where the input member 218 together with the lateral part 218 a forms a chamber 218 b to accommodate the arc-shaped springs 229 with the wear-protection shells 218 d inserted at the contact surfaces. In order to form the axial plug-in connection 278 , the axially directed portion of the input member 218 is extended at the outer circumference towards the turbine in such a manner that its axially directed toothed rim 226 can engage the outward-pointing toothed rim 220 of the radially directed flange-like part 222 that is attached to the turbine.
Input member 218 and lateral part 218 a are connected by means of fasteners represented in the present embodiment by the rivets 231 with spacer bolts 231 a to hold them at a fixed distance from each other. Arranged in the space extending in the axial direction between input member 218 and lateral part 218 a is the intermediate part 227 in the shape of a disk-shaped part 227 serving as output member of the first damper stage 228 a and as input member of the second damper stage 228 b. The detail configuration of the disk-shaped part 227 is illustrated in a partial view of FIG. 4 .
The FIGS. 3 and 4 show a disk-shaped part 227 with radially directed extremities 227 a arranged at the exterior circumference and serving as force-introduction elements for the arc-shaped springs (FIG. 3 ). Distributed along a circle of smaller radius in the disk-shaped part are elongated openings 233 through which the rivets 231 pass, permitting relative rotation between the input member and the output member of the first damper stage 228 a within a limited angular range. As soon as the rivets 231 reach the borders of the cutouts 233 , the first damper stage 228 a is bypassed and the applied torque is transmitted through the contact points between the rivets 231 and the cutouts 233 , whereby the arc-shaped springs are protected against greater amounts of torque and angular displacement. The rest position of the rivets 231 in the illustrated embodiment is not centered within the cutouts 233 (seen in the circumferential direction), meaning that the range of angular displacement is not equal in both directions but is smaller in the “push” direction than in the “pull” direction. In an inventive embodiment not shown in the drawing, the rivets 231 can be in direct contact with the border 233 a of the elongated openings 233 so that this damper stage is being bypassed immediately in the push direction without an angular displacement, thus providing a damper with one active stage in the push direction and two active stages in the pull direction. Distributed over another yet smaller circle in the disk-shaped part are further openings 227 b to hold the energy-storing devices in the form of short helix springs 230 nested inside each other (FIG. 3 ). At their radius, the openings 227 b have flaps 230 a that are bent towards the lockup clutch 215 to secure the helix springs 230 in the axial direction. By means of the rivets 232 passing through holes 227 c (FIG. 4) distributed along a circle of intermediate radius between the openings 233 , 227 b, the disk-shaped part 227 is connected to a further flange-like part ( 227 b ) that has openings with flaps ( 227 c ) bent axially towards the turbine to accommodate the helix springs 230 . The flange-like part ( 227 c ) is formed into the shape of a cup extending in the axial direction to provide space in the axial dimension between the intermediate part 227 and the flange-like part ( 227 b ) to accommodate the hub 214 . The hub 214 is extended radially into a disk shape to serve as output member 217 of the damper 213 and thus of the second damper stage 228 b. To provide space for and couple a force to the helix spring 230 , the output member 217 has openings 217 a distributed along a circle so that the hub 217 is rotatable relative to the intermediate part 227 against the restoring force of the helix springs 230 . This produces the damping effect of the second damper stage 228 b wherein the range of angular displacement is limited by the play of the bolts 273 in the openings 274 .
The input member 218 and the output member 227 of the first damper stage 228 a as well as the input member 227 and the output member 217 of the second damper stage 228 b are elastically clamped against each other by the action of the interposed plate springs 244 , 245 . Thus, with an appropriate selection of the spring characteristic, a friction effect of a desired magnitude can be generated between the respective input and output members 218 , 227 and 227 , 217 at the friction surfaces 244 a, 245 a, where the friction surface 245 a is provided by a series of projections distributed along a circle on the lateral part 218 a.
FIG.5 illustrates an embodiment of a damper 313 in single-stage configuration. The torque to be transmitted is introduced into the damper 313 through the two lateral parts 318 a, 318 b that form the input member 318 . The contributions to the torque coming from the lockup clutch 315 are introduced into the damper 313 through the toothed rim 321 of the lateral part 318 a of the input member 318 . The contributions to the torque coming from the turbine 310 are introduced through the inventive plug-in connection 378 into the input member 318 , represented by its lateral part 318 b. In addition, a disk-shaped part 322 is connected by means of rivets 332 with the turbine 310 , with the hub 314 (that represents the output element and is connected to the transmission shaft 372 through a toothed profile 316 ) and with the output member 317 . The spacer bolts 332 a are provided to allow an angular displacement of the output member 317 relative to the turbine 310 , hub 314 and lateral part 322 within a range that is delimited by the borders of elongated openings 334 . The disk-shaped part 322 is engaged in a toothed exterior profile 314 a of the hub 314 without play. At its outer circumference, the disk-shaped part 322 has an exterior toothed rim 326 that forms the play-free plug-in connection 378 . Also engaged in the toothed exterior profile 314 a of the hub 314 is the output member 317 of the damper 313 , which has a toothed inner perimeter 317 a with an amount of play between the opposing tooth flanks that determines the range of relative angular displacement between the input member and the output member in opposition to the restoring torque of the energy-storing devices 329 . It should be noted, however, that the openings 334 and the elongated further openings 333 that are located farther out in the radial direction on the output member 317 will permit a larger amount of angular displacement. Nevertheless, it is conceivable in principle that the maximum amount of angular displacement is determined by any one of the three elements 317 a, 333 , 334 .
The energy-storing devices 329 have the shape of arc-shaped springs 329 . The configuration of the chamber 318 c that accommodates the arc-shaped springs 329 as well as the arrangement and function of the force-introducing elements have been described previously in the context of FIGS. 2 and 3.
The lateral parts 318 a, 318 b are connected in the axial direction by means of rivets 331 and spacer bolts 331 a and are held at a suitable distance from each other to allow the output member 317 to be arranged within the axial space between them. Interposed between the lateral part 318 a and the output member 317 is a plate spring whose axial thrust determines the intensity of the frictional engagement between the output member 317 and a circular ridge 318 d formed on the lateral part 318 b.
FIG. 6 illustrates a further embodiment of a two-stage damper 413 of the kind that was described in the context of FIG. 3, except for the following distinguishing features: The turbine 410 is supported in a manner permitting relative rotation directly by the hub 414 that forms the output element; it is centered on a shoulder 414 b provided for this purpose and secured in the axial direction by a retaining ring. Thus the hub 210 a shown in FIG. 3 can be omitted. The bolts 473 delimiting the maximum angular displacement between output member 417 and output member 418 are distributed along a circle and configured to protrude directly from the hub 414 into the axial direction, engaging the input member 418 through elongated openings 474 that provide the limiting stops. For the form-locking engagement with the lockup clutch (not shown), a ring 418 e of rectangular profile is attached to the input member 418 by means of rivets ( 231 ) that are arranged along a circle. The radially directed portion of the ring 418 e is riveted to the input member 418 , while the axially directed portion provides the form-locking engagement with the lockup clutch by means of an axially directed profile.
FIG. 7 illustrates a further inventive embodiment of a torque-transmitting apparatus 501 with a single-stage damper 513 and a modified lockup clutch 515 .
The control piston 543 of the lockup clutch 515 , which is axially displaceable, sealed and centered on the transmission shaft 572 , carries a friction lining 542 along its radially exterior peripheral area on the side that is facing the friction surface 504 a on the housing 504 . When the clutch is closed or slipping, the friction lining 542 is frictionally engaged with the friction surface 504 a of the housing 504 and thereby introduces the torque to the input member 518 consisting of lateral parts 518 a and 518 b.
At a point between the housing 504 and the piston 543 , converter fluid is suctioned off through an outlet channel (not shown), whereby an under pressure is generated relative to the converter chamber 512 , resulting in an axial displacement of the piston 543 , thus providing the capability of controlling the slipping engagement, closing and opening of the lockup clutch 515 . The friction engagement between the friction surface 504 a and the friction linings 542 can be controlled so that the lockup clutch 515 slips while the friction linings 542 are being cooled by the passing flow of the converter medium. However, it is also possible to engage the lockup clutch without slippage. The friction surface 504 a and the control piston 543 are cone-shaped in the vicinity of the friction engagement, so that the closure and friction engagement of the lockup clutch are enhanced by the effect of the centrifugal force.
In a circular area of smaller radius than the friction linings 542 , the piston 543 has protuberances 543 a projecting in the axial direction towards the input member 518 where the piston 543 is connected to the lateral parts 518 a and 518 b by means of bolts 543 b in a manner permitting axial but blocking rotational movement of the piston in relation to the input member 518 . The two lateral parts 518 a, 518 b are riveted together at their outer circumference (rivets not shown) , while the bolts 543 b are inserted into cutouts 518 c on the lateral parts 518 a, 518 b that are open at the outer perimeter and thereby permit an axial play between the piston 543 and the input member 518 . The purpose is to prevent negative effects on the axial mobility of the piston 543 from stresses that occur during the engagement and disengagement of the lockup clutch between the piston 543 and the already torque-loaded input member 518 .
The torque introduction through the turbine 510 occurs by means of a turbine hub 510 a that is centered on the hub 514 representing the output element. The turbine hub 510 a is fixedly attached to the turbine 510 and has axially directed projections 573 distributed along its outer perimeter that are engaged without play—in order to avoid a one-sided introduction of torque—in openings of both lateral parts 518 a, 518 , thereby forming the inventive plug-in connection 578 between the turbine 510 and the input member 518 .
The disk-shaped output member 517 that is formed out of the hub 514 , together with the input member 518 and the energy-storing devices in the form of nested helix springs 530 , represent an essentially known damper device 513 . A series of openings ( 574 ) is distributed along a circle on the output member 517 . The projections 573 of the turbine hub 510 a pass through the openings ( 574 ) and stop the relative angular displacement between the input and output members 518 , 517 against the restoring torque of the energy-storing devices 530 as soon as the projections 573 run against the borders of the openings ( 574 ).
FIG. 8 illustrates a further possible configuration of a damper device 613 of the inventive torque-transmitting apparatus. In contrast to the damper devices described above, the hub 614 is composed off two hub components 614 a, 614 b. The hub component 614 a is mounted on the transmission shaft 672 in play-free and rotation-blocking connection. The hub component 614 b is supported and aligned on a shoulder 614 d arranged axially on the hub component 614 a on the side towards the transmission. The hub component 614 b is secured axially by means of a retaining ring 614 c. The turbine 610 is firmly connected with the hub component 614 b, e.g., by welding or keying. To form a meshing engagement with play between the first and second hub components 614 a, 614 b, the second hub component 614 b has axially directed projections 673 distributed along its circumference, which engage openings 674 of the hub component 614 a. The dimension of the openings 674 in the circumferential direction is such that the projections 673 in concert with the openings 674 permit a desired amount of relative angular displacement between the turbine 610 and the hub component 614 a, with the damper 613 being interposed between them. The output member 617 of the damper device 613 is arranged axially between the two hub components 614 a, 614 b, centered on the hub component 614 a and rotationally tied to it by means of the eyed connection 614 e. The output member 617 rests against the hub component 614 a along a series of projections distributed on a circle or a circular ridge 614 f protruding in the axial direction. At locations that correspond to the openings 674 , the flange-like output member 617 of the damper device 613 has openings 675 that are engaged by the projections 673 of the hub component 614 b. It is advantageous if the openings 675 are wider in the circumferential direction than the openings 674 , so that the limits of angular play are determined by the openings 674 . This prevents the torque from entering the hub component 614 a through the keyed connection 614 e, so that the latter does not have to be dimensioned for the torque loads that would occur in that case. The function of the further components of the damper device 613 is otherwise comparable with the other damper devices that have been described above.
The FIGS. 9-12 show partial sectional views of embodiments of dampers 713 a-d that are similar to the damper 213 of FIG. 3 . The dampers 713 a-d differ from the damper 213 and in part among each other in the different configuration of the input member 718 a-d and the output member 717 .
In contrast to the hub 214 and the output member 217 being configured together as one piece as in FIG. 3, the dampers 713 a-d of FIGS. 9-12 have output members 717 and hubs 714 in a two-piece configuration, in which the output members 717 are sheet metal stampings attached to and centered on the hub 714 in a rotation-blocking connection, e.g., by shrink-fitting. To accommodate the energy-storing devices of the second damper stage, the disk-shaped output members 717 have window-shaped openings 717 a distributed along a circle. The disk-shaped output members 717 limit the angular displacement of the second damper stage by means of radially directed extremities 717 b distributed along the circumference, which are engaged with the required amount of angular play in corresponding openings of the disk-shaped part 727 b that serves as input member of the second damper stage.
In the dampers 713 a, 713 c of the FIGS. 9 and 11, respectively, the input members 718 a, 718 c of the damper that transmit an applied torque from the converter lockup clutch 715 and/or from the turbine 710 to the damper 713 a, 713 c are of single-piece configuration, i.e., they have at their inner circumference an axially directed extension 778 a, 778 c with a profile 780 a, 780 b for a rotation-blocking engagement of the disks 742 a, 742 b. The profile 780 a (FIG. 9) is impressed into the exterior circumference of the extension 778 a, while the profile 780 c (FIG. 11) is formed by axially oriented openings distributed over the circumference of the extension 778 c for a rotation-blocking engagement of the correspondingly profiled disks 742 b.
The dampers 713 b, 713 d of FIGS. 10, 12 have an input member 718 b, 718 d firmly connected, preferably riveted as shown here, to the flange-like part 778 b, 778 d of L-shaped cross-section. The flange-like parts 778 b, 778 d have profiles 780 b, 780 d corresponding to the extensions 778 a, 778 c of FIGS. 9, 11 for a rotation-blocking connection with the disks 742 a, 742 b of the converter lockup clutch 715 .
FIG. 13 represents a cross-sectional view of an embodiment of a torque-transmitting apparatus 801 . Its damper 813 , shown here in a two-stage configuration working in serial mode, is at its outer perimeter solidly connected and thereby axially constrained to the turbine 810 . At its inner perimeter, the damper 813 has an axially displaceable but non-rotatable connection to the hub 814 .
The damper 813 is attached to the turbine shell 823 by means of a weld seam or spot welds 822 a using essentially known welding methods such as, e.g., induction welding, laser welding, impulse welding, or other suitable welding methods. It is to be understood that any other fastening method such as riveting, as well as self-locking connections, could also be used advantageously. In the illustrated embodiment, a connector flange 822 —or alternatively an arrangement of connector lugs in the shape of circular segments distributed over a circumference —is attached, e.g., welded, to the turbine shell 823 . The axially directed extension 820 of the input member 819 is slipped over the connector flange 822 or the connector lugs and then attached as described above. It can be advantageous if in the attachment process the connector flange 822 is centered on the turbine and the input member 819 is centered on the connector flange.
Additionally or alternatively, it can be of advantage if the second damper stage is centered on the first damper stage in order to prevent displacement of the two damper stages relative to each other. Thus it is possible to accomplish the centering through a configuration in the area 888 where a component 818 a of the input member of the first damper stage overlaps radially with a component 827 b of the output member of the first damper stage (which is also the input member of the second damper stage), allowing the two damper stages to be positioned relative to each other.
The output member 817 of the damper 813 is connected to the hub 814 through an inward-facing toothed profile that engages an exterior toothed profile of the hub 814 , allowing axial but preventing angular relative displacement, so that stresses between the outer attachment 822 a and the interior connection of the damper 813 are prevented.
The turbine 810 is supported through a turbine hub 873 on an axially projecting shoulder 814 b of the hub 814 . The turbine hub 873 has limited rotational play relative to the hub 14 and is axially secured by a retaining ring 814 c. The angular displacement of the turbine 810 relative to the hub 814 , i.e., the working range of the damper 813 , is limited by axially directed projections 873 a distributed along a circle on the turbine hub 873 that are engaged with angular play in the exterior toothed profile 814 a of the hub 814 . It is to be understood that the toothed interior rim 817 a of the output member 817 and the projections 873 a of the turbine hub 873 do not have to be arranged side by side as shown in FIG. 13 but may instead be one above the other for the benefit of minimizing the overall axial dimensions, in which case it is advantageous if the projections 873 a are arranged inside the radius of the toothed rim 817 a.
FIG. 14 illustrates a damper 913 that has been modified in comparison to the damper 813 of FIG. 3 in that the disk-shaped input member 927 b of the second damper stage is shaped at its interior periphery in such a manner that by means of an axially directed extension 927 c, the damper 913 can be centered on the exterior toothed profile 914 a of the hub 914 . By means of the centering feature 988 , the first damper stage 928 a can be centered on the second damper stage 928 b. The axially and rotationally fixed connection of the input member 918 to the turbine shell (not shown) can thus be made with a tighter tolerance, e.g., according to the embodiment of FIG. 15 .
An alternative to the solution shown in FIG. 13 for attaching the damper 813 to the turbine shell 823 by means of a connector flange 822 is illustrated in the detail view of FIG. 15 . The rim 920 a of the axially directed extension 920 of the input member 918 of the damper is adapted to the shape of the turbine shell 923 of the turbine 9 l 0 and attached along a circle by the continuous weld seam or individual spot welds 922 a.
FIG. 16 shows a partial section of a further embodiment of a torque-transmitting apparatus device 1001 that is similar to the embodiment of FIG. 13 . Modifications that deviate from the embodiment of FIG. 13 are in the hub area, including a hub 1014 that is also shown in the detail view of FIG. 17 .
As may be seen in FIGS. 16 and 17, the two form-locking connections for the transmission of the torque from the damper 1013 through its output member 1017 , and from the turbine 1010 through the turbine hub 1073 , to the hub 1014 and from there through the toothed-profile connection 1016 to the transmission shaft are spatially separated from each other. At its exterior circumference, the hub 1014 has an outward-facing profile, such as the illustrated toothed rim 1014 a, that meets the complementary interior profile 1017 a of the output member 1017 in a form-fitting engagement that is preferably free of play and permits axial displacement. Inside of the toothed rim of the hub 1014 are window-shaped openings 1014 b distributed along a circle, shown here in an arrangement of four, but arrangements of two or six openings may also be advantageous. The axially directed projections 1073 a of the turbine hub 1073 pass through the window-shaped openings 1014 b and establish a positive engagement with a maximum play angle a-b (amounting to, e.g., 10° to 70° in the case where four openings are used), between the hub 1014 and the turbine hub 1073 that is rotatable and axially constrained on the hub 1014 , whereby the maximum angular working range a-b of the damper 1013 is being determined in an advantageous manner. For reasons of structural integrity, the openings 1014 b are widened and rounded in both radial directions in the vicinity 1014 c of the contact areas for the projections 1073 a. The toothed rim profile 1014 a is interrupted in the circumference segments 1014 d adjacent to the radial enlargements 1014 c.
The axial fixation of the damper 1013 is modified slightly in comparison to the embodiment 801 of FIG. 13 in that, unlike the connector flange 822 of FIG. 13, the connector flange 1022 is not fitted to the radial share of the turbine shell 1023 and then continued in an outward radial direction. Rather, the connector flange 1022 has a planar, radially outward-directed shape with a taper 1022 b at the contact surface to the turbine shell 1023 and is connected to the latter preferably at its inner perimeter through weld seams or a string of evenly distributed spot welds 1022 c, 1022 d. The connection 1022 a between the connector flange 1022 and the input member 1018 of the damper 1013 is made in the same manner as in the embodiment 801 shown in FIG. 13 .
The function of the damper 1013 , likewise, is similar to the dampers 213 , 813 of the FIGS. 3 and 13, respectively, where it should be noted that the dampers shown in the illustrated sample embodiments are serially configured two-stage dampers. However, in applying the invention it may also be of advantage to provide a parallel mode of operation for dampers with two or more stages. It may further be beneficial, to provide individual limits for the angular displacement of each damper stage, as in the present case for the damper stages 1013 a, 1013 b, in addition to the delimitation of the relative angular displacement of the entire damper 1013 by means of the projections 1073 a in combination with the openings 1014 b. For this purpose, the first damper stage 1013 a as well as its output member 1077 have window-shaped openings 1033 distributed along a circle that are engaged with angular play by the rivet bolts 1031 that connect the two input members 1018 , 1018 a. In case of a rotation of the input members 1018 , 1018 a relative to the output member 1077 of the first damper stage 1013 a, when the range of play has been used up, the rivet bolts will act as stops and thereby cause the damper stage 1013 a to be bypassed.
In analogous manner, the rivet bolts 1032 connecting the input member 1077 of the second damper stage 1013 b (which also represents the output member of the first damper stage 1013 a ) with the disk-shaped part 1078 restrict the angular displacement of the second damper stage 1013 b as they perform the function of rotation-limiting stops for the radially directed extremities 1017 e on the circumference of the output member 1017 , whereby the range of relative rotation between the input members 1077 , 1078 and the output member 1017 is determined by the amount of play between the river bolts 1032 and the extremities 1017 e. Preferably, the ranges between stops for the first and second damper stages 1013 a 1013 b as well as for the entire damper are coordinated in such a manner that the individual damper stages 1013 a, 1013 b reach their stops at a point before the limit angle of the entire damper has been attained by the projections 1073 a reaching the end of their play. For specific applications is may further be advantageous if the first damper stage is stopped before the second stage or vice versa.
It must be understood that features and functions described for individual embodiments of the torque-transmitting apparatus can also be advantageously applied in the rest of the embodiments, regardless of whether or not they are being shown, even it these features and functions have not been described in detail in the context of the respective embodiment and that, therefore, such features and functions are considered to be included in the coverage of all embodiments to which they are applicable.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of the aforedescribed contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims. | A torque-transmitting apparatus, particularly for motor vehicles, with a fluid coupling or a hydrodynamic torque converter and a damping system has an improved design providing the advantages of stress-free mounting of the damper, technical and cost improvements in the manufacture of the apparatus, modular assembly, capability to transmit large torque and attenuate rotational perturbations over a wide RPM range so as to minimize wear to prolong the useful life of the entire unit. | 5 |
DESCRIPTION
1. Technical Field
This invention relates generally to a linkage arrangement for supporting a blade on a vehicle and more particularly to a linkage arrangement which controls the tendency of the blade to draft into the ground.
2. Background Art
There are a variety of methods to correct the tendency for a blade to draft into the ground during use. Most methods involve manual operator correction through powered lifting. In many applications, the blade is held in a fixed position through the use of a control valve and associated components. Many times it is beneficial to allow the blade to "float" relative to the ground. In "float", the blade follows the contour of the ground without being forced to cut the ground at some desired height. Other systems use a skid shoe positioned adjacent the blade to keep the blade from drafting into the ground. These systems are deficient since the blade correction is based upon the skid shoe moving over ground that is outside of the area traversed by the blade and in many cases, the width of the blade is wider than the vehicle. Consequently, uneven ground under the skid shoe causes unwanted blade correction and the extra width of the blade may interfere with obstacles when the blade is being carried in the raised position. It is desirable to have a system that will automatically follow the contour of the ground being traversed by the blade while prohibiting the blade from drafting into the ground.
U.S. Pat. No. 3,400,764 which issued on Sept. 10, 1968 to Walter Schneider teaches a linkage arrangement for supporting one or more soil working implements. A lost motion linkage is used as a control member which actuates a main cylinder via a control valve to cause adjustment of the working implement. The lost-motion stroke allows the implement to rise and fall, depending on soil conditions, within a limited range without operator correction. Although this arrangement provides for automatic adjustment, it still relies on an input of power in order to correct downdraft of the implement.
U.S. Pat. No. 4,013,307 which issued on Mar. 22, 1977 to Allyn C. Dowd and John D. Rogowski teaches stabilizing arms for vehicles which are vertically movable from the transport position to the ground engagement position. The mounting apparatus may be adjusted to vary the angular disposition of the stabilizers relative to the vehicle. This apparatus provides ground engagement of the stabilizer pad at longitudinally spaced positions while still allowing full retraction of the stabilizers within the width of the vehicle.
U.S. Pat. No. 4,796,366 which issued Jan. 10, 1989 to Robert M. Scully teaches an earth mover vehicle that has a blade mounted on the front thereof. The blade can be positioned relative to the vehicle for use as a bulldozer blade, a cutting edge for a scraper bowl, or a bucket for hauling and dumping materials. The blade is movable to the various operating positions by a complex linkage arrangement.
A blade arrangement developed by Pearson Engineering and illustrated in a brochure (date of publication not available) teaches a mine clearing blade for use on a military tank. In this arrangement, the width of the blade is wide enough to remove any obstacles from the front of the respective vehicle tracks. This arrangement has a skid plate located adjacent the leading edge of the blade. Consequently the skid plate is subject to foreign obstructions and would not have the ability to closely control blade depth since the skid plate does not engage the terrain covered by the blade. In this arrangement, there are two blades, one in front of each track. The blades are raised and lowered together by a single hydraulic cylinder. Each blade extends beyond the width of the vehicle at all times.
The present invention is directed to overcoming one or more of the problems as set forth above.
DISCLOSURE OF THE INVENTION
In one aspect of the present invention a blade and linkage mechanism is provided for use on a work vehicle. The blade has an operating position at which the blade is in contact with the ground at a preselected operative level and is subject to downward draft in response to the blade being moved across the ground. The blade has a moldboard and top and bottom portions connected to and rearward of the moldboard. The blade and linkage mechanism includes a push arm and a tilt arm. The push arm has first and second end portions and is pivotally attached at the first end portion thereof to the bottom portion of the blade. The push arm is pivotally attached at the second end portion thereof to the work vehicle. The tilt arm has first and second end portions and is pivotally attached at the first end portion to the top portion of the blade. The tilt arm is pivotally attached at the second end portion to the work vehicle. The tilt arm is pivotal relative to the vehicle through an arc. When extended, the arc intersects the push arm between the pivot connections thereof with the blade and the vehicle so that operation of the blade below the preselected operative level results in a change in the preselected pitch angle.
This invention provides a blade and linkage mechanism which connects a blade to a work vehicle and is operative to control downdraft of the blade into the ground. The linkage mechanism is a passive control which does not require operator intervention. Furthermore, no active power input is required to reverse the downward draft of the blade. When the vehicle is travelling with the blade in the carry position, the outermost edge of the blade is within the outermost confines of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a blade and linkage mechanism incorporating an embodiment of the present invention with the blade in an operative position;
FIG. 2 is a top view of the blade and linkage mechanism of the present invention with the blade remaining in the operative position;
FIG. 3 is a front view of the blade and linkage mechanism of the present invention with the blade remaining in the operative position;
FIG. 4 is a front view of the blade and linkage mechanism of the present invention with the blade in the carry position;
FIG. 5 is a side view of the blade and linkage mechanism of the present invention in a position lower than the operative position; and
FIG. 6 is a side view of an alternate embodiment of the blade and linkage mechanism of the present invention with the blade in the operative position.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring now to the drawings, and more particularly to FIGS. 1, 2, and 3, a blade and linkage mechanism 10 is shown and adapted for use on a work vehicle 12. The work vehicle 12 has first and second front side portions 14, 16 and first and second outermost sides 18, 20. The work vehicle 12 also includes a vehicle carrier and propelling mechanism 22, for example, first and second endless track systems 24, 26.
As clearly shown in FIGS. 2 and 3, the work vehicle 12 includes a second blade and linkage mechanism 10' adapted for use thereon and connected to the first blade and linkage mechanism 10 by a beam member 27. Since each of the blade and linkage mechanisms 10, 10' are mirror images of each other, only the first one of the two will be discussed in detail. Each of the corresponding elements of the second blade and linkage mechanism 10' has the same element number as that of the first blade and linkage mechanism 10 with a prime symbol attached.
The first blade and linkage mechanism 10 includes a blade 30, a linkage mechanism 32, and a frame member 34. Even though the frame member 34 is noted as being part of the blade and linkage mechanism 10, it is well recognized that the frame member 34 could be an integral part of the frame of the work vehicle 12 without departing from the essence of the invention. The blade 30 includes a moldboard 36 with a bottom edge 37. The blade 30 also includes a top portion 38, a bottom portion 40, an innermost edge 42, and an outermost edge 44. The blade 12 has a predetermined width "W" and has an operating position at both a preselected operative level and a preselected pitch angle. During operation, the pitch angle of the moldboard 36 continually subjects the blade 30 to downdraft of the blade 30 below a surface "G". A skid plate 46 having a bottom surface 48 is connected to the moldboard 36 at and rearward of the bottom edge 37 thereof. The bottom surface 48 of the skid plate 46 has a predetermined shape and longitudinal length "L s ". In the preselected operative position of the subject embodiment, the skid plate 46 is substantially flat and parallel to the ground surface. The width of the skid plate is substantially the same as the width "W" of the blade 30. The blade 30 also includes a plurality of teeth 50 attached to the bottom portion 40 thereof and behind the moldboard 36. Each tooth of the plurality of teeth 50 has a predetermined length "L t ".
The linkage mechanism 32 includes a push arm 56 and a tilt arm 58. The push arm 56 has a first end portion 60 pivotally connected at spaced locations to the bottom portion 40 of the blade 30. The push arm 56 also includes a second end portion 62 pivotally connected to the frame member 34. The connection of the first end portion 60 of the push arm 56 with the bottom portion 40 of the blade 30 is movable, with respect to the frame member 34, through an arc "C". As shown in FIG. 2, a transverse vertical plane 64 is defined with respect to the front of the vehicle 12 and intersects the pivotal connection of the push arm 56 with the bottom portion 40 of the blade 30. The pivotal connection of the push arm 56 with the bottom portion 40 of the blade 30 forms an acute angle with the transverse vertical plane 64. The pivotal connection of the push arm 56 with the bottom portion of the blade 30 is substantially parallel with the surface "G" of the ground when the blade 30 is in its preselected operative position. The push arm 56 also has a preselected length "L p ".
The tilt arm 58 has a first end portion 66 pivotally connected to the top portion 38 of the blade 30. The tilt arm also has a second end portion 68 pivotally connected to the frame member 34. The pivotal connection of the tilt arm 58 to the frame member 34 and the blade 30 are universally connected. It is recognized that other types of connections could be utilized. The tilt arm 58 has a preselected length "L 1 " which is less than the length of the push arm 56. The connection of the first end portion 66 of the tilt arm 58 is movable through an arc "B" relative to the frame member 34 such that if extended, the arc "B" would intercept the push arm 56 between its respective points of connection with the blade 30 and the frame member 34.
As further shown in FIG. 2, a second transverse vertical plane 70 is defined in the work vehicle 12 and it intersects the pivotal connection of the push arm 56 with the frame member 34. The push arm 56 is pivotally connected to the frame member 34 by a mounting pin 72 secured thereto. The mounting pin 72 is secured to the frame member 34 in substantial alignment with the transverse vertical plane 70.
Referring to FIG. 4, a transverse horizontal plane 76 is defined in the work vehicle 12 perpendicular to the second transverse vertical plane 70. The transverse horizontal plane 76 also intersects the pivotal connection of the push arm 56 with the frame member 34. An acute angle "B" is formed between the mounting pin 72 and the transverse horizontal plane 76.
A lift cylinder 78 is connected to the frame member 34 and the push arm 56. The lift cylinder 78 is operative to raise the blade 30 from the operative position illustrated in FIGS. 1, 2, and 3 to the carry position as illustrated in FIG. 4. Furthermore, the lift cylinder 78 is a single acting cylinder which is raised by a power input and allowed to float when operated in the lowered position. As further illustrated in FIG. 4, with the blade 30 in a carry position, the outermost edge 44 thereof is within the first outermost side 18 of the work vehicle 12.
FIG. 5 illustrates the blade and linkage mechanism 10 in a position where the blade 30 has downdrafted below the preselected operative position. For clarity, the degree of downdraft has been exaggerated. As clearly shown, the back end of the skid plate 46 is being pressed against the ground causing the front end of the blade 30 to raise with respect to the ground. This action effectively, automatically compensates for the downdraft condition and returns the blade 30 to the preselected operative position.
FIG. 6 illustrates an alternate embodiment of the blade and linkage mechanism 10 as set forth above. In this arrangement, the linkage mechanism 32 is the same as previously described. The major difference of this embodiment is the skid plate 46. In various applications, the plurality of teeth 50 break up the soil of the ground to such a degree that the soil builds up in front of the blade 30. In the subject arrangement, the bottom surface 48 of the skid plate 46 is angled downwardly and rearwardly from the bottom edge 37 of the moldboard 36. The angle of downward projection with respect to the surface of the ground and the vertical depth of downward projection depends on the type of soil being worked. As an example, a typical skid plate 46 has a 6 degree angle with the surface of the ground and extends 50 mm (approximately 2 inches) below the initial unworked surface of the ground. This shape provides adequate compaction of the soil to sustain the weight of the blade 30 and to maintain the blade 30 in the preselected operative position.
It is recognized that various forms of the blade and linkage mechanism 10, 10' could be utilized without departing from the essence of the invention. As previously noted, the frame member 34 could be an integral portion of the frame of the work vehicle 12. Furthermore, the tilt arms 58 could be an adjustable member such as a hydraulic cylinder for changing the pitch of the moldboard 36 during various operating conditions. Likewise, the plurality of teeth 50 could be adjustable in length to compensate for working in differing types of materials and the skid plate 46 could be narrower than the width of the blade 30.
INDUSTRIAL APPLICABILITY
In the operation of the blade and linkage mechanism 10, as illustrated in FIG. 1 through 5, the blade 30 is traversing the surface "G" of the ground with the plurality of teeth 50 attached thereto submerged in the ground. Simultaneously, the skid plate 46 is sliding across the top of the ground and maintaining the blade 30 at a depth equivalent to the preselected operative position. Since due to the curvature of the moldboard 36, the preselected pitch angle of the blade 30, and the penetration of the plurality of teeth 50, the blade 30 is continually subjected to forces causing downdraft of the blade 30 into the ground. The only thing stopping the downdraft of the blade 30 into the ground is the skid plate 46 and the corrective action of the linkage mechanism 32. This is true since the lift cylinder 78 is a single acting cylinder which has power available only to raise the blade 30. In this system, the blade 30 is continually in the "float" position when it is being operated in the down or lower position.
As more clearly shown in FIG. 5, any movement of the blade 30 downwardly from the preselected operative position results in the preselected pitch angle of the moldboard 36 changing. The changing of the pitch angle from its preselected position results in the bottom surface 48 of the skid plate 46 changing from the horizontal position parallel to the surface "G" of the ground to a position that is not parallel to the ground surface. This change in position of the bottom surface 48 causes the back end of the skid plate 46 to be lower than the front end of the skid plate 46. Since the rear end of the skid plate 46 is in contact with the ground and cannot penetrate the ground, the front portion of the skid plate 46 and the moldboard 36 are raised with respect to the ground. Since the bottom edge 37 of the moldboard 36 is raised, the portion of the ground being subjected to the bottom edge 37 of the moldboard 36 is higher. Consequently, the bottom surface 48 of the skid plate 46 slides onto the higher ground surface which automatically raises the blade 30 to its preselected operative position. Any further downdrafting of the blade 30 from the preselected operative position automatically results, as set forth above, in the linkage mechanism 32 functioning to return the blade 30 to its preselected operative position.
The upward movement of the blade 30, resulting from the rear end of the skid plate 46 causing the front end thereof to raise up, is attributed to the linkage mechanism 32. More specifically, any downward rotation of the push arm 56 and the tilt arm 58 through the respective arcs "A, B" result in the connection point of the tilt arm 58 to the top portion 38 of the blade 30 moving rearwardly with respect to the connection point of the push arm 56 with the bottom portion 40 of the blade 30. Referring to FIGS. 1 and 5, the paths followed by the tilt arm 58 and the push arm 56, during downdrafting of the blade 30, are clearly illustrated by the pre-established arcs "A and B".
Referring to FIGS. 2 and 3, the width "W" of the blade 30 is sufficient to cover the portion of the ground traversed by the first endless track system 24. Furthermore, the outermost edge 44 of the blade 30 extends beyond the first outermost side 18 of the work vehicle 12 when the blade and linkage mechanism 10 is being operated in the preselected operative position. As illustrated in FIG. 4, the outermost edge 44 of the blade 30 is substantially within the first outermost side 18 of the work vehicle 12 when the blade and linkage mechanism 10 is in the carry position. The ability to have the blade 30 extend beyond the first outermost side 18 of the work vehicle 12 during operation and to have the outermost edge 44 positioned within the first outermost side 18 when in the carry position is attributed to the connection of the push arm 56 to the frame member 34. By having the mounting pin 72 at an acute angle "O" with respect to the transverse horizontal plane 76, the blade 30 is automatically positioned inwardly with respect to the work vehicle 12. Furthermore, by having the connection of the push arm 56 with the blade 30 at an acute angle "C" with the first transverse vertical plane 64, the bottom of the blade 30 is maintained, when in the carry position, generally parallel with the ground. Therefore, the work vehicle 12 can traverse terrain having obstacles on either side without worry of the blade 30 striking the obstacles.
The second blade and linkage mechanism 10, functions identically to the first blade and linkage mechanism 10. The first and second blade and linkage mechanisms 10, 10' are effective to allow the blades 30, 30' to operate in the float position for clearing obstacles from the path of the first and second endless track systems 24, 26 while automatically controlling downdraft of the respective blades 30, 30'. Furthermore, the blades 30, 30' are positioned within the outermost sides 18, 20 of the work vehicle 12 when they are raised to the carry position.
Other aspects, objects, and advantages of this invention can be obtained from the study of the drawings, the disclosure, and the appended claims. | Blade mechanisms being operated along the ground have a tendency to draft into the ground unless some positive form of control is provided to prohibit the downdrafting of the blade. In the subject arrangement, a blade and linkage mechanism is provided for stopping a blade from drafting downward with respect to the ground. The linkage mechanism includes a tilt arm attached between a work vehicle and a top portion of the blade and a push arm attached between the work vehicle and a bottom portion of the blade. The tilt arm is movable relative to the vehicle through an arc which if extended intersects the push arm between its pivot connections. When the blade drafts downward, the different orientations of the tilt arm and the push arm corrects the downdraft due to the rear of a skid plate attached thereto being tilted with respect to the ground. The changing orientation of the skid plate with respect to the ground causes the front of the blade to raise with respect to the ground. Consequently, the problem of downward draft of the blade during operation is overcome without a complex mechanism. | 5 |
This invention relates to improved journal bearings for use in heavy duty applications. More particularly, this invention relates to the incorporation of a nickel-tin-copper trilaminate barrier layer between the babbitt and copper-lead layers of a conventional, heavy-duty, journal bearing.
BACKGROUND
Increasing the output and efficiency of a heavy-duty diesel engine also increases the load on the journal bearings in which the crankshaft runs. Where such an engine is to be run for many thousand hours at temperatures above 120° C., crankshaft bearing failure may be precipitated by a slow change in the alloy compositions which comprise the various layers of the bearings.
One type of heavy-duty journal bearing that has provided good service for many years consists of a steel backing, a copper-lead alloy matrix adjacent the backing and a working surface of lead-tin babbitt. A very thin layer of nickel is interposed between the babbitt and copper-lead layers to prevent migration of metals therebetween. Such migration may create intermetallic compounds that do not have acceptable properties for use in a bearing when it is subjected to high temperatures and heavy loads. Bearing failure from scoring or sieze may result. Accordingly, it is an object of this invention to provide an improved, migration inhibiting, barrier layer between the babbitt and copper-lead alloy layers of a conventional heavy-duty journal bearing.
BRIEF SUMMARY
In accordance with a preferred practice of the invention, a heavy-duty journal bearing is made having the following configuration: a tough backing layer of steel or other suitable material; a layer of copper-lead alloy adjacent the backing which alloy comprises a continuous spongelike matrix of copper metal in which the voids are filled with lead; then, a thin layer of nickel metal; a thin layer of tin metal; a thin layer of copper metal; and a top layer of babbitt, a combination of about 90 percent lead and ten percent tin. The thin nickel, tin and copper layers together form a trilaminate interlayer that prevents the undesirable migration of tin from the babbitt layer. The interlayer also precludes the formation of alloys detrimental to bearing performance during prolonged operation at elevated temperatures over 120° C. and under heavy loads. That is, any diffusion coupling that naturally occurs between the metals of the several different bearing layers does not create an intermetallic compound that promotes bearing failure by scoring distress or sieze.
In a preferred practice, the bearing is made up of a mated pair of semicircular half bearings which together form a complete journal for a rotating shaft. The bearing halves are preferably made by successively plating the several layers over the backing. A conventional lubricant is preferably employed between the working surface of the bearing (i.e., the babbitt layer) and the shaft.
DETAILED DESCRIPTION
The invention will be better understood in view of the following Figures and Description in which:
FIG. 1 is a sectional view of a conventional bearing half for the crankshaft of a heavy-duty diesel engine.
FIG. 2 is a sectional view of a bearing half for heavy-duty applications in accordance with the invention.
FIG. 3 is a ternary phase diagram for copper, tin and nickel where the subject bearing compositions, i.e., the acceptable ratios of the metals in the trilaminate barrier layer, are indicated by the shaded region.
The subject invention is a novel improvement of conventional journal bearings of the type depicted in FIG. 1 and described in Table I below. The backing layer 2 is steel. A copper-lead alloy matrix 4 is applied over backing 2 by sintering copper and lead powders or applying a layer of molten alloy and cooling it. The matrix can be described as a major spongelike phase of copper metal in which the microscopic pores of the sponge are filled with lead metal. A layer of relatively pure nickel metal 6 is electroplated over the copper-lead layer 4. A layer of babbitt 8 is applied over the nickel layer 6 by electroplating from a conventional bath of lead and tin fluoroborates. Nickel layer 6 prevents the migration of tin into copper-lead layer 4 under normal bearing operating conditions.
TABLE I______________________________________Composition of Bearing______________________________________BabbittSAE 19 Material SpecificationComposition: 84.5-92% lead 8-12% tin 3.5% total othersThickness: 0.025 mm (0.001 in.) overplateNickel Barrier LayerComposition: Pure electroplated nickelThickness: 0.00127-0.00254 mm (0.000050-0.000100 in.)Copper-LeadSAE 49 Material SpecificationComposition: 73-79% copper 21-27% lead 0.5% tin 0.35% iron 0.45% total othersThickness: 0.635 mm (0.025 in.) heavy wallThe total bearing thickness, including the steel back,is about 4.0 mm (0.157 in).______________________________________
The subject invention relates to a new bearing shown at FIG. 2 which is better able to stand up to thousands of hours of use at temperatures over 120° C. at high loads. It is more durable than the prior art bearing of FIG. 1 under such abusive heavy-duty conditions. The babbitt layer 10, copper-lead layer 12 and steel backing layer 14 are the same as those of FIG. 1 and Table I. However, the nickel interlayer 6 of FIG. 1 is replaced by a trilaminate interlayer. This trilaminate barrier layer consists of a pure nickel layer 16 plated onto copper-lead layer 12 by conventional means. Then, a layer of tin metal 18 is electroplated over layer 16 in a conventional electroplating bath described in Table II.
TABLE II______________________________________Electro Cleaner 60 g/L McGean 154 MP at 65°Copper BathCopper cyanide 52.5 g/LPotassium cyanide 102 g/LFree potassium cyanide 26 g/LPotassium sodium 17.5 g/LTartrateTemperature 55° C.Tin BathPotassium stannate 189 g/LPotassium hydroxide 35 g/LTemperature 65° C.Lead-Tin BathLead (as lead fluoborate) 100 g/LTin (as stannous fluoborate 26 g/LPeptone 2 g/LTemperature AmbientAcid DipTemperature 120 g/L Udylite oxyvate #345 Ambient______________________________________
A copper layer 20 is electroplated over tin layer 18 in the copper bath of Table II. The babbitt layer is applied over layer 18 in the lead-tin bath of Table II. Thus, the trilaminate barrier layer consists of a nickel layer adjacent the copper-lead layer; a tin layer over the nickel layer, and a copper layer over the tin. This nickel-tin-copper trilaminate barrier layer effectively prevents the migration of tin from the babbitt overlayer and has proven effective in avoiding the formation of alloys unsuitable for bearing use as will be described hereafter.
Under heavy-duty applications, there is an apparent tendency for the metals of the initially distinct trilaminate barrier layer to alloy with one another. We have discovered that in order to avoid the formation of unacceptable alloys of the metal constituents of the various bearing layers, the relative proportions of metals in the trilaminate layer should be controlled. This may be accomplished by regulating the relative thicknesses of the nickel, tin and copper layers. Although this "alloying" phenomenon does not occur in heavy-duty diesel engines, for example, until after about 5,000 hours of operation at temperatures over about 120° C. at loads over 5000 psi, it is imperative that the intermetallic alloys created by such in situ alloying do not cause bearing failure. In particular, the alloys must not score if they are contacted by the rotating shaft and they must not deteriorate to the point where the bearing siezes to the shaft. Under sieze conditions, the bearing layer most adjacent the shaft welds to it. After this occurs, the bearing layers may be ripped apart at the weakest bond between layers causing catastrophic failure of the bearing.
We have determined what we believe to be optimum thicknesses for the nickel, tin and copper layers used in a six inch diameter diesel journal bearing having steel backing, copper-lead matrix, and babbitt layers of the compositions and thicknesses set out for the conventional bearing in Table I. These preferred thicknesses and the ratios of thicknesses are set out in Tables III and IV, below.
TABLE III
Thickness of the Tri-Metal Layers
nickel 0.00127-0.00254 mm (0.000050-0.000100 in.)
tin 0.00064-0.00254 mm (0.000025-0.000100 in.)
copper 0.00064-0.00380 mm (0.000025-0.000150 in.)
Thus our new bearings feature a working surface of babbitt, an underlayer of bimetallic copper-lead and a steel backing layer with an improved barrier laminate layer between the babbitt and the copper-lead layers. The laminate barrier layer comprises a copper layer adjacent the babbitt layer, a nickel layer adjacent the copper-lead alloy layer and a layer of tin therebetween. The preferred thickness of the copper layer is about 25 to 150 microinches (1×10 -6 in); the tin layer about 25 to 50 microinches; and the nickel layer about 50 to 100 microinches. The copper layer should be at least as thick as the tin layer.
TABLE IV
Thickness Bounds of Tri-Metal Barrier
1. Ni≦2.54 μm (100μ")--commercial limit
2. Ni≧1.27 μm (50μ")--commercial limit
3. Sn≦Ni thickness
4. Sn≧1/4 Ni thickness
5. Sn≧0.64 μm (25μ")
6. Cu≧Sn thickness
7. Cu≦3×Sn thickness
8. Cu≦11/2×Ni thickness
9. Cu≦3.80 μm (150μ")
10. Cu≧0.64 μm (25μ")
FIG. 3 is a phase diagram that graphically illustrates the relative amounts of nickel, tin and copper that are suitable for this invention. The shaded area which lies inside the intersection of the compositional range limit lines avoid formation of intermetallic compositions of the elements nickel, tin and copper that have poor score resistance or unsuitable hardness.
EXAMPLE
The bearings used in this Example were standard 6 inch diameter diesel crankshaft journal bearings purchased from Gould, Inc., designation F-77. The bearings in cross section comprised (1) a topmost layer of babbitt--SAE 19; (2) a nickel barrier layer; (3) a copper lead matrix base layer--SAE 49; and (4) a steel backing layer. The thicknesses and compositions of the several layers are reported in Table I above. The copper-lead layer was applied to the steel backing by spreading a molten mixture of the elements onto a steel sheet and cooling the sheet from below. All other layers of the production bearing were applied by electroplating.
To form the subject trilaminate barrier layer bearings, Gould production bearings were reverse electroplated to selectively remove the top babbitt layer. The tin and copper layers were then sequentially electroplated over the remaining nickel base layer. The babbitt was reapplied to the working surface of the bearings by electroplating. All electroplating operations were conducted for times and at current densities appropriate to creating the desired layer thickness.
The bearings were tested in the following manner. Each bearing was retained in a journal around the crankshaft of a V-6, 92 cubic inch per cylinder, diesel engine with a power rating of 336 brake horsepower. The engine was run at a constant rate of 1200 revolutions per minute throughout the test. The bearing was lubricated with oil pumped from a 50 quart capacity open sump. Twenty-five quarts of new SAE 10W-40 oil were initially introduced into the sump.
During each test cycle, the engine was run continuously for five hours. It was then allowed to stand without running until it cooled to room temperature.
The first cycle was run with the original 25 quarts of clean oil in the sump. After the first cooling cycle, one half quart of a mixture of 50% ethylene glycol and 50% water was added to the oil in the sump. Obviously this diluted the oil with a less effective liquid so far as lubrication is concerned. The engine was then subjected to another five hour run and allowed to cool to room temperature.
On the second and each successive cycle, an additional half quart of glycol and water were added to the sump. That is 1/2 quart was added for the first cycle, 1 quart for the second cycle, 1.5 quarts for the third cycle, 2 quarts for the fourth cycle, etc. As the sump itself was not closed, the water tended to evaporate during each 5 hour running cycle and the glycol appeared to chemically degrade.
Test failure was that point at which friction between the bearing and the crankshaft created a bearing temperature about 23.5° C. above the normal bearing operating temperature of 110° C. Table V reports the test results for the following bearings: (1) a new Gould F-77 production bearing, (2) a heat aged Gould F-77 production bearing, (3) a new trilaminate plated bearing in accordance with the invention and (4) a heat aged trilaminate bearing in accordance with the invention. The "Average Lubrication Dilution at Failure" is reported as the sum of all the quarts of glycol and water added to the original 25 quarts of oil in the sump at the time the bearing temperature rose to about 133° C.
Aging the new bearings at 220° C. for 400 hours produces about the same amount of diffusion of the constituent metals of the several bearing layers as does 5000 or more hours of wear at a load of about 6000 psi at a temperature of about 120° C. Thus the heat treatment is a means of accelerating the testing of bearing life cycle.
TABLE V______________________________________SCORE RESISTANCE TESTGlycol & Water in Oil Lube6" Diesel Crank Shaft Bearing Thickness Average Lube (1 × 10.sup.-6 Dilution toBearing inches) Failure______________________________________1. 75 Cu 25 Pb (NEW) 2500 (sum of Quarts 50:50 Glycol: H.sub.2 O added) Ni 50 90 Pb 10 Sn 1000 2272. 75 Cu 25 Pb (AGED)* 2500 Ni 50 156 90 Pb 10 Sn 10003. 75 Cu 25 Pb (NEW) 2500 Cu 50 264 Sn 50 Ni 50 90 Pb 10 Sn 10004. 75 Cu 25 Pb (AGED)* 2500 Cu 50 Sn 50 248 Ni 50 90 Pb 10 Sn 1000______________________________________ *Aged Bearings heated at 220° C. for 400 hours. Heat aging simulates wear of more than 5000 hours in a heavyduty diesel engine at an approximate load of 6000 PSI.
Referring to Table V, it is clear that use of the trilaminate barrier layer in the subject bearings improves bearing life under heavy-duty applications. The new trilaminate barrier bearing clearly surpasses the heat aged nickel-only barrier bearing. Very significant, however, is the fact that the life of the heat aged and the new trilaminate barrier bearings are about the same. That is, the subject novel bearings do not degrade under use in heavy-duty applications. Stated in another way, the trilaminate barrier bearing starts out with good score and sieze resistance and maintains these characteristics as the constituent metal layers gradually diffuse with one another. In the field, this diffusion is precipitated by wear while in the accelerated test the diffusion is precipitated by a heating cycle.
Manufacture of the subject bearings has been described in terms of electroplating the barrier and babbitt layers. However, like results can be obtained using any other suitable metal application technique such as flame spraying, rapid D.C. sputtering, sintering, electroless plating, etc.
In summary, we have discovered that interposing a thin trilaminate layer of nickel, tin and copper between the babbitt and copper-lead layers of a conventional heavy-duty bearing increases its life and improves its performance when subjected to rugged operating parameters. The order of the layers in the bearing is chosen to optimize the migration characteristics of the constituent metals, particularly to prevent excessive loss of tin from the babbitt overlayer. We believe the heat diffusion results indicate that application of a single interlayer of suitable alloy of copper, nickel and tin (i.e., those having a composition in the shaded region of FIG. 3) would produce the same result as using three separate layers.
While our invention has been described in terms of specific embodiments thereof, other forms may be readily adapted by one skilled in the art. Accordingly, the scope of the invention is limited only by the following claims. | The heavy-duty performance of babbitt-lined, copper-lead based journal bearings is improved by a novel trimetallic barrier layer interposed between the babbitt and copper-lead layers. The trimetallic barrier layer contains the elements nickel, tin and copper in suitable proportions. In a preferred embodiment, the barrier layer consists of layers of nickel, tin and copper metals successively plated over the copper-lead base. | 5 |
[0001] This application is a continuation-in-part of U.S. Ser. No. 09/639,807 filed Aug. 17, 2000, which is a continuation of U.S. Ser. No. 09/145,658 filed Sep. 2, 1998, now U.S. Pat. No. 6,127,505, which is a continuation-in-part of U.S. Ser. No. 08/595,262 filed Feb. 1, 1996, now U.S. Pat. No. 5,962,617, which is a continuation-in-part of U.S. Ser. No. 08/382,562 filed Feb. 2, 1995, now abandoned, all of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a rigid, optically transparent heat and impact resistant polyurethane.
[0004] 2. Background of the Invention
[0005] Currently, the standard material to which all optically transparent plastic materials are compared to for impact resistance is polycarbonate. These materials can be characterized by impact resistance and the temperature and pressure at which the material undergoes distortion. The heat distortion temperature of polycarbonate is about 280° F. at 264 psi fiber stress.
[0006] Polycarbonate extruded sheet at a thickness of 0.25 inches has a 0.22 caliber FSP (fragment simulating projectile) V 50 impact rating of 925 ft./sec. The V 50 is the measure of the velocity at which 50% of 22-caliber projectiles fired through a 0.25 inch polycarbonate sheet penetrate a 20 millimeter-thick 2024 T6 aluminum sheet (the “witness sheet”) placed 6 inches behind the back surface of the polycarbonate sheet.
[0007] U.S. Pat. No. 3,866,242, which is incorporated herein by reference, discloses a polyurethane polymer protective shield. The polyurethane is produced by:
[0008] (a) reacting either a polyether glycol or a polyester glycol having a molecular weight of from about 700 to 1,000 with methylenebis(cyclohexyl isocyanate) in an equivalent ratio of about three NCO to each hydroxyl to form a prepolymer, and
[0009] (b) reacting the prepolymer with an aromatic amine curing agent having a methylene bridge between two aromatic rings, such as 4,4′-methylenebis(2-chloroaniline), in an equivalent ratio of 0.90 to 1.04 NH 2 /1.0 NCO.
[0010] U.S. Pat. No. 4,808,690, which is incorporated by reference herein, discloses a transparent polyurethane polymer made from a polyol cured prepolymer. The prepolymer is made from a polyisocyanate and at least one multifunctional hydroxy-containing intermediate.
[0011] U.S. Pat. No. 4,208,507 discloses a flexible polyurethane-urea elastomer prepared by reacting: (A) a prepolymer obtained by reacting an essentially difunctional polyhydroxy compound having a molecular weight of from 600 to 10,000, and an organic diisocyanate having at least one NCO group bonded to a cycloaliphatic structure, in amounts which provide a total OH:NCO ratio of from 1:1.2 to 1:10, with (B) 3,3′5,5′-tetramethyl-4,4′-diamino-diphenylmethane, A and B being reacted in a molar ratio of from about 1:0.8 to 1:1.2.
SUMMARY OF THE INVENTION
[0012] The optically clear polyurethane of this invention can be prepared by first producing a prepolymer by reacting one or more polyester glycols, polycaprolactone glycols, polyether glycols, or polycarbonate glycols having a weight average molecular weight of from about 400 to about 4000 with an aliphatic or cycloaliphatic diisocyanate in an equivalent ratio of about 2.5 to 4.0 NCO for each OH. The prepolymer is then reacted with an aromatic diamine curing agent such as diethyltoluene diamine in an equivalent ratio of about 0.85 to 1.02 NH 2 /1.0 NCO, preferably about 0.90 to 1.0 NH 2 /1.0 NCO, and more preferably about 0.92 to 0.96 NH 2 /1.0 NCO.
[0013] The polyurethane of the present invention is particularly useful for transparency applications that require excellent impact resistance coupled with high heat distortion temperatures, such as architectural glazings, vehicle glazings, riot shields, aircraft canopies, face masks, visors, opthalmic and sun lenses, protective eyewear, and transparent armor.
[0014] One object of this invention is to provide transparent polyurethanes having excellent optical clarity, excellent ballistic properties, high chemical resistance, and high heat distortion temperatures compared to prior art materials.
[0015] Another object of this invention is to provide reduced cost transparent impact resistant polyurethanes for commercial applications.
[0016] Yet another object of this invention is to enhance production processing of transparent impact resistant polyurethanes by decreasing reaction time, processing temperature, and mold residence time.
[0017] These and other objects of the present invention are described in greater detail in the detailed description of the invention, the examples and the attached claims.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The polyurethane of the present invention is prepared from aliphatic or cycloaliphatic diisocyanates, OH-containing intermediates, and aromatic diamine curing agents. The following is a detailed description of each of these constituents:
[0019] OH-Containing Intermediates
[0020] The OH-containing intermediates which can be used to prepare the polyurethanes of this invention include polyester glycols, polycaprolactone glycols, polyether glycols, and polycarbonate glycols having a weight average molecular weight of from about 400 to about 4000, preferably about 400 to about 1000.
[0021] Polyester glycols that can be used include the esterification products of one or more dicarboxylic acids having four to ten carbon atoms, such as adipic, succinic and sebacic acids, with one or more low molecular weight glycols having two to ten carbon atoms, such as ethylene glycol, propylene glycol, diethylene glycol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol and 1,10-decanediol. Preferred polyester glycols are the esterifiation products of adipic acid with glycols of two to ten carbon atoms.
[0022] Polycaprolactone glycols that can be used include the reaction products of Ecaprolactone with one or more of the low molecular weight glycols listed above. In addition, useful OH-containing intermediates may include teresters produced from one or more low molecular weight dicarboxylic acids, such as adipic acid, and caprolactones with one or more of the low molecular weight glycols listed above.
[0023] The preferred polyester glycols and polycaprolactone glycols can be derived by well known esterification or transesterification procedures, as described, for example, in the article D. M. Young, F. Hostettler et al., “Polyesters from Lactone,” Union Carbide F-40, p. 147.
[0024] Polyether glycols that can be used include polytetramethylene ether glycol.
[0025] Polycarbonate glycols that can be used include aliphatic polycarbonate glycols. Preferred aliphatic polycarbonate glycols are those manufactured and sold by Enichem under the tradename Ravecarb 102 (molecular weight=1,000) and Ravecarb 106 (molecular weight=2,000).
[0026] The most preferred OH-containing intermediates are: (a) esterification products of adipic acid with one or more diols selected from 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, and 1,10-decanediol; (b) reaction products of E-caprolactone with one or more diols selected from 1,4-butane diol, 1,6-hexane diol, neopentyl glycol, and 1,10-decanediol; (c) polytetramethylene glycol; (d) aliphatic polycarbonate glycols, and (e) mixtures of such OH-containing intermediates.
[0027] Diisocyanates
[0028] The diisocyates that are useful in the present invention include aliphatic and cycloaliphatic diisocyanates. As used herein, the terms “aliphatic” and “cycloaliphatic” diisocyanates are intended to encompass diisocyanates in which the NCO group is bonded directly to an aliphatic or cycloaliphatic moiety, even if the molecule also includes an aromatic moeity, but is not intended to encompass aromatic diisocyanates in which the NCO group is bonded directly to an aromatic moiety. The aliphatic or cycloaliphatic diisocyanates which can be used to prepare the polyurethanes of this invention include dicyclohexylmethane diisocyanate and preferably isomeric mixtures thereof containing from about 20-100 percent of the trans,trans isomer of 4,4′-methylenebis(cyclohexyl isocyanate), hereinafter referred to as “PICM”, (paraisocyanato cyclohexylmethane). Other components usually present in the mixtures of position and/or stereoisomers of the dicyclohexylmethane diisocyanate used in this invention are the cis,trans and cis,cis isomers of PICM and stereoisomers of 2,4′-methylenebis(cyclohexyl isocyanate). These, as well as the trans,trans PICM isomer, are present in amounts which can be controlled by the procedures used to prepare the dicyclohexylmethane diisocyanate. Preferred diisocyanates are isomeric PICM mixtures. An especially preferred mixture contains not less than about 20 percent of the trans,trans isomer and no more than about 20 percent of the cis,cis isomer of 4,4′-methylenebis(cyclohexyl isocyanate). Three isomers of 4,4′methylenebis(cyclohexyl isocyanate) are shown below:
[0029] The PICM used in this invention is prepared by phosgenating the corresponding 4,4′-methylenebis(cyclohexyl amine) (PACM) by procedures well known in the art, as disclosed in, e.g., U.S. Pat. Nos. 2,644,007, 2,680,127, and 2,908,703, which are incorporated herein by reference. The PACM isomer mixtures, upon phosgenation, yield PICM in a liquid phase, a partially liquid phase, or a solid phase at room temperature. The PACM isomer mixtures can be obtained by the hydrogenation of methylenedianiline and/or by fractional crystallization of PACM isomer mixtures in the presence of water and alcohols such as methanol and ethanol.
[0030] Additional aliphatic and cycloaliphatic diisocyanates that may be used include 3-isocyanato-methyl-3,5,5-trimethyl cyclohexyl-isocyanate (“IPDI”) from Arco Chemical, which has the following structural formula:
[0031] and meta-tetramethylxylene diisocyanate (1,3-bis(1-isocyanato-1-methylethyl)-benzene) which is sold by Cytec Industries, Inc. under the trademark TMXDI® (Meta) Aliphatic Isocyanate and which has the following structural formula:
[0032] Diamine Curing Agents
[0033] The preferred aromatic diamine curing agents for use in preparing the polyurethanes of the invention are 2,4-diamino-3,5-diethyl-toluene, 2,6-diamino-3,5-diethyl-toluene and mixtures thereof (collectively “diethyltoluenediamine” or “DETDA”), which is sold by Albemarle Corporation under the trade name Ethacure 100. DETDA is a liquid at room temperature with a viscosity of 156 cs at 25° C. DETDA is isomeric, with the 2,4-isomer range being 75-81 percent while the 2,6-isomer range is 18-24 percent. DETDA has the following structure:
[0034] The color stabilized version of Ethacure 100, which is available under the name Ethacure 100LC, is particularly preferred.
[0035] Additional diamine curing agents for use in the present invention include compounds having the following chemical formula:
[0036] wherein R 1 and R 2 are each independently selected from methyl, ethyl, propyl, and isopropyl groups, and R 3 is selected from hydrogen and chlorine. Examples of the such additional diamine curing agents are the following compounds, manufactured by Lonza Ltd. (Basel, Switzerland):
LONZACURE ® M-DIPA R 1 = C 3 H 7 ; R 2 = C 3 H 7 ; R 3 = H LONZACURE ® M-DMA: R 1 = CH 3 ; R 2 = CH 3 ; R 3 = H LONZACURE ® M-MEA: R 1 = CH 3 ; R 2 = C 2 H 5 ; R 3 = H LONZACURE ® M-DEA: R 1 C 2 H 5 ; R 2 = C 2 H 5 ; R 3 H LONZACURE ® M-MIPA: R 1 = CH 3 ; R 2 = C 3 H 7 ; R 3 = H LONZACURE ® M-CDEA: R 1 = C 2 H 5 ; R 2 = C 2 H 5 ; R 3 = Cl
[0037] wherein R 1 , R 2 and R 3 refer to the above chemical formula. Among these, the preferred diamine curing agent is 4,4′-methylenebis(3-chloro-2,6-diethylaniline), (Lonzacure® M-CDEA), which is also available from Air Products and Chemical, Inc. (Allentown, Pa.). The foregoing diamine curing agents may be used in addition to or in place of DETDA, as a polyurethane curing agent.
[0038] Preparation of the Invention
[0039] The polyurethanes of this invention can be prepared by quasi-prepolymer or full prepolymer methods, both of which are well known in the art. The preferred method of preparing the polyurethanes according to the invention is as follows: The diisocyanate is first mixed with the OH-containing intermediate in an equivalent ratio of about 2.5 to 4.0 NCO/1.0 OH, preferably about 3.0 NCO/1.0 OH, and then reacted at 212° to 230° F. for a period of 3 to 5 hours, or 260° to 265° F. for 5 to 10 minutes, or 275° to 290° F. for 3 to 5 minutes. The heat source is then removed, the prepolymer is cooled to about 160° F. and allowed to stabilize at that temperature for about 24 hours prior to determining the percent NCO in the prepolymer. Additional diisocyanate can then be added to achieve an exact equivalent weight. The prepolymer is then reacted at about 160° F. to 180° F. with the aromatic diamine curing agent in an equivalent ratio of about 0.85 to 1.02 NH 2 /1.0 NCO, preferably about 0.90 to 1.0 NH 2 /1.0 NCO, and more preferably about 0.92 to 0.96 NH 2 /1.0 NCO. The polymer is then cured at 230-275° F. for 4 to 24 hours. The curing time is longer at lower temperatures and shorter at higher temperatures.
[0040] The polyurethane polymers of this invention can be cast or compression molded. Casting is the preferred method because it produces a polyurethane polymer with optimal optical characteristics.
[0041] The prepolymer and curing agent mixture is cast into a mold prior to curing. The polyurethane material according to the invention may also be partially cured, by selecting an appropriate curing time and temperature, and then removed from the casting molds and formed into the desired shape. Using this process, the polyurethane material can be formed into a simple or complex shape and then subsequently fully cured.
[0042] A triol may be added to the prepolymer in an amount sufficient to produce about one percent cross-linking based upon equivalents of reactants. Triols that are useful in the present invention include trimethylol ethane and trimethylol propane. The addition of a triol to the prepolymer increases the heat distortion temperature and in some cases improves the ballastic properties of the cured polyurethane. A triol may be added to the prepolymer in an amount of 0.01 to 0.5 hydroxyl equivalents, preferrably 0.01 to 0.2 hydroxyl equivalents, and most preferrably 0.06 to 0.15 hydroxyl equivalents, based on a total of 1.0 hydroxyl equivalents in the prepolymer. In a preferred embodiment of the invention, the prepolymer contains 0.85 to 0.94 equivalents of an OH-containing intermediate and 0.06 to 0.15 equivalents of a triol, for a total of 1.0 equivalents. In one example, the prepolymer contains a polyester glycol prepared from E-caprolactone and 1,6-hexane diol having an equivalent weight of 200, a similar polyester glycol having an equivalent weight of 375, together with 0.15 equivalents of trimethylol propane. In another example, the prepolymer contains three different OH containing intermediates, namely a polyester glycol prepared from E-caprolactone and 1,6-hexane diol having an equivalent weight of 200, a similar polyester glycol having an equivalent weight of 375, and a polyester glycol prepared from E-caprolactone and 1,4-butane diol having an equivalent weight of 2000 in amounts of 0.8 equivalents, 0.115 equivalents, and 0.025 equivalents, respectively, together with 0.06 equivalents of trimethylol propane. The OH-containing intermediate and triol are preferrably reacted with 2.7 equivalents of a diisocyanate to form the prepolymer.
[0043] Various anti-oxidants, ultraviolet stabilizers, color blockers, optical brightners, and mold release agents may be used in the preparation of the polyurethanes of this invention. For example, one or more anti-oxidants may be added to the prepolymer in an amount of up to 5% by weight based on total reactants. Anti-oxidants that are useful in the present invention include those of the multifunctional hindered phenol type. One example of a multifunctional hindered phenol type anti-oxidant is Irganox 1010, available from Ciba Geigy, which has the following chemical formula:
[0044] A UV-stabilizer may also be added to the prepolymer in an amount up to about 5.0%, preferably about 0.5 to 4.0% by weight based on total reactants. UV-stabilizers that are useful in the present invention include benzotriazoles. Examples of benzotriazole UV-stabilizers include Cyasorb 5411 and Tinuvin 328. Cyasorb 5411, available from American Cyanamid, has the following chemical formula:
[0045] Tinuvin 328, available from Ciba Geigy, has the following chemical formula:
[0046] Another UV-stabilizer that may be used is Cyasorb 3604, available from American Cyanamid, which has the following chemical formula:
[0047] In addition to the benzatriazoles, a hindered amine light stabilizer may be added to further enhance UV protection. An example of a hindered amine light stabilizer is Tinuvin 765, available from Ciba-Geigy, which has the following chemical formula:
EXAMPLES I-VII
[0048] A cycloaliphatic diisocyanate is mixed with one or more polyester glycols, polycaprolactone glycols, polyether glycols, or polycarbonate glycols. The reactants are then heated to 275° F. to 290° F. under dry nitrogen, held at that temperature for 3 to 5 minutes, and allowed to react to form a prepolymer. The prepolymer is cooled to 220° to 250° F., and the UV stabilizer, anti-oxidant, color blocker, and/or optical brightener are added. The prepolymer is further cooled to 170° to 200° F. and then evacuated and stored for 24 hours at 160° F. The percent NCO is then determined.
[0049] The prepolymer is then reacted at about 160° F. to 180° F. with an aromatic diamine curing agent in an equivalent ratio of 0.85 to 1.02 NH 2 to 1.0 NCO. The polymer is then cured at 230° to 275° F. for 4 to 24 hours.
[0050] The reactants used in the Examples are described in Table I below:
TABLE I Ingredient Description Available From Ruco Polyester glycol prepared from Ruco Polymer S-105-110 adipic acid and 1,6 hexanediol; Corp. equivalent weight of about 500 Ruco Polyester glycol prepared from Ruco Polymer S-105-210 adipic acid and 1,6 hexanediol; Corp. equivalent weight of about 268 Solvay Polyester glycol prepared from Solvay Interox Interox Ecaprolactone and 1,6-hexane diol; 396-005 equivalent weight of about 387 Solvay Polyester glycol prepared from Solvay Interox Interox Ecaprolactone and 1,6-hexane diol; 524-021 equivalent weight of about 200 Solvay Polyester glycol prepared from Solvay Interox Interox Ecaprolactone and 1,6-hexane diol; 439-045 equivalent weight of about 954 Ravecarb Aliphatic polycarbonate glycol; Enichem 102 equivalent weight of about 255 Desmodur W 4,4-methylenebis(cyclohexyl Bayer Corp. isocyanate) containing 20% of the trans, trans isomer and 80% of the cis, cis and cis, trans isomers Ethacure 2,4-diamino-3,5-diethyl-toluene Albemarle 100 and 2,6-diamino-3,5-diethyl- Corporation toluene Ethacure 2,4-diamino-3,5-diethyl-toluene Albemarle 100S and 2,6-diamino-3,5-diethyl- Corporation toluene with color stabilizer Lonzacure ® 4,4-methylenebis(3-chloro-2,6- Lonza Ltd. (Basel, M-CDEA diethylaniline) Switzerland); Air Products and Chemical, Inc. (Allentown, Pennsylvania). Tinuvin 328 UV-stabilizer; see supra for Ciba Geigy chemical formula Tinuvin 765 UV-stabilizer; see supra for Ciba Geigy chemical formula Irganox 1010 Anti-oxidant; see supra for Ciba Geigy chemical formula Exalite Blue Dye used as a color blocker Exciton 78-13 Unitex OB Optical brighener Ciba Geigy
[0051] The amounts of each reactant used in each example are set forth in Table II below:
TABLE II eactant Example I Example II Example III Example IV Example V Example VI Example VII Example VIII uco S-105-110 1.0 equiv. 0.7 equiv. 0.4 equiv. uco-S-105-110 0.3 equiv. 0.6 equiv. olvay Interox 0.5 equiv. 96-005 olvay Interox 0.4 equiv. 24-021 olvay Interox 0.1 equiv. 39-045 avecarb 102 1.0 equiv. 1.0 equiv. 0.8 equiv. 0.8 equiv. ,6 hexane diol 0.2 equiv. 0.2 equiv. esmodur W 3.0 equiv. 3.0 equiv. 3.0 equiv. 3.0 equiv. 3.0 equiv. 3.5 equiv. 3.5 equiv. 3.25 equiv. thacure 100S 1 0.93 equiv. 0.93 equiv. 0.93 equiv. 0.93 equiv. 0.93 equiv. 0.93 equiv. 0.93 equiv. 0.93 equiv. inuvin 328 1.0 wt. % 1.0 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % inuvin 765 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % 0.75 wt. % rganox 1010 0.40 wt. % 0.40 wt. % 0.40 wt. % 0.40 wt. % 0.40 wt. % 0.40 wt. % 0.40 wt. % 0.40 wt. % xalite Blue 78-13 1.25 ppm 1.25 ppm 1.25 ppm 1.25 ppm 1.25 ppm 1.25 ppm vitex OB 0.60 ppm 0.60 ppm 0.60 ppm 0.60 ppm 0.60 ppm 0.60 ppm
[0052] The resulting materials are evaluated for their optical, hardness, solvent resistance, heat distortion, and ballistic properties.
[0053] The polyurethane materials of Examples I-IV all have excellent optical properties with haze as low as 0.3 percent, and luminous transmittance as high as 95% at a thickness of 0.080 to 0.250 inches. The Shore D hardness of Examples I-IV ranges from 79 to 82. For examples V-VIII, the Shore D hardness is 77 to 82.
[0054] The polyurethane materials of Examples I, II, and III have a stress craze resistance of >7000 pounds per square inch when measured using isopropanol.
[0055] The V 50 rating of Examples I-IV was evaluated using a 0.25 inch thick sheet and a 0.22 caliber fragment simulating projectile. After multiple tests, the average V 50 rating is about 1,210 feet per second.
[0056] For Examples I-III, the heat distortion temperature of a 0.25 inch thick sample at 264 psi fiber stress ranges from 290° F. to 305° F., and a similar sample of the Example IV material has a heat distortion temperature of 270° F. to 280° F. at 264 psi fiber stress.
[0057] The heat distortion temperatures and ballistic properties for 0.25 inch thick samples of the Example V-VIII formulations are given in the following table:
TABLE III Property Example V Example VI Example VII Example VIII Heat 126° C. 155° C. 145° C. 157° C. distortion (259° F.) (311° F.) (293° F.) (315° F.) temperature, 264 psi fiber stress V 50 0.22 1,183 1,233 1,207 1,169 caliber FSP ft./sec. ft./sec. ft./sec. ft./sec rating
[0058] The foregoing disclosure of examples and other embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise examples and embodiments disclosed. Many variations and modifications of the examples and embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. | The present invention is an optically clear, high hardness, impact resistant polyurethane comprising the reaction product of: (a) a polyurethane prepolymer prepared by reaction of an aliphatic or cylcoaliphatic diisocyanate with (i) at least one OH-containing intermediate having a molecular weight of 400 to 2000 selected from polyester glycols, polycaprolactone glycols, polyether glycols, polycarbonate glycols, and mixtures thereof, and (ii) a triol, in an equivalent ratio of 2.5 to 4.0 NCO/1.0 OH; and (b) at least one aromatic diamine curing agent selected from 2,4-diamino-3,5-diethyl-toluene, 2,6-diamino-3,5-diethyl-toluene, and mixtures thereof in an equivalent ratio of about 0.85 to 1.02 NH 2 /1.0 NCO. The polyurethane provides exceptionally high heat distortion temperatures and excellent chemical resistance. The invention is particularly useful for transparency applications that require excellent impact resistance coupled with high heat distortion temperatures, such as architectural glazings, vehicles, glazings, riot shields, aircraft canopies, face masks, visors, opthalmic and sun lenses, protective eyewear, and transparent armor. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a surface treatment agent which is possible to make a metal surface rust-proofing and to improve the coating film adhesion, and in particular to a metal surface treatment agent suitable for use with aluminum products such as pre-coated aluminum sheets.
[0003] 2. Description of the Related Art
[0004] Metal surfaces have been treated conventionally to improve the corrosion resistance of the metal surfaces, with a number of types of metal surface treatment agent being used. Of the various types of metal surface treatment, chromate treatment using a compound containing chromic acid is commonly used, since chromate treatment gives metal excellent corrosion resistance and also exhibits good properties in terms of adhesion to paints.
[0005] However, it has been pointed out that the chromium used in chromate treatment causes environmental pollution, and hence in recent years alternative metal surface treatment methods and surface treatment agents have been developed. Materials of such surface treatment agents include tannic acid, organophosphorus compounds, silane type coatings, and surfactants, as disclosed in Hyomen Gijutsu (‘Surface Technology’), 49 (3), 221 (1998). Moreover, a surface treatment agent obtained by copolymerizing an unsaturated carboxylic acid (Japanese Patent Publication No. H5-222324) and a surface treatment agent that is a copolymer of a glycidyl-group-containing unsaturated monomer and an acrylic acid ester (Japanese Patent Publication No. H3-192166) are known. These materials all use an acrylic type resin, and to achieve sufficient corrosion resistability the coating film must be made thick. Moreover, the adhesion of these materials to various metals such as iron and aluminum is not always adequate, and in a wet environment the adhesion may drop markedly resulting in the coating film peeling off. Epoxy resin type materials, on the other hand, give improved adhesion to the substrate. For example, a water-soluble coating composition comprising water and an alkali-neutralized reaction product of the reaction between a phosphoric acid containing P—OH bonds, an epoxy resin and a glycidyl (meth)acrylate (Japanese Patent Publication No. H5-148447), and an epoxy resin composition comprising a polyglycidyl compound and a phosphoric acid ester containing P—OH bonds obtained from a phosphoric acid and a monoglycidyl ether or ester compound (Japanese Patent Publication No. H9-176285), have been proposed. However, although these materials give good adhesion, it is necessary to make the coating film thick to improve the corrosion resistability.
[0006] In contrast with the above, in Japanese Patent Publication No. 2001-39927, the present inventors disclosed a novel tricarbonyl compound, a novel tricarbonyl-group-containing acrylic copolymer, and a metal surface treatment agent using the same, as a surface treatment agent that adheres strongly to a metal surface and gives excellent corrosion resistance and corrosion resistability even in the case of a thin film. Furthermore, in Japanese Patent Publication No. 2001-316835, the present inventors disclosed a metal surface treatment agent in which an epoxy ester reaction mixture between a phosphoric acid type compound and an epoxy resin is assorted with a silane compound or a titanium compound.
[0007] However, although the metal surface treatment agents according to the prior art described above give excellent corrosion resistability and are suited to applications in which this treatment is the finishing process (for example an automobile evaporator), application to so-called pre-coated aluminum sheets, i.e. aluminum plates further coated with a polyester, a fluororesin, an epoxy resin or the like, is difficult. In the case of aluminum plates used in automobile evaporators, corrosion resistability is required first of all, and coating film adhesion is not required that much. With pre-coated aluminum sheets, on the other hand, the surface is painted, and hence various properties are required of the aluminum plate after the painting. Specifically, not to mention the corrosion resistability of a painted aluminum plate, the user may use the aluminum plate after bending, and hence coating film adhesion, flexibility and ease of bending are important. In addition, with surface treatment agents applied to pre-coated aluminum sheets, there are calls to move from organic solvents to water-based solvents.
[0008] Furthermore, depending on the usage environment, surface treatment agents applied to pre-coated aluminum sheets may be required to give the pre-coated aluminum sheet surface acid resistance.
SUMMARY OF THE INVENTION
[0009] It is thus an object of the present invention to provide a water-based metal surface treatment agent that forms a coating film having excellent corrosion resistability, coating film adhesion and flexibility, and can be used with various types of metal surface, including pre-coated aluminum sheets.
[0010] The present inventors studied assiduously, and as a result discovered that a water-based metal surface treatment agent having the following (1) to (3) as essential components is effective for attaining the above object.
[0011] (1) A copolymer, containing in a side chain a diketone or ketoester capable of switching between keto and enol tautomeric forms, and containing at least one hydrophilic side chain containing a cationic group, an anionic group or a nonionic group.
[0012] (2) An epoxy resin modified with a phosphoric acid type compound.
[0013] (3) A water-soluble curing agent.
[0014] In particular, the copolymer used in the water-based metal surface treatment agent of the present invention preferably contains a compound represented by undermentioned structural formula (I) as one of the monomers thereof.
[0015] In formula (I), R 1 is a hydrogen atom or a methyl group, R 2 is a C 2-10 alkenyl group having a double bond at the end thereof or a C 1-10 alkyl group, 1 is 1 to 3, and x and y are independently each 0 or 1. Note, however, that the compound is shown only in the keto form above, but the compound may also exist as an enol tautomeric form as shown below; the enol form is also deemed to be included in the present invention.
[0016] Examples of unsaturated monomers which form the copolymer with a compound represented by above-mentioned formula (I) include alkyl acrylates such as methyl acrylate and isopropyl acrylate, hydroxyethyl acrylate, polyethylene glycol acrylate, dimethylaminoethyl acrylate, glycidyl acrylate, 2-cyano acrylate, benzyl acrylate, phenoxyethyl acrylate, tetrahydrofuryl acrylate, dicyclopentenyloxy acrylate, fluoroacrylates, sulfopropyl acrylate, β-ethoxyethyl acrylate, γ-acryloxypropylalkoxysilanes and methacrylates thereof, and unsaturated-bond-containing carboxylic acids such as acrylic acid and methacrylic acid. However, to make the copolymer water-soluble, a side chain containing at least one cationic group such as an amino group, an imino group, a tertiary amine group, a quaternary ammonium salt group or a hydrazine group, anionic group such as a carboxyl group, a sulfone group, a sulfate ester group or a phosphate ester group, or nonionic group such as a hydroxyl group, an ether group or an acido group is necessary. Moreover, 4-vinylphenyltrimethoxysilane or the like can also be used as the above-mentioned unsaturated monomer. Moreover, examples of unsaturated monomers having an alkoxysilyl group such as the above-mentioned γ-acryloxypropylalkoxysilanes include γ-acryloxypropyltrimethoxysilane, γ-acryloxypropylmethyldimethoxysilane and methacryloxy derivatives thereof, and 4-vinylphenyltrimethoxysilane. Furthermore, styrene compounds such as 4-chlorostyrene and pentafluorostyrene can also be preferably used. Moreover, it is possible to use a plurality of these materials together.
[0017] An organic peroxide, an organic azo compound, or a persulfate can be used as a radical polymerization initiator when forming the polymer or copolymer. Preferable examples of organic peroxides include benzoyl peroxide and t-butyl peroxypivalate. Preferable examples of organic azo compounds include 2,2′-azobisisobutyronitrile and 2,2′-azobis(2,4-dimethylvaleronitrile).
[0018] As exemplified by the undermentioned general formula, the copolymer of the present invention can be obtained as a substantially linear structure. In the case that R 2 in general formula (I) is an alkenyl group, a hardenable copolymer is obtained having a structure in which the alkenyl groups hang down. After applying onto the metal surface, such a copolymer can be crosslinked and thus cured by heat, ultraviolet rays, or a curing catalyst or curing agent. The molecular weight of the linear copolymer of the present invention, although not being particularly limited, should be about 1,000 to 1,000,000, preferably 5,000 to 200,000.
[0019] In addition to the copolymer described above, the metal surface treatment agent of the present invention also has as essential components an epoxy resin modified with a phosphoric acid type compound, and a water-soluble curing agent.
[0020] The epoxy resin modified with a phosphoric acid type compound can be obtained by epoxy ester reaction of a phosphoric acid type compound and an epoxy resin.
[0021] Here, phosphoric acid, phosphorous acid, or hypophosphorous acid, or an ester thereof is preferable as the phosphoric acid type compound; in the case of the ester, a lower alkyl monophosphate ester is preferable.
[0022] Moreover, there are no particular limitations on the epoxy resin reacted with the phosphoric acid type compound, but for example a bisphenol type epoxy resin synthesized using bisphenol A or the like is preferable.
[0023] The phosphoric acid type compound and the epoxy resin is reacted such that there are 0.5 to 4.0 equivalents of P—OH groups in the phosphoric acid type compound per 1 equivalent of epoxy groups. It is preferable for the reaction to be proceeded at a reaction temperature of 60 to 150° C. Moreover, the reaction can be carried out in a solvent. Examples of solvents that can be used include alcohol solvents such as ethylene glycol, propylene glycol and methylpropylene glycol, and ether compounds thereof, ethyl acetate, butyl acetate, cellosolve acetate, methyl ethyl ketone, dimethylformamide, and dioxane. After the reaction has been completed, water is added to the reaction mixture to obtain an aqueous solution. Moreover, it is also possible to treat the mixture with an alkali to neutralize active hydrogen groups in the product.
[0024] Examples of alkalis that can be used include ammonia, dimethylamine, diethylamine, methylamine, ethylamine, trimethylamine, triethylamine and dimethylaminoethanolamine. It is preferable for the amount of the alkali used to be 0.8 to 1.5 equivalents per 1 equivalent of active hydrogens in the resin.
[0025] There are no particular limitations on the water-soluble curing agent, but examples include melamine resins and blocked isocyanate resins.
[0026] A water-soluble resin may be included in the metal surface treatment agent of the present invention. A water-soluble resin contributes to improving the film formation ability of the surface treatment agent, and further improves the corrosion resistance of the surface coating film. Examples of such a water-soluble resin include polyvinyl alcohol, saponified polyvinyl acetate, cellulose, alkyd resins, polyester resins, polyethylene glycol, epoxy resins, acrylic resins, urethane resins, and acrylic silicones.
[0027] A preferable composition of the metal surface treatment agent of the present invention is 10 to 50, preferably 20 to 40, parts by weight of the phosphoric-acid-modified epoxy resin, 30 to 70, preferably 40 to 60, parts by weight of an acrylic dicarbonyl copolymer, and 5 to 40, preferably 10 to 30, parts by weight of the water-soluble curing agent, where the treatment agent is 100 parts by weight in total.
[0028] Additives such as viscosity regulators, antifoaming agents, ultraviolet absorbers, preservatives, surfactants and the like may also be used in the metal surface treatment agent of the present invention.
[0029] A publicly known application method can be used for applying the metal surface treatment agent of the present invention onto a metal surface, for example spray coating, dip coating, brush application, roll coating or spin coating.
[0030] To further improve the corrosion resistability of a metallic material using the metal surface treatment agent of the present invention, it is preferable to dry by heating after applying the treatment agent. This drying by heating is preferably continued for 30 seconds to 60 minutes at 100 to 230° C. The thickness of the coating film after the drying is preferably 0.1 to 100 μm, more preferably 0.5 to 10 μm. If this thickness is less than 0.1 μm then it will not be possible to obtain sufficient corrosion resistability, whereas if this thickness is greater than 100 μm then it will not obtain a uniform coating film.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Following is a detailed description of the water-based metal surface treatment agent of the present invention through examples and comparative examples.
EXAMPLE 1
[0032] In the present example, firstly the phosphoric-acid-modified epoxy resin and the acrylic dicarbonyl copolymer used in the water-based metal treatment agent of the present invention were synthesized. Next, the metal surface treatment agent was prepared using the phosphoric-acid-modified epoxy resin and the acrylic dicarbonyl copolymer, and surface of an aluminum plate was treated with the agent. Finally, a description will be given of the method of evaluating the metal surface after the treatment and the results of the evaluation.
[0033] (1) Synthesis of Phosphoric-Acid-Modified Epoxy Resin
[0034] 42.85 g of 85% phosphoric acid and 33.8 g of methylpropylene glycol were put into a 3-mouth 11 flask, this solution was agitated, and nitrogen gas was purged into the flask for 30 minutes. The phosphoric acid solution was then heated to 120° C., and then a solution prepared by dissolving 141.25 g of an epoxy resin (Epikoto 828 made by Yuka Sheru Epokishi) in 24.95 g of methylpropylene glycol was instilled into the phosphoric acid solution over 60 minutes under the nitrogen atmosphere. After completing the instillation, the materials were reacted for 30 minutes at the same temperature (120° C.). 31.7 g of ion exchange water was then instilled in, and reaction was continued for a further 2 hours. The solution was then cooled to 70° C., 83.8 g of triethylamine was added, and reacted for 15 minutes. Next, the reaction solution was cooled to room temperature, and 1482.65 g of ion exchange water was added, thus obtaining a 10 wt % phosphoric-acid-modified epoxy resin aqueous solution.
[0035] (2) Synthesis of Acrylic Dicarbonyl Copolymer
[0036] 6 g of methyl methacrylate, 14.22 g of isobutyl methacrylate, 1.56 g of styrene, 6.70 g of methacrylic acid, 5.21 g of hydroxyethyl methacrylate, 20.95 g of acetoacetoxyethyl methacrylate, 0.66 g of 2,2′-azoisobutyronitrile, 55.30 g of methylpropylene glycol and 304.70 g of isopropanol were put into a 3-mouth flask, and nitrogen gas was purged into the flask for 30 minutes. The reaction vessel was then heated in an oil bath, and the materials were agitated for 4 hours at 85° C. under the nitrogen atmosphere, thus polymerizing. Next, the isopropanol was removed from the polymer solution obtained. 15.75 g of triethylamine was then added, and the solution was agitated, and then 426.65 g of ion exchange water was added, thus obtaining a 10 wt % acrylic dicarbonyl copolymer aqueous solution.
[0037] (3) Preparation of Metal Surface Treatment Agent
[0038] The phosphoric-acid-modified epoxy resin synthesized in (1) above, a melamine resin (Saimeru 350 made by Mitsui Saitekku, diluted with pure water to make a solution having a nonvolatile content of 10 wt %) and the acrylic dicarbonyl copolymer synthesized in (2) above were mixed together in the proportions by mass shown in Table 1 below, thus preparing a surface treatment agent. Note that Table 1 also shows the component proportions for Comparative Examples 1 and 2 described below.
TABLE 1 Proportions by mass of components of surface treatment agent Comparative Comparative Component Example 1 Example 2 Example 1 Phosphoric-acid- 3 3 — modified epoxy resin Water-soluble 2 2 2 curing agent Acrylic 5 — 5 dicarbonyl copolymer
[0039] (4) Surface Treatment of Aluminum Plate
[0040] The surface treatment agent prepared in (3) was applied onto an aluminum plate (A1050P, 55×55×0.6 mm, made by Kobe Seiko) using a spin coating method. The plate was heated for 10 minutes at 220° C., thus producing a test substrate. The thickness of the surface treatment coating film after the drying was about 1 μm.
[0041] (5) Evaluation of Test Substrate
[0042] 1) Evaluation of Corrosion Resistability
[0043] The test substrate produced in (4) was subjected to a saltwater spray test as stipulated in JIS-Z-2371, and the corrosion resistability was evaluated by visual inspection. The test time was 168 hours. There were 3 evaluation levels as follows, and the evaluation results are shown later in Table 2.
[0044] ◯: Virtually no rusting
[0045] Δ: Pitting in places
[0046] X: Corrosion over whole surface
[0047] 2) Evaluation as a Coating Film Foundation (Primer)
[0048] A polyester paint was applied by spin coating onto the surface treatment coating film on the test substrate produced in (4). The substrate was then heated for 5 minutes at 245° C. The thickness of the polyester paint film formed on the test substrate was about 15 μm. Using this test substrate, coating film adhesion, flexibility and acid resistance were tested as described below. The test results are shown later in Table 3.
[0049] (a) Paint Film Adhesion
[0050] The test substrate was immersed in boiling water for 5 hours, and then a checkerboard tape peeling test was performed as stipulated in JIS-K-5400. There were 3 evaluation levels as follows, with evaluating by visual inspection.
[0051] ◯: No peeling
[0052] Δ: Slight peeling seen at intersections in checkerboard pattern
[0053] X: Peeling over whole surface
[0054] (b) Flexibility
[0055] Using a bending test apparatus as stipulated in JIS-K-5400, the test substrate was first bent to the 180° graduation mark under conditions of a mandrel diameter of 3 mm and an auxiliary plate thickness of 3.5 mm. The test substrate was then immersed in boiling water for 5 hours, and then the bent part of the test substrate was visually observed. There were 3 evaluation levels as follows.
[0056] ◯: No cracking at bent part
[0057] Δ: Slight cracking seen at bent part
[0058] X: Paint film peeled away from bent part
[0059] (c) Acid Resistance
[0060] Cross cuts were put in close to the center of the test substrate using a cutter, the test substrate was immersed for 24 hours in a 5 w/v % sulfuric acid solution, and then a tape peeling test was carried out on the cross cut part. There were 3 evaluation levels as follows, with evaluating by visual inspection.
[0061] ◯: No peeling
[0062] Δ: Slight peeling seen at intersections of cross cuts
[0063] X: Peeling over whole surface
EXAMPLE 2
[0064] A solution was prepared by weighing out the components used in Example 1 in the prescribed amounts and then dissolving in pure water and diluting such that the solid content became 20%. Then, the solution was applied by spin coating onto a zinc-plated steel plate (Jinkoto nonkurometohin, 60×80×0.6 mm, made by Shin Nippon Seitetsu). The plate was then heated for 10 minutes at 220° C., thus producing a test substrate, and then a pencil-scratching test was carried out as stipulated in JIS-K-5400. The result was that the pencil hardness was above 5H. Note that the thickness of the surface treatment film was about 3 μm.
COMPARATIVE EXAMPLES 1 AND 2
[0065] In Comparative Example 1, a metal surface treatment agent was prepared having a composition as in Example 1 but without the acrylic dicarbonyl copolymer. Moreover, in Comparative Example 2, a metal surface treatment agent was prepared having a composition as in Example 1 but without the phosphoric-acid-modified epoxy resin.
[0066] Using these metal surface treatment agents, aluminum test substrates were produced as in Example 1, and evaluated. The evaluation results are shown later in Tables 2 and 3.
COMPARATIVE EXAMPLE 3
Comparison 1 with Chromate Treatment
[0067] Chromic phosphate treatment (using Arusafu 407-47, made by Nippon Peinto, chemical conversion coating film chrome amount approx. 2 mg/m 2 ) was carried out as foundation treatment on an aluminum substrate (A1050P, 55×55×0.6 mm, made by Kobe Seiko). The substrate was then subjected to the same saltwater spray test as in Example 1.
[0068] Moreover, an epoxy resin type primer was applied by spin coating onto the chromic phosphate-treated aluminum substrate, and then the substrate was heated for 5 minutes at 245° C. The film thickness of the primer was about 5 μm. As a topcoat, a polyester resin was then applied by spin coating onto the aluminum substrate, and then the substrate was heated for 5 minutes at 245° C. The film thickness of the topcoat was about 15 μm. The resulting substrate was subjected to evaluations as a coating film foundation as in Example 1.
COMPARATIVE EXAMPLE 4
Comparison 2 with Chromate Treatment
[0069] A polyester resin as a topcoat was applied by spin coating directly onto a chromic phosphate-treated aluminum substrate produced as in Comparative Example 3 without applying a primer first, and then the substrate was heated for 5 minutes at 245° C. The film thickness of the topcoat was about 15 μm. The resulting substrate was subjected to evaluations as a coating film foundation as in Example 1.
TABLE 2 Corrosion resistability evaluation results Example 1 ∘ Comparative Example 1 Δ Comparative Example 2 x Comparative Example 3 ∘
[0070] [0070] TABLE 3 Coating film adhesion, flexibility and acid resistance evaluation results Coating film Acid adhesion Flexibility resistance Example 1 ∘ ∘ ∘ Comparative x x x Example 1 Comparative x x x Example 2 Comparative Δ Δ ∘ Example 3 Comparative x x x Example 4
[0071] As can be seen from Tables 2 and 3, the test substrate surface-treated using the surface treatment agent of the present invention showed excellent results in terms of all of the properties corrosion resistability, coating film adhesion, flexibility and acid resistance.
[0072] If the water-based metal surface treatment agent of the present invention is used, then an excellent corrosion resistability effect is exhibited after the surface treatment, even though chrome, which causes environmental pollution, is not used. Moreover, the water-based metal treatment agent of the present invention does not contain silane compounds, and hence the metal surface coating film formed has excellent acid resistance. In addition, the metal surface coating film has excellent coating film adhesion and flexibility. The water-based metal surface treatment agent of the present invention is thus suitable for use with aluminum products such as pre-coated aluminum sheets. | A water-based metal surface treatment agent that is for the surface treatment of metals including aluminum products such a as pre-coated aluminum sheets and gives excellent coating film adhesion, flexibility and acid resistance is provided.
The water-based metal surface treatment agent comprising components following (1) to (3):
(1) A copolymer, containing in a side chain a diketene or ketoester capable of switching between keto and enol tautomeric forms, and containing at least one hydrophilic side chain containing a cationic group, an anionic group or a nonionic group;
(2) An epoxy resin modified with a phosphoric acid type compound; and
(3) A water-soluble curing agent. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to heat exchangers and in particular to an apparatus for heating liquid by use of either a liquid or a vapor.
2. Description of the Prior Art
Liquids have been heated by fluids such as steam or other hot liquids in various manners. It is known that heat transfer coefficients and the efficiency of the heat exchanger improve with the velocity of the fluids. One type of heat exchanger employing high flow rates uses concentric pipes. The cold liquid is forced through the inner pipe while steam is forced through the annular space. Heat is transferred from the steam through the walls of the inner pipe. However the heat transferred to the outer pipe walls is lost, since the liquid to be cooled is located only in the interior pipe.
In U.S. Pat. No. 403,123, a steam water heater is disclosed that uses a bundle of concentric tubes in a tank. Cold water flows up through the annular passage of some of the tube pairs and down the annular passages of others. Some of the steam flows up the inner tubes, while the remainder passes exterior of the outer tubes and out the top of the tank. The velocity of flow is reduced in the resultingly large steam flow areas. In addition, a portion of the steam flows over the cold water intake at a point where thermal stresses and expansion cannot be easily alleviated.
SUMMARY OF THE INVENTION
It is accordingly a general object of this invention to provide an improved apparatus for exchanging heat between two fluids.
It is a further object of this invention to provide an improved apparatus for exchanging heat between two fluids using concentric tubes and high velocity flow of each fluid to create high heat transfer coefficients on the walls of both tubes.
It is a further object of this invention to provide an improved apparatus for heating a liquid with another fluid that utilizes concentric tubes and avoids stresses due to thermal expansion.
In accordance with these objects, a heat exchanger is provided that contains concentric inner and outer tubes to define an inner passage and an annular passage. A first manifold directs a first fluid into the inner passage. A second manifold directs a second fluid into the annular passage to enable high velocity flow. A third manifold on the opposite end directs the second fluid from the annular passage out so that it will not mix with the first fluid of the inner passage. The exterior of the outer tube is immersed in the first fluid that flows through the inner passage. Thus, heat is transferred between the second fluid and the first fluid through the wall of the inner tube and simultaneously through the wall of the outer tube. None of the tubes are restrained from movement at their ends, allowing thermal stresses to be relieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partially in section, of a heat exchanger constructed in accordance with the teachings of this invention.
FIG. 2 is a cross sectional view taken along the longitudinal axis of the heat exchanger of FIG. 1.
FIG. 3 is a cross sectional view taken along the lines III--III of FIG. 2.
FIG. 4 is a perspective view, partially in section, of an alternate embodiment of a heat exchanger constructed in accordance with the teachings of this invention.
FIG. 5 is a perspective fragmentary view, partially in section, of another alternate embodiment of a heat exchanger constructed in accordance with the teachings of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 3, a heat exchanger 11 is shown. The heat exchanger 11 has a plurality of concentric tubes or tube-pairs 13 spaced in a bundle. Referring to FIG. 2, each tube-pair comprises an outer tube 15 within which an inner tube 17 is carried, defining an inner passage 19 and an annular passage 21.
These tube-pairs 13 are carried in a bundle by four partitions or tube sheets. The first partition 23 is located on the first end and comprises a circular plate with apertures for sealingly receiving the inner tubes 17. The second partition 25 is spaced from the first partition 23 and comprises a circular plate with apertures for sealingly receiving the outer tubes 15, which terminate at this plate. The third partition 27 is identical to the second partition 25, comprising a plate with apertures for receiving the outer tubes 15, whose second ends terminate at partition 27. The fourth partition 29 is spaced substantially at the second end of the heat exchanger and, similar to the first partition 23, has apertures for sealingly receiving inner tubes 17. Consequently the inner tubes 17 extend from the first to the fourth partitions, while the outer tubes 15 extend from the second to the third partitions. As shown in FIG. 3, one bottom tube 33 does not contain an inner tube, to facilitate flow of condensate if steam is used as the heating medium.
The first partition 23 and second partition 25 are sealingly enclosed in a cup-shaped housing 31, with the mouth of the housing at the second partition 25 and the closed end 35 of the housing spaced away from the first partition 23 a short distance. An inlet 37 is located in the center of the closed end 35 of housing 31 for receiving incoming fluid, normally water to be heated. Consequently the closed end 35, inlet 37, and partition 23 serve as first manifold means for directing all of the incoming first fluid to the inner passages 19.
A baffle 39 extends between the first and second partitions 23, 25 perpendicular to them and parallel with the tube-pairs 13. Baffle 39 is a solid plate sealingly secured to the first and second partitions and located approximately midway in the bundle. Baffle 39 divides the space enclosed by housing 31 into two separate chambers, designated as intake chamber 41 and discharge chamber 43. An inlet 45 is located in housing 31 on the side in communication with intake chamber 41. Inlet 45 is connected to the source of the second fluid, thus serves with intake chamber 41 as second manifold means for directing all of the second fluid to the annular passages 21.
An outlet 47 is located in housing 31 in communication with the discharge chamber 43. Outlet 47 is connected to the return or downstream side of the second fluid source. A cylindrical housing 49 sealingly encloses the space between the third and fourth partitions 27, 29, defining a reversing chamber 50, which in combination with the discharge chamber 43, outlet 47 and interconnecting annular passages 21, serve as third manifold means for directing second fluid out of the heat exchanger 11.
A cylindrical housing or jacket 51 has a closed end 53 at the second end of the heat exchanger 11, and extends the length of the concentric tubes 13, terminating at the second partition 25. A reversing chamber 52 is defined by the space between closed end 53 and the fourth partition 29. The only outlet in jacket 51 is outlet 55, located approximately at the first end of the concentric tubes 13, near partition 25. There is a clearance between housing 49 and jacket 51, causing the outer tubes 15 to be immersed in the first fluid of the inner passage 19 as the fluid flows toward outlet 55. Baffles could be spaced between the jacket 51 and the concentric tubes 13 to increase the velocity in this area by causing the first fluid to flow out in an "S" pattern.
In the operation of the heat exchanger of FIGS. 1 through 3, a liquid may be used to heat a liquid, or a vapor such as steam may be used for heating the liquid. Preferably the liquid to be heated enters inlet 37, and as shown by a solid-line arrows 57 of FIG. 2, passes from the first manifold to all of the inner passages 19. This liquid is discharged at the second end and reverses its direction of flow in reversing chamber 52. It then passes through the space between jacket 51 and the tube bundle, then out outlet 55, immersing substantially the entire length of the outer tubes 15 in the liquid.
Steam enters through inlet 45 into intake chamber 41, then passes into the annular passages 21 that are in communication with the intake chamber 41, as shown by the dotted-line arrows 59 of FIG. 2. Heat from the steam is transferred to the water across the walls of the inner tubes 17 and across the walls of the outer tubes 15. When the steam reaches the reversing chamber 50, the direction of flow is reversed, returning the steam in the outer tubes 15 that terminate at the discharge chamber 43. Steam flows through these passages, exchanging heat with water in the inner passages 19 and on the exterior of the outer tubes 15. Condensate flows through tube 33 to discharge chamber 43. The remaining steam and condensate are discharged through outlet 47.
The tubes are allowed to expand and contract due to thermal changes, since the third and fourth partitions are not attached to jacket 51. The first and second partitions 23, 25 are attached to housing 31, but the inner tubes 17 merely pass through the second partition 25 and are not connected to it so as to restrain expansion.
A heat exchanger constructed as shown in FIG. 1 was tested, resulting in an increase of water temperature from 60° F. to 100° F. with steam as the heating fluid. Thirty eight gallons per minute of water was flowing at six feet per second in inner passages 19 and the steam pressure was fifteen pounds gauge pressure per square inch at an altitude of 600 feet above sea level. Thirteen tube-pairs 13 were used with 1/2 inch O.D. inner tubes 17 and 3/4 inch O.D. outer tubes 15. The length of the heat exchanger was 35 inches, and the diameter of jacket 51 was four inches. The clearance between the housing 49 and the jacket 51 was 1/4 inch, and segmental baffles were placed in the spaces between the concentric tubes and the jacket at four inch intervals.
The apparatus disclosed will also function if the passages for the heating fluid and the liquid to be heated are interchanged. The hotter or first fluid can enter through inlet 37 into the inner passages 19, and the liquid to be heated or second fluid can pass through the annular passages 21. Also the directions of flow of one or both fluids can be reversed. The first fluid can enter outlet 55 of the jacket, flow over the outer tubes 15, reverse in reversing chamber 52 then pass through the inner passages 19 from the second end to the first end. In that case the first manifold means for directing incoming first fluid to the inner passages 19 would comprise outlet 55, partition 29, and jacket 51. The second fluid could also flow in reverse. If so, the second manifold means for directing incoming second fluid into the annular passages would include discharge chamber 43 and outlet 47. However, if steam is used as the second fluid, an outlet on the bottom for condensate should be provided, and the steam should preferably enter from an upper outlet. If the second fluid flow is reversed, the third manifold means for directing second fluid out of the heat exchanger would include reversing chamber 50, the interconnecting annular passages 21 with the intake chamber 41, and outlet 45.
FIGS. 4 and 5 disclose alternate embodiments. The embodiment of FIG. 5 is designed particularly for heating a liquid by steam. A single discharge conduit 61 extends from the third partition (not shown) through the second partition 25', thence out of the housing 31', which encloses the space between first and second partitions 23', 25'. An inlet 45' in housing 31' provides communication for the steam to annular passages 21', as shown by the dotted-line arrows 59'. Water enters inner passages 19' by a first manifold (not shown) similar to that in the embodiment of FIGS. 1 through 3, as shown by the solid-line arrows 57'. This embodiment does not require a baffle between the first and second partitions 23', 25' because of conduit 61, which serves as part of the third manifold means for directing second fluid out of the heat exchanger. The steam exchanges heat primarily when in the annular passages 21'.
FIG. 4 discloses an embodiment primarily for use in a storage tank 63, with most of the length of the concentric tubes being on the interior of the tank and surrounded by liquid discharged from the inner passages. The inner tubes 17" extend parallel to each other and are connected by conventional means to the liquid to be heated. Outer tubes 15" are connected by conventional L-shaped fittings 65 to the source and return of the heating fluid. At the second or interior end of the heat exchanger, the outer tubes 15" are closed and connected together by a passage 67. A jacket 51', with a closed interior end, extends around the concentric tubes and terminates at the wall of the storage tank 63. An outlet 55' is provided in jacket 51' at the tank 63 wall to allow fluid discharged from the inner passage 19' to flow into the storage tank.
In operation, the liquid to be heated enters the inner passage 19' of each concentric tube as shown by the solid-line arrows 57". After heating, the fluid discharges from the second end, flows back over the outer tubes 15" within jacket 51', and then out into storage tank 63. The heating fluid enters one of the inlet connections 65 and flows through one of the annular passages 21", as shown by the dotted-line arrows 59", with connection 65 serving as the second manifold. The second fluid enters passage 67 at the second end and flows back down into the other annular passage 21" and out connection 65, this connection and passage 67 serving as the third manifold means. Heat is exchanged through the walls of the inner tube 17" and outer tube 15". Since the heat exchanger of this embodiment is suspended only at a point intermediate its ends, the concentric tubes are free to expand and contract due to thermal changes.
It should be apparent that an invention having significant improvements has been provided. By forcing all of the incoming fluids through the inner and annular passages of the concentric tubes, both fluids can flow at high velocities. Greater efficiency is achieved by immersing the outer tubes in the fluid of the inner passage, causing heat to be transferred across the walls of both the inner and outer tubes. This is particularly efficient when using the jacket, which reverses the direction of flow of the fluid of the inner tube and causes fluid flow back across the outer tubes. The ends of the concentric tube-pairs are not restrained, allowing change in length due to thermal changes.
Having described the invention in connection with certain embodiments thereof, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A heat exchanger for heating liquids with other liquids or vapors. An inner flow tube is carried concentrically within an outer flow tube to define an inner passage and also an annular passage. A first manifold directs all of the incoming fluid from one fluid source to either the inner or annular passage. A second manifold directs all of the incoming cooler fluid from the other fluid source to the other passage. A third manifold at the other end of the outer tube discharges the fluid from it so that it does not mix with the inner tube fluid. The outer tube is immersed in inner tube fluid to cause heat transfer through the walls of the inner tube and outer tube. | 5 |
FIELD OF THE INVENTION
The present invention relates to a self-cleaning bar screen for storm water and the like large water volumes carrying solids or suspended matters.
BACKGROUND OF THE INVENTION
It is known to provide a self-cleaning screen that is a screen which does not require any mechanical equipment as rotating or travelling rake for periodically cleaning the same from the solids filtered out of the water flowing through the screen bars.
In a known construction, the bars are set at an angle and the solids flow down the bars by gravity into a collecting trough disposed transverse to the lower end of the screen bars. However, it frequently happens that the solids fail to flow down the bars and rapidly clog the screen with the result that the screen is overpassed and the water is not properly screened, and will require more maintenance attention.
OBJECTS OF THE INVENTION
It is therefore the main object of the present invention to provide an improved self-cleaning bar screen of the character described in which screen clogging is eliminated.
Another object of the present invention is to provide such a self-cleaning which is devoid of any moving parts.
Another object of the present invention is to provide a bar screen of the character described of very simple and inexpensive construction, which will have a long useful life and which does not require any attention for its operation.
SUMMARY OF THE INVENTION
The present invention relates to a self-cleaning bar screen for storm water and the like large water volumes.
The gist of the invention is to provide an improved self-cleaning bar screen in which screen clogging is eliminated.
More particularly, the invention discloses a bar screen comprising a plurality of parallel spaced inclined bars having an upper end and a lower end, each bar being formed with a channel in the upstream edge face thereof, each channel having a cross-sectional area which decreases from said upper end to said lower end of the bar.
The invention furthermore discloses the combination of an inflow basin having a water inlet and a weir over the top of which the water is discharged and drops into an outflow basin, a solid collecting trough spaced from and generally parallel to said weir and at a level intermediate the level of said weir and the water level in said outflow basin, a bar screen extending between said weir top and said trough and including a plurality of inclined, spaced, parallel, straight screen bars each having an upper end fixed to said weir top and a lower end fixed to said trough, whereby water overflowing said weir drops into said outflow basin between said screen bars and while solids in said water are filtered out by said screen bars, each bar having an upstream edge face formed with a longitudinal channel for receiving water overflowing said weir and discharging the same into said trough, whereby the water flowing within said channels causes downward movement of said solids along said upstream edge faces of said bars and are discharged into said trough.
Preferably, the cross-sectional area of each channel decreases from said upper end to said lower end of the bar.
Preferably, the depth of the channel decreases while its width remains constant from the upper end to the lower end of the bar.
Advantageously, the rate of decrease of said cross-sectional area of said channel is constant from said upper end to said lower end of said bar.
Preferably, the rate of decrease of said depth is constant from said upper end to said lower end of said bar.
Advantageously, each screen bar has a progressively decreasing thickness from its upstream edge face to its downstream edge face.
Preferably, each channel has a flat bottom face and flat inner side faces.
Advantageously, the combination further includes a lip fixed to said weir top and overhanging said inflow basin.
Preferably, the ratio of the channel width over the bar thickness at said upstream edge face varies from 1/2 to 5/6.
BRIEF DESCRIPTION OF THE DRAWINGS
In the annexed drawings:
FIG. 1 is top plan section, taken along line 1--1 of FIG. 2, of an installation in which the self-cleaning screen is used for screening storm water;
FIGS. 2 and 3 are vertical sections taken along lines 2--2 and 3--3 respectively of FIG. 1;
FIG. 4 is a vertical section at an enlarged scale taken along line 4--4 of FIG. 2;
FIG. 5 is a top plan view taken along line 5 of FIG. 4; and
FIGS. 6, 7 and 8 are sections taken along lines 6--6, 7--7 and 8--8 respectively of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The bar screen 2 in accordance with the present invention is installed within a storm water screening assembly generally indicated at 4 and comprising an inflow basin 6 fed with rain water by an inlet pipe 8, the water network e.g. rain storm water having a sufficient capacity to accept water from a storm. Adjacent inflow basin 6 is a chamber 10 which is connected by an outlet pipe 12 to the sewer network. Inflow basin 6 is separated from an outflow basin 14 by a weir 16. Outflow basin 14 is connected to a storm water outlet pipe 17. Bar screen 2 is composed of a series of spaced, parallel straight screen bars 18 and intervening spacer blocks 23 secured together byte rods (or equivalent attachment means). Bars 18 are all coplanar and are vertically inclined, having their upper ends 20 secured to the top of weir 16 and their lower ends 22 secured over a trough 24 which extends transversely of the screen bars 18 and is adapted to collect the solids filtered out of the storm water flowing between the screen bars 18. Trough 24 is at a level intermediate the top of weir 16 and the maximum water level in basin 14. The solids moving down along bars 18 are collected by the trough 24 is directed into the chamber 10 through an opening 26 made in wall 28 separating the two basins 6 and 14 from sewer chamber 10.
In normal condition, the rate of flow of the water entering inflow basin 6 through storm water inlet pipe 8 is not sufficient to flow over weir 16. It simply enters a flow regulator 30 through the regulator inlet 32 at the bottom of inflow basin 6. The flow regulator discharges the water directly into the sewer chamber 10. The flow regulator is adjusted so that it controls the flow to an amount which is not above the flow capacity of the sewer network outlet pipe 12.
Whenever the flow rate of the water entering inflow basin 6 through inlet pipe 8 exceeds the controlled flow rate of the regulator, the water level within inflow basin 6 rises and the water flows over the top of weir 16 onto the upstream edge faces 34 of the screen bars 18. The water flows between the bars to be discharged to a river or the like by the storm water outlet pipe 17.
The solids filtered out of the storm water and resting on the upstream edge faces 34 of the screen bars 18 move down by gravity along the screen bars to be collected within the trough 24. In order to assist the solids in their downward movement towards the trough, the upstream edge faces 34 of each bar is provided with a longitudinally extending channel 36 opening at both the upper end 20 and lower end 22 of the bar 18. A portion of storm water flowing over the top of weir 16 enters the channels 36 and flows down these channels to be discharged into trough 24. It has been found that a downward moving water film is formed on the upstream edge faces 34 of the bars effectively carrying the screened solids into trough 24 therefore continuously effecting cleaning of the bar screen 2.
The water flowing down channels 36 serves also to transport the screened solids along trough 24 into sewer chamber 10.
In one embodiment, as shown in cross-section in FIGS. 6 and 7, each channel 36 is of generally quadrangular cross-section defining straight parallel inner walls 38 and a straight bottom face 40. In an alternate embodiment (not shown), straight bottom face 40 could be made transversely concave to form a rounded surface merging with the straight inside faces 38.
Preferably, the cross-sectional area of each channel 36 progressively decreases along the screen bar 18 from its upper end 20 to its lower end 22 so that the channel will remain filled with water along its entire length despite the fact that the water accelerates down the channel 36 due to the inclination of the screen bars 18. In practice, this progressively decreasing cross-sectional area is obtained by progressively decreasing the depth of the channel 36, as clearly shown in FIG. 8.
The pitch between adjacent screen bars 18 may vary in accordance with the fineness of the solids to be filtered out, this pitch being indicated as a variable pitch PV in FIG. 6. This pitch is naturally composed of the maximum thickness of each bar plus the width of the interbars slots indicated at BV at FIG. 6, which is also variable. The height of each screen bar 18 together with its thickness will depend on the length of the screen bars 18 from the upper to the lower supported ends 20, 22. The width A of each channel 36 may vary and, as shown in FIGS. 6 and 7, the depth of the channel indicated at A' in section 6--6 of the screen bars 18 is about twice the channel depth in the area of the screen bars taken along line 7--7 of FIG. 5 and indicated as A'/2.
Preferably, each screen bar 18 is downwardly tapered, as indicated by angle α from its upstream edge face 34 to its downstream edge face 35. This facilitates clearing of the debris which might become trapped between the inter-bar slots 42.
Screen bars 18 are preferably extruded from a thermoplastic such as the Delrin P acetal resin sold by Dupont.
Preferably, as shown in FIG. 4, the top edge of weir 16 is fitted with a lip 44 which extends inwardly over the inflow basin 6. It has been found that this lip 44 acts as a baffle or deflector which, in high water flow over the weir, prevents the water from shooting high over the weir 16 and land on the screen bars 18 in a zone spaced a substantial distance form their upper ends 20 so that all the upper portion of the bar screen will remain useless for filtering. With the lip 44, the water is caused to flow outwardly from the weir 16 then over the curved top of the lip to fall immediately adjacent the upper ends 20 of the screen bars 18. Thus the entire surface of the bar screen is effective for screening solids of the storm water. The width A of the channels 36 may vary between 1/2 and 5/6 of an inch. The following are typical dimensions of the screen bars 18 in relation to their maximum bar thickness and the width of their channels 36:
______________________________________Maximum bar thickness Channel width A(in inches) (in inches)______________________________________1/8 1/16 3/16 1/81/4 3/163/8 1/41/2 1/43/4 5/8______________________________________
From this table, it is seen that the ratio of the channel width over the maximum bar thickness varies from 1/2 to 5/6. Obviously, for maximum bar self-cleaning efficiency, the ratio should be maximum.
The width of the interbar slots 42 is preferably 1/4 of an inch, but will vary in accordance with the size of the solids to be removed from the water.
The preferred inclination of the bar screen 2 is between 30° and 45°. However, it is possible to vary the inclination between 15° to 75°.
Whenever is mentioned the word basin, it is envisioned to include any duct, conduit or other reservoir or tank capable of holding and retaining a volume of liquid, particularly water. Moreover, it is noted that the application of the present invention is not to be exclusively limited to the sewer waste water treatment industry, but could easily be expanded to other suitable industries, in particular the pulp and paper industry and the food processing industry. | The screen comprises a set of spaced parallel grating bars set at an inclination of about 35 degrees. The grating bars retain solids carried by the water flowing between the bars. These solids are automatically pushed down the bars and away into a collecting trough transverse to the bars by water streams flowing within longitudinal grooves formed from the top of the bars. The cross-sectional area of each groove decreases from the upper end to the lower end of the bar, so that the water accelerating down the bar grooves will constantly fill the same. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims a benefit of priority under 35 U.S.C. §119 to Provisional Application No. 61/914,935 filed on Dec. 11, 2013, which is fully incorporated herein by reference in its entirety.
BACKGROUND INFORMATION
1. Field of the Disclosure
Examples of the present disclosure are related to systems and methods to secure an infant to a parent. More particularly, embodiments relate to coupling an article of clothing configured to be worn by the parent with a basinet.
2. Background
Studies in obstetrics and pediatrics have raised initiatives to maximize time spent between parents and their newborn infants. The initiatives desire that the parents spend time with their infant immediately following birth to facilitate maternal, breast feeding, and other activities. Particularly, the initiatives advocate the rapid bonding of mothers and their infant, which will minimize a timing window for introducing the infant to antibodies and nutritional benefits derived from maternal, breast feeding.
Health care facilities, such as hospitals, generally demonstrate support for such initiatives by rapidly pairing infants with their mothers following delivery, and by allowing infants to stay with their parents in their hospital room for prolonged periods after birth. Conventionally, the pairing occurs by co-locating an infant and mother in the mother's hospital room, which includes a bed or comparable device, such as a chair.
However, parental fatigue following a child birth is prevalent for the parents. Parental fatigue may occur due to the parents of an infant having to stay awake for long, consecutive time periods during child birth. Additionally, parental fatigue may occur due to the stressful nature of child birth.
Combining the health initiatives with parental fatigue may lead to circumstances where a parent needs secondary support mechanisms to ensure infants are not dropped, released, etc. while the parent is holding the infant. For example, during maternal, breast feeding, a mother may need a secondary support system immediately following a long and stressful birth of the infant. Furthermore, secondary support mechanisms may be desired during any activity that may require the parent to hold the infant, such as holding the infant while walking, feeding the infant, etc.
Accordingly, needs exist for more effective and efficient methods and systems for secondary, supplemental support systems to secure an infant to a parent.
SUMMARY
Embodiments of this disclosure may be configured to be a secondary, supplemental, extra, etc. support system to help a parent secure an infant to the parent, wherein the supplemental support system is designed for comfort and flexibility. While a plurality of potential hazardous situations may arise while a parent is holding an infant, such as dropping, choking, circulation impairment etc., embodiments may limit, reduce, or eliminate the hazards and injuries to the infant and/or parent.
Embodiments disclosed herein describe systems and methods including a bassinet and an adult article of clothing configured to be worn by a parent.
The bassinet may be any container configured to hold an infant, wherein the bassinet may include at least one first coupling interface. The adult article of clothing may be a vest, belt, strap, sash, etc. with a second coupling interface, wherein the first coupling interface is configured to couple with the second coupling interface.
Embodiments may provide a flexible yet robust solution to circumvent scenarios leading to an accidental drop of an infant by fatigued parents, or parents distracted for any number of reason. Embodiments may be used in hospital settings to limit, reduce, or eliminate the risk of serious injury to an infant, while also limiting, reducing, or eliminating the potential emotional trauma to a parent of a newborn infant due to drop incidents.
These, and other, aspects of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. The following description, while indicating various embodiments of the invention and numerous specific details thereof, is given by way of illustration and not of limitation. Many substitutions, modifications, additions or rearrangements may be made within the scope of the invention, and the invention includes all such substitutions, modifications, additions or rearrangements.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
FIG. 1 depicts one embodiment of a portion of support system to secure an infant to an adult.
FIG. 2 depicts one embodiment of a portion of support system to secure an infant to an adult.
FIG. 3 depicts one embodiment of a portion of support system to secure an infant to an adult.
FIG. 4 depicts one embodiment of a method for a secondary, stabilization system to secure infants to adults.
FIG. 5 depicts one embodiment of a stabilization system in use.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present disclosure. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure.
DETAILED DESCRIPTION
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present embodiments. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present embodiments. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present embodiments.
FIG. 1 depicts one embodiment of a portion of support system 100 to secure an infant to an adult. Support system 100 may include a bassinet 110 and infant coupling members 120 .
Bassinet 110 may be comprised of any type of fabric or a plurality of different types of fabric including cotton, wool, nylon, acrylic, etc., and may be manufactured in a variety of styles. Bassinet 110 may be cradle, bed, enclosure, etc. configured to hold an infant. In further embodiments, bassinet 110 may be a garment configured to be positioned on an infant's upper body and/or lower body. For example, infant article of clothing 110 may be a shirt, jumpsuit, onesie, jacket, sweater, etc. Infant article of clothing 110 may be configured to be worn by the infant for protection and warmth.
Bassinet 110 may include a plurality of sidewalls 112 with an opening 114 . In embodiments, sidewalls 112 may be configured such that opening 114 may be a permanent opening, wherein sidewalls 112 do not fold over themselves. Accordingly, an infant positioned within the bassinet 110 may not be fully covered by sidewalls 112 via opening 114 . Furthermore, a circumference of opening 114 may be comprised of a semi-rigid, semi-flexible polymer that may be expanded and contracted.
FIG. 2 depicts one embodiment of infant coupling interface 120 positioned on a sidewall 112 of bassinet 110 . Infant coupling interface 120 may be permanently positioned on a front and outer surface of bassinet 110 , such that infant coupling interface 120 may be positioned on a sidewall 112 . However, one skilled in the art will appreciate that infant coupling interface 120 may be positioned at any location on an outer surface of bassinet 110 . For example, infant coupling interface 120 may be configured to be positioned to extend vertically across a sidewall 112 , extend horizontally across a sidewall 112 , extend diagonally across a sidewall 112 , etc.
The positioning of infant coupling interface 120 on bassinet 110 may vary to provide coupling support to the infant from the parent based on the activity the parent is engaging in.
Infant coupling interface 120 may also be configured to be removably coupled with an adult article of clothing, shown in FIG. 3 . In embodiments, infant coupling interface 120 may include first infant coupling members 122 , and second infant coupling member 124 . First infant coupling members 122 may be a male type coupling interface, such as male portions of fasteners, snaps, buckle, buttons, clips, etc. Second infant coupling member 124 may be a second type of coupling interface, which is a different coupling member that first coupling member 122 . Second infant coupling member 124 may be configured to be positioned in-between the first infant coupling members. In embodiments, second infant coupling member 124 may include snaps, a hoop and lock mechanism such as Velcro, a zipper, button(s), buckle(s), clip(s), etc.
FIG. 3 depicts one embodiment of a portion of support system 200 to secure an infant to an adult. Coupling system 200 may include an adult article of clothing 210 and adult coupling interface 220 .
Adult article of clothing 210 may be comprised of any type of fabric or a plurality of different types of fabric including cotton, leather, cloth, etc., and may be manufactured in a variety of styles. Adult article of clothing 210 may be an adjustable belt-like device, such as a belt, sash, scarf, etc. that may be configured to fasten securely, yet comfortably around a parent's body, such as around the parent's midsection, waist, or any other portion of the parent's body where article of clothing 210 fastens comfortably, yet securely to the parent. Adult article of clothing may be configured to fasten around a parent's mid-section, and may be secured using hook and loop fasteners.
Disposed on at least a portion of outer surface of adult article of clothing 210 may be adult coupling interface 220 . In embodiments, adult coupling interface 220 may be positioned on an entire outer surface of adult article of clothing 210 , or on only a front portion of adult article of clothing 210 . In embodiments, adult coupling interface 220 may be fixedly or removably attached to the outer surface of adult article of clothing 210 , such that an adult may wear adult article of clothing as a conventional belt, sash, strap, etc.
Adult coupling interface 220 may include first adult coupling members 222 , and second adult coupling member 124 . First adult coupling members 222 may be a female type coupling interface, such as female portions of fasteners, snaps, buckle, buttons, clips, etc. In embodiments, first adult coupling members 222 may be configured to align with and couple with first infant coupling members 122 , such that first adult coupling members 222 and first infant coupling members 122 may be removably connected with one another. Second adult coupling member 324 may be a second type of coupling interface, which is a different coupling member that first adult coupling member 222 . Second adult coupling member 224 may be configured to be positioned in-between the first adult coupling members 222 . In embodiments, second adult coupling member 224 may include snaps, a hoop and lock mechanism such as Velcro, a zipper, button(s), buckle(s), clip(s), etc. In embodiments, second adult coupling member 224 may be configured to align with and couple with second infant coupling members 124 , such that second adult coupling members 224 and second infant coupling members 124 may be removably connected with one another. Accordingly, adult article of clothing 210 may couple with bassinet 110 via different coupling devices and systems, which may provide extra support while an infant is positioned within bassinet 110 .
FIG. 4 illustrates a method 400 for a secondary, stabilization system to secure infants to adults. The operations of method 400 presented below are intended to be illustrative. In some embodiments, method 400 may be accomplished with one or more additional operations not described, and/or without one or more of the operations discussed. Additionally, the order in which the operations of method 400 are illustrated in FIG. 4 and described below is not intended to be limiting.
At operation 410 , an infant may be positioned within a bassinet. Operation 410 may include an infant article of clothing that is the same as or similar to bassinet 110 , in accordance with one or more implementations.
At operation 420 , a parent may wear an adult article of clothing. The parent may wear the adult article of clothing by adjusting the adult article of clothing to be secured tightly around a portion of an adult's body. In embodiments, the adult article of clothing may be adjusted to be positioned adjacent to the parent's midsection, such that the adult article of clothing is secured to the parent. Operation 420 may include an adult article of clothing that is the same as or similar to adult article of clothing 210 , in accordance with one or more implementations.
At operation 430 , adult coupling interface positioned on the adult article of clothing may be removably coupled to an infant coupling interface positioned on clothing surface of the bassinet. The adult coupling interface may include adult coupling members, which may include a male or female component, to couple with infant coupling member including infant coupling members, wherein the infant coupling members may include corresponding male or female components.
In embodiments, when the adult coupling interface may be coupled with the infant coupling interface, an infant may be securely coupled to the parent in a position adjacent to the parent while the infant is raised off a ground surface. Accordingly, the infant may be positioned adjacent to the parent's mid-section while the parent positions one hand underneath the bassinet. Accordingly, the parent may have a second free hand. The coupling of the coupling members may secure the infant to the parent for a period of time, which may be any desired period of time. For example, in embodiments, the period of time may be a temporary period of time lasting from a couple of seconds, to a couple of minutes, or when the adult performs actions to apply enough force to decouple the coupling members.
Accordingly, the coupling members may be configure to act as a secondary support to couple an infant to a parent when the infant is raised off a floor surface to protect against an accidental drop of the infant, but the coupling members may not apply force to independently maintain the infant in an elevated state without support from the parent. Operation 430 may include infant coupling members and adult coupling members that are the same as or similar to infant coupling interface 120 and adult coupling interface 220 , in accordance with one or more implementations.
At operation 440 , the infant may be removed from the bassinet, and then a parent may perform actions to apply enough force to decouple the infant coupling interface and adult coupling interface. Operation 440 may include an adult article of clothing that is the same as or similar to adult article of clothing 210 , in accordance with one or more implementations.
FIG. 5 depicts one embodiment of an infant stabilization system in use. As depicted in FIG. 5 , an infant may be positioned within bassinet 110 and an adult may be wearing adult article of clothing 210 , wherein bassinet 110 is coupled to adult article of clothing 210 . Furthermore, the adult may be providing additional support to secure the infant within bassinet 110 .
Although the present technology has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the technology is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present technology contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.
Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” or “an example” means that a particular feature, structure or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.
The flowcharts and block diagrams in the flow diagrams illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowcharts 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). | Embodiments disclose a secondary, supplemental, extra, etc. support system to help a parent secure an infant to the parent, wherein the supplemental support system is designed for comfort and flexibility. While a plurality of potential hazardous situations may arise while a parent is holding an infant, such as dropping, choking, circulation impairment etc., embodiments may limit, reduce, or eliminate the hazards and injuries to the infant and/or parent. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of German Application No. 102 04 993.9, filed Feb. 5, 2002, the complete disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
a) Field of the Invention
The invention is directed to an arrangement for machining workpieces by means of a laser, particularly for cutting, perforating, notching, engraving, drilling and inscribing workpieces with three-dimensional structures of different sizes. It can also be used advantageously for removing layers from such workpieces.
b) Description of the Prior Art
Arrangements for machining a workpiece by means of a laser basically comprise a laser, a device for guiding the laser beam to the workpiece and a device for holding the workpiece. For processes in which a relative movement (forward feed) must be carried out between the laser beam, as tool, and the workpiece (e.g., cutting, perforating, ablating), this relative movement is usually realized by the device for guiding the laser beam, while the workpiece is held so as to be stationary.
Various basic principles are known for such devices for guiding the laser beam to the stationary workpiece surface.
For machining of large-area workpieces in particular, arrangements are known in which a laser head focusing the laser beam can be moved freely in a parallel to the workpiece surface by means of an overhead gantry or frame. The laser beam travels from the laser to the laser head by way of an articulated mirror arm. This is advantageous in that, when suitably dimensioned, a frame of this kind can guide the laser beam also over very large workpiece surfaces. Its disadvantages consists in a large space requirement, limited machining speed, particularly when the machining direction is changed often, and the fact that it is applicable exclusively on plane workpiece surfaces.
Arrangements in which a laser head is arranged at a robot arm which is freely movable in three dimensions are also known for machining large workpiece surfaces. In this case also, the laser beam, is guided to the laser head by an articulated mirror arm. The size of the workpiece surface to be machined is limited only by the free space for the movement of the robot arm and mirror articulation arm. The inertia of the mechanics of the robot arm and of the articulated mirror arm also allow only a limited machining speed.
In both solutions, it is known to arrange at the laser head a gas nozzle through which a flow of gas is directed to the surface to be machined in order to prevent flames which lead to unwanted soot deposits and to prevent depositing of melted material. Since the laser radiation exits the laser head in a fixedly defined direction and is guided over the workpiece surface at a defined distance, the gas nozzle is mounted on the laser head at a fixed angle to the laser beam such that the laser beam and the gas jet exiting from the gas nozzle are always directed to the same point on the workpiece surface.
It is known to use optical beam deflecting units, also known as laser scanners, for machining small, plane surfaces. The beam is guided by the tilting of mirrors. This is advantageous because of the high speed that can be achieved and due to the accurate precision of the beam deflection. It is disadvantageous that the laser beam can only sweep over a small spatial area. A combination of such arrangements with a gas feed to the machining location is not known.
Therefore, the only solutions used in the prior art for arrangements in which workpieces with large surfaces extending in three dimensions are to be machined are those in which the laser beam is guided along the desired machining line on the workpiece surface by means of an articulated mirror arm fastened to a robot arm.
OBJECT AND SUMMARY OF THE INVENTION
It is the primary object of the invention to provide an arrangement for machining workpiece surfaces extending in three dimensions in which a flow of gas is directed to the machining location and which permits a faster machining speed compared to conventional arrangements independent of the extent and shape of the machining line.
This object is met for an arrangement according to the invention, the arrangement being for machining workpiece surfaces extending in three dimensions by a laser comprising a stationary laser, an articulated mirror arm, a robot arm connected to a robot for guiding the second end of the articulated mirror arm, a holding device for fixing a workpiece, at least one gas nozzle by which a flow of gas is directed to the workpiece surface and a control device for controlling the robot arm, and in that a laser scanner is fastened to the robot arm and is connected to the articulated mirror arm in such a way that the beam exiting from the second end of the articulated mirror arm is coupled into the laser scanner and the gas nozzles are arranged at the laser scanner so as to be movable in such a way that they can be oriented to the workpiece surface by a gas nozzle propulsion communicating with the control device, so that the gas flow and the radiation exiting from the laser scanner via an exit face coincide at a point on the workpiece surface.
The invention will be described more fully in the following in an embodiment example with reference to a drawing.
BRIEF DESCRIPTION OF A DRAWING
FIG. 1 shows a schematic view of a construction of an arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The arrangement shown in FIG. 1 essentially comprises a laser 1 which is mounted in a stationary manner, a robot arm 2 which is fastened to a robot shown in the drawing only as a fixed bearing, an articulated mirror arm 3 , a laser scanner 4 , a control device 5 , a gas nozzle propulsion unit 6 , at least one gas nozzle 7 , and a holding device 8 .
With respect to the connections between the devices, the thick solid lines represent mechanical connections, the thin dotted lines show signal connections, and the thick lines with multiple dots represent optical connections.
The stationary laser 1 is mechanically and optically connected to the first end of the articulated mirror arm 3 , the second end of the articulated mirror arm 3 being fixedly connected to the free end of the robot arm 2 . The second end of the articulated mirror arm 3 through which the beam coupled in by the laser 1 exits the articulated mirror arm 3 is accordingly freely movable in three dimensions. The laser scanner 4 which is fixedly coupled to the second end of the articulated mirror arm 3 optically and mechanically on the input side is likewise arranged at the free end of the robot arm 2 . The gas nozzle propulsion unit 6 and at least one gas nozzle 7 are fastened to the laser scanner 4 . A signal line provides a control connection from the laser 1 , the robot arm 2 , the laser scanner 4 and the gas nozzle propulsion unit 6 to the control device 5 .
The radiation emitted from the laser 1 is coupled into the first end of the articulated mirror arm 3 and exits the articulated mirror arm ( 3 ) by the second end at a point within the space above a workpiece fixed to the holding device ( 8 ), which point is determined by the spatial position of the free end of the robot arm ( 2 ). Upon exiting the articulated mirror arm ( 3 ), the radiation is coupled into the laser scanner ( 4 ), where the beam can be deflected by the mirror elements around the above-mentioned point in two or three spatial directions. The beam is guided in the desired manner for machining the workpiece by means of a coordinated control of the spatial position and speed of the articulated mirror arm 3 and mirror elements of the laser scanner 4 . The position of the beam when striking the workpiece surface is accordingly determined by a coordinated superposition of the beam control in the articulated mirror arm ( 3 ) and in the laser scanner ( 4 ). The person skilled in the art is familiar with the particulars of beam control in an articulated mirror arm ( 3 ) and laser scanner ( 4 ). The gas nozzle 7 is movably arranged at the laser scanner 4 and follows the laser beam by means of the gas nozzle propulsion unit 6 , so that the direction of the gas flow intersects with the laser beam on the workpiece surface in the respective machining location. A plurality of gas nozzles 7 are advantageously arranged about the exit face of the laser beam at the laser scanner 4 . In a conventional laser scanner 4 in a square arrangement around the exit face, for example, the gas nozzles 7 can be arranged at each of the four comers of the laser scanner. More than four nozzles can also be arranged in a ring shape around the exit face.
The inventive combination of an articulated mirror arm 3 and a laser scanner 4 with a gas nozzle propulsion unit 6 and gas nozzles 7 makes it possible, by coordinated simultaneous or alternate control, to guide the laser beam and gas flow to the machining location in an optimal manner depending on the size and shape of the workpiece and depending on the size and contour of the machining surface (e.g., for ablating) or machining line (e.g., for cutting or perforating).
The uniformity with which the gas flow strikes the machining location increases as the number of gas nozzles 7 arranged about the exit face in a centrally distributed manner increases.
In principle, an arrangement according to the invention can be operated in three machining modes:
1. The robot arm 2 moves the laser scanner 4 to a first machining position and remains stationary during machining. The machining surface or machining line is machined only by controlling or deflecting the mirrors in the laser scanner 4 . The gas nozzles 7 are deflected by the gas nozzle propulsion unit 6 in such a way that the gas flow is directed to the machining location, i.e., to the precise point on which the laser beam also impinges. The robot arm 2 subsequently moves the laser scanner 4 to a second machining position, where the machining process is repeated (stop-and-go operation). During machining, the beam is guided on the workpiece surface exclusively by means of the laser scanner 4 . An operation of this kind is advantageous for cutting hole contours, for example.
2. The laser scanner 4 is moved over the workpiece surface continuously by the robot arm 2 and, in addition, the laser scanner 4 deflects the beam in one, two or three directions (flying motion operation). During the machining, the beam is accordingly guided by a coordinated time-controlled and position-controlled deflection of the articulated mirror arm 3 and mirror elements of the laser scanner 4 . The spatial guidance (machining contour) and timed guidance (machining speed) of the laser beam moved by the laser scanner 4 is controlled in accordance with the movement speed of the robot arm 2 which guides the articulated mirror arm 3 . This machining mode is particularly suitable for longer non-straight machining lines, e.g., a sinusoidal line.
3. The robot arm 2 is guided over the workpiece surface continuously and the laser scanner 4 keeps the beam stationary (motionless operation). The beam is guided exclusively by means of the robot arm 2 . This mode is provided particularly for machining very long, large contours.
Circles with a diameter of 10 mm, for example, can be produced at a speed of 10 ms with an arrangement according to the invention compared to a speed of 1 s with an arrangement having only one robot arm for guiding the beam. Rectangles measuring 10 mm ×10 mm can be machined in 40 ms instead of 1.3 s.
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.
REFERENCE NUMBERS
1 laser
2 robot arm
3 articulated mirror arm
4 laser scanner
5 control device
6 gas nozzle propulsion unit
7 gas nozzles
8 holding device | An arrangement for machining workpieces by a laser, particularly for cutting, perforating, notching, engraving, drilling and inscribing workpieces with three-dimensional structures of different sizes. The laser beam is directed to the workpiece, which is fixed on a holding device, by means of a robot-guided articulated mirror arm and a laser scanner. The laser beam is guided by a coordinated time-controlled and position-controlled deflection of the articulated mirror arm and of the mirror elements of the laser scanner. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. nonprovisional patent application Ser. No. 12/616,817 filed Nov. 12, 2009, which is incorporated by reference herein in its entirety, which claims benefit to U.S. provisional application No. 61/243,866 filed Sep. 18, 2009, which is also incorporated by reference herein in its entirety. This application also claims the benefit of U.S. provisional patent application No. 61/769,659 filed Feb. 26, 2013, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present device relates to protective barriers that are typically installed beneath ceilings during construction work being performed on ceilings or roofs of buildings. A protective barrier can comprise sections connected by seams. These seams or the entire protective barrier can be designed to fail when contacted by water, either by dissolution, melting or by some other destructive process. Failure of one or more of the seams can create access points from the ceiling through the protective barrier to the area being protected by the barrier.
BACKGROUND
[0003] Protective barriers, such as those described herein, prevent dust and debris from falling on floors, on people, or on equipment located below a ceiling or roof being repaired or constructed. In this way, the protective barrier protects from added costs from damage or injury resulting from this falling material and allows work to continue below the ceiling or roof. Such barriers are commonly constructed from polyethylene sheets or similar materials, which have proven to be durable, easy to work with, and inexpensive. However, a problem can arise with this type or protective barrier when it is installed below a fire suppression sprinkler system, which is often required in order to meet performance expectations. Such an installation can impair the flow of water from the fire suppression sprinkler system to a fire located beneath the protective barrier.
[0004] What is needed is a protective barrier that can perform its primary function of protecting people and property from falling dust and debris, but also has the capacity to allow water from a fire suppression sprinkler system to gain access to a fire located below the barrier.
SUMMARY OF THE INVENTION
[0005] It is an aspect of the present device to provide a protective barrier which can protect people and property from falling dust and debris, but also has the capacity to allow water from a fire suppression sprinkler system to gain access to a fire located below the barrier.
[0006] The above aspects can be obtained by a protective barrier, comprising: at least two sections of waterproof material; and a plurality of seams comprising a temperature sensitive material attaching the at least two sections of waterproof material.
[0007] The above aspects can also be obtained by a protective barrier that comprises at least two sections of waterproof material and a plurality of seams comprising a material that reacts exothermically with water, the seams attaching the at least two sections of waterproof material.
[0008] The above aspects can also be obtained by a method that comprises providing a planar sheet comprising a material that is either water soluble or reacts exothermically with water; and elevating the planar sheet above a floor and under a sprinkler system, wherein the planar sheet prevents dust or debris from reaching the floor.
[0009] These together with other aspects and advantages which will be subsequently apparent, reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Further features and advantages of the present device, as well as the structure and operation of various embodiments of the present device, will become apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0011] FIG. 1 is a schematic drawing of a protective barrier comprised of a water soluble material or a material that reacts exothermically with water according to an embodiment;
[0012] FIG. 2 is a schematic drawing of a protective barrier comprising water soluble seams, according to an embodiment;
[0013] FIG. 3 is a schematic drawing of a protective barrier comprising seams, which further comprise a material that can react exothermically with water, according to an embodiment;
[0014] FIG. 4 is a perspective drawing of a protective barrier installed beneath a fire suppression system, according to an embodiment;
[0015] FIG. 5 is a perspective drawing of a protective barrier installed beneath a fire suppression system, wherein a fire is located beneath the protective barrier and a sprinkler above the fire and protective barrier has been activated thereby releasing water, according to an embodiment;
[0016] FIG. 6 is a perspective drawing of a protective barrier installed beneath a fire suppression system, wherein a seam has failed due to contact with water and/or elevated temperatures, creating an opening in the protective barrier and allowing water from a sprinkler to reach a fire, according to an embodiment;
[0017] FIG. 7 is a schematic drawing of a protective barrier comprising temperature sensitive seams, according to an embodiment;
[0018] FIG. 8 is a schematic drawing of a protective barrier 800 comprised of a temperature sensitive material that reacts at a certain temperature lower than the temperature set to activate a sprinkler; and
[0019] FIG. 9 is a schematic drawing of a protective barrier 900 comprised in part of a temperature sensitive material that reacts at a certain temperature lower than the temperature set to activate the sprinkler and in part of a water-soluble material, according to an embodiment.
DETAILED DESCRIPTION
[0020] This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
[0021] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0022] FIG. 1 is a schematic drawing of a protective barrier 100 comprised of a water soluble material or a material that reacts exothermically with water according to an embodiment.
[0023] A protective barrier 100 can be comprised entirely of a water soluble polymer, which can prevent dust and debris from reaching a protected area when dry. This protective barrier can dissolve in full or in part when contacted by water allowing water from a fire suppression sprinkler system 101 to reach a fire 102 located below the protective barrier 100 . The protective barrier 100 can be comprised of a polymer comprising polyvinyl alcohol or any other suitable water soluble material known to one of ordinary skill in the art.
[0024] A protective barrier 100 can also be comprised entirely of materials that react exothermically with water, which can prevent dust and debris from reaching a protected area when dry. This exothermic reaction can cause the protective barrier to melt in full or in part when contacted by water allowing water from a fire suppression sprinkler system 101 to reach a fire 102 located below the protective barrier 100 . The protective barrier 100 can be comprised of a polymer or similar material further comprising magnesium metal or any other suitable material that react exothermically with water, that is known to one of ordinary skill in the art.
[0025] FIG. 2 is a schematic drawing of a protective barrier 200 comprising water soluble seams 201 , according to an embodiment.
[0026] A protective barrier 200 comprising water soluble seams 201 can be comprised of sections 202 of standard, waterproof or water resistant material, such as polyethylene, vinyl or some other suitable material known to those with ordinary skill in the art of protective barriers. These sections 202 can be connected by seams 201 made from water soluble materials. Such seams 201 can comprise strips of water soluble materials which can be connected to the edges of the sections 202 . These strips of water soluble material can be connected to the sections 202 by stitching, adhesives, glues, rivets, staples, or any other similar devices known to those with ordinary skill in the art (not pictured). Furthermore, the seams 201 can be totally comprised of water soluble stitchings, adhesives, glues, or similar connecting devices which are known to those of ordinary skill in the art (not pictured). Seams 201 , comprising these water soluble materials, can dissolve upon contact with water allowing the sections 202 to fall to the floor or for openings to form between the sections 202 allowing water to pass by or through the protective barrier 200 . In this way, the protective barrier 200 could allow water from a fire suppression system (not pictured) to reach a fire located below the barrier 200 .
[0027] FIG. 3 is a schematic drawing of a protective barrier 300 comprising seams 301 that comprise a material that can react exothermically with water, according to an embodiment.
[0028] A protective barrier 300 comprising exothermically reactive seams 301 can be comprised of sections 302 of standard, waterproof or water resistant material, such as polyethylene, vinyl or other suitable material known to those of ordinary skill in the art of protective barriers. These sections 302 can be connected by exothermically reactive seams 301 made from materials, or treated with chemicals that react exothermically with water to create heat sufficient to melt the exothermically reactive seams 301 . This reactive material can be magnesium metal or any other material known to sufficiently react exothermically with water so that the heat reactive seams 301 , comprising these heat reactive materials, can melt or otherwise disintegrate the exothermically reactive seams 301 comprising the protective barrier 300 . This melting or disintegration can allow the sections 302 of the protective barrier to either fall to the floor or for openings to form between the sections 302 allowing water from a fire suppression sprinkler (not shown in FIG. 3 ) to pass by or through it 300 .
[0029] The material(s) used for the seams in any of the embodiments described herein can cost more than the waterproof or water resistant material used in the sections. Thus, by combining the seams and sections as described herein, a more cost effective barrier can be produced. Furthermore, in addition to the square checkerboard pattern illustrated in FIGS. 2-3 , the sections and seams can be formed and connected using other shapes as well, such as triangles, diamonds, polygons, curves, arbitrary shapes, etc.
[0030] FIG. 4 is a perspective drawing of a protective barrier 400 installed beneath a fire suppression system.
[0031] The protective barrier 400 is located below a fire suppression system 405 . The protective barrier 400 can comprise sections 402 of standard, waterproof or water resistant material, such as polyethylene, vinyl or other similar material known to those with ordinary skill in the art of protective barriers. These sections 402 can be connected by seams 401 made from water soluble materials, or materials that react exothermically with water and melt when contacted with water, heat sensitive materials or any other material that will cause the sections 402 to separate when exposed to water or fire. When dry, this protective barrier 400 can prevent dust and debris from reaching the protected area located beneath it.
[0032] FIG. 5 is a perspective drawing of a protective barrier 500 installed beneath a fire suppression system 505 , wherein a fire 510 is located beneath the protective barrier 500 and a sprinkler 506 above the fire 510 and protective barrier 500 has been activated thereby releasing water 508 .
[0033] Water 508 released by the sprinkler 506 , which is part of the fire suppression system 505 , contacts one or more seams 501 attaching sections of the protective barrier 500 . This water 508 can dissolve seams 501 comprising water soluble materials, reducing their tensile strength and causing them to fail, according to an embodiment.
[0034] In an alternative embodiment, the entire protective barrier can be comprised of one or more water soluble materials. Water contacting any part of this protective barrier would cause the contacted part to dissolve resulting in openings in the protective barrier.
[0035] In another alternative embodiment, water 508 released by the sprinkler 506 , can contact one or more seams 501 comprising the protective barrier 500 . This water 508 can react exothermically with the seams 501 which can be made from materials such as magnesium metal, which react with water to create heat. This heat can cause the seams to melt or to sufficiently reduce their tensile strength to cause them to fail.
[0036] In another alternative embodiment, the entire protective barrier 500 can be comprised of materials that react exothermically with water. Water 508 contacting any part of this protective barrier 500 can cause the contacted part to melt or disintegrate resulting in openings in the protective barrier 500 .
[0037] FIG. 6 is a perspective drawing of a protective barrier 600 installed beneath a fire suppression system 605 , wherein a seam 601 has failed due to contact with water 608 , creating an opening in the protective barrier 600 allowing water 608 from a sprinkler 606 to reach a fire 610 , according to an embodiment.
[0038] FIG. 7 is a schematic drawing of a protective barrier 700 comprising temperature sensitive seams 701 , according to an embodiment.
[0039] A protective barrier 700 comprising temperature sensitive seams 701 can be comprised of sections 702 of standard, waterproof or water resistant material, such as polyethylene, vinyl or other suitable material known to those of ordinary skill in the art of protective barriers. These sections 702 can be connected by temperature sensitive seams 701 made from materials that can allow the temperature sensitive seams 701 to fail at a temperature lower than the temperature set to activate the sprinkler (not shown). In an embodiment, this heat-reactive material can be thread comprising copolyamide, which is marketed under the trade name GRILON LT, or polycaprolacton, which is marketed under the trade name GRILON VLT 1, or any other material known to be sufficiently heat sensitive so that the temperature sensitive seams 701 , comprising these temperature reactive materials, can melt, open up, fall apart or otherwise disintegrate when the temperature sensitive seams 701 , comprising the protective barrier 700 are heated to a certain temperature. This melting or disintegration can allow the sections 702 of the protective barrier 700 to either fall to the floor or for openings to form between the sections 702 allowing water from a fire suppression sprinkler to pass by or through the protective barrier 700 .
[0040] In an embodiment, the temperature sensitive seams 701 can comprise a combination of water soluble seams and temperature sensitive seams where the water soluble seams can dissolve upon contact with water and the temperature sensitive seams can open up or disintegrate upon contact with a certain temperature lower than the temperature set to activate the fire suppression sprinkler. In an embodiment, the temperature sensitive seams can be integrated into the water soluble seams. The integrated temperature sensitive seams can open up when it contacts a certain temperature lower than the temperature set to activate the sprinkler. The water soluble seams can dissolve upon contact with water. The opening up of the temperature sensitive seams and the dissolving of the water soluble seams can allow the sections 702 of the protective barrier 700 to either fall to the floor to for openings to form between the sections 702 allowing water from a sprinkler to pass by or through the protective barrier 700 . In an embodiment, the water soluble seams can comprise one or more slits or holes and the slits or holes can be covered with temperature sensitive seams that can comprise a tape or glue or other material that can fall apart or open up at a certain temperature lower than the temperature set to activate the sprinkler.
[0041] In an embodiment, the temperature sensitive seams 701 can comprise metal or wire that can be electrically activated in the event of a fire or alarm. Electrical activation can comprise heating the temperature sensitive seams 701 to a certain temperature lower than the temperature set to activate the sprinkler which can allow the temperature sensitive seams 701 to open up or fall apart.
[0042] The material(s) used for the temperature sensitive seams 701 in any of the embodiments described herein can cost more than the waterproof or water resistant material used in the sections 702 . Thus, by combining the temperature sensitive seams 701 and sections 702 as described herein, a more cost effective barrier can be produced. Furthermore, in addition to the square checkerboard pattern illustrated in FIG. 7 , the sections 702 and temperature sensitive seams 701 can be formed and connected using other shapes as well, such as triangles, diamonds, polygons, curves, arbitrary shapes, etc.
[0043] FIG. 8 is a schematic drawing of a protective barrier 800 comprised of a temperature sensitive material that reacts at a certain temperature lower than the temperature set to activate the sprinkler.
[0044] A protective barrier 800 can be comprised entirely of temperature sensitive material, which can prevent dust and debris from reaching a protected area when heated to a particular temperature. In an embodiment, this temperature can be within a range between 140 degrees and 180 degrees. Openings in this protective barrier 800 can form any part is heated to a certain temperature, which can be lower than the temperature set to activate a fire suppression sprinkler, allowing water from a sprinkler system (not shown) to reach a fire (not shown) located below the protective barrier 800 . The protective barrier 800 can be comprised of copolyamide, which is marketed under the trade name GRILON LT, or polycaprolacton, which is marketed under the trade name GRILON VLT 1, or any other material known to be sufficiently heat sensitive so that the temperature reactive materials, can melt, open up, fall apart or otherwise disintegrate when any part of the protective barrier 800 is heated to a certain temperature.
[0045] FIG. 9 is a schematic drawing of a protective barrier 900 comprised in part of a temperature sensitive material that reacts at a certain temperature lower than the temperature set to activate the sprinkler and in part of a water-soluble material, according to an embodiment.
[0046] In an alternative embodiment, wherein the entire protective barrier is made from temperature sensitive materials, holes can be created in the barrier at any place where it is contacted by water.
[0047] FIG. 10 is a close-up view of a heat sensitive seam 1201 , such as those shown in FIG. 2 , wherein the seam 1201 can be comprised of one or more heat sensitive threads 1703 , which can interlock with heat insensitive threads 1704 to connect sections 1202 of the protective barrier 1200 , which do not comprise heat sensitive materials, according to an embodiment. These heat sensitive threads 1703 can be comprised of a copolyamide, a polycaprolacton, or any other suitable heat sensitive material.
[0048] In an alternative embodiment, the heat insensitive threads 1704 can be made from a water soluble material such as a polyvinyl alcohol thus creating a seam that can be designed to fail when either subjected to elevated temperatures or contacted by water. The seam depicted in FIG. 7 comprises an interlocking sewing pattern, which is designed to fail if either of the interwoven threads is broken. Therefore, if the seam shown in FIG. 7 comprised a heat sensitive thread 1703 and a water soluble thread 1704 , such a seam would fail if it were either heated to a particular temperature or contacted by water.
[0049] FIG. 11 is a perspective top and side view of a heat sensitive seam 1201 , such as that shown in FIG. 10 , covered by a dust cap 1805 according to an embodiment. In this embodiment, the dust cap 1805 can prevent dust or other material from accessing the seam 1201 , which can comprise small holes or other openings that may allow these materials to pass through the protective barrier. In an embodiment, this dust cap 1805 can also be configured to fail when the seam 1201 that it is covering fails.
[0050] Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. | A protective barrier that will typically be installed beneath ceilings during construction work being performed on ceilings or roofs of buildings. The protective barrier can be comprised entirely of one material or of different materials connected by seams. Some or all of these materials can be designed to fail when contacted by water via dissolution, melting or through some other destructive process initiated by contact with water. Some or all of the materials comprising the protective barrier can be designed to fail at a certain temperature. This failure can create access points from the ceiling through the protective barrier to the area being protected by the barrier, which can allow water from a fire suppression system to reach a fire located below the protective barrier. | 4 |
BACKGROUND OF THE INVENTION
This application is related to commonly assigned U.S. patent application Ser. No. 924,229 as filed on Sep. 5, 1997, now U.S. Pat. No. 5,884,494, entitled "Oil Flow Protection Scheme" as invented by Ronald W. Okoren, Sean A. Smith, Daniel C. Leaver, John R. Moilanen, Paul D. Ulland and Michael D. Carey.
The present invention is directed to a liquid level sensor for an air conditioning or refrigeration system. The system is an active and robust system which uses a binary sensor to provide an analog output.
The present invention is discussed in terms of lubricating screw compressors for air conditioning systems, but is contemplated to apply to all systems whatever the application. Like many other compressors, screw compressors require oil flow to the compressor so as to lubricate bearings and prevent long term degradation's of the bearings. Additionally, oil flow is needed to seal the rotors in a screw compressor to avoid reduced performance and to cool the rotors to prevent frictional heating.
Oil flow is needed by a compressor to lubricate the bearings and enhance their life. Additionally, in screw and scroll compressors, oil is used to seal the rotors, the absence of such a seal resulting in reduced compressor performance. Also, the lubrication of rotors can prevent frictional heating while cooling the rotors, and can prevent the radial growth and interference of rotors with adjacent compressor components. If the oil circulation system fails and compressor operation is allowed to continue, compressor failure and damage will ultimately result.
U.S. Pat. Nos. 5,431,025 and 5,347,825, both to Oltman et al., are directed to an oil charge loss protection arrangement for a compressor. Essentially both patents disclose comparing the temperature of a liquid in the oil system with the temperature of saturated refrigerant, and generating a signal to shutdown the compressor when the comparison indicates that the differential is off range. These patents are commonly assigned with the present invention and are incorporated herein by reference.
A system is desired which proves that a flow of lubricant is high in oil quantity (i.e., less than 30% refrigerant by weight).
SUMMARY OF THE INVENTION
It is an object, feature and advantage of the present invention to solve the problems in prior systems.
It is an object, feature and advantage of the present invention to provide a binary sensor which provides a binary condition of an inactive system and which provides an analog condition of an active system.
It is an object, feature and advantage of the present invention to use a binary sensor to provide an analog signal.
It is an object, feature and advantage of the present invention to provide an oil protection system which verifies both the quantity and quality of lubricant flow to the compressor.
It is a further object, feature and advantage of the present invention to provide a liquid level sensor in one of the compressor lubricant feed lines to verify oil presence at start-up, and to further use the liquid level sensor to verify oil quality during compressor operation.
It is an object, feature and advantage of the present invention to provide a liquid level sensor, which is normally used only at start-up to verify the presence or absence of liquid at a certain height, in a dynamic environment to determine the quality of a liquid vapor mixture.
It is an object, feature and advantage of the present invention to prove that there is either already lubricant in a compressor at start-up or that there is an immediately available lubricant supply trapped in the lines feeding the compressor prior to compressor start-up.
It is an object, feature and advantage of the present invention to prove lubricant flow in the compressor lubricant feed lines during compressor operation within predetermined time periods.
It is an object, feature and advantage of the present invention to prove that the flow in a lubricant feed line to a compressor is a liquid rather than a vapor.
It is a further object, feature and advantage of the present invention to prove that flow of liquid even in the presence of some normal amount of foam.
It is an object, feature and advantage of the present invention to prove that flow in a lubricant feed line is high in oil quality.
It is a further object, feature and advantage of the present invention to prove that that high quality oil flow is less than 30% refrigerant by weight.
It is an object, feature and advantage of the present invention to provide an oil protection system which allows for inverted start of other normal transient conditions.
It is an object, feature and advantage of the present invention to provide checks where possible in the operation of the components involved in an oil protection system for a compressor and to verify that no flow occurs when there clearly should be no flow.
The present invention provides a sensor system. The sensor system comprises a binary sensor issuing a signal representative of a first or second condition; sampling circuitry, operatively connected to the binary sensor, for monitoring the number of transitions between the first and second conditions during a sampling period; integration circuitry for accumulating the sampled number of transitions over time; and signal generation circuitry for issuing an analog signal representative of the accumulated transitions.
The present invention further provides a method of using a sensor. The method comprises the steps of: sensing a condition; transmitting a binary signal having either a first state or a second state indicative of the sensed condition; determining either a first or a second mode of operation of a prime mover to be in effect; operating the prime mover, in the first mode of operation, responsive to the first or second state of the binary signal; and operating the prime mover, in the second mode of operation, responsive to the rate of transition of the binary signal between the first and second states.
The present invention still further provides a controller and sensor. The controller and sensor comprise a liquid level sensor monitoring the presence or absence of a liquid and providing a binary signal indicative of the presence or absence of the liquid; and a controller operably connected to the sensor and receiving the binary signal. The controller includes components to sample the rate of transitions of the binary signal between a presence indicating signal and an absence indicating signal and to convert the sampled signal to an analog signal. The controller further includes components to integrate the analog signal and to issue control signals responsive to that integrated accumulation.
The present invention yet further provides the circuitry for using a digital sensor as an analog sensor. The circuitry comprises a digital sensor issuing a binary signal having a first or a second state; sampling circuitry for receiving the binary signal, for sampling the state of the binary signal at a moment in time, and converting the sampled signal to a signal representative of a bit count; integrator circuitry to integrate the bit count over time; and circuitry to transmit an analog signal representative of the accumulated integral.
The present invention additionally provides a method of using a digital sensor as an analog sensor. The method comprises the steps of: measuring a binary state with a digital sensor; constantly transmitting a binary signal indicative of either a first or a second binary state; sampling the transmitted signal at a first sampling rate to determine a bit count; integrating the product of the bit count over time; and issuing an analog signal reflected of the integrated bit count accumulation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an air conditioning or refrigeration system including a temperature conditioning subsystem, a lubrication subsystem, and a controls subsystem and which also includes the oil protection system of the present invention.
FIG. 2 is a cutaway diagram of a liquid level sensor in accordance with the present invention.
FIG. 3 depicts a block diagram for processing a signal from the liquid level sensor of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an air conditioning or refrigeration system 10. The system 10 includes three subsystems: a temperature conditioning system 12 (illustrated by wide double lines) which conditions the temperature of a fluid, a lubrication system 16 (illustrated by narrow double lines) which lubricates the mechanical components of the conditioning system 12, and a control system 18 (illustrated by single lines) which coordinates and controls the operation of the conditioning system 12 and the lubrication system 16.
The conditioning system 12 includes a compressor 20 which compresses a refrigerant and directs the compressed refrigerant and lubricant from a compressor rotor 21 and a compressor bearing 23 through a compressor discharge 22 to one or more oil separators 24. Exemplary compressors are shown in U.S. Pat. Nos. 5,341,658 to Roach et al., 5,201,648 to Lakowske and 5,203,685 to Andersen et al. and exemplary oil separators are shown in U.S. Pat. Nos. 5,502,984 to Boehde et al. and 5,029,448 to Carey, all of which are commonly assigned with the present invention and all of which are incorporated herein by reference.
In the oil separators 24, the lubricant and the refrigerant are separated into a primarily lubricant mixture and a primarily refrigerant mixture. The primarily refrigerant mixture (with some entrained lubricant) is directed by conduit 26 to a condenser 28 where the refrigerant is condensed from a hot vapor to a hot liquid. The hot liquid refrigerant passes through conduit 30 to an expansion valve 32. The expansion valve 32 meters the operation of the conditioning system by controlling the flow of the hot liquid refrigerant from the condenser 28. The hot liquid refrigerant leaving the expansion valve 32 enters conduit 34 where some of the liquid refrigerant flashes into a hot vapor leaving a cooler liquid refrigerant. The mixture of vapor and liquid refrigerant enters a liquid vapor separator 36 where the hot vapor is separated out and preferably directed to the compressor 20. The cooled liquid mixture leaves the liquid vapor separator 36 by means of conduit 38 and enters an evaporator 40 where the refrigerant cools the fluid, the refrigerant vaporizing in the process. Lubricant entrained in the primarily refrigerant mixture remains and pools in the bottom 44 of the evaporator 40. A conduit 42 directs the hot vaporous refrigerant from the evaporator 40 back to the compressor 20 to continue the temperature conditioning cycle.
The lubrication system 16 includes the compressor 20 where a lubricant is injected or provided to the compressor rotor or rotors 21 and to the compressor bearing or bearings 23. The lubricant mixes with the refrigerant and the lubricant/refrigerant mixture exits through the compressor discharge 22 to the oil separator 24. The oil separator 24 separates the lubricant/refrigerant mixture into a primarily lubricant mixture and a primarily refrigerant mixture. The primarily lubricant is directed by conduit 50 to an oil sump 52. The oil sump 52 includes a vent 54 and an oil heater 56. From the oil sump 52 the primarily lubricant mixture travels through conduit 58, oil filter 60, an optional oil cooler 62, and a check valve 64 provided in the conduit 58 to prevent backflow. The conduit 58 also includes a master oil line solenoid 66 for automatic control of flow of lubricant through the conduit 58 and includes a manual service valve 68. The conduit 58 ultimately directs the primarily lubricant mixture to a large capacity, vertical line 70 which acts as a trap during compressor shutdown. The vertical line 70 feeds a rotor feed line 72 providing lubricant to the compressor rotor or rotors 21 and feeds a bearing feed line 74 providing lubricant to the compressor bearing or bearings 23. The rotor feed line 72 includes an optical oil detector 76 such as the S-9400 series level switch sold by AC&R Components of Chatham, Ill. and also includes an oil charging service port 78 for adding or removing oil lubricant. The bearing feed line 74 includes a check valve 80 and a restrictor orifice 82. A differential pressure switch 84 is provided and arranged about the restrictor orifice so as to measure a differential pressure across that orifice 82.
The lubrication system 16 also includes an oil return gas pump 86 for returning pooled lubricant from the bottom 44 of the evaporator 40. The oil return gas pump 86 returns the lubricant that accumulates from the refrigerant mixture as the refrigerant vaporizes in the evaporator 40. The accumulated lubricant passes through conduit 96 and a filter 98 and is returned to the compressor 20. Associated with the oil return gas pump is a vent line 88 whose operation is controlled by a fill solenoid 90, and a condenser pressure conduit 92 whose operation is controlled by a drain solenoid valve 94. This is more fully described in commonly assigned U.S. patent application Ser. No. 08/801,545, now U.S. Pat. No. 5,761,914 entitled "Oil Return from Evaporator to Compressor in a Refrigeration System", filed on Feb. 18, 1997, and incorporated herein by reference.
The control system 18 includes a controller 100 which may be implemented as a single controller or a plurality of controllers working in concert. The controller 100 is operably connected to the compressor 20 by an electrical line 102 so as to control the operation and capacity of the compressor 20. The controller 100 also controls the operation of the expansion valve by means of an electrical line 104 and controls the operation of the oil heater 56, the master oil line solenoid 66, and the solenoid valves 90 and 94 by means of an electrical lines 106. The controller 100 also includes an electrical line 108 connecting the controller 100 to a compressor discharge temperature sensor 110 located in the compressor discharge 22 so a to sense the discharge temperature of the lubricant/refrigerant mixture, and an electrical line 132 connecting the controller 100 to a saturated condenser temperature sensor 130 so as to sense the saturated condenser temperature. The controller 100 is also connected by an electrical line 112 to the differential pressure sensor 84 so as to receive a signal representative of a differential pressure from the sensor 84. The controller 100 is also connected to the optical oil detector 76 by an electrical line 114 so as to receive a signal from the optical oil detector 76 representative of the presence of oil, refrigerant or foam. The controller 100 also includes a variety of other sensors including sensors 120 associated with the evaporator and connected to the controller 100 by electrical lines 122 so as to sense the delta T across the evaporator 40 in any conventional manner.
The large capacity vertical line 70 is arranged to trap oil very near the compressor 20 at shutdown. Compressor start will not be allowed by the control system 18 until oil is detected by the oil detector sensor 76 thus guaranteeing a minimum volume of oil available at compressor start. The oil flow differential pressure sensor 84 is also checked in the off cycle to guard against a failed switch or a wiring fault.
During compressor operation, all three key components of an oil protection system are required for optimal operation. These key components are: the differential pressure sensor 84, the oil detector sensor 76, and the discharge temperature sensor 110.
The discharge temperature sensor 110 is constantly monitored and compared against the saturated condenser temperature as determined by the sensor 130. The comparison of the saturated condenser temperature with the discharge temperature determines a discharge superheat. A low superheat condition suggests that the oil separator 24 will begin to separate liquid refrigerant along with the lubricant and thus the primarily lubricant mixture will become too dilute. The controller 100 has a "time to trip" integral so that, if the superheat is deemed to be too low for too long, the system 10 will safely shutdown. The superheat value below which indefinite operation is not allowed and the total integral trip point are each determined from empirical tests on an actual system.
The differential pressure sensor 84 senses pressure across the orifice 82 and the check valve 80 in the bearing feed line 74. The differential pressure sensor 84 is calibrated for a switch point relating to a desired minimum oil flow rate and the sensor 84 basically indicates the presence or absence of that minimum oil flow rate. The orifice 82 serves to provide pressure drop to indicate actual flow, while balancing oil flow to the bearing 23 as compared to the oil flow to the rotor 21. Since previous compressors 20 had orifices located within the compressor, the removal of the orifice 82 outside the compressor 20 improves oil quality by extending the dwell time that the oil is at a lower pressure to thereby release more refrigerant to vapor before the lubricant enters the compressor 20 to lubricate the bearings 23. The longer dwell time helps vaporize any liquid refrigerant still entrained in the lubricant to ensure that a liquid comprising highly concentrated lubricant is used to lubricate the compressor 20. The pressure sensor 84 is constantly monitored in normal operation and will shutdown the system 10 if flow is lost for more than a predetermined time period such as two seconds.
The oil detector sensor 76 was previously used only as a binary level switch but is used in the present invention additionally as an analog sensor for foam quality. This is described as follows.
Under most normal operating conditions, the oil flow in the rotor feed line 72 has only a small amount of vapor and the flow is generally clear with only a small amount of bubbles or foaming present. In certain operating conditions foaming in the line 72 is normal and must be differentiated from the very dry foam condition which occurs as oil is lost from the primary lubrication system 16 and the level of oil in the oil sump 52 falls.
Referring to FIG. 2, the sensor 76 uses an infrared LED 150 and a matching infrared detector 152 in conjunction with a conical glass prism 154 having an interface 156 exposed to the rotor feed line 72. Owing to the properties associated with the index of refraction of light as light passes through a glass to vapor interface as opposed to a glass to liquid interface, the light from the LED 150 is either reflected back to the detector 152 when vapor is present within the rotor feed line 72 or is only marginally reflected when oil is present within the rotor feed line 72. The detector 152 then controls an open collector transistor for a discrete binary output. The off state (or high output) implies dry as illustrated by a liquid level at line 160, while the on state (or low output) implies wet as illustrated by a liquid level at line 162. This concept has previously been patented by others as evidenced by U.S. Pat. No. 5,278,426 to Barbier, the disclosure of which is hereby incorporated by reference. In these previous uses, the sensor was used solely at start-up when the liquid level had already stabilized so the liquid level could be sensed relative to the interface 156 such as shown by the liquid level lines 160 and 162. However, once the compressor 20 commences operation, the interior of the large capacity vertical line 70 and the rotor feed line 72 represents a dynamic mix of liquid lubricant and refrigerant as well as vaporous refrigerant resulting in a foamy mix indicated by the bubbles 164. Conventionally, the sensor 76 can no longer be used because there is no stable liquid level to sense. The present invention enables the conventional sensor to be used in a dynamic environment to sense the quality of the foam, enabling the verification that enough lubricant is present in the foam to ensure proper compressor operation.
With minor modifications to the internal components of the sensor 76 to control the sensitivity of the detector 152 and a calibration process to adjust the LED light output from the LED 150, the sensor 76 is used for foam determination. The internal components of the sensor 76 are selected so that the detector 152 has a gain lying within a desired range. The desired gain and the desired range are empirically determined based on the environment to be sensed and will vary with any particular lubricant and refrigerant combination. Only detectors 152 which meet the desired gain and range criteria are used in the sensor 76. The intensity of the LED 150 is then calibrated to get the correct output for the desired criteria. This calibrated intensity will vary with the environment being sensed specifically including the lubricant and the refrigerant combinations being sensed.
When such a calibrated sensor 76 is used in the oil protection system of the present invention, the calibrated sensor 76 creates a very "noisy" signal due to the random nature of foamy flow, reacting very quickly to the small vapor bubbles 164 moving over the prism 154 and reflecting light back to the detector 152. As the vapor content of the foam 158 in the rotor feed line 72 increases, so does the DC level of the signal from the sensor 76.
FIG. 3 depicts a block diagram 200 for processing the signal from the sensor 76 in the controller 100. This signal is processed by the controller 100 using special filtering to create an analog value representative of the foam content. A time to trip function is implemented in the software in the controller 100 to define a foam content level beyond which a time integral is begun and the ultimate trip value for the integral at which compressor operation is terminated. The values for the protection level were empirically determined.
The signal from the sensor 76 is provided on an electrical line 202 and passes through a first order filter and voltage divider 204 which roughly filters the signal and converts the 24 VDC signal to a 5 VDC signal. As depicted in FIG. 3, the filter and voltage divider 204 includes a pull-up resistor 206, a 200 k ohm resistor 208, a 30.1 k ohm resistor 210, a 0.1 microfarad capacitor 212, diodes 214 and 216, a 100 k ohm resistor 218 and a 15 microfarad capacitor 220. Of course, these values are dependent upon the application and will vary accordingly.
After leaving the filter and voltage divider 204, the signal is sampled at a rate of 200 milliseconds by a sampler 222 and then the signal is converted to a 10 bit digital signal by the analog to digital converter 224. The resultant digital signal enters a infinite impulse response filter 226 having a time constant of 6.4 seconds. This filter 226 smoothes out the resultant digital signal by taking a running historical sample of the last 32 samples and averaging them according to the following formula:
Filtered signal=1/32 of the latest signal+31/32 of the old average.
The filtered signal from the filter 226 is provided to a 24 volt compensator 228 which compensates for variations in the sensor supply voltage to avoid errors resulting from variations in the 24 VDC supply voltage, these errors typically ranging between 19 and 26 VDC.
The compensation signal is passed to an integrator control 240, an offset and time scaling block 242 and an integrator 244. In the preferred embodiment, time scaling is unnecessary since the integration rate is the same as the sampling rate of 200 milliseconds used by the sampler 22. Otherwise, the data of one rate must be adjusted, prorated or synchronized to equate to the date sampled at the other rate.
The offset portion of the block 242 is used to establish a desired level of lubricant quality. Of course, multiple such levels may be established, or the accumulated integral may be used as a conventional analog signal.
The integrated control 240 specifies a must integrate level of 778 bit counts, this level being an empirically determined offset level differentiating dry foam from lubricant laden foam and corresponding to 3.8 VDC. The integrate level 778 is empirically selected to avoid transient levels which might occur at start-up as well as any other transient fluctuations in the line level. Integration is enabled above this level and the integrator 244 will continue to integrate the produce of bit count times time while the bit count remains above 778. The integration of new bit counts will terminate between 573 and 778 bit counts but the already integrated amount will be held unless the bit count level in the compensated signal drops below 573, this bit count being the equivalent of 2.8 VDC. When the bit count measure drops below 573 bit counts, the accumulated integral in the integrator 244 will be cleared. Between 573 and 778 bit counts, the accumulated integral will be held but no new integral values will be added. Only above 778 bit counts will the integrator control 240 allow the accumulation of bit counts.
The summed integral will be provided as an analog signal to a comparitor 246 which trips whenever the integrated bit count exceeds 3,200 bit count seconds. This trip count is empirically determined and will vary for any particular system or application. Protective action will be called for when the trip count is exceeded.
Essentially, the foam causes a high number of transitions between the high and low states, and the high number of transitions caused by such foam is treated as "chatter" and measured to determine an analog signal representative of the state of the fluid in the conduit 72. Thus, a binary sensor 76 provides and analog output representative of the quality of the bubbles 164. As discussed above, the new use applies to dynamic operation as opposed to start-up or static operation.
What has been described is a binary sensor which is used in a new way to provide an analog signal rather than a digital signal. A person of ordinary skill in the art will recognize that many modifications of the sensor will be apparent including the application of the invention to various other applications particularly those having both static and dynamic requirements to monitor liquid and vaporous fluids. Additionally, the invention can be generalized with regard to the liquid level sensor to apply to other environments where the presence of a certain quality of foam in a conduit is desired to be measured. Other modifications and alterations are also evident specifically contemplating modifications and alterations to the implementing circuitry of FIG. 3 and the sensor selected and shown in FIG. 2. All such modifications and alterations are contemplated to fall within the spirit and scope of the attached claims.
What is desired to secured as Letters Patent of the United States is as follows. | A sensor system. The system comprises a binary sensor issuing a signal representative of a first or second condition; sampling circuitry, operatively connected to the binary sensor, for monitoring the number of transitions between the first and second conditions during a sampling period; integration circuitry for accumulating the sampled number of transitions over time; and signal generation circuitry for issuing an analog signal representative of the accumulated transitions. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application No. 60/723,560, filed Oct. 3, 2005, which is incorporated herein by reference.
BACKGROUND
U.S. Pat. Nos. 6,868,289 and 7,016,725, each of which is incorporated herein by reference, disclose methods and apparatuses for treating tumors using AC electric fields in the range of 1-10 V/cm, at frequencies between 50 kHz and 500 kHz, and that the effectiveness of those fields is increased when more than one field direction is used (e.g., when the field is switched between two or three directions that are oriented about 90° apart from each other). Those alternating electric fields are referred to herein as Tumor Treating Fields, or TTFields.
SUMMARY OF THE INVENTION
The effectiveness of TTFields in stopping the proliferation of and destroying living cells that proliferate rapidly (e.g., cancer cells) can be enhanced by choosing the rate at which the field is switched between the various directions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of two pairs of insulated electrodes that alternately apply TTFields to target region.
FIG. 2 shows examples of waveforms that are suitable for switching the fields that are applied between the electrodes on and off.
FIG. 3 depicts the changes in growth rate of a glioma cell culture treated with alternating electric fields switched between two directions at different switching rates.
FIG. 4 is a graph of tumor volume vs. time for fields that were switched between two directions at different switching rates.
FIG. 5 is a block diagram of a system for generating the TTFields in different directions.
FIG. 6 illustrates a preferred waveform for driving the electrodes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Since electric fields sum as vectors, two or more fields with different directions cannot be applied simultaneously at a given location. Instead, the different field directions must be applied sequentially, by applying a first field in one direction for a certain period of time t 1 , and then applying a second field in another direction for a period t 2 . During t 2 the first field is not active and during t 1 the second field is inactive. When this cycle is repeated over and over, the result is that sequential field pulses of changing directions are applied in a cyclic manner.
The inventor has determined that that the effectiveness of TTFields for destroying proliferating cells in tissue culture as well as malignant tumors in experimental animals is dependent on the rate of switching between the various directions of which the fields are applied. In a set of experiments, TTFields were applied to the tissue cultures or experimental animals by means of two pairs 11 , 12 of insulated electrodes that alternately apply TTFields 15 , 16 normal to each other, shown schematically in FIG. 1 . The waveforms applied were 100-200 kHz alternating fields modulated to stay On and Off for half cycle durations ranging from 10 ms to 1000 ms.
FIG. 2 shows two examples of waveforms that are suitable for modulating the AC signals that were applied between the electrodes: a first pair A of 50% duty cycle waveforms 21 , 22 time shifted with respect to each other such that one is on when the other is off, and a second pair B of 50% duty cycle waveforms 23 , 24 that is similar to the first set of waveforms, but switched at twice the frequency. Note that each set of waveforms consists of two 50% duty cycle square waves that are shifted in phase by one half cycle with respect to each other.
FIG. 3 depicts the results of one set of experiments by plotting the changes in growth rate of a glioma cell culture (F98) treated with 200 kHz alternating electric field waveforms switched between two directions at different switching rates. Experimental data was also obtained for the case where the field was applied continuously in one direction only. (Note that the control baseline of 100% is for the case when no field was applied.) The data shows that some switching frequencies are more effective than others for reducing the proliferation of glioma tumor cells in culture. The highest effectiveness was found when the half cycle duration was 50 ms (with a similar Off duration) waveform. However, the effectiveness differences in the range of 250 ms to 50 ms were small. Within this range, the cell proliferation rate is reduced to about half of what it is when either a continuous field was applied, or when a 1000 ms half cycle duration waveform is used.
FIG. 4 is a graph of tumor volume vs. time for a set of experiment, and it shows the effect of 200 kHz TTFields on Vx2 carcinoma growth in vivo, when the fields were applied in two different directions at different switching rates. In the experiment, tumors from the carcinoma line Vx2 were inoculated under the kidney capsule in rabbits. As expected, the tumor size increases with time during the 4 week follow up period in the control, non-treated, group of rabbits (curve 31 ). The growth rate was slower when the fields were applied in different directions with a switch in direction every 1000 ms (curve 32 ); and the growth rate was even slower when the field's direction was switched every 250 ms (curve 33 ) or every 50 ms (curve 34 ). Thus, we see that the effectiveness of the treatment is significantly higher for waveform having half duty cycle durations of between 50 and 250 ms, as compared with 1000 ms half cycles.
Based on the above, the following approach is recommended for tumor treatment with TTFields: Treatment should be carried out with at least two field directions, such that each pair of electrodes is activated for On periods of a duration that is preferably between 50 and 250 ms, interposed by Off periods of a similar duration. The TTFields basic alternation frequency (which corresponds to the carrier frequency in an amplitude modulation system) should preferably be in the range of 50-500 kHz, and more preferably in the range of 100-200 kHz. The field intensity is preferably at least 1 V/cm, and more preferably between 1 and 10 V/cm.
FIG. 5 is a block diagram of a system for generating the TTFields in different directions by driving a first electrode pair 11 and a second electrode pair 12 that are positioned about a target. An AC signal generator 41 generates a sinusoid, preferably between 100-200 kHz, and a square wave generator 43 generates a square wave that resembles the wave 21 shown in FIG. 2 . Preferably the output of the square wave is high between 50 and 250 ms and low for an equal amount of time in every cycle, although duty cycles that deviate from 50% may also be used. An inverter 44 inverts this square wave, thereby providing the second wave 22 shown in FIG. 2 . The amplifiers 42 amplify the sinusoid when their control input is in one state, and shut off when their control input is in the other state. Since the control input for the two amplifiers are out of phase, the amplifiers will alternately drive either the first electrode pair 11 or the second electrode pair 12 to generate either the first field 15 or the second field 16 in the target region. Of course, persons skilled in the relevant arts will recognize that a wide variety of other circuits may be used to alternately drive either the first or second pair of electrodes. For example, a suitable switching circuit may provided to route the output of a single amplifier to either the first or second pair of electrodes in an alternating manner, with the switching controlled by a single square wave.
As explained in U.S. Pat. No. 6,868,289, insulated electrodes are preferred for in vivo applications. Preferably, care should be taken to avoid overheating of the tissues by the capacitive currents and dielectric losses in the insulated electrodes. It is also preferable to avoid the generation of spikes during the switching process. This can be done, for example, by carrying out the switching itself while the AC signal is turned off and immediately afterwards turning the signal on. The rate of turning the field on t 3 and off t 4 should preferably be done at a rate that is slow relative to the reciprocal of the field frequency (i.e., the period t 5 ), and fast relative to the half cycle duration t 1 , t 2 , as seen in FIG. 6 for waveform 61 . An example of a suitable turn-on rate t 3 and turn-on rate t 4 is to reach 90% of the steady-state values within about 1-5 ms. Circuitry for implementing this slow turn on may be implemented using a variety of approaches that will be apparent to persons skilled in the relevant arts, such as using a slow-rising control signal to drive an accurate AM modulator, or by driving a gain control of the amplifier with a square wave and interposing a low pass filter in series with the gain control input.
While examples of the invention are described above in the context of F98 glioma and Vx2 carcinoma, the switching rate may be optimized for other cancers or other rapidly proliferating cells by running experiments to determine the best switching rate, and subsequently using that switching rate to treat the problem in future cases. | AC electric fields at particular frequencies and field strengths have been shown to be effective for destroying rapidly proliferating cells such as cancer cells. The effectiveness of such fields is improved when the field is sequentially switched between two or more different directions. The effectiveness of such fields can be improved even further by choosing the rate at which the field is switched between the various directions. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional patent application Ser. No. [30706480], filed [2011 Dec. 13].
BACKGROUND OF THE INVENTION
[0002] I have invented a wireless audio/video signal transmitter/receiver. One application of this device could be to wirelessly send audio and video signals from a handheld device to a projection device such as a television or other projector.
BRIEF SUMMARY OF THE INVENTION
[0003] This device is a tablet computer (e.g., an Apple iPad or similar unit) audio/video accessory consisting of two parts: the first part, a plastic and electrical wiring composite device that attaches to the ‘audio/video out’ port of the tablet computer and is coupled to a transmitter that sends the tablet's audio and video signals using industry-standard radio frequencies to the second part, which consists of another plastic and electrical wiring composite that is a radio frequency receiver coupled with an MDMI/VGA video attachment. Users attach the transmitter portion to a tablet computer, and the receiver portion to a standard LCD projector or other device such as a television, in order to display the contents of the tablet computer on an LCD projector or television without the use of a VGA cable directly linking the two devices. In summary then, the device consists of two parts, and each part has two distinct but joined sections. The first part consists of an ‘audio/video out’ section and a radio frequency transmitter; the second part consists of a radio frequency receiver and an HDMI/VGA female connector. Together, these two parts will work in concert to [1] attach to a tablet computer such as an iPad and transmit its audio and video signals wirelessly to the second part which will [2] receive the audio and video signals and convert them to standard HDMINGA display and stereo audio format for use with numerous computer monitors, televisions, and projectors.
[0004] What are the advantages of this invention? The main advantage this device has over existing devices is that is lets the user roam freely while displaying the contents of a computing tablet such as an iPad; all previous devices are based on a VGA cable connecting the tablet computer directly to a projector; this wireless device allows for a wireless connection more in keeping with the mobile nature of computing tablets such as the Apple iPad. Hence, the main advantage of this wireless audio/video signal transmitter/receiver is that it allows for greater freedom of movement during presentations and teaching sessions. Although there are other projector connecting devices, they are all cable-based. That makes this connector superior because it is:
More versatile Less awkward for the user to move about during presentations More in line with the interactive nature of teaching and presentations More able to give presenters and teachers the freedom to allow others to use their computing device during a class or presentation while carrying their computing device with them Simpler to use for mobile computing pad presenters Easier to connect since it does not require long, expensive cables Less expensive to connect since long HDMI and VGA cables are very expensive More capable of being customized to varying heights and placements of projectors than a heavy, long cable
[0013] The principle advantage is to reduce the problem of being tethered to a heavy, thick, long cable while using a light, mobile computing tablet. The wireless nature of this transmitter/receiver means only a very small unit is attached to the mobile tablet, offering a distinct advantage over devices that require being directly connected to an audio/video cable.
DETAILED DESCRIPTION OF THE INVENTION
[0014] What are the components of the device, and how do they interact? This application includes eight drawings describing the device parts. FIGS. 1 , 2 , and 3 are various views of the wireless transmitter. FIG. 1 is a side perspective FIGS. 4 , 5 and 6 are various views of the wireless receiver. FIGS. 7 and 8 are flow charts indicating how the audio and video signals travel from origination to destination using the wireless transmitter and receiver. FIGS. 9 and 10 are block electrical diagrams of the transmitter and receiver.
[0015] More specifically, FIG. 1 is a front elevated view of the transmitter portion of the device, showing a computer tablet attachment 1 as it connects to a cable 2 which sends audio and video signals to a wireless transmitter 3 . FIG. 4 then shows a wireless signal receiver 4 attached to a VGA connector 5 , which connects to a standard computer monitor, LCD projector, flat screen television, or other display device.
[0016] How does the invention achieve its result? The technological computing landscape has been changed drastically in the recent past by the proliferation of mobile computing pads. These pads offer long battery life, powerful display features, and a high degree of mobility. However, technology to display the contents of these mobile computing pads, such as the Apple iPad, currently are based on long clunky cables that tie the user to a specific location when presenting information from such a tablet device. This restriction of movement goes against the grain of the mobility inherent in these computing pads and tablets. Therefore a wireless device, which increases the mobility of the presenter while still allowing the contents of the computing pad to be displayed to a large audience, would be both effective and desirable.
[0017] How the wireless audio/video signal transmitter/receiver achieves its result (see FIG. 7 and FIG. 8 ): The purpose of this device, its desired result, is to send the audio/video signal of a mobile computing pad to a display device wirelessly, without the use of a bulky cable that tethers the device to one location.
[0000] How the device achieves this result (see FIG. 2 ): A user attaches the transmitter portion of the device to a mobile computing tablet using 1 . The audio/video signal from the tablet travels from 1 through the wires in 2 to the transmitter 3 as shown in FIG. 2 . That signal travels wirelessly to the receiver 4 in FIG. 4 where it is then sent to a VGA connector 5 in FIG. 4 . This connector 5 attaches to any number of standard VGA male connectors on monitors and projectors, thus sending the audio/video signal from the mobile tablet to a display device. As shown specifically in FIGS. 9 and 10 , a power controller and power switch supplies the transmitter with power through a 5 volt supply and an internal rechargeable battery for local logic, a programming connector, and also to an HPD to a display port HDMI level translator and a 30-pin Apple connector. The HDMI level translator communicates with an auxiliary integrated circuit to a video network processor and an RF transceiver with multiple antennas for spatial diversity. The audio and video signal from the iOS or other handheld computing tablet or smartphone device is thus sent to a receiver. The receiver uses a grounded 5V power supply and multiple antennas for spatial diversity to receive the sent audio and video signals into a video network processor as HDMI. This then flows into an MUX device that separates HDMI 1 and HDMI 2 signals; 1 is sent to an HDMI to VGA adapter; while # 2 is sent to an HDMI external connector. The VGA adapter then runs RGB and HSynch/VSynch signals to an external VGA connector; the video networking ‘in’ processor also separates the stereo audio signal into an on-board audio buffer, through a line level audio apparatus, and into a stereo audio connector. The end user connects this receiver to a projection device such as an LCD projector, television, or other display device, and then wirelessly mirrors the display of the handheld computing tablet device onto the television or other display.
[0018] Description of components: A Video Graphics Array (VGA) connector is a three-row 15-pin DE-15 connector. The 15-pin VGA connector is found on many video cards, computer monitors, and some high definition television sets. A DE-15 is also conventionally called an RGB connector.
[0019] DE-15 is also conventionally called an RGB connector, or HD15 (High Density, to distinguish it from the older and less flexible DE-9 connector used on older VGA cards, which has the same shell size but only two rows of pins). VGA connectors and cables carry analog component RGBHV (red, green, blue, horizontal sync, and vertical sync) video signals, and video display data. The same VGA connector can be used with a variety of supported VGA resolutions, ranging from 640×400 px @70 Hz (24 MHz of signal bandwidth) to 1280×1024 px @85 Hz (160 MHz) and up to 2048×1536 px @85 Hz (388 MHz). This makes the connector compatible with a wide range of projection devices, from standard computer monitors to LCD projectors to HD televisions.
[0020] In a female DE15 socket (the side contained in the proposed new device), Pin 1 is RED for red video, Pin 2 is GREEN for green video, Pin 3 is BLUE for blue video, Pin 4 is ID2/RES, formerly Monitor ID bit 2, and is reserved; Pin 5 is a GND for Ground (HSync), Pin 6 is RED_RTN for red return, Pin 7 is GREEN_RTN for green return, Pin 8 BLUE_RTN is for blue return, Pin 9 is KEY/PWR formerly key, now +5V DC, Pin 10 is GND for Ground (VSync, DDC), Pin 11 is ID0/RES formerly Monitor ID bit 0 and is reserved, Pin 12 is ID1/SDA, Pin 13 is HSync for the horizontal sync, Pin 14 is VSync for the vertical sync, and Pin 15 is ID3/SCL for Monitor ID bit 3. This detailed listing is for the 15-pin VESA DDC2/E-DDC connector; the pin numbering is that of a female connector functioning as the graphics adapter output. In the male connector, this pin numbering corresponds with the mirror image of the cable's wire-and-solder side. The device's receiver part would have a ‘female’ VGA attachment. VGA production is well-known and well-established. Its production history is by its designer, IBM based on the D-subminiature architecture from 1987 to the present day.
[0000] HDMI is a compact audio/video interface for transferring uncompressed digital audio/video data from an HDMI-compliant device (“the source device”) to a compatible digital audio device, computer monitor, video projector, or digital television. Because HDMI is electrically compatible with the CEA-861 signals used by digital visual interface (DVI), no signal conversion is necessary, nor is there a loss of video quality when a DVI-to-HDMI adapter is used. As an uncompressed CEA-861 connection, HDMI is independent of the various digital television standards used by individual devices, such as ATSC and DVB, as these are encapsulations of compressed MPEG video streams (which can be decoded and output as an uncompressed video stream on HDMI).
For digital audio, if an HDMI device supports audio, it is required to support the baseline format: stereo (uncompressed) PCM. Other formats are optional, with HDMI allowing up to 8 channels of uncompressed audio at sample sizes of 16-bit, 20-bit and 24-bit, with sample rates of 32 kHz, 44.1 kHz, 48 kHz, 88.2 kHz, 96 kHz, 176.4 kHz and 192 kHz. HDMI also supports any IEC 61937-compliant compressed audio stream, such as Dolby Digital and DTS, and up to 8 channels of one-bit DSD audio at rates up to four times that of Super Audio CD. With version 1.3, HDMI supports lossless compressed audio streams Dolby TrueHD and DTS-HD Master Audio.
Some tablet computers, such as the Microsoft Surface, Motorola Xoom, BlackBerry PlayBook, Vizio Vtab 1008 and Acer Iconia Tab A500, support HDMI using Micro-HDMI (Type D) ports. Others, such as the ASUS Eee Pad Transformer support the standard using Mini-HDMI (Type C) ports. The iPad has a special AN adapter that converts Apple's data line to a standard HDMI (Type A) port. Samsung has a similar proprietary thirty-pin port for their Galaxy Tab 10.1 that can adapt to HDMI as well as USB drives. The Dell Streak 5 smartphone/tablet hybrid is capable of outputting over HDMI. While the Streak uses a PDMI port, a separate cradle is available which adds HDMI compatibility. Most of the Chinese made tablets running Android OS support HDMI output using a Mini-HDMI (Type C) port. Most new laptops and desktops now have built in HDMI as well. Many recent mobile phones support output of HDMI video via either a mini-HDMI connector or MHL output.
[0021] Next, wireless communication between the two parts of the device. Wireless communications is the transfer of information between two points (in this case, the transmitter portion and the receiver portion of the device) that are physically not connected. Distances can be long or short, as a few meters as in this example. The device's two parts could be constructed using the block diagrams attached to this description by any competent electrical engineer. Other common and frequently-used examples of wireless technology include GPS units, garage door openers, wireless computer mice, and cordless telephones. The wireless operation referred to here permits short range communications that are impractical to implement with the use of wires or cables. Since the idea behind tablet computing is mobility, especially when teaching, training, or delivering information to audiences, wireless frees the presenter from being cabled to the front of a classroom or auditorium; such cabling limits the presenter's movements and restricts their ability to move around the room interact with their audience Furthermore, wireless allows a teacher to lend control of the tablet computer to students or attendees, increasing their interaction with the device and the material being presented without having to leave their seat.
[0022] The term wireless is commonly used to refer to systems (e.g. radio transmitters and receivers, remote controls, computer networks, network terminals, etc.) which use some form of energy such as radio frequency (RF) to transfer information without the use of wires. Information is transferred in this manner over both short and long distances—for the purposes of this device, that distance would not exceed 20 meters.
[0023] The transmitter module is an electronic component using a variety of radio signals to remote control the target device which has a built-in receiver module. RF modules are widely used in garage door openers, wireless alarm systems, industrial remote controls and wireless home automation systems as well as classroom tools including wireless teaching tablets such as eInstruction's “Mobi” and Smart Technology's “SMART Tablet.” The same technology is used in the receiver portion of the device.
[0024] What are alternative ways that the invention can achieve its result? The way the device parts are shown in FIGS. 2 and 4 , the transmitter portions are joined by a cable, and the receiver portions are not. However, the invention could achieve its result in the following alternative ways:
Both parts could have their sections joined by a cable; Neither part could have their sections joined by a cable, The transmitter could be cable-free, and The receiver could have a cable.
The idea behind a cable on the transmitter is to allow it more flexibility when moving around the room; if a presenter bumped a chair or table or desk with the device, the cable will flex and prevent damage to that section. But the device could achieve its result by:
Both parts having cables,
Both parts not having cables, or
Either part having or not having a cable.
Different sizes and lengths of transmitters and receivers can be used.
Bluetooth™ or any other wireless send-receive technology can be used in place of radio frequency technology in both the transmitter and the receiver. The mobile computing device video out attachment is shown as one for an Apple iPad; it can be altered to fit numerous other devices, including but not limited to the Motorola Xoom, the Samsung Galaxy Tab, the BlackBerry PlayBook, the Kindle Nook, the Kindle Fire, the HP TouchPad, the Microsoft Surface, and any number of other mobile tablet computers and computer netbooks, as well as laptop and notebook computers. | This invention is new to the field in two ways: [1] it sends audio/video signals wirelessly between tablet computing devices and smartphones to projection devices instead of using attached cables, and [2] it does not require an app, a second computing device, a driver, a download, or a “jailbreak” of the computing device to function properly. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a test cell for testing fluids at elevated pressures. More specifically, the test cell of the present invention comprises a pressure-neutral cylinder for use in pressure, volume and temperature (pVT) studies of reservoir fluids and their properties in the laboratory and in the field.
[0003] In pVT cells and condensate cells, petroleum fluids can be studied at varying pressure and temperature simulating the conditions in oil reservoirs before and during production. Typically, these fluids contain gas. The change in fluid density (compressibility) and the tendency for the gas to come out of solution at decreasing pressure, are of particular interest.
[0004] pVT cells are optimised to study oils with dissolved gas, while condensate cells are optimised to study light oils with a high gas to oil ratio. In the following, they are both denoted pVT cells.
[0005] 2. Description of Related Art
[0006] Until the late eighties, the method for controlling the pressure in these pVT cells was to pump mercury in and out of the cell, mercury being considered as inert with respect to the petroleum fluids.
[0007] There were however some health risks involved in the handling of mercury at high pressure and temperature, and this method has to a large extent been replaced by other methods for changing the volume in pVT cells. Several of the new designs are based on cylindrical cells with a sealed piston that can be moved by either direct mechanical drive or hydraulic drive.
[0008] A problem with the piston solution is that the diameter of the cell will change with pressure, and thus the clearance between piston and wall will change, which makes rather high demands on the seals.
[0009] In order to solve the problem of varying clearance with pressure, a relatively thin inner cylinder, which is in contact with a dynamic seal on the piston and with the fluids, is enclosed in a thick-walled high pressure cylinder. The space between the cylinders is filled with hydraulic fluid, and is connected to the same line that provides such fluid under high pressure to hydraulically control the piston position. Thus it is ensured that the (differential) pressure across the inner cylinder is negligible.
[0000] This solution gives the following advantages:
1. The material of the inner cylinder can be selected independently to meet various specifications. The material of the inner cylinder can be selected to be chemically compatible with the fluids (e.g. Hastelloy C, glass, Inconel) while the outer cylinder needs only to be strong enough to meet pressure specification (e.g. high strength steel) or a combination of weight and strength specifications (e.g. Ti-6Al-4V). 2. The diameter of the inner tube does not change with pressure, and the volume of the test fluid chamber is therefore only dependent on the position of the piston which can be monitored directly.
This solution is applied in the so-called “DBR Jefri” cells with utilisation of a pressure-neutral inner cylinder made of a glass material, and with external connection for the pressure outside the inner cylinder and the pressure behind the piston.
[0012] If the piston position accidentally is at the bottom of the cylinder, a pressure difference across the inner cylinder wall may occur due to elevated pressure in the inside test fluid (caused by temperature increase or charging with more test fluid), or by a falling pressure in the hydraulic system. This pressure difference might burst or cause plastic flow of the inner cylinder wall, depending on the cylinder material being brittle or ductile.
[0013] While the DBR solution provides a pressure-neutral inner cylinder and chemical compatibility with test fluids, both material deformation properties and clearances are such as to allow the inner cylinder to deform and/or break.
[0014] Hence, an alternative apparatus from those described above is needed to perform pVT studies without the risk and inconvenience of bursting or deforming the inner cylinder.
SUMMARY OF THE INVENTION
[0015] The present invention solves the problem of providing an improved pVT cell relative to the prior art cells.
[0016] In accordance with the present invention, the solution lies in providing a test cell for testing fluids at elevated pressures, which test cell comprises
an inner cylinder inside which a piston is movable axially by hydraulic means to control pressure and volume of a fluid contained at a test fluid side of the piston, the inner cylinder having a thin cylinder wall and being closed at an end at the test fluid side, an outer cylinder coaxially arranged outside the inner cylinder, thereby forming an annular space between the cylinders, the outer cylinder having a thick and sturdy construction, and at least one port for introducing hydraulic fluid to a hydraulic side of the piston opposite the test fluid side, and to the annular space. The test cell of the invention is characterized in that the annular space has a radial dimension less than a maximum elastic expansion range of the inner cylinder, whereby rupture of the inner cylinder from a differential pressure across the cylinder wall can be avoided, due to restriction by the outer cylinder.
[0019] In order to provide a favourable and effective mounting procedure, as well as a simple layout for the hydraulic port arrangement for a test cell in accordance with the invention, the following preferable embodiment of the invention is provided: the outer cylinder is closed by a sealing plug having an axial clearance to an open end of the inner cylinder, thereby providing fluid communication between the hydraulic side inside the inner cylinder and the annular space. Hence, only one port for hydraulic fluid is necessary.
[0020] Further, in order to provide simple and effective means for measuring the test fluid volume, there is in another preferable embodiment provided an axially arranged piston rod attached to the piston and extending out of the cell through a sealed opening in an end closure, and past a measurement device for piston position.
BRIEF DESCRIPTION OF THE DRAWING
[0021] In the following, a more detailed explanation of the invention will be given with reference to FIG. 1 , which shows a cross-section through a schematic (idealized) embodiment of a pVT cell in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] In FIG. 1 appears a pVT cell 1 in accordance with an embodiment of the present invention. A relatively thin inner cylinder 2 which is in contact with a dynamic seal 3 on a piston 4 and with a fluid 9 to be tested as well as a hydraulic fluid 10 , is enclosed by a thick-walled high pressure cylinder 5 . An annular space 6 between cylinders 2 and 5 is filled with hydraulic fluid, by connection to the same line 7 that controls the piston position. High pressure fluids 9 that are subjected to study are fed through a high pressure port 8 at the top of the cell 1 .
[0023] The gap 6 between the inner and outer cylinders 2 , 5 is so small that it is less than the limit for elastic deformation of the inner cylinder 2 , so that the inner cylinder, on sudden expansion, will rest on the outer cylinder 5 before being damaged. The cell is therefore robust, and will not be damaged by deformation caused by inner pressure, even if the outer pressure drops significantly.
[0024] The reason for expansion of the inner cylinder 2 , may be an inside overpressure, contained fluid elevated temperature or elevated temperature of fluid and/or surrounding outer cylinder material transferring heat to increase the temperature of the inner cylinder wall.
[0025] With further reference to FIG. 1 , it appears that the test cell embodiment provides a burst-safe and pressure-neutral pVT cell with a cylindrical design. Innermost there is a slideable piston 4 that divides the inner cylinder space into an upper compartment for receiving high-pressure test fluid 9 therein, and a lower compartment for receiving hydraulic fluid 10 therein. The piston 4 can move inside a relatively thin-walled fluid container 2 that has a substantially uniform inside diameter and concentrically an equally uniform outside diameter. At the top end, this inner cylinder 2 is closed at a position 11 by an end closure 15 that is preferably integral with the thin-walled cylinder 2 . There is a fluid port 8 through the end closure 15 for letting test fluid in and out of the test chamber above piston 4 . When port 8 is closed, the volume and pressure of a fluid inside the top chamber is determined by the position of piston 4 .
[0026] An outer cylinder 5 surrounds the thin-walled inner cylinder 2 . The outer cylinder needs not necessarily have an outer shape that is cylindrical, but the inside shape must be a cylinder coaxial with the inner cylinder and with an inside diameter only somewhat larger than the outside diameter of the inner cylinder. Hence, what is essential is that there is a substantially uniform and coaxial circumferential clearance 6 between the two cylinders. This clearance 6 has the shape of an annular channel. This annular channel extends all the way along the length of the inner cylinder. In the embodiment shown, the outer cylinder 5 is provided with a small shoulder at the position indicated by reference numeral 17 . Above that position, the outer cylinder 5 is joined tightly to the end closure 15 of the inner cylinder 2 .
[0027] It is important that the radial dimension of the annular channel 6 is less than the elastic range of deformation of the inner cylinder 2 . If the inner cylinder 2 is exposed to an overpressure from the inside, compared to the outside pressure, the wall of the inner cylinder 2 will tend to expand. The inner wall of the outer cylinder 5 will then restrict further expansion of the inner cylinder and save it from rupture.
[0028] In order to provide the same hydraulic pressure to fluid 10 both in the annular channel 6 and in the hydraulic pressure chamber underneath piston 4 , it is possible to provide fluid communication between these two spaces such as indicated in the embodiment shown in FIG. 1 , namely by providing a small axial clearance 13 between the lower end of inner cylinder 2 and a sealing plug 12 just therebelow. The sealing plug 12 is a tightening member entered from below and fastened inside the outer cylinder 5 .
[0029] In this embodiment, it is only necessary with one port 7 for hydraulic fluid from a hydraulic pressure source (not shown), because the hydraulic fluid will enter the annular space 6 from the lower part of the cylinder interior.
[0030] However, in another embodiment, a closure element at the lower end of the cylinder interior may be attached to the inner cylinder 2 itself, or there may be no clearance between a sealing plug like plug 12 and the inner cylinder 2 . In such a case, at least one further port for hydraulic fluid must be provided through outer cylinder 5 to the annular channel 6 .
[0031] In principle, one might consider a further embodiment in which the end closure part 15 of the inner cylinder would be integrated with the outer cylinder 5 at area 16 , so that the inner and outer cylinders would actually be in one piece, i.e. with the annular space 6 machined out from one “start cylinder” piece. However, such an operation is rather difficult, so the preferred embodiment is to have a separate inner cylinder 2 such as shown in the drawing, joined tightly together with the outer cylinder at top end 15 , 16 by a thread connection. It appears that in a mounting operation, one would then preferably screw together the outer cylinder 5 and the inner cylinder 2 in the top area ( 15 , 16 , 17 ), and thereafter piston 4 would be entered into the inner space from below. Finally, an end plug 12 might be screwed tightly into the lower end of the outer cylinder. At the top end 16 of the outer cylinder, there is a shoulder inside for defining a stop for the first part of the mounting operation. Another shoulder at reference numeral 17 provides the axial dimension of the important annular channel 6 .
[0032] FIG. 1 also shows an indication regarding a measurement apparatus for determining the position of the piston 4 , and hence the volume of test fluid 9 in the top chamber. A dotted line represents a piston rod 18 attached to the underside of piston 4 and extending all the way out through the sealing plug 12 . Hence, there is of course a thin through channel in plug 12 , with seals so as to avoid leakage therethrough. The piston rod is sufficiently long to extend to a marker or reading device 19 even when the piston 4 is in a top position. The reading device 19 cooperates with markings on the piston rod 18 to establish piston position.
[0033] As regards materials, the material of the inner cylinder 2 would be selected not so much for strength, as for being chemically compatible with the fluids. Hence the previously mentioned materials Hastelloy C, glass or Inconel are candidate materials. The outer cylinder needs only be sufficiently strong to meet pressure specifications, e.g. high strength steel, or specifications regarding a combination of strength and weight, for instance Ti-6Al-4V.
[0034] In a practical example, the length dimension of a pVT cell such as appearing in FIG. 1 , would be approximately 500 mm, the outer diameter would be variable within wide limits (as previously mentioned, the outer shape needs not even be cylindrical), but the outer diameter of the inner cylinder 2 might be approximately 50 mm while the wall of the inner cylinder 2 would be about 2 mm. The radial dimension of the annular channel 6 may typically be in the range 0.05 mm-1.0 mm. A typical axial dimension of the inner cylindrical space would be 200 mm, and the axial dimension of the piston 4 might be approximately 50 mm.
[0035] Neither the materials given as examples here, nor the dimensions given, should be construed as limitative regarding the scope of the present invention. | An apparatus for a burst safe pressure-neutral high pressure cylinder in pVT and condensate cells is described. The dimensions of an outer cylinder are such as to prevent plastic flow of the inner cylinder wall caused by elevated inside pressure and/or temperature. | 6 |
FIELD OF THE INVENTION
This invention relates to current sensors and, in particular, to a compact magnetoresistive current sensor of high sensitivity.
BACKGROUND OF THE INVENTION
Current sensing is important in many electrical and electronic circuits as a source control signals, including those used in automatic feedback control. However most current sensing elements, especially those based on conductive coils, are bulky or expensive to make. The two well-known current sensor devices are the current-sense transformers and the resistive shunt sensor. The former gives electrical isolation between the sensor and the active device but is generally bulky and expensive. The latter, which measures the IR drop directly from the active circuit, is compact but does not provide isolation between the sensor and the active circuit, and the power loss is high. Accordingly, there is a need for a compact, low-cost current sensor of high sensitivity that also provides electrical isolation.
SUMMARY OF THE INVENTION
The present inventors have discovered that a compact, highly sensitive current sensor can be made for any inductive component having an air gap in its magnetic path by disposing a layer of magnetoresistive material in the path of the fringing magnetic field. In the preferred embodiment, a thin magnetoresistive film of La w Ca x Mn y O z on a LaAl O 3 /Al 2 O 3 substrate provides a high sensitivity in the range of 1-100 mV/ampere of DC current in the inductive component. The current sensor consumes a very small amount of power and provides the desirable electrical isolation between the sensor and the active device circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to be described in detail in connection with the accompanying drawings. In the drawings:
FIG. 1 is a schematic view of an inductive element including a magnetoresistive current sensor device (CSD);
FIG. 2 is an enlarged view of the current sensing element of FIG. 1;
FIG. 3 is a graphical plot of the voltage across the FIG. 2 sensing element as a function of the input current in the Winding of the inductive device;
FIGS. 4 and 5 are alternative embodiments of sensing elements; and
FIG. 6 is an alternative form of the FIG. 1 embodiment showing the current sensor of FIG. 5 extending across an air gap.
It is to be understood that these drawings are for purposes of illustrating the concepts of the invention and, except for graphical illustrations, are not to scale.
DETAILED DESCRIPTION
Referring to the drawings, FIG. 1 is a schematic perspective view of a first embodiment of an inductive element 10 including a magnetoresistive current sensor 11 in accordance with the invention. The inductive element, which is conventional, comprises a magnetic core or substrate 12, such as ferrite or iron alloy, a solenoid 13 for generating a magnetic field within the core or substrate 12, and an air gap 14 within an associated fringing flux 15 of the magnetic field. The current sensor 11 is disposed within the fringing flux.
The magnetoresistive current sensor 11 can be four terminal or two terminal. FIG. 2 is an enlarged view of a four terminal sensor comprising an insulating substrate 20, a layer of magnetoresistive material 21 disposed on the substrate, a pair of current electrodes 22, 23 and a pair of voltage electrodes 24, 25 preferably disposed between the current electrodes in a four terminal configuration. In a preferred embodiment the magnetoresistive material is La w Ca x Mn y O z and the substrate is LaAlO 3 or LaAlO 3 /Al 2 O 3 composite.
Fabrication of the preferred magnetoresistive material is described in detail in the co-pending U.S. patent application Ser. No. 08/154,766, filed by S. Jin et al. on Nov. 18, 1993 and entitled "Article Comprising Magnetoresistive Material". A preferred composition layer can be made as follows. A 100 nm thick layer of nominal composition La 0 .67 Ca 0 .33 MnO y was deposited on a (100) LaAlO 3 substrate by laser ablation using a 12 mm diameter×5 mm thick target of the same composition. Other insulating substrates such as SrTiO 3 and MgO may also be used. It is preferable to have some epitaxy or at least some c-axis texture for higher magnetoresistance in the film. The ablation was carried out in a partial oxygen atmosphere (100 mTorr). The resulting layer was epitaxial with the substrate and had nominally the same composition as the target. The layer was maintained 3 hours at 900° C. in an oxygen atmosphere in a tube furnace. After removal of the sample from the furnace and cool-down, the magnetoresistive layer exhibited decrease in electrical resistance by more than a factor of 65 times at 77 K. in a field of 6T, parallel to the direction of the current in the layer.
The magnetoresistive sensor material could be in the form of epitaxial or non-epitaxial thin films prepared by physical deposition such as laser ablation, sputtering, evaporation or by chemical deposition such as electroless, electrolytic or chemical vapor deposition or other techniques such as plasma spray or screen printing. Alternatively, thick films or bulk materials can also be used if a sufficiently high signal can be obtained.
The electrodes 22-25 can be metallic electrodes deposited and defined by conventional photolithographic techniques. FIG. 4 shows an alternative embodiment of the FIG. 2 current sensor employing two terminals rather than four.
FIG. 5 shows yet another alternative embodiment of the FIG. 2 current sensor designed to fit across and optionally into the air gap of the inductive element as shown in FIG. 6. Except for geometry, the device is the same as that shown in FIGS. 1 and 2. The advantage of the FIG. 6 arrangement is that the magnetic field through the sensor is higher, producing a higher output signal. The sensor can also be placed inside the winding on the surface of the core material (within the solenoid). Instead of a separate sensor piece placed near the core, the sensor can also be deposited directly on the surface of the core material such as Ni--Zn or Mn--Zn ferrites as a thin film or thick film. Multiple magnetoresistive elements may sometimes be desirable, for example, to compensate for the temperature variation of the output voltage signal.
In operation, the current electrodes 22, 23 are connected to a source of current in the range 0.001 to 10,000 μA and preferably in the range 0.01 to 2000 μA. The optimal current level can be decided based on specific device design requirement. Voltage is then read between the voltage electrodes 24, 25 in the four terminal sensor or between the current electrodes in the two terminal device. With constant sensor input current, the sensed voltage is essentially proportional to the current in the inductive device.
FIG. 3 is a plot of the voltage change in the magnetoresistive film at 273° K. as a function of the input current in the winding of the inductive device. As can be seen, the voltage change in the sensor film increases linearly with the input current.
While the invention has been described in relation to a preferred magnetoresistive material, more generally the sensor material can be any magnetoresistive material having high electrical resistivity (ρ>0.5 mΩ.cm and preferably ρ>5 mΩ.cm). Such a high resistivity is advantageous for high sensing voltage output at a low input power. Metallic magnetoresistive materials such as Ni-20% Fe (permalloy, ρ>0.05 mΩ.cm), on the other hand, are so conductive that an undesirably very high input current (and hence undesirably large power consumption in the sensor device) has to be employed in order to obtain a significant voltage output signal in the sensor. The material should also have a ferromagnetic Curie temperature higher than the sensor operating temperature, preferably by at least 30° C. Thus for room temperature operation, the material should have a Curie temperature ≧330° K.
Suitable magnetoresistive films can be made of compounds of the form A w B x C y O z where A is chosen from one or more rare earth elements (La, Y, Ce, Nd, Sin, Eu, Tb, Dy, Ho, Er, Tin, Yb and Lu). B is chosen from one or more group IIa elements of the periodic table (Mg, Ca, Sr, and Ba), or other elements such as Pb or Cd, and C is chosen from Cr, Mn, Fe and Co. Advantageously, 0.4≦w≦0.9, 0.1≦x≦0.6, 0.7≦y≦1.5, and 2.5≦Z≦3.5. Preferably 0.5≦w≦0.7, 0.15≦x≦0.50, 0.8≦y≦1.2, and 2.7≦z≦3.3. In a preferred compound, A is La, B is Ca, Sr or Ba, and C is Mn. In a more preferred compound, B is Ca or Ca with partial substitution by Sr or Ba by not more than 40%.
EXAMPLE 1
A leg of rectangular shape ferrite core (picture frame configuration with an air gap slit) was magnetized by passing a DC current into a seven-turn winding on a device such as shown in FIG. 1. The air gap dimension was 5 mm×1.5 mm cross sectional area and ˜1 mm wide. A magnetoresistive film of La--Ca--Mn--O, about 3×3 mm area and 1000 Å thick was placed over the air gap with the film side facing the ferrite material (upside down) with an insulating paper in between. The film had four thin lead wires (two for constant current and two for voltage) soldered onto it for four point measurements of the sensing voltages. The fringing magnetic field near the sensing film is estimated to be ˜1000 Oe at 5A input current in the winding. The La--Ca--Mn--O film was prepared by pulsed laser deposition using a target with a nominal composition of La 0 .67 Ca 0 .33 MnO x at about 100 millitorr oxygen partial pressure and at a substrate temperature of about 700° C. A single crystal (100) LaAlO 3 substrate, about 3 cm square size, was used. The deposited film was cut to size and heat treated at 900° C./3 hours in oxygen. The electrical resistivity of the film was ˜30 milliohm.cm at 273 K. and ˜260 milliohm.cm at 77 K. The voltage change in the sensor film increases almost linearly with the input current in the winding. The input of 5A current induces ˜2% change in the resistance (ΔV signal of ˜460 mV for input sensor current of ˜1 mA) at 77 K. and ˜12% change in resistance (ΔV signal of ˜32 mV for input sensor current of ˜0.1 mA) at 273 K.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments which can represent applications of the principles of the invention. Numerous and varied other arrangements can be made by those skilled in the art without departing from the spirit and scope of the invention. | The present inventors have discovered that a compact, highly sensitive current sensor can be made for any inductive component having an air gap in its magnetic path by disposing a layer of magnetoresistive material in the path of the fringing magnetic field. In the preferred embodiment, a thin magnetoresistive film of La w Ca x Mn y O z on a LaAlO 3 /Al 2 O 3 substrate provides a high sensitivity in the range of 1-100 mV/ampere of DC current in the inductive component. The current sensor consumes a very small amount of power and provides the desirable electrical isolation between the sensor and the active device circuit. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to manufacturing processes and equipment, and more particularly to manufacturing of products employing a flexible bag for dispensing a fluent material to articles.
Many manufacturing processes and apparatus have as a component element the dispensing of a fluent material to an article. As one example, packaging machinery which fills a container and seals or closes the container is widely employed to package a variety of products. For certain applications, the same machines also make the container. So called form, fill and seal machines typically form a bag from a web of flexible material and pass the bag directly to a filling station where the product is fed by gravity otherwise moved into the bag through an opening in the bag. The same machine then seals the bag opening to enclose the product. The bag may also be itself placed inside another container such as a cardboard box.
Food and medicinal products are commonly packaged in the way and by the type of machine described above. These products are of the type which can flow under the force of gravity, or when pushed by a pump, auger or other suitable device. Of course, liquid materials can be packaged in this manner, but often the product is a solid (e.g., potato chips, cereal or pills) which is sufficiently granular to flow. Naturally, food and medicinal products must be handled by the machine in such a way as to maintain aseptic conditions. Accordingly, the parts of the machine which handle the food are made of materials (e.g., stainless steel) which are highly resistant to corrosion and can be cleaned. However, such materials are expensive and significantly increase the cost of the machine. The machines must be periodically shut down to clean surfaces which handle the food product and the bags. Many food products are prone to leave crumbs, residue or other debris as they are handled, which cause the machinery to become unsanitary. Although necessary, it is inefficient to stop the machine frequently for cleaning and this increases the cost of packaging the product.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of apparatus and method for dispensing a fluent material to an article; the provision of such an apparatus and method which handle fluent materials while keeping the apparatus clean; the provision of such an apparatus and method which are capable of maintaining aseptic conditions; the provision of such an apparatus and method which do not require frequent stoppage for cleaning; the provision of such an apparatus and method which are effective in mass production; the provision of such an apparatus and method which can operate rapidly; and the provision of such an apparatus and method which are economical and easy to use.
Further among the several objects and features of the present invention may be noted the provision of a flexible bag used to dispense a fluent material which is capable of dispensing at multiple outlets; the provision of such a bag which can be manipulated to dispense directly onto an article from the bag within any intervening structure; the provision of such a bag which can store and deliver a product in an aseptic condition; and the provision of such a bag which is economical to use in manufacture.
Generally, a method of automatically filling containers with a fluent material for mass production of filled receiving members comprises providing an array of receiving members adapted to receive fluent material. A charge of fluent material is metered from a flexible bag to plural ones of the receiving members at the same time.
In another aspect of the invention, a method of dispensing a fluent material to articles which receive the fluent material in a manufacturing operation generally comprises selectively dispensing fluent material to plural ones of the articles at the same time by deforming a flexible reservoir to eject fluent material therefrom. The flexible reservoir is replaced with another flexible reservoir upon substantial depletion of fluent material from the reservoir as a result of the dispensing step, for continued dispensing of the fluent material.
In still another aspect of the present invention, apparatus for manufacturing fluent material receiving members having a fluent material applied thereto generally comprises a flexible bag containing the fluent material and having outlets therein from which fluent material may be dispensed. Means adapted to receive portions of the bag is capable of metering a charge of fluent material from the bag to plural ones of the receiving members at the same time.
In a further aspect of the present invention, apparatus for manufacturing articles having a fluent material applied thereto from a flexible bag containing the fluent material generally comprises a support adapted to releasably hold the flexible bag containing fluent material in position for dispensing to the articles. A conveyor moves the articles past the support for receiving fluent material from the flexible bag. A flow control adapted to receive at least a portion of the flexible bag is capable of deforming the bag to produce flow of fluent material out of the bag to the articles.
In a still further aspect of the present invention, apparatus for manufacturing articles having a fluent material applied thereto generally comprises a flexible bag containing the fluent material and adapted to dispense fluent material to multiple ones of the articles at the same time. A support is adapted to releasably hold the flexible bag containing fluent material in position for dispensing to the articles. A flow control adapted to receive multiple portions of the flexible bag is capable of deforming the bag to produce flow of fluent material out of the bag to plural ones of the articles at the same time.
Other objects and features of the present invention will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of apparatus for automatically filling containers of the present invention;
FIG. 2A is a diagrammatic flow of the apparatus illustrating its operation in a forward feed mode;
FIG. 2B is a diagrammatic flow of the apparatus illustrating its operation in a fill, seal and separate mode;
FIG. 3 is an elevation of a flexible bag with parts broken away to show the integral connection of nipples to the bag;
FIG. 4 is an enlarged perspective of the apparatus showing a pump thereof without the bag and open in preparation for receiving the bag nipples;
FIG. 5 is a enlarged, fragmentary elevation taken from the vantage indicated by line 5 — 5 of FIG. 1 with parts broken away to illustrate the reception of nipples in the pump;
FIG. 6 is a fragmentary, schematic elevation similar to FIG. 5 but showing another pump capable of delivering fluent material at different rates or in different amounts from the different nipples;
FIG. 7 is an enlarged, fragmentary view of apparatus similar to that shown in FIG. 1 but including a bag squeezing mechanism to force fluent material toward the nipples and pump; and
FIG. 8 is a fragmentary view of the flexible bag showing on of the nipples receiving a needle in its outlet.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIG. 1, apparatus of the present invention for forming containers 10 , filling the containers with a fluent material F and sealing the containers is indicated generally at 12 . The apparatus includes a support 14 which suspends a flexible bag (or “reservoir”) 16 holding the fluent material F, and mounts a pump 18 (the reference numerals designating their subjects generally). The fluent material F may be a food or medicinal product, but is not limited to materials consumed or otherwise used on or in the body. Moreover, the material may be of such a nature that it is fluent only at the time it is delivered from the bag 16 . The present invention is particularly adapted for use to maintain an aseptic environment for the fluent material F, but has application where it is not necessary that such an environment be maintained. Although the substance is preferably a liquid or semi-liquid, solids which are sufficiently granular to flow may also be held in the flexible bag 16 . As one example of the type of product packaged, the fluent material F could be honey to be packaged in small, disposable containers 10 such as for single serving use by customers of a restaurant.
A conveyor of the apparatus 12 is generally indicated at 19 and includes in the illustrated embodiment a first feed roller 20 holding a roll of material to form containers 10 extending forward from the first feed roller in a web 22 , and a take-up roller 24 which receives a remnant of the web. A first guide roller 26 is provided to locate the web 22 in a horizontal position while permitting the web to change direction to reach the take-up roller 24 . A belt conveyor 28 located under the web 22 at the downstream end of the web receives sealed containers 10 which are separated from the web, and conveys them for tumble packaging in a box B. It is to be understood that the illustration of the conveyor 19 is schematic as the details of construction are well known to those of ordinary skill in the art in the field of such apparatus. Moreover, although the conveyor 19 is illustrated to include rollers 20 , 24 which let out and take up the web 22 of material from which the containers 10 are formed, other conveyors are envisioned. For instance, a belt or other moving surface or support (not shown) which receives pre-formed containers could be used without departing from the scope of the present invention. In that instance, the first feed roller 20 and belt conveyor 28 would not be present.
Further, it is envisioned that a conveyor for establishing relative motion between the containers 10 and the flexible bag 16 could include not only the conveyor 19 , but also structure for moving the bag while the containers are stationary, or structure which produces some combination of movement of the bag and movement of the containers. In any event if the bag 16 is the frame of reference, the containers 10 will move past the bag. Still further, it is not necessary that the fluent material F be used to fill containers of any type. Indeed the fluent material can be applied to the exterior of an article (or “receiving member”), such as the application of icing to a manufactured food product, which does not “contain” the fluent material. The fluent material could also be injected into the article.
In the illustrated embodiment, containers 10 are formed from the web 22 by a die 32 and a form (not shown) which come together just upstream from the first feed roller 20 to deform the web into rectangular, flat-bottomed depressions constituting the containers. The die 32 contains recesses 34 having shapes substantially the same as that of the containers 10 to be formed. The form, which would be located above the web 22 , has not been shown so as not to obstruct the view of the flexible bag 16 . The shape of the end of the form is the reverse of the recess so that the form may fit into the recess, forming the web 22 between them. The form and die 32 create one laterally extending row of containers 10 from the web 22 on a single stroke. In the illustrated embodiment, the rows constitute an array of containers 10 . However as used herein, an array can refer to a single file line of containers or only a single container placed under the bag 16 for filling. As shown, the containers 10 are formed by stretching the web 22 without substantially affecting the lateral dimension or shape of the web. However, some dimensional variation can be tolerated if the containers 10 retain their relative arrangement. Once formed, the containers 10 retain their shape, but remain part of the web 22 and move with the web.
The web 22 passes forwardly from the form and die 32 under the flexible bag 16 held by the support 14 . The bag 16 is made of a flexible material (which as used herein would include a limp material), which can be formed in a sterile environment or formed and filled in a non-sterile environment and then subject to a sterilizing process. However as mentioned above, the bag 16 could also be used for products not requiring a aseptic conditions. Any suitable material could be used to form the bag 16 , such as an appropriate polymer, including without limitation polyvinyl chloride, polyolefin, polymer laminates and polymer alloys. As shown, the bag 16 is transparent so that the flowable product carried by the bag can be readily seen to determine if the bag is empty. However, other ways (not illustrated) of establishing whether the bag 16 is nearing empty can be employed, such as electronic eyes which view the level of fluent material F, and devices to weigh the bag.
Referring to FIG. 3, the bag 16 comprises a thin-walled body 38 which encloses a volume containing the large majority of the fluent material F. At the upper end of the body 38 , two laterally elongate loops 40 , together constituting in the illustrated embodiment “a hanger”, are formed as one piece with the remainder of the bag 16 . The loops 40 can be also formed separately from the bag 16 and attached to the body 38 in a suitable manner such as by welding, adhesive or with a mechanical fastener(s). The loops 40 receive a mounting rod 42 of the support 14 which extends laterally of the bag and holds the bag on the support. The ends of the rod 42 are received in upwardly opening, U-shaped receptacles 44 at the upper ends of uprights 45 of the support 14 . The receptacles 44 hold the rod 42 and the bag 16 , but permit the bag to be removed from the support 14 and replaced, by lifting the rod out of the receptacles, sliding the loops 40 off of the rod and sliding a new bag (not shown) onto the rod. The rod 42 supporting the new bag can then be replaced with its ends in the U-shaped receptacles 44 for continued operation. Of course other ways of supporting the bag 16 may be employed without departing from the scope of the present invention. Preferably, the bag 16 is supported so that it can be readily removed and replaced. It is envisioned that structure, such as a second support and pump (not shown), could be used so that bags could be changed out without any interruption in operation of the apparatus 12 .
At the lower end of the body 38 , four nipples 46 extending down from the body are in fluid communication with the interior of the bag 16 for delivery of the fluent material F out of the bag and into the containers 10 , as will be described more fully hereinafter. The number of nipples 46 is preferably the same as the number of containers 10 formed in each row. Naturally, the number of nipples and their precise arrangement can be varied as necessary for the particular manufacturing operation. The nipples 46 are generally elongate tubes which are integral with the body 38 . The nipples 46 may be formed separately from the body 38 and attached in a suitable manner, such as by welding, adhesive or mechanical fastener(s) to achieve integration with the bag material which forms the body. However in the preferred embodiment, the nipples 46 are formed of the same piece of material as the body 38 of the bag 16 . As initially formed, the lower ends of the nipples 46 are closed (as shown in FIG. 3) to seal the interior of the bag 16 to hold the fluent material F in the bag. In manufacturing operation, the ends are cut or otherwise made to have outlets to allow the fluent material F to flow out of the bag 16 . Preferably, the nipples 46 are tubular with no internal structure. However, it is envisioned that the nipples could be equipped with internal valves or re-expansion devices (not shown) without departing from the scope of the present invention.
The bag 16 can be formed in any suitable fashion. A typical way of forming the bag 16 is to provide two webs of material which are brought together and cut to shape by a die (not shown) to form an enclosure. At the same time the webs are cut to shape, adjacent the peripheral edges of the bag are welded together in the die, such as by a solvent or RF welding. The adjacent edges could also be heat sealed, for example. As one alternative, a single web of polymeric material could be folded over against itself to form the enclosure. The folded web could be cut and sealed in a similar way as for the bag formed from two webs. Adjacent peripheral edges may be left unattached along a portion of the bag 16 to provide an opening for filling the bag with fluent material.
The nipples 46 are received through the pump 18 which acts on the nipples as by deforming the nipples to produce a metered flow of the fluent material F out of the bag 16 . The pump 18 is mounted on the support 14 which also holds the bag 16 and extends transversely over the web 22 . The pump 18 illustrated in FIGS. 1, 4 and 5 is a shuttle pump, which includes a shuffle 50 and an anvil 52 . The shuttle is mounted on a stationary crosspiece 54 for sliding movement relative to the crosspiece and anvil 52 in a direction transverse to the web 22 . A housing 56 at the left end of the crosspiece 54 encloses a shuttle actuation mechanism (not shown). A door 58 hingedly attached to the crosspiece 54 carries the anvil 52 . The door can be opened as shown in FIG. 4 to facilitate reception of the nipples 46 in the pump 18 , and locked with a latch 60 in a closed position for operation, as will be more fully described. Referring to FIG. 4, both the shuttle 50 and the anvil 52 are shaped to have five flat plateaus ( 50 A, 52 A) separated by four valleys ( 50 B, 52 B). Except when the pump 18 is actuated to deliver fluent material F, the plateaus 50 A, 52 A and valleys 50 B, 52 B of the shuttle 50 and the anvil 52 are in substantial registration when the door 58 is closed. The nipples 46 are received in the aligned valleys 50 B, 52 B such that each nipple is surrounded by the shuttle 50 and anvil 52 . In the illustrated embodiments, the nipples 46 are the portions or regions of the bag 16 which are received in or acted upon by the pump 18 . Two of the nipples 46 are illustrated in FIG. 5 as received in the valleys 50 B, 52 B, but only the valleys 50 B may be seen because the door 58 and anvil 52 have been broken away. The crosspiece 54 is further formed with upper and lower aligned slots 62 which are vertically aligned with the valleys of the anvil 52 . The nipples 46 pass through these slots 62 upon entering and exiting the pump 18 . An upper pincher 64 and a lower pincher 66 located on one side of each slot 62 are mounted for extension and retraction from the crosspiece 54 across the slot (i.e., transverse to the web 22 ). The pinchers 64 , 66 extend to pinch the nipples off, closing the nipples from fluid flow past the points where the nipples are pinched. The pinchers 64 , 66 are separately actuated from the shuttle 50 and the upper pinchers are separately actuated from the lower pinchers, as will be described more fully hereinafter, to facilitate accurate dispensing of the fluent material F. A pump of the same general type is disclosed in U.S. Pat. No. 5,151,019, the disclosure of which is incorporated herein by reference.
Although the shuttle pump 18 is believed to be adequate for use in the apparatus 12 , other forms of pumps may be used without departing from the scope of the present invention. The present pump 18 may be so configured that the upper pinchers 64 in each slot are separately actuated from each other, as are the lower pinchers 66 so that fluid flow from each nipple 46 is independent of that of the other nipples. However, the pump or fluid flow control device may take on other, entirely different forms. For instance and without limitation, a peristaltic pump (generally indicated at 70 ) of the type shown in FIG. 6 could be used. The peristaltic pump 70 has a pump wheel 72 for each nipple 46 including pegs 74 which extend perpendicularly outward from the wheel near its periphery. Each wheel 72 is mounted for rotation, such as by an individual electric motor (not shown) so that the pegs 74 are brought into sequential engagement with the nipple 46 to force fluent material F out of the nipple. By stopping the wheel 72 as shown in FIG. 6, the nipple would be pinched off so that no fluent material would exit the bag 16 . The wheels 72 could be run at different times and at different speeds to vary the sequence of fluid delivery and/or the flow rate between nipples 46 . The angular spacing between adjacent pegs 74 on the wheels 72 could be different so that the amount of fluent material dispensed for the same angular rotation of the wheels is different. It is to be understood that FIG. 6 is but one example of an alternate pump which could be used.
It will be necessary for viscous fluent material F to provide a mover in addition to the pump 18 to cause the fluent material to flow for refilling the nipples 46 after a discharge by the pump. A second mover of this type is indicated generally by the reference numeral 90 in FIG. 7 . The second mover is shown to comprise a pair of rollers 92 mounted on arms 94 and located on opposite sides of the bag 16 . The rollers 92 are mounted for free rotation about their longitudinal axes, and can be separated to facilitate removal and replacement of the bag 16 . The arms 94 are connected to a controlled actuator (not shown) which is capable of indexing the arms down to gradually squeeze the bag 16 from top to bottom to empty the bag. The downward movement of the arms 94 to squeeze the body 38 of the bag 16 is used to force the fluent material F downwardly into the nipples 46 . It is envisioned that the arms 94 could be indexed down after the pump 18 has discharged to assist in refilling the nipples 46 for the next discharge.
As stated previously, the apparatus 12 has application where fluent material F is applied onto an article, or injected into an article. Referring to FIG. 8, the bag 16 may have a fitment, in this case in the form of an injection needle 96 , attached to each nipple 46 (only one is shown). The needle 96 is formed of a suitably rigid material and sealingly attached in the outlet of the nipple 46 . The needle 96 could be captured by an injection device (not shown) to move the needle down into the article before operation of the pump 18 to eject fluent material. Alternatively, the needle 96 could be held stationary and the articles moved upward into the needles. It is to be understood that other types of fitments (not shown) could be used without departing from the scope of the present invention. For instance a fitments which allow the nipple 46 to be attached to another nipple or tube (not shown), or which shape the fluent material F as it flows out of the nipple could be used. Moreover, the end of the nipple 46 could be formed to shape or control flow of the fluent material. Further, polymer material having different material characteristics (e.g., such as density and rigidity) could be integrally formed with the material of the bag 16 at the outlets for such purposes.
Downstream from the support 14 and the bag 16 is a mechanism for closing the containers 10 filled with fluent material F. As shown in FIG. 1, a web 78 from a roll of closure material held by a second feed roller 80 is fed downwardly under a second guide roller 82 toward and under the first guide roller 26 to the take-up roller 24 . Thus, it may be seen that the take-up roller 24 collects both remnants of the container material web 22 and the closure material web 78 . After passing under the second guide roller 82 , the closure material web 78 is in face-to-face relation with the unformed material of the web 22 surrounding the open tops of the containers 10 . The closure mechanism comprises a heat sealing device 84 capable of coming down against the closure material web 78 and sealing the closure material with the container material of the web 22 so that the open tops of all four containers 10 in the row are separately closed, sealing in the fluent material F in the containers. A punch 86 and a die 88 downstream from the closing mechanism are operable to move together to punch through the closure material web 78 and the container material web 22 to separate each container 10 (including its own closure) from the container material web and the closure material web. The remnants of the container material web 22 and the closure material web 78 remain in tact for movement to the take-up roller 24 . The punch 86 has four rectangular projections 86 A (only one is shown) and the die has four holes 88 A (only one is shown), one for each container 10 in the row. The projections 86 A are received in the holes 88 A when the punch 86 and die 88 are activated to cut through the closure material web 78 and container material web 22 . The containers 10 drop down through the die 88 to the belt conveyor 28 for transport to the box B.
Having described the construction of the apparatus 12 and the flexible bag 16 , the operation of the apparatus will be described. As an initial matter, flexible bags such as bag 16 will have been formed, filled with the fluent material F (e.g., honey) to be packaged in the containers 10 , and sealed at a remote location, such as a processing plant. The method of the present invention is not limited to remote forming, filling and sealing of the bags, but is suited for this type of manufacturing arrangement. The bags 16 are formed, filled with the fluent material F and sealed at the processing plant, and then placed in a suitable transport to the manufacturing facility where the final packaging is to be done. The bags can be formed, filled and sealed in an aseptic form/fill/seal machine, or could be formed under non-aseptic conditions and then sterilized along with the fluent material after the bag is filled. As previously stated, it is not necessary that the bags 16 be aseptic where the conditions do not require it, but bags of this type are particularly adapted for use where aseptic conditions are needed, such as in food or medicine packaging.
Once at the final packaging site, one of the bags 16 is loaded into the apparatus 12 by lifting at least one end of the rod 42 out of the U-shaped receptacles 44 and sliding the bag onto the rod so that the rod is received through both of the loops 40 at the top of the bag. The rod 42 is then replaced on the support 14 with its ends in the receptacles 44 . The door 58 of the pump 18 is open, substantially as shown in FIG. 4, and the nipples 46 are positioned in the upper and lower slots of the crosspiece 54 in registration with the valleys of the shuttle 50 . The door 58 is then closed and the latch locked so that the nipples 46 are received in both the valleys of the shuttle 50 and the valleys of the anvil 52 (FIG. 5 ). The first feed roller 20 will have had a roll of container material mounted thereon and the web 22 of container material is threaded from the roll around the first guide roller 26 and attached to the take-up roller 24 . Similarly, the roll of closure material is received on the second feed roller 80 and the web 78 of closure material is threaded around the second guide roller 82 to the first guide roller 26 and then attached to the take-up roller 24 . The apparatus 12 is ready for production operation to form, fill and seal containers 10 .
Referring now to FIGS. 2A and 2B, the sequence of operation of the apparatus 12 is described. As illustrated in FIG. 2A, the first and second feed rollers 20 , 80 and the take-up roller 24 are actuated (such as by one or more electric motors, not shown) to index the container material web 22 and the closure material web 78 forward one increment. The increment in the illustrated embodiment corresponds to the dimension of one containers 10 to be formed which is parallel to the lengthwise extent of the web 22 plus a predetermined amount corresponding to the spacing between adjacent rows of containers. The first and second feed rollers 20 , 80 and the take-up roller 24 are halted to stop the forward advance of the container material web 22 and closure material web 78 for a dwell. The form and die 32 are actuated to engage the container material web 22 to form a row of containers 10 still attached to the container material web. The index and form steps are initially repeated until a row of formed containers 10 underlies the nipples 46 when the container material web 22 dwells.
This time the shuttle pump 18 is actuated to deliver a preselected charge of fluent material F to each of the four containers 10 in the row. After the bag 16 was installed in the apparatus 12 as described above, the lower pinchers 66 were extended (to the position shown in solid lines in FIG. 5) to pinch the nipples 46 near, but spaced somewhat above their lower ends against the crosspiece 54 in the slots 62 . The ends of the nipples 46 were cut open to form outlets for delivering fluent material F. The upper pinchers 64 are then extended to pinch off the nipples 46 near their upper ends (the position shown in solid lines in FIG. 5) and define a charge of fluent material F located in each nipple between the upper pincher and the lower pincher 66 . After the first row of containers 10 stops under the nipples 46 , the pump 18 is activated to retract the lower pinchers 66 into the crosspiece 54 (the position shown in phantom lines in FIG. 5) and slide the shuttle 50 in a direction transverse to the container material web 22 . Retraction of the lower pinchers 66 allows fluent material to flow out of the nipples 46 under the force of gravity. However, the pump 18 also deforms the nipples 46 by squeezing to make certain the charges of fluent material F between the pinchers 64 , 66 is delivered out of the nipples. The sliding of the shuttle 50 moves the valleys 50 B substantially out of registration with the nipples 46 and moves the plateaus 50 A substantially into registration with the valleys 52 B of the anvil 52 , squeezing the nipples and forcing the fluent material out of the outlets at the lower ends and into the containers 10 .
The shuttle 50 moves back to its original position and the lower pinchers 66 are extended to close off the nipples 46 against further flow of fluent material F. The upper pinchers 64 are retracted and more fluent material moves down into the nipple, re-filling it. The upper pinchers 64 are then closed to pinch off the upper ends of the nipples and define new charges of the same volume as the previous charges and the cycle is repeated. The re-filling of the nipples 46 preferably occurs in the time it takes for the container material web 22 to be advanced forward one row. It will be appreciated that the pump 18 operates at the same time a new row of containers 10 is being formed during a dwell of the container material web 22 . It is envisioned that additional rollers or other devices (not shown) to hold the web 22 from vibrating under the bag 16 as a result of the act of forming of the containers could be used as needed.
The filled containers 10 in the row move downstream with each feed of the container material web 22 , eventually passing under the closure material web 78 . The open tops of the containers 10 are covered by the closure material web 78 when the containers reach the heat sealing device 84 . During the dwell, the heat sealing device 84 moves down against the closure material web 78 and seals the closure material to the unformed material of the container material web 22 surrounding the open upper ends of the containers 10 . The fluent material F is now sealed inside the containers 10 . The containers continue to be attached to the container material web 22 and are now also attached to the closure material web 78 . The attachment is illustrated by the dashed lines on the closure material web 78 .
At a subsequent dwell, the row of sealed containers 10 is aligned with the punch 86 and die 88 which are actuated to cut through the closure material web 78 and container material web 22 to separate the sealed containers from the webs. The containers 10 fall through the holes 88 A in the die 88 onto the belt conveyor 28 . The belt conveyor may run continuously to carry the loose containers to the box B. In the illustrated embodiment, the containers 10 simply fall into the box B (i.e., are tumble packed). It will be understood that other final packing arrangements within the knowledge of those of ordinary skill could be used. The remnants of the container material web 22 and the closure material web 78 continue on around the second guide roller 82 to the take-up roller 24 .
When the bag 16 is exhausted of fluent material F, it may be removed and replaced with a new bag. The exhausted bag 16 can be disposed. It will be appreciated that none of the machinery of the apparatus 12 comes into contact with the fluent material F in the packaging operation. The bags 16 themselves, rather than the fluent material F, are acted upon by the pump 18 to cause the containers 10 to be filled so that the bags may serve as the aseptic surfaces in the apparatus 12 . Of course, the container material and the closure material must be aseptic when conditions require it, but in every circumstance it will be easier to keep the parts of the apparatus 12 which handle this material clean. It will not be necessary in the ordinary course to clean the fluent material from the apparatus 12 .
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A method for manufacturing in which a fluent material is dispensed to an article such as a container from a flexible bag The fluent material is dispensed directly to the container without any intervening structure which contacts the fluent material. Accordingly, the apparatus can be constructed of less expensive materials and does not require frequent cleaning. The apparatus acts on the bag to dispense and does not act on the fluent material. Thus, the apparatus has particular application where aseptic conditions need to be maintained such as in the packaging of the food and medicine The flexible bag is preferably formed with multiple outlets permitting simultaneous dispensing to multiple containers. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to solar collector covers and specifically to such covers which transfer or admit solar radiation to an energy exchange component of the solar collector.
With the apparent shortage of traditional energy sources in the United States, a greatly increased effort has been made to obtain usable energy from the sun. One prevalent method for collecting solar energy utilizes an energy exchange mechanism such as an element which is heated by solar radiation and the heat thus produced is transferred from the heated element for storage or use elsewhere by a fluid transferring medium such as water or air. This type of solar collector is generally designed so that the elements to be heated are arranged in a flat plate or series of flat plates with maximum exposure to the suns rays. The efficiency of such flat plate solar collectors is limited by the heat energy loss through the front cover.
One method of limiting the loss of energy through the front cover is to utilize multipane covers with optimum spacing between covers. Another method is to incorporate a special reflective coating on the cover surfaces. The use of these techniques have not increased efficiency of flat plate solar collectors by a large factor. Solar collector covers commonly in use demonstrate a substantial heat loss through the front cover, thereby limiting the efficiency of the collector.
There is, consequently, a need for a solar collector cover that is simple, easily constructed, economical, self-contained, and one which minimizes the heat loss when in use, thereby increasing the efficiency of the solar collector.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to solar collector cover for mounting on existing heat exchange solar collectors. The novel cover substantially improves the efficiency of the collector.
The cover provides a light and solar radiation transferring core material having a plurality of sealed and evacuated cavaties or passageways disposed therein.
The thermal insulative properties of a vacuum are well known. By covering a solar collector with a light transferring evacuated area the insulative properties of the vacuum can be utilized to reduce heat loss through the cover. The heat loss through the cover is inversely proportional to the ratio that the evacuated area represents with respect to the total area of the cover. By increasing the amount of vacuum area per area of the cover, the amount of conductive heat transfer can thereby be reduced by a significant amount.
An object of the present invention is to provide a solar collector cover with improved efficiency for use with various designs of solar collectors.
Another object of the instant invention is to provide a solar collector cover for use in increasing the efficiency of flat plate solar collectors.
A further object of the invention is to provide a solar collector cover which is simple in design, easily fabricated, and improves the reduction of heat loss through the cover.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
Of the known prior art devices, none meet the existing need for an efficient solar collector front cover which is simple, compact, inexpensive to produce, is dependable and efficient and is easily adaptable for use in existing solar collectors. The instant invention is directed to a novel solar collector cover which meets all of these existing needs.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, as well as other objects and further features thereof, reference is made to the following detailed disclosure of the invention taken in conjunction with the accompanying drawings wherein:
Fig. 1 is an exploded perspective view of the invention;
FIG. 2 is a perspective view illustrating the assembled device in use atop a solar collection unit;
FIG. 3 is a sectional view taken along the lines 3--3 in FIG. 1;
FIG. 4 is an exploded perspective view of a second embodiment of the invention;
FIG. 5 is a perspective view of the second embodiment illustrating the assembled device;
FIG. 6 is a cross sectional view of a modified embodiment of the sealing trough portion of the second embodiment;
FIG. 7 is a sectional view taken along the lines 7--7 in FIG. 6;
FIG. 8 is a perspective view of a third embodiment of the invention; and
FIG. 9 is a sectional view taken along the lines 9--9 in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings the solar collector cover of this invention is indicated generally at 10 in FIG. 1. The cover 10 (FIGS. 1 and 3) includes a center block 13 sandwiched between a pair of cover plates 14 and 15. The center block 13, in the form of a hexahedron is transparent or translucent and has a top wall 16, a bottom wall 17 and a peripheral wall made up of a pair of side walls 18 and 19 and a pair of end walls 20 and 21.
Passageways are formed in the center block 13 (FIG. 1) by drilling or forming a plurality of holes 22 through the block from the top wall to the bottom wall. A plurality of grooves 23 are formed in the top surface of the block to fluidly interconnect the holes 22 and a terminal groove 24 is formed in the top surface to fluidly interconnect grooves 23, with the atmosphere at the peripheral wall 21.
Secured to the center block 13 (FIGS. 1 and 2) by an adhesive or the like are the cover plates 14 and 15. The cover plates are also translucent or transparent and hexahedron in shape. Upon securement of the plates to the block with the block 13 sandwiched therebetween the holes and grooves are effectively sealed from the atmosphere with only the terminal groove 24 fluidly open. The terminal groove 24 provides a passageway for the substantial evacuation of the air in the holes 22 and grooves 23. Upon evacuation of the air a plug unit 25 is inserted into the terminal groove to effectively seal it and the passageways thus preventing the entrance of any air thereto.
A second embodiment of the invention is disclosed in FIGS. 4-5 and indicated generally at 30. This embodiment includes a center block 31, a pair of end plates 32 and 33, and a plug unit 34. The center block 31, sandwiched between the end plates, is formed from a transparent or translucent material into a hexahedron, and has a bottom wall 36, a top wall 37, a pair of end walls 38 and 39, and a pair of sidewalls 41 and 42. A plurality of holes 43 are formed through the block from end wall to end wall and a groove 44 is formed in one end wall from a sidewall to all of the holes, thereby fluidly interconnecting them. The end plates 32 and 33 are bonded to the center block 31 and thereby effectively seal the groove and the holes from the atmosphere. A plug unit 34 is disposed in the groove to prevent the reentry of air after the holes and groove have been substantially evacuated of air.
FIGS. 6 and 7 disclose a modified embodiment of an end plate 32 or 33 wherein the interior thereof is hollowed out to form a cavity 46 which replaces the groove 44 in the center block 31. A passage 47 is formed through a side wall which communicates with the cavity 46 and the cavity 46 is in fluid communication with the holes 43, thus permitting the holes and cavity to be evacuated. A plug unit 34 FIG. 5 is then used to seal the passage.
A third embodiment of the invention is depicted in FIGS. 8 and 9 and indicated generally by the numeral 50. This embodiment includes a plurality of hollow, evacuated balls 51 encased in a plastic matrix 52. Although the balls are shown to be of uniform size and spaced equally apart, they can be of varying sizes and arbitrarily spaced to provide the maximum amount of evacuated space within the cover 50.
In certain instances, it may be necessary to utilize a vacuum pump to continuously or frequently evacuate the passages. Under this circumstance the plug unit 34 could include a valve, a vacuum line, and possibly a pump (all not shown).
The center block, covers, or plates can be formed of any solar radiation transferring material such as glass, plastic, fiberglass or the like of sufficient strength to permit the substantial evacuation of air from the passageways and to serve as a cover unit.
With reference to FIG. 2, one potential use of the cover 10 may be seen with specificity. A solar collector unit 56 is depicted of a very general type. An inlet port 58 is provided to allow some medium such as water to enter the collector 56 and an outlet port 57 is provided to allow these same waters to exit once heated. The cover 10 is placed over the collector 56 such that the sun's radiation (not shown) must pass through the cover 10 before the heat radiation may be absorbed by the collector 56. As the collector absorbs heat, the water contained within the collector is heated, and the heated water is removed via the outlet port 57. The cover 10 protects the heat absorption surface of the collector 56 from losing heat, other than to the water, and thereby serves to insulate the collector 56 and to promote the efficiency of the units operation. There are many collector units well known in the art, of which the above is only one, and it is understood that the above collector 56 was depicted for illustration only, and that the cover 10 may be successfully used with any collector where the cover may be operably placed between the collector unit and the sun. | An improved solar collector cover for reducing energy loss in flat plate solar collectors is disclosed. The cover provides a solar radiation transmitting material containing a plurality of sealed evacuated passageways or cavities. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process for the production of microcrystalline cellulose.
DESCRIPTION OF PRIOR ART
[0002] Canadian application No. CA 2,313,261 (JOLLEZ) describes a process for the production of microcrystalline cellulose. This process is characterised in that the pulp obtained at the end of a thermo mechanical pulping step is submitted to a sudden and violent depressurisation and a shear force. This step has for effect the production of a non-selective fragmentation of the microcrystalline cellulose resulting in the production of impurities by the oxidation during and after the explosion of the pulp.
[0003] Canadian patent No. CA 1,198,703 (DELONG) describes a process which generates a mixture of sugar and cellulose more or less degraded. This process uses wood as the starting material and sulphuric acid, sulphurous (SO 2 ) or hydrochloric acid.
[0004] Canadian patent No. CA 2,137,890 (AKZO) describes the conversion of cellulose fibers derived from a conventional process, into microcrystalline cellulose by using benign reactives like O 2 and CO 2 . More particularly, it shows that a low degree of polymerisation can be obtained by the application of high-pressure at 140° to 180° C. for 15 minutes to 5 hours on aqueous suspensions of cellulose (solid/liquid ratio of 1/8 to 1/20) in the presence of O 2 and CO 2 in autoclaves in non-continuous mode.
SUMMARY OF THE INVENTION
[0005] A first object of the present invention is to provide a process for the manufacture of microcrystalline cellulose having a fibrous appearance and the integrity of which is kept.
[0006] A second object of the present invention is to provide a process for the production of microcrystalline cellulose that does not necessitate the use of any mineral acids, sulphur dioxide or carbon dioxide.
[0007] A third object of the present invention is the production of microcrystalline cellulose in the absence of violent non-selective depressurisation. The present process allows the application of a controlled depressurisation, which in turn permits a high yield of microcrystalline cellulose, at all conditions, while limiting the production of non-desirable derivatives.
[0008] A fourth object of the present invention is to provide a process which can produce a commercially acceptable pharmaceutical grade microcrystalline cellulose product in the absence of violent nonselective depressurization.
[0009] In accordance with an embodiment of the present invention, a process is provided for manufacturing hydrolyzed cellulose suitable for use in preparing microcrystalline cellulose, comprising:
[0010] a) preparation of a pulp by repulping,
[0011] b) pressing of the pulp obtained in a),
[0012] c) decompaction of the pulp obtained in b),
[0013] d) feeding of the pulp obtained in c) into a pre-heated reactor,
[0014] e) cooking of the pulp at a temperature, a time and a pressure allowing to obtain a pulp having a desired degree of polymerisation (the cooked pulp being hydrolysed cellulose),
[0015] f) cooling and partial controlled depressurisation of the reactor by purging the reactor, followed by a water injection into the jacket of the reactor and directly into the reactor, and
[0016] g) filtration of the pulp obtained in f).
[0017] It should be noted that the appropriate time, temperature, and pressure for the cooking in step (e) will be dependent not only upon the desired degree of polymerization, but also on the particular pulp used as a starting material. Moreover, it should be noted that the desired degree of polymerization may differ from pulp to pulp.
[0018] In certain further embodiments of the present invention, a commercially acceptable pharmaceutical grade microcrystalline cellulose product is produced by performing steps a through g above, and then:
[0019] h) neutralizing a solution of the hydrolyzed cellulose and water to obtain a neutralized solution having a pH of at least 5.5, and preferably between 5.5 and 7.5,
[0020] i) applying a shear force to deaggregate the hydrolyzed cellulose particles and provide a more uniform hydrolyzed cellulose material, and
[0021] j) spray drying the hydrolyzed cellulose.
[0022] One of the advantages provided by such a process is that there is no disorganised destruction of the cell structure such as it is seen during a violent depressurisation in the processes using a thermo-mechanical pulping step. In fact, contrary to the cases of thermo-mechanical pulping, in the process of the present invention, there is no exposure of the burst material to air, light or hot metallic sides. Thus there is no formation, or very limited formation of oxycellulose or non-desired functionalisations since such formation is favoured, in thermo-mechanical processes by the contact of the fibers to air and metals at the flashing temperature.
[0023] Another advantage provided by the process of the invention is that the filtration of the treated product is much faster, thanks to the absence of fine fragments resulting from the random and non-selective breaking of the cellulose chains during the violent depressurisation, which occurs during the thermo-mechanical treatments like steam explosion treatment.
[0024] A further advantage of the process of the invention is that controlled depressurisation prevents a disorganised destruction of the cell and allows a high yield of microcrystalline cellulose.
[0025] In one embodiment in which the pulp is Temalfa 93, a yield of higher than 95% can be obtained using the process of the present invention.
[0026] It is believed that the higher yields achieved in the present invention can be explained by explain the decrease of the suspended solids and dissolved pollutants in the water phase by more than half compared to a thermo-mechanical pulping process. It is further believed that the decrease is due to the absence of non-selective fragmentation in the process of the present invention and the absence of products of decomposition, which are generated by oxidation during and after the explosion in a thermo-mechanical pulping process.
[0027] The process of the invention also has the advantage of allowing more efficient brightening or bleaching, facilitated by the absence of fines resulting from the random breaking of the cells in a conventional steam treatment which retain the impurities and consume much more bleaching reactives. In preferred embodiments, the yield of this method is superior to 99% and the peroxide brightens the pulp without delignifying or contributing to the purification of the surrounding impure environment, like in the case of explosive treatments. The degree of brightness of a bleached final product is much higher than in any other treatment by thermo-mechanical pulping.
[0028] Another advantage provided by the process of the present invention is that the process is carried out in a low acidity environment. The advantages of low acidity resides on the fact that it does not cause a massive depolymerization of the cellulose as in the case of the DELONG patent in which the starting material is wood and the final product is a cellulose that has been cut in a non-selective fashion therefore, giving a mix of sugars and fragments of cellulose chains in the presence of numerous degradation products like furfural and other products coming from hemicelluloses or lignin.
[0029] The present invention and its advantages will be more easily understood after reading the following non-restrictive description of the preferred embodiments thereof, made with reference to the hereinbelow drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a side view of the apparatus that is adapted to carry out the process of the present invention.
[0031] [0031]FIG. 2 is a photographic representation of the Temalfa cellulose 93 TEM prior to being processed.
[0032] [0032]FIG. 3 is a photographic representation of the Temalpha cellulose of FIG. 1, treated by a steam explosion process.
[0033] [0033]FIG. 4 is a photographic representation of the Temalpha cellulose of FIG. 1, treated by the process of the present invention.
[0034] [0034]FIG. 5 illustrates the compaction and flow characteristics of Example E as compared to Emcocel 50 M.
[0035] [0035]FIG. 6 shows the results of the USP/NF tests on Example E.
DETAILED DESCRIPTION OF THE INVENTION
[0036] As mentioned hereinabove, the process of the invention comprises the steps of:
[0037] a) preparing a pulp by repulping,
[0038] b) pressing the pulp obtained in a),
[0039] c) decompacting the pulp obtained in b),
[0040] d) feeding the pulp obtained in c) into a pre-heated reactor,
[0041] e) cooking the pulp at a temperature, a time and a pressure allowing to obtain a pulp having a desired degree of polymerisation (the cooked pulp being hydrolyzed cellulose),
[0042] f) cooling and partial depressurising the reactor by purging the reactor, followed by a water injection into the jacket of the reactor and directly into the reactor, and
[0043] g) filtrating the pulp obtained in f).
[0044] It should be noted that the appropriate time, temperature, and pressure for the cooking in step (e) will be dependent not only upon the desired degree of polymerization, but also on the particular pulp used as a starting material. Moreover, it should be noted that the desired degree of polymerization may differ from pulp to pulp.
[0045] In certain further embodiments of the present invention, a commercially acceptable pharmaceutical grade microcrystalline cellulose product is produced by performing steps a through g above, and then:
[0046] h) neutralizing a solution of the hydrolyzed cellulose and water to obtain a neutralized solution having a pH of at least 5.5, and preferably between 5.5 and 7.5,
[0047] i) applying a shear force to deaggregate particles and provide a more uniform hydrolyzed cellulose material, and
[0048] j) spray drying the hydrolyzed cellulose.
[0049] During the cooking process at high temperature, the lignocellulosic material undergoes controlled hydrolysis to obtain hydrolyzed cellulose. In certain embodiments of the present invention, the hydrolysis can be accelerated or slowed down by the presence of acids or bases during the cooking. In further embodiments, an oxidation also can take place at the same time if the environment is favourable.
[0050] In another embodiment, a hydrolysis of hemicelluloses and lignin, if there are any left, may take place along with the hydrolysis of the amorphous zones of the cellulose, under the effect of the temperature and the acidity of the reaction medium. This hydrolysis may be more or less severe depending on the raw material, on the aqueous environment and obviously on the conditions of pressure, time and temperature applied during the treatment.
[0051] The hydrolysis can take place thanks to the organic acids such as acetic acid, freed by the thermal rupture of the acetyl groups of the hemicelluloses chains. Such organic acids may serve as catalysts for the hydrolysis of other products, notably cellulose.
[0052] This phenomenon is illustrated by the fact that the pH during steam cooking, goes rapidly from about 4.5 to 3.5 depending on the type of the pulp. A kraft pulp from softwood, for an equal treatment, will give a lower pH than a sulphite pulp from softwood, because of the higher content of hemicelluloses in the kraft pulp. Obviously, the extent of such effect depends on the severity of the applied treatment.
[0053] This is distinguished from the addition of known quantities of mineral acids to the reaction environment which can result in the same effect, but is very hard to control.
[0054] Oxidation of the product present in the process can take place with more or less intensity depending on the time of exposure to air, the temperature, the environment and the accessibility to the treated product. This oxidation can lead to degradation of products hence, to a cellulose product of lower quality than desired as well as lower yields.
[0055] The non-controlled oxidation can also give coloured products. It may also degrade or alter the product resulting in the production of oxycelluloses for example.
[0056] Types of Celluloses That Can be Treated by the Process of the Present Invention
[0057] The cellulose employed in the process of the present invention may be derived from a wide variety of cellulosic feedstock including but not limited to, wood and wood products, such as wood pulp fibres, non-woody paper-making fibres, from cotton, from straws and grasses, such as rice and esparto, from canes and reeds such as bagasse, from bamboos, from stalks with bast fibres, such as jute, flax, kenaf, cannabis, linen and ramie, and from leaf fibres such as abaca and sisal.
[0058] Suitable wood sources include softwood sources such as pines, spruces and firs, and hardwood sources such as oaks, eucalyptuses, poplars, beeches and aspens.
[0059] Bleached, partially bleached or non bleached celluloses from resinous or hardwoods, and resulting from chemical processes such as kraft process or sulphite as well as cellulose resulting from alternative processes such as steam explosion treatment may also be used.
[0060] Types of Additives That Can be Used with the Present Process
[0061] In certain embodiments, a suitable antioxidant may be used, for the purpose of the present invention. More particularly, any other product having antioxidant function and that is acceptable with the desired applications of the finished products and compatible with the operation conditions may be used.
[0062] Preferably, these antioxidants may be selected from the group consisting of:
[0063] Propyl gallate,
[0064] Hydroquinone,
[0065] Sodium sulfite, and
[0066] Citric acid.
[0067] Commercial products such as EDTA and Dequest from Monsanto may also be used in the process of the present invention.
[0068] Steps of the Process
[0069] The pulp used as the starting material of the process of the present invention can be prepared by repulping the cellulose in water in the presence or absence of an additive, antioxidant or sequestrant, in a reactor mixed with the recirculation pump working at a 2% to 3% consistency
[0070] The repulped pulp is pumped towards a pressing system such as a screw press or any other device allowing the pulp to drain and lowering the moisture of the fibre to 70% or less in weight (wet basis).
[0071] The humid pulp is then decompacted and aerated on a shredder or a coarse grinder. The reactor is then pre-heated to the temperature desired or to any other temperature chosen to reduce the condensation due to the heating of the walls during the treatment. This can be done via the jacket of the reactor or by injecting vapour directly and then emptying the reactor before opening it to charge it.
[0072] The reactor is then fed with wet grounded pulp. In a preferred embodiment, an apparatus such as that shown in FIG. 1 is used. The reactor can be fed in continuous mode, in which the feeding is done through an airlock or by any other mechanism allowing feeding of a vessel that is under pressure, for example a co-axial system. The reactor can also be fed in a batch mode with the reactor closed. In certain embodiments, vacuum can be applied before the steam feed to purge the gases present, such as air.
[0073] The reactor is then fed with steam directly up to a predetermined pressure. This method allows to rapidly reach a temperature between 200° and 235° C.
[0074] In certain embodiments where a batch reactor is used, a purge of non-condensables, through the top of the reactor, is desirable if the purge was not carried out. Furthermore, steam must be re-introduced in the reactor to maintain the pressure.
[0075] The cooking is maintained during about 4 to 25 minutes depending on the nature of the cellulose and the chosen working temperature. The goal is to reach a stable degree of polymerisation indicative of reaching the desired degree of polymerization (DP) for microcrystalline cellulose (MCC). As one of ordinary skill in the art will appreciate, however, the cooked pulp itself is not MCC. Rather, the cooked pulp is hydrolyzed cellulose, which can be subsequently processed and dried to form MCC.
[0076] In the case of batch mode, the reactor is then rapidly cooled by an injection of water in the jacket and in the reactor itself. A preliminary depressurisation of the excess vapour can also be carried out before the injection of cooling water.
[0077] In the case of continuous mode, the treated product is pushed to one or several partially decompressed chambers for partial decompression. This insures the transport of the product towards the exit, without causing any explosion. The product can thereafter be cooled down by water injection and further transported for the next step.
[0078] In one embodiment of the present invention a variant of the decompression chambers may be carried out by means of a set of screw spindles and/or gears and/or inverted pump. This variant insures a rapid cooling of the product by a partial decompression with no explosion of the latter.
[0079] The mixing can then start and the reactor is cooled down to around 60° C. by adding water to recover all the cellulose present in the reactor.
[0080] When the treated pulp is a pulp of sulphite or bleached kraft quality, it preferably is sent directly to filtration before going to “brightening” and/or bleaching.
[0081] In the case of a pulp of intermediate quality, it is preferable to treat the pulp with a caustic soda solution that is diluted in a way to eliminate leftover lignin and other impurities present, after which the pulp is filtered, then washed before being sent to bleaching, which will be done according to the initial quality of the starting cellulose.
[0082] After filtration, the product is brightened with hydrogen peroxide, for example using the following conditions:
[0083] Peroxide: 2% w/w on dry mass;
[0084] Magnesium sulphate: 0.5% w/w on dry mass; and
[0085] Sodium hydroxide: 0.5% w/w on dry mass.
[0086] The treatment could be done between 60 and 120° C. and under air or oxygen pressure reaching up to 120 psi.
[0087] The brightening and bleaching process can be adapted in function of the quality of the initial product, and in the more extreme cases, known bleaching methods can be used, such as hypochlorite or chlorine dioxide bleaching. The bleaching consistency will preferably be 25% but this can also be done at lower consistencies.
[0088] The bleached pulp (e.g., bleached hydrolyzed cellulose) is filtered and may be used as such or in a dry state for new applications comprising a new generation of microcrystalline cellulose of fibrous appearance, but having the same specifications as a classical microcrystalline cellulose in crystallinity index and DP.
[0089] The filtered pulp can also be homogenized in water at a consistency from 0.5 to preferably 3% and then filtered and washed to rid the residue of bleaching reactives. Prior to the homogenization step, the pH of the solution is adjusted with hydrochloric acid (HCL) or, ammonium hydroxide (NH 4 OH), so as to obtain a pH at least 5.5 and preferably between 5.5 and 7.5 (with the particular pH being dependent upon the initial pH of the solution and the desired pH of the final product). In any event, the filtered pulp (which is hydrolyzed cellulose) is homogenized by subjecting the solution of filtered pulp and water to sufficient shear force to deaggregate the hydrolyzed cellulose particles, thereby providing a more uniform hydrolyzed cellulose material. Preferably, the shear force is applied with an apparatus of the blender type or colloid mill, which allows the separation (e.g, deaggregation) of hydrolyzed cellulose particles to produce non-colloidal microcrystalline cellulose when subsequently dried.
[0090] After filtration, the suspension obtained is brought to a dryer of the type “spray dryer” to obtain the size required in the desired dryness of classical microcrystalline cellulose, for instance at a consistency of 10 to 20%.
[0091] The following shows representative results which can be obtained using the process of the present invention. Of course, these results can vary depending on the desired properties of the microcrystalline cellulose.
[0092] Results: Yield of MCC Obtained by the Process of the Invention
ALPHA 93 KRAFT Repulping 100 100 Hydrolysis and washing 95.0 88.0 H 2 O 2 and washing 99.0 99.0 NaOCl and washing 99.0 (if needed) Homogenization 99.5 98.5 Drying 99.5 99.0 Total Yield 93.1 84.1
[0093] As seen above, there can be an increase in the yield of the alfa-pulp of 20% and an increase in the yield of the kraft pulp of 23% compared to the thermo-mechanical pulping process using steam explosion treatment.
[0094] [0094]FIG. 2 shows the fibrous appearance of the Temalfa cellulose 93 TEM at the natural state.
[0095] [0095]FIG. 3 shows the fibrous appearance of the Temalfa cellulose 93 TEM when it is treated with a process comprising a thermo-mechanical pulping step.
[0096] [0096]FIG. 4 shows the fibrous appearance of the Temalfa cellulose 93 TEM when it is treated with the process of the present invention.
[0097] Applications of the Microcrystalline Cellulose Obtained by the Process of the Present Invention
[0098] If the bleached hydrolyzed cellulose is homogenized (e.g, via a blender or colloidal mill) and spray dried to form microcrystalline cellulose, it has similar applications to conventional microcrystalline cellulose such as Avicel PH 101, or Emcocel 50 M. For example:
[0099] Tableting (excipient with bonding properties);
[0100] Cream used in pharmaceuticals and cosmetics;
[0101] Fat replacer (lipid free ice cream and mayonnaise);
[0102] Chromatography support; and
[0103] Complexation with transition metals for enzyme immobilisation.
[0104] If the bleached hydrolyzed cellulose is not treated (e.g., not homogenized or spray dried), a fibrous microcrystalline cellulose product is achieved that is of very high purity and that may serve as a support for a new type of catalyst.
[0105] Since the structure of the product has a fibrous aspect and that, contrary to classical MCC, OH groups from the anhydroglucose molecule are not available, they will not react with the metals used to obtain a catalyst. Furthermore, in mixing this preparation with inorganic products for a sufficient mixing and drying time, the distribution of the active sites formed then dried and charred, will be different than the one obtained with a classical microcrystalline cellulose conferring new properties to the finished product. The spherical substrate of the catalyst, after charring, contains holes of controlled dimension making it different than the one obtained with colloidal MCC or with ground cellulose, which is, on top of that, limited by its initial inferior quality.
[0106] In preferred embodiments, the process of the present invention can provide for one or more of the following:
[0107] Steam cooking of humidified cellulose that is saturated in water.
[0108] Cooking without any mineral acids or dioxides.
[0109] Presence or absence of additives (e.g. antioxidant).
[0110] No explosion of the treated product.
[0111] It is applicable to many types of cellulose of deciduous or resinous trees.
[0112] Cooking of the humidified cellulose with saturated vapour.
[0113] Controlled cooking allowing to obtain the desired degree of polymerization of the cellulose.
[0114] Very short time of treatment thanks to the instantaneous heating of the cellulose with saturated vapour.
[0115] Limited vapour consumption that is 1 to 1.2 ton of vapour per ton of dry cellulose.
[0116] Contrary to the thermo-mechanical pulping, this new process can prevent exposure of burst material to air, to light, or to the hot metallic sides. Therefor, there is no possible or very little formation of oxycelluloses, which is favoured in the presence of metals at these temperatures. Moreover, when the pulp is subjected to violent depressurisation such as going from 350 psi to atmosphere pressure in a few fractions of second, such as in the case of thermo-mechanical pulping, the substance is treated in a destructive fashion. This also has an abrasive effect on the material of the reactor located near the exit, thus increasing the chance for the treated product to be contaminated with metallic particles.
[0117] The addition of certain cooking additives can help to avoid even more oxidation of the cellulose and its impurities.
[0118] Very low formation of colour on the treated product with the recommended process.
[0119] Increased efficiency of washing (which means reduction of water quantities used).
[0120] A degree of brightness of the finished bleached product higher than any other treatment by steam explosion.
[0121] If need be, a homogenisation of the finished product can be carried out and the breaking of the cellulose chains is done in a methodical manner contrary to what is done by classical thermo-mechanical pulping with the random explosion of cells as well as with the shear and the impact produced by the violent depressurisation.
[0122] In a particular embodiment, alpha 93 pulp can produce a yield of the initial dry pulp of 95% at the hydrolysis including the washing whereas with an explosive process where in the best of the cases as disclosed in patent no. CA 2,313,261 this yield is at best of 87% under similar conditions.
[0123] In another embodiment using kraft pulp, a yield under similar conditions of 88% can be obtained versus 83% by steam explosion treatment.
[0124] As one of ordinary skill in the art will appreciate, in order to be considered suitable for use in pharmaceutical products, a microcrystalline cellulose product must conform to the definition of microcrystalline cellulose in the United States Pharmacopoeia 24/National Formulary 19 (USP/NF). The USP/NF sets forth a standard test for determining compliant microcrystalline cellulose. For example, the USP/NF has requirements relating to i) total aerobic microbial count; ii) conductivity; iii) pH; iv) loss on drying; v) residue on ignition (ROI); vi) bulk density; vii) water solubility; and viii) ether solubility. In the context of the present invention, a pharmaceutical grade microcrystalline cellulose product is a product that complies with the requirements of USP/NF.
[0125] However, in addition to being USP/NF compliant, it is also desirable for a microcrystalline cellulose product to be equivalent or superior to the existing commercial standard microcrystalline cellulose products in terms of compaction and powder flow. Currently, there are two commercial standards for pharmaceutical grade microcrystalline cellulose: Emcocel 50 M, manufactured by Penwest Pharmaceuticals and Avicel PH 101, manufactured by FMC Corp. Therefore, in the context of the present invention, a commercially acceptable pharmaceutical grade microcrystalline cellulose product is a produce that complies with the requirements of USP/NF, and which has equivalent or superior compaction and powder flow to at least one of Avicel PH 101 and Emcocel 50 M.
[0126] As set forth above, a a commercially acceptable pharmaceutical grade microcrystalline cellulose product can be prepared in accordance with an embodiment of the present invention by performing the steps of:
[0127] a) preparing a pulp by repulping
[0128] b) pressing the pulp obtained in a
[0129] c) decompacting the pulp obtained in b
[0130] d) feeding the pulp obtained in c into a pre-heated reactor
[0131] e) cooking the pulp at a temperature, a time, and a pressure sufficient to obtain a pulp having a desired degree of polymerization;
[0132] f) cooling and partially depressurizing the reactor by purging the reactor, followed by a water injection into the jacket and directly into the reactor;
[0133] g) filtering the pulp obtained in step f
[0134] h) neutralizing a solution of the hydrolyzed cellulose and water to obtain a neutralized solution having a pH of at least 5.5, and preferably between 5.5. and 7.5;
[0135] i) applying a shear force to deaggregate the hydrolyzed cellulose particles and thereby provide a more uniform hydrolyzed cellulose material, and
[0136] j) spray drying the hydrolyzed cellulose to obtain a commercially acceptable pharmaceutical grade microcrystalline cellulose product.
[0137] In this regard, it is believed that performing the homogenization step (step i) after the filtration (step g) facilitates the production of a commercially acceptable pharmaceutical grade microcrystalline cellulose product.
EXAMPLES OF TRIALS CARRIED OUT BY THE PROCESS OF THE INVENTION
[0138] A) TEMALFA 93 cellulose: small scale test without additives
[0139] B) TEMALFA 93 cellulose: small scale test with additives
[0140] C) Kraft cellulose: small scale test without additives
[0141] D) TEMALFA 93 on a commercial scale without additives.
[0142] E). Q 90 Domtar Pulp: continuous mode manufacture
[0143] The Temalfa 93 cellulose from Tembec Company is obtained by the sulfite process from resinous trees. Given its quality, its standards of whiteness, its purity and its low content in resin, this pulp can be easily used in the production of carboxy-methyl cellulose, of methyl cellulose and of microcrystalline cellulose (MCC) for the grades 100 or 200. This pulp is characterised in that it gives a degree of polymerisation of the MCC in the vicinity of 225.
[0144] Temalfa 93 is the most commonly used feedstock around the world for the fabrication of microcrystalline cellulose in classical processes using mineral acid.
[0145] The composition of the Temalfa cellulose is the following:
Pentosans: 2.40% Ashes: 0.05% S10 at 25 C.: 8.6% S8 at 25 C.: 5.6% Alpha cellulose 92.5%
[0146] The kraft cellulose from Donohue at 100% resinous has the following composition:
Pentosans: 7.00% Ashes: 0.36% Alpha cellulose: 89%.
[0147] Domptar pulp may also be used in the context of the present invention.
A—Example 1
TEMALFA 93 Cellulose
[0148] 1 kg of Temalfa 93 cellulose was repulped at a consistency of 2.5% in water, then partially dried with the help of a press and coarsely grounded to obtain a residual moisture of 60.3%.
[0149] From the above-obtained product, 229 g (equivalent to 90.913 g of cellulose) were introduced in a 24 litres reactor pre-heated with saturated steam. The steam is then introduced directly from the bottom of the reactor and a rapid purge is carried out to evacuate the non condensables.
[0150] Within 1 minute the product reached a temperature of 220° C. where it is maintained for 13 minutes. The pressure is then partially released and pressurised cold water is injected in the reactor in such a way as to allow rapid cooling of the pulp. Mixing is initiated at this stage to ensure an homogeneous discharge and to carry on to the next step of the treatment. The washed filtered product (252 g at 65.7% moisture) is white, slightly greyish.
[0151] The pH of the filtered solution is 5.3.
[0152] Using a sample of 59.7 g a brightening with hydrogen peroxide was carried out with 2% peroxide in the presence of 0.5% magnesium sulphate (on a dry pulp basis) at a pH of 10.5. The operation was carried out for 1 hour at 60° C.
[0153] After filtration and washing, 56.7 g of pulp is recovered (64.2% moisture).
[0154] A homogenization of 55.7 g of brightened pulp with a blender gives, after filtration and washing, 50.7 g of pulp at 60.8% moisture (19.9 g of dry product).
[0155] Analysis
[0156] DP (Degree of Polymerisation)=214
[0157] Cr.I (Crystallinity Index)=84.6
[0158] MS (Microcrystal Size)=46.6 Å
B—Example 2
Temalfa 93 Cellulose with Additives
[0159] A solution of 1% sodium sulphite is used at a ratio of 20/1 on 100 g of Temalfa cellulose. After pressing and coarse grinding, 214 g of soaked cellulose at 75.3% moisture is introduced into the pre-heated reactor.
[0160] The product is treated as in the example 1 for 12 minutes. After filtration and washing, 363 g of pulp at 75.3% moisture is obtained and the pH of the filtrate is 4.3.
[0161] 357 g of bleached pulp obtained above is brightened with peroxide at the same conditions as in example 1. After washing and filtration, 253.3 g of pulp is recovered (moisture=65.5%).
[0162] A homogenisation is carried out with 250 g of brightened pulp described above and after filtration and washing, 237.7 g of pulp is recovered (64% moisture).
[0163] Analysis
[0164] DP=219
[0165] Cr.I=88.9
[0166] MS=46.6 Å
C—Example 3
Kraft Cellulose
[0167] 210 g of kraft cellulose humidified at 55.8% is treated at 220° C. for 13 minutes.
[0168] After filtration and washing, 366.4 g of cellulose are recovered at 77.7% moisture. The pH of the filtered solution is 4. The cellulose obtained is coloured, light brown/caramel.
[0169] A brightening step is carried out with the same conditions as previously described. A bleaching step is then carried out with hypochlorite with 1% hypochlorite (on dry cellulose basis) at a pH of 11 at 40° C. during 2 hours. The filtered bleached product has a weight of 237.5 g and a humidity of 66.2%. The homogenisation allowed the recovery of 240.4 g of pulp at 67.1% humidity.
[0170] Analysis
[0171] DP=224
[0172] Cr.I=88.8
[0173] MS=43.1 Å
D—Example 4
Example at a Commercial Scale
[0174] 120 kg of Temalfa 93 cellulose was repulped in the reactor mixed with cold water at a consistency of 3%. The operation is done in 6 steps of repulping of 20 kg each.
[0175] The pulp is then sent to a screw press of Atara/Spirac Spiropress U-260 brand to be dried up to a residual humidity of approximately 65%. The wet cellulose obtained goes through a moulding granulator that will decompact it.
[0176] The product obtained is loaded in a cylindrical stainless steel reactor. The reactor's volume is 2 cubic meters. After having closed the reactor, it is directly fed with steam to obtain the pressure required for the treatment. In just a few minutes the temperature into the reactor reaches 220° C.
[0177] After 12 minutes of cooking at 220° C., water is injected in the reactor in order to lower the temperature rapidly and allow a discharge of the cooking product. The discharge of the reactor is done several times with water injection to allow for a complete recuperation of the product.
[0178] 4 cubic meters of water are required to complete this operation.
[0179] A rotating filter of 0.9 meter diameter and 0.6 meter length is then used for the filtration and the washing of the cellulose that is obtained.
[0180] The product has a fibrous aspect, reflecting from a non-destructive process. It is whitish.
[0181] Analysis
[0182] DP=214
[0183] Cr.I=85.2
[0184] MS=46.6 Å.
E—Example 5
Microcrystalline Cellulose Manufacture in Continuous Mode
[0185] 20 kg of Q 90 Domtar pulp was re-pulped at a consistency of 3% in water, than partially dried with the help of a press and coarsely ground to obtain residual moisture of 64%.
[0186] The reactor is heated up to 220° by direct steam injection and the rate of the screw is determined to have a residence time of 16 minutes.
[0187] The moist cellulose is fed to the hopper during 6 hours accordingly with the opening cycle of the ball valves. The cooked product is exits the reactor accordingly with water cycle. At the same time, water is injected into the vessel above the reactor. When the water reaches predetermined level into the vessel the ball valves opens and closes without loss of steam through the valve.
[0188] The product is then filtered on rotary filter and the sequence of washing and bleaching with hydrogen peroxide continues. After adjustment to pH 6.5 with ammonium hydroxide the microcrystalline cellulose is finally homogenised into a colloid mill and then dried into a commercial spray drier in order to give an average powder of 50 microns.
[0189] As illustrated in FIG. 5, MCC made in accordance with Example E has comparable characteristics to the commercial standard Emcocel 50M manufactured by Penwest Pharmaceuticals. Specifically, the MCC of Example E and Emcocel 50 M MCC were each tableted on a Korsch PH106 instrumented tablet press. In each case the MCC was tableted “neat” (i.e., without any additives such as lubricants, etc). ⅜″ flat face punches were used on the tablet press and tablet dimensions and hardness were measured on a Erweka TBH-30 Tablet Tester. The results of the tests are set forth in Tables 1 and 2 below, and in FIG. 5:
TABLE 1 Emcocel 50 M Compaction Std. dev. Tensile Std. dev. force (kN) (kN) strength (Mpa) (Mpa) 2.89 0.10 2.49 0.09 6.29 0.21 6.23 0.28 8.87 0.31 8.49 0.24 12.38 0.26 11.34 0.25
[0190] [0190] TABLE 2 Example E Compaction Std. dev. Tensile Std. dev. force (kN) (kN) strength (Mpa) (Mpa) 2.81 0.07 2.07 0.08 6.36 0.14 5.61 0.31 9.74 0.39 8.60 0.50 12.85 0.55 10.25 0.28
[0191] Referring to FIG. 5, it can be observed that the compaction characteristics of Example E are quite comparable to Emcocel 50 M. Similarly, the flow characteristics of Example E are quite comparable to Emcocel 50 M. As one of ordinary skill in the art will appreciate, the flow characteristics can be derived from the x and y axis error bars (which in turn are derived from the compaction force and tensile strength standard deviation), with the smaller error bars indicative of better flow characteristics.
[0192] [0192]FIG. 6 sets forth the results of the USP/NF tests on Example E with regard to Particle Size (%), Scott Density (g/mL), Bulk Density (g/mL), Tapped Density (g/mL) , Water Soluble Sub. (%), pH , Conductivity (S/cm), Loss on Drying (%), ID test C, ID test B, Ether Soluble Sub. (%), and Residue on Ignition (%).
[0193] As one of ordinary skill in the art will appreciate, the data in FIGS. 5 and 6 indicate that the process used to product Example E is suitable for producing a commercially acceptable pharmaceutical grade microcrystalline cellulose product.
[0194] Although the present invention has been explained hereinabove by way of a preferred embodiment thereof, it should be pointed out that any modifications to this preferred embodiment within the scope of the present description is not done to alter or change the nature and scope of the present invention. | A process is provided for preparing a commercially acceptable pharmaceutical grade microcrystalline cellulose which comprises: a) repulping a pulp, the pulp having a composition, b) pressing the pulp obtained in a; c) decompacting of the pulp obtained in b; d) feeding the pulp obtained in c) into a pre-heated reactor; e) cooking the pulp in the reactor until the pulp obtains a desired degree of polymerization, said cooking being performed at a temperature, a time, and a pressure which is a function of the desired degree of polymerization and the composition of the pulp, the cooked pulp being hydrolyzed cellulose; f) partially depressurizing the reactor; g) injecting water into the reactor; h) discharging the hydrolyzed cellulose from the reactor, i) filtrating the hydrolyzed cellulose; j) deaggregating the hydrolyzed cellulose of step i; and k) drying the hydrolyzed cellulose to form microcrystalline cellulose. | 3 |
CROSS REFERENCE
[0001] This application is a continuation of U.S. patent application Ser. No. 14/957,609 filed on Dec. 3, 2015, which is a divisional of U.S. patent application Ser. No. 13/960,308 filed on Aug. 6, 2013 now U.S. Pat. No. 9,228,387 issued on Jan. 5, 2016. The entire contents of U.S. patent application Ser. No. 14/957,609 and U.S. patent application Ser. No. 13/960,308 are incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to door catches, and more particularly door catches utilizing a ball catch mechanism.
[0003] Door catches can generally be utilized to hold doors or similar structures in either an open or closed position. In addition, door catches used to hold a door or the like in an open position can be configured to prevent the door from hitting and damaging a wall and therefore can also perform the function of a doorstop.
[0004] Door catches come in a variety of different types. For example, roller catches, magnetic catches, hinge pin doorstops, kick down holders, j-hook catches, strike and catch automatic wall holders, and ball catches. One class of door catches relies on tension between two portions of the door catch to hold the door open.
[0005] One of the challenges in door catch design, is adjustment of catch tension, particularly for door catches that can be utilized to hold a door in the open position by relying on tension between two portions of the door catch. For example, catch tension adjustment sometimes requires that one of the mounting members be moved relative to the mounting surface. Alternatively, catch tension adjustment may require removal of one of the mounting members from the mounting surface. Either of these can be inconvenient for the installer or maintainer of the door. In many door catch designs, the installer or maintainer is required to drill new holes in order to adjust the position or catch tension. In these designs, micro-adjustments are not possible. Micro-adjustment of catch tension may be particularly important over time, as the door or doorframe shift and settle or as the door sags.
SUMMARY
[0006] Doors often sag under their own weight over time. This can damage the hinges or cause the door not to close properly when the door is no longer in alignment with the door opening. This problem is particularly exasperated for heavy or tall residential or commercial doors. The inventor recognized that a door catch could be devised that helps to prevent door sag in addition to solving the problem of providing for micro-adjustments of catch tension while the door catch is mounted to the door.
[0007] Disclosed is a door catch that can help to prevent door sag, and provide for post-installation catch tension adjustment without removal or adjustment of mounting members. In one aspect, the door catch includes a ball plunger assembly, a catch bar bracket, and a ball catch base. The ball plunger assembly includes a ball captive within the body of the ball plunger assembly. The exterior of the ball plunger body is threaded. The bottom surface of the ball plunger assembly includes a tool-receiving pattern, such as a slot head, Philips, hex head, or Torx head pattern. The catch bar bracket includes a mounting portion for mounting the catch bar to a door, wall, or doorframe. A catch bar includes a detent on the side facing the ball catch base. The catch bar projects away from the mounting base of the catch bar bracket. The ball catch base also includes a mounting portion for mounting the ball catch base to a door, wall, or wall frame. The ball catch base also includes a base portion that projects away from the ball catch mounting portion. The base portion includes a threaded aperture and the ball plunger assembly is threaded into the threaded aperture with the ball facing and aligned with the detent when the catch is engaged.
[0000] The catch bar bracket and the ball catch base are mountable on opposing surfaces of a wall structure and the door so that the ball and detent frictionally engage to hold the door open when the door is in an extended position. The frictional force impinging the ball against the detent is adjustable by rotatably engaging the tool-receiving pattern causing the ball to raise or lower with respect to the detent.
[0008] In order to ensure that the door catch can properly sustain the downward force of the door and help keep if from sagging, it is helpful to make sure that door catch components are designed to sustain the force without slippage. One way to help assure this is to provide apertures on the mounting portions that are shaped to hold the fastener in a fixed and non-adjustable position, for example, a recessed aperture with corresponding complementary fastener head.
[0009] The catch bar bracket and or corresponding mounting portion in one aspect, can be fabricated from a single piece of metal or otherwise made as a non-separable unit. Alternatively, in another aspect, the catch bar can be separable from the rest of the catch bar bracket. This allows for the possibility of creating a catch bar bracket where the distance between the downward facing detent and its corresponding mounting portion is adjustable.
[0010] One example of a catch bar bracket where the distance between the downward facing detent and its corresponding mounting portion is constructed with an integrated base portion projecting away from the mounting portion that includes a serrated top surface. The catch bar includes a serrated bottom surface configured to engage the serrated top surface of the base portion. In combination, they adjust a distance of the detent with respect to the mounting portion of the catch bar bracket. The base portion can include a fastener receiving threaded aperture through the serrated top surface and the catch bar bracket, a slot for receiving and securing a threaded fastener to the fastener receiving threaded aperture.
[0011] Another aspect of the disclosed door catch that allow for distance adjustment of the detent with respect to the catch bar mounting portion separates the catch bar bracket into a mounting portion and a catch bumper portion where the catch bumper portion includes the downward facing detent. The two portions are separated by a rod. If the rod is threaded, the distance between the catch bumper portion and the mounting portion may be adjusted by screwing the threaded rod into the mounting portion or the bumper portion. Alternatively the rod may allow for distance adjustment by a securing a pin between the bumper portion or the mounting portion and one of several holes mounted at various distances along the rod.
[0012] In another aspect, the disclosed door catch can be adapted to work on a pivot door. In this aspect, the catch bar is formed in the shape of a downward facing L-bracket and the mounting portion of the catch bar bracket is configured as a planar back with respect to the downward facing L-bracket.
[0013] This Summary has introduced a selection of concepts in simplified form that are described the Description. The Summary is not intended to identify essential features or limit the scope of the claimed subject matter.
DRAWINGS
[0014] FIG. 1 shows a door catch of the present disclosure mounted near the top of a door and corresponding wall.
[0015] FIG. 2 shows a portion of FIG. 1 detailing the door catch in relation to the door and corresponding wall.
[0016] FIG. 3 shows a portion of the door and frame in the open position of FIG. 1 with corresponding door catch.
[0017] FIG. 4 shows the door catch of FIG. 1 in top perspective view.
[0018] FIG. 5 shows a sectional view of the door catch of FIG. 4 shown along section lines 5 - 5 .
[0019] FIG. 6 shows a top perspective exploded view of the ball catch base and the ball plunger of the door catch of FIG. 4 .
[0020] FIG. 7 shows a top assembled view of the ball catch base and ball plunger assembly of FIG. 6 .
[0021] FIG. 8 shows a sectional view of the FIG. 7 shown along section lines 8 - 8 .
[0022] FIG. 9 shows a front view of the ball catch base and ball plunger assembly of FIG. 7 .
[0023] FIG. 10 shows a bottom view of the ball catch base and ball plunger assembly of FIG. 7 .
[0024] FIG. 11 shows the ball plunger assembly of the door catch of FIG. 4 in top view.
[0025] FIG. 12 shows a cross sectional view of the ball plunger assembly of FIG. 11 taken along section lines 12 - 12 .
[0026] FIG. 13 shows a side view of the ball plunger assembly of the door catch of FIG. 4 .
[0027] FIG. 14 shows a bottom view of the ball plunger assembly from the door catch of FIG. 4 .
[0028] FIG. 15 shows a front top perspective view of the catch bar bracket of the door catch of FIG. 4 .
[0029] FIG. 16 shows a front bottom perspective view of the catch bar bracket of FIG. 15 .
[0030] FIG. 17 shows a top view of the catch bar bracket of FIG. 15 .
[0031] FIG. 18 shows a sectional view of FIG. 17 taken along section lines 18 - 18 .
[0032] FIG. 19 shows a top view of a door catch with alternative catch bar bracket and alternative ball catch base construction.
[0033] FIG. 20 shows a sectional view of the catch bar bracket of FIG. 19 taken along section lines 20 - 20 .
[0034] FIG. 21 shows a bottom view of the catch bar bracket of FIG. 19 .
[0035] FIG. 22 shows a bottom view of the ball catch base of FIG. 19 .
[0036] FIG. 23 shows a top perspective view of a door catch with an alternative catch bar bracket and catch bar base where the position of the catch bar detent from the wall or doorframe is adjustable.
[0037] FIG. 24 shows a cross sectional view of the door catch of FIG. 23 taken along section lines 24 - 24 .
[0038] FIG. 25 shows a cross sectional view of the door catch of FIG. 23 taken along section lines 24 - 24 with an optional spacer.
[0039] FIG. 26 shows a top view of the catch bar of FIG. 23 .
[0040] FIG. 27 shows a bottom view of the catch bar of FIG. 23 .
[0041] FIG. 28 shows a side view of the catch bar of FIG. 23 .
[0042] FIG. 29 shows a top view of the catch bar base of FIG. 23 .
[0043] FIG. 30 shows a sectional view of FIG. 29 taken along section lines 30 - 30 .
[0044] FIG. 31 shows a top perspective view of the catch bar base of FIG. 29 .
[0045] FIG. 32 shows a top view of an alternative door catch where the position of the catch bar detent from the wall or doorframe is adjustable by a threaded rod.
[0046] FIG. 33 shows a sectional view of FIG. 32 taken along section lines 32 - 32 .
[0047] FIG. 34 shows a side exploded view of catch bar assembly of FIG. 32 .
[0048] FIG. 35 shows a top view of an alternative door catch where the position of the catch bar detent from the wall or doorframe is adjustable by a rod and pin arrangement.
[0049] FIG. 36 shows a sectional view of FIG. 32 taken along section lines 36 - 36 .
[0050] FIG. 37 shows a side exploded view of the catch bar assembly of FIG. 35 .
[0051] FIG. 38 shows a bottom exploded view of the catch bar assembly of FIG. 35 .
[0052] FIG. 39 shows an upper portion of a partially open pivot door in top front perspective view illustrating an alternative door catch.
[0053] FIG. 40 shows a bottom view of the pivot door and door catch of FIG. 39 with the pivot door in the closed position.
[0054] FIG. 41 shows a bottom view of the pivot door and door catch of FIG. 39 with the pivot door in the open position and with the door catch fully engaged.
[0055] FIG. 42 shows a front perspective view of the catch bar bracket of the door catch of FIG. 39 .
[0056] FIG. 43 shows a front view of the catch bar bracket of FIG. 42 .
[0057] FIG. 44 shows a side view of the catch bar bracket of FIG. 43 .
[0058] FIG. 45 shows a bottom view of the catch bar bracket of FIG. 44 .
[0059] FIG. 46 shows a front detail view of the door catch assembly mounted to the door and door frame in closed position.
[0060] FIG. 47 shows an alternative door catch in top perspective view mounted to the bottom of a door and wall.
[0061] FIG. 48 shows a sectional view of the door catch of FIG. 47 shown along section lines 48 - 48 .
DESCRIPTION
[0062] The following description is made with reference to figures, where like numerals refer to like elements throughout the several views, FIG. 1 shows a door catch 10 of the present disclosure mounted near the top of a door 11 and corresponding wall 13 . FIG. 2 shows a portion of FIG. 1 detailing the door catch 10 in relation to the door 11 and corresponding wall 13 . FIG. 3 shows a portion of the door 11 in the open position where the catch portions are separate and not engaged. Referring to FIGS. 2-3 , the door catch 10 of FIG. 2 includes a catch bar bracket 15 secured to the door and a ball catch base 17 secured to the wall. Referring to FIG. 3 , the catch bar bracket 15 includes a detent 19 in the lower surface of the catch bar portion of the catch bar bracket 15 . The door catch 10 holds the door 11 in place through friction. When the door 11 is in the fully open position, the detent 19 aligns a ball plunger assembly 21 in order to create a friction force that holds the door open. One of the utilities of the door catch 10 of this disclosure is the ability to adjust the frictional force that holds the door in place without removing or moving the catch bar bracket 15 or ball catch base 17 . The friction between the ball plunger assembly 21 and the detent 19 can be adjusted by moving the ball plunger assembly 21 up and down relative to the top of the ball catch base 17 . The ball plunger assembly 21 is shown from the bottom with a slot 27 for engaging a screwdriver or similar tool for adjusting the height of the ball plunger assembly 21 relative to the ball catch base 17 .
[0063] In FIGS. 1-3 , the catch bar bracket 15 and ball catch base 17 are shown as mounted between a door 11 and a wall 13 . It should be understood by the reader, that in FIGS. 1-3 , and throughout this disclosure, that the catch bar bracket 15 and ball catch base 17 can be mounted between the door 11 and other mounting surfaces that can be intersected by a door when open; for example, a folding door panel.
[0064] FIG. 4 shows the door catch 10 of FIG. 1 in top perspective view showing the relationship between the catch bar bracket 15 and the ball catch base 17 when frictionally engaged; for example, when the door 11 is open and proximate to the wall 13 . FIG. 5 shows a sectional view of the door catch 10 of FIG. 4 shown along section lines 5 - 5 . Referring to FIGS. 4-5 , the catch bar bracket 15 and ball catch base 17 are secured respectively to the door 11 and wall 13 by apertures 23 and corresponding threaded fasteners 25 through the apertures 23 through the surface of the catch bar bracket 15 and the ball catch base 17 . The catch bar bracket 15 and the ball catch base 17 need to be mounted in a way to withstand the rotational torque of the door 11 with respect to its hinges in order prevent the door 11 from sagging over time. One way to assure this is to provide mounting holes where the fastener is mounted in fixed mounting holes without any possibility for vertical or horizontal movement within the hole. As an example, the apertures 23 in FIGS. 4-5 are round and countersunk.
[0065] In FIG. 5 , the ball plunger assembly 21 is shown threaded into the ball catch base 17 and can be rotated to increase or decrease friction between the ball plunger assembly 21 and the catch bar bracket 15 . A slot 27 is provided to engage a screwdriver or other similar tool. When the ball plunger assembly 21 is rotated upward into the ball catch base, the friction between the ball plunger assembly 21 and the catch bar bracket 15 is increased. As the ball plunger assembly 21 is rotated downward out of the ball catch base, the friction between the ball plunger assembly 21 and the catch bar bracket 15 is decreased.
[0066] The door 11 is illustrated in FIG. 5 as being made of wood. The wall 13 is illustrated as having a drywall outer surface with the threaded fasteners 25 engaging drywall anchors or the like. The door catch 10 can be mounted on most common commercial or residential door materials. For example, the door material can be steel, steel over foam core, metal, wood, or fiberglass framed-glass.
[0067] FIG. 6 shows a top perspective exploded view of the ball catch base 17 and the ball plunger assembly 21 of the door catch of FIG. 4 . FIG. 7 shows a top assembled view of the ball catch base 17 and ball plunger assembly 21 of FIG. 6 . FIG. 8 shows a sectional view of the FIG. 7 shown along section lines 8 - 8 . FIG. 9 shows a front view of the ball catch base 17 and ball plunger assembly 21 of FIG. 7 . FIG. 10 shows a bottom view of the ball catch base 17 and ball plunger assembly 21 of FIG. 7 . Referring to FIGS. 6-10 , a bumper 29 is shown optionally attached to the ball catch base 17 . Depending on the whether the ball catch base 17 is secured to the door 11 , wall 13 of FIG. 1 for example, or a doorframe, the bumper 29 can be used to protect the opposing surface from damage. The bumper 29 can be made generally of a pliant material such a soft plastic or an elastomer such as silicone rubber or butyl rubber. Those skilled in the art will readily recognize materials suitable for the bumper 29 .
[0068] Referring to FIG. 6 , the ball catch base 17 is illustrated in the shape of a bracket. The ball catch base 17 includes a base portion 31 that when mounted to a wall or door projects approximately perpendicularly away from the door. If the door is mounted vertically, as in the door 11 illustrated in FIGS. 1-3 , then a top surface 33 of the base portion 31 lies substantially in the horizontal plane. The ball catch base 17 includes a mounting portion 35 that lies in the same plane as the mounting surface of the door, wall, or doorframe. The mounting portion 35 projects approximately perpendicularly away from the plane of the top surface 33 of the base portion 31 of the ball catch base 17 . While the mounting portion 35 is shown projecting upward from the base portion 31 , the mounting portion 35 can optionally be constructed to project both upward and downward with respect to the base portion 31 for additional support.
[0069] FIGS. 6-10 all show the mounting portion 35 in various views. FIGS. 6, 8 , and 9 show the apertures 23 for mounting the ball catch base 17 to the wall or door in relation to the mounting portion 35 . FIGS. 6 and 8 shows the apertures 23 as countersunk. As previously described, the aperture 23 is shaped so that threaded fastener 25 of FIGS. 4-5 is fixed in position without the opportunity to slide or move under the downward torque of the open door.
[0070] FIG. 6 shows a threaded aperture 37 sized and threaded to receive the ball plunger assembly 21 . FIG. 8 shows the ball plunger assembly 21 threaded inside the threaded aperture 37 . The ball plunger assembly 21 can be moved up and down with respect to the top surface 33 of the base portion 31 of the ball catch base 17 by rotationally engaging the slot 27 with a screwdriver or similar tool. Referring to FIGS. 6-9 , the ball plunger assembly 21 includes a tension ball 39 . Referring to FIGS. 8-10 , the ball plunger assembly 21 includes a tool-engaging plunger base 41 with a slot 27 or other shape for engaging a tool in rotational motion.
[0071] FIG. 11 shows, in top view, the ball plunger assembly 21 of the door catch 10 of FIG. 4 . FIG. 12 shows a cross sectional view of the ball plunger assembly 21 of FIG. 11 taken along section lines 12 - 12 . FIG. 13 shows a side view of the ball plunger assembly 21 . FIG. 14 shows a bottom view of the ball plunger assembly 21 . FIGS. 11-13 show the tension ball 39 . The tension ball 39 is shown in cross section in FIG. 12 . The tension ball 39 generally has a circular profile or spherical shape. Other shapes can be used to produce specific frictional profiles. For example, an elliptical shape with the top of the tension ball 39 along the major axis of the elliptical shape, assuming uniform deformation of the tension ball 39 , the force at the point of contact with the detent 19 of FIG. 3 would tend to be concentrated over less of an area than a tension ball 39 that is spherically shaped. The door would tend to release more abruptly as the force of friction would be overcome over less surface area than the tension ball 39 of spherical shape. Similarly, an elliptical shape with the top of the tension ball 39 along the minor axis of the elliptical shape, assuming uniform deformation of the tension ball 39 , would tend to release less abruptly than a tension ball 39 with a corresponding spherical shape.
[0072] FIG. 12 shows the internal construction of ball plunger assembly 21 including the tension ball 39 , the threaded ball plunger body 43 , tool-engaging plunger base 41 , and the slot 27 . The ball plunger assembly 21 is similar in construction to spring plungers used in the art for positioning fixtures, punch presses, or forging dies. The tension ball 39 is typically installed through the top opening using a plunger wrench. The plunger wrench typically includes projections that are complementary to rectangular insertion points 45 shown in FIG. 11 .
[0073] Referring again to FIG. 12 , the ball plunger assembly 21 includes a spring 47 . The spring provides compression force, and thereby holding friction, when the tension ball 39 makes contact with the detent 19 of FIG. 3 . In FIGS. 13-14 , the ball plunger assembly 21 , when rotated, moves linearly as an integrated unit within the threaded aperture 37 of ball catch base 17 of FIG. 6 . The slot 27 of the tool-engaging plunger base 41 is a typical tool-engaging screw drive. Alternatively, other tool-engaging screw drives may be used, for example, Phillips, Frearson, Cross, Robertson (square shaped), Allen (hex shaped), Torx, or TTAP, as long as they are able to engage the ball plunger assembly 21 with sufficient force and grip to prevent stripping.
[0074] FIG. 15 shows a front top perspective view of the catch bar bracket 15 of the door catch 10 of FIG. 4 . FIG. 16 shows a front bottom perspective view of the catch bar bracket 15 . FIG. 17 shows a top view of the catch bar bracket 15 . FIG. 18 shows a sectional view the catch bar bracket 15 of FIG. 17 taken along section lines 18 - 18 . Referring to FIGS. 15-18 , the catch bar bracket 15 includes an integrated catch bar/base 49 and a mounting portion 51 . The mounting portion 51 projects approximately perpendicularly away from integrated catch bar/base 49 . In FIGS. 15-16 and 18 , the mounting portion 51 is shown projecting perpendicularly away from both above and below both the integrated catch bar/base 49 . With a typical vertically mounted door, wall, and doorframe, the mounting portion 51 would be oriented vertically and the integrated catch bar/base 49 would be projecting horizontally away from the door. The mounting portion 51 includes apertures 23 . The apertures 23 of the catch bar bracket 15 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door 11 with respect to its hinges in order prevent the door 11 from sagging over time as previously described.
[0075] FIGS. 17 and 18 show the detent 19 for frictionally engaging the tension ball 39 of FIGS. 11-14 . The detent 19 is shown having a circular profile that is complementary to the spherical shape of the tension ball 39 of FIGS. 11-14 . Other arcuate shapes can be used to adjust the frictional force of engagement or disengagement. For example, given the same spherically shaped tension ball, an elliptical shaped with the center line along its minor axis would tend to more gradually disengage and engage but potentially provide a weaker frictional holding force than a comparable spherical shaped detent.
[0076] FIG. 19 shows a top view of a door catch 10 with alternative construction of the catch bar bracket 15 and alternative construction of the ball catch base 17 . FIG. 20 shows a sectional view of the door catch 10 of FIG. 19 taken along section lines 20 - 20 . FIGS. 19-20 show the alternatively constructed versions of the catch bar bracket 15 , ball catch base 17 , the ball plunger assembly 21 , and an alternatively shaped version of the bumper 29 , in engaged cooperation as previously described. A catch stop 53 projects downward from the catch bar bracket 15 and functions to horizontally limit the motion of the ball catch base 17 when frictionally engaged with the catch bar bracket 15 . The bumper 29 , here shown as hemi-spherically shaped, dampens the force between the catch stop 53 and the ball catch base 17 .
[0077] FIG. 21 shows a bottom view of the catch bar bracket 15 of FIG. 19 . FIG. 22 shows a bottom view of the ball catch base 17 of FIG. 19 . FIG. 21 shows in the detent 19 and the catch stop 53 . FIG. 22 shows bumper 29 and the bottom of the ball plunger assembly 21 . The ball plunger assembly 21 is shown with the slot 27 for rotationally engaging the ball plunger assembly 21 , as previously described.
[0078] FIGS. 23-38 show several configurations of door catches 10 where the catch bar is horizontally adjustable with respect to its mounting surface. This may be desirable when a specific distance between the open door and wall needs to be maintained. FIGS. 23-31 illustrate horizontal adjustment using a serrated catch bar and catch bar base with complementary serrations. FIG. 23 shows a top perspective view of a door catch with a catch bar 55 and catch bar base 57 where the position of the detent 19 from the wall 13 or doorframe is adjustable. The ball catch base is shown secured to a door 11 . The detent 19 is shown in hidden lines. FIG. 24 shows a cross sectional view of the door catch 10 of FIG. 23 taken along section lines 24 - 24 with the catch bar base secured to the wall 13 and the ball catch base secured to the door 11 . The door 11 is illustrated as having a fiberglass or metal frame, and the wall including a wood member. As previously described, the door catch 10 can be mounted to most common residential door and wall materials. FIG. 25 shows a cross sectional view of the door catch 10 of FIG. 23 taken along section lines 24 - 24 with a spacer 59 . FIG. 26 shows a top view of the catch bar 55 of FIG. 23 . FIG. 27 shows a bottom view of the catch bar 55 of FIG. 23 . FIG. 28 shows a side view of the catch bar 55 of FIG. 23 . FIG. 29 shows a top view of the catch bar base 57 of FIG. 23 . FIG. 30 shows a sectional view of the catch bar base 57 of FIG. 29 taken along section lines 30 - 30 . FIG. 31 shows a top perspective view of the catch bar base 57 of FIG. 29 .
[0079] Referring to FIG. 23 , the door catch 10 includes the ball catch base 17 previously described for FIGS. 6-10 , the catch bar 55 and catch bar base 57 . Referring to FIGS. 27-28 , the catch bar 55 includes a detent 19 that frictionally engages the ball plunger assembly 21 ; the ball plunger assembly 21 is illustrated frictionally engaging the catch bar 55 in FIGS. 24-25 . The force of friction between the ball plunger assembly 21 and the catch bar 55 is adjustable by rotationally engaging the ball plunger assembly 21 causing it to move up or down depending on the direction of rotation as previously described. The distance between the catch bar base 57 and the ball catch base 17 can be adjusted by extending the catch bar 55 along the catch bar base 57 . A slot 61 , shown in FIGS. 23, and 26-27 , can adjustably secure the position of the catch bar 55 relative to the catch bar base 57 . Complementary serrations on the bottom surface of the catch bar 55 , shown in FIGS. 23-25, and 27-28 , and the catch bar base 57 , shown in FIGS. 23-25, and 29-31 ensure that the when secured, slippage may not occur between the catch bar 55 and catch bar base 57 under the forces exerted by the door. The threaded fastener 25 is illustrated in FIGS. 23-25 . FIGS. 29-30 show the threaded aperture 37 for receiving the threaded fastener 25 .
[0080] The catch bar 55 of FIGS. 23-28 can be manufactured in different standard lengths to accommodate various distance ranges between the door and wall/doorframe. Alternatively, a universal catch bar can be supplied that can be designed to be cut to length to accommodate a specific installation requirement. In FIG. 25 a spacer 59 secured to the front of the catch bar base 57 to provide a bumper surface between the catch bar base 57 and the ball catch base 17 . The spacer 59 is shown secured to the catch bar base 57 by a threaded fastener 25 . The spacer 59 can similarly be secured by a spring-loaded snap fit fastener.
[0081] FIGS. 30-31 show the mounting portions 51 projecting perpendicularly upwardly and downwardly away from the horizontal plane of the catch bar base 57 . As previously discussed, the mounting portion 51 includes apertures 23 . The apertures 23 of the catch bar bracket 15 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0082] FIG. 32 shows a top view of the door catch 10 alternatively constructed where the position of the detent from the door 11 or alternatively the wall is adjustable by a threaded rod 63 . FIG. 33 shows a sectional view of FIG. 32 taken along section lines 32 - 32 showing the door catch assembly in the catch position between the door 11 and wall 13 . FIG. 34 shows a side exploded view of catch bar assembly 65 of FIG. 32 showing the detent 19 in broken lines representing hidden lines. Referring to FIGS. 32-34 , the catch bar assembly 65 includes the threaded rod 63 , a mounting base 67 , jamb nut 69 , and a catch bumper 71 . Referring to FIG. 34 , the mounting base 67 and the catch bumper 71 include a threaded aperture 37 for receiving the threaded rod 63 . The jamb nut 69 locks the threaded rod 63 in place once the distance is adjusted. The threaded rod 63 can come in a variety of standard lengths to accommodate specified distances between the door 11 and wall 13 of FIGS. 32-33 . Optionally, a universal length version of the threaded rod 63 can provided and cut to length by the door installer. The ball catch base 17 of FIGS. 32-33 and the ball plunger assembly 21 of FIG. 33 can be the same ball catch base 17 and ball plunger assembly 21 as previously described in FIGS. 6-10 . The apertures 23 of the mounting base 67 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0083] FIG. 35 shows a top view of the door catch 10 of alternative construction where the position of the catch bar detent from the wall or doorframe is adjustable by a rod and pin arrangement. FIG. 36 shows a sectional view of the door catch 10 of FIG. 32 taken along section lines 36 - 36 . FIG. 37 shows a side exploded view of the catch bar assembly 65 of FIG. 35 . FIG. 38 shows a bottom exploded view of the catch bar assembly 65 of FIG. 35 showing the detent 19 . Referring to FIGS. 35-37 , the catch bar assembly 65 includes a non-threaded rod 73 , a mounting base 67 , holding pins 75 , and a catch bumper 71 . Referring to FIG. 37 , the mounting base 67 and the catch bumper 71 each include an aperture 23 for receiving the non-threaded rod 73 . Each of the apertures 23 is indicated by broken lines. FIG. 38 shows a series of apertures 23 in the non-threaded rod 73 and a corresponding apertures 23 in the mounting base 67 and the catch bumper 71 for receiving the holding pin 75 of FIG. 37 . In FIG. 36 , the holding pins 75 are inserted in place in the non-threaded rod 73 once the distance is adjusted. The non-threaded rod 73 of FIGS. 35-38 can come in a variety of standard lengths to accommodate specified distances between the door and the wall. Optionally, a universal length version of the non-threaded rod 73 can provided and cut to length by the door installer. The ball catch base 17 of FIGS. 35-36 and the ball plunger assembly 21 of FIG. 36 can be the same ball catch base 17 and ball plunger assembly 21 as previously described in FIGS. 6-10 . The apertures 23 of the mounting base 67 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed.
[0084] The door catch of this disclosure may readily be adapted for use with a pivot door. FIG. 39 shows an upper portion of a pivot door 77 in a partially open position in top front perspective view. An alternative version of the door catch 10 is shown mounted to the top of the pivot door 77 with respect to a doorframe 79 . FIG. 40 shows a bottom view of the pivot door 77 , the door catch 10 of FIG. 39 , the doorframe 79 , and the wall 13 with the pivot door 77 in the closed position. FIG. 41 shows a bottom view of the pivot door 77 and door catch 10 of FIG. 39 with the pivot door 77 in the open position and with the door catch 10 fully engaged. FIG. 41 shows the pivot door 77 in relation to the doorframe 79 and the wall 13 . In FIGS. 39-40 , the door catch 10 includes a ball catch base 17 and a catch bar bracket 15 . The same ball catch base 17 can be used as previously described, for example, in FIGS. 6-10, 23-25, and 32-33 . Using the same ball catch base 17 across multiple applications simplifies manufacturing, forecasting, and inventory management.
[0085] FIGS. 42-46 shows the catch bar bracket 15 of FIGS. 39-40 in several views. FIG. 42 shows the catch bar bracket 15 in a front perspective view, FIG. 43 in front view, FIG. 44 in side, and FIG. 45 in bottom view. Referring to FIGS. 42-45 the catch bar bracket 15 of FIGS. 39-40 includes a downward facing L-bracket portion 81 and a planar-back mounting portion 83 . The planar-back mounting portion 83 is shown with apertures 23 for mounting the planar back to doorframe 79 of FIGS. 39-41 . The apertures 23 of the catch bar bracket 15 of FIGS. 42-43, and 46 are round and countersunk to prevent any possibility of vertical or horizontal movement within the hole so as to withstand the rotational torque of the door with respect to its hinges in order prevent the door from sagging over time as previously discussed. In FIG. 46 the catch bar bracket 15 is shown secured to the doorframe 79 with threaded fasteners 25 . A metal stiffener plate 85 is shown to provide added support if needed. In FIG. 44-45 , the bottom the downward facing I-bracket portion 81 includes the detent 19 for frictionally engaging the top of the ball plunger assembly 21 of FIG. 46 . Note that in FIG. 46 , the ball plunger assembly 21 and the corresponding ball catch base 17 is mounted in the opposite direction as in FIG. 6-10 . This reversible configuration allows the ball catch base 17 to be used in a variety of different applications. In FIG. 46 , the ball catch base 17 is shown mounted to the door 11 with the mounting portion 35 facing downward. As in the other disclosed configurations, the ball plunger assembly 21 is rotationally adjustable from below.
[0086] FIG. 47 shows an alternative door catch in top perspective view mounted to the bottom of a door 11 and wall 13 . FIG. 48 shows a sectional view of the door catch of FIG. 47 shown along section lines 48 - 48 . Referring to FIGS. 47-48 , the door is shown with the catch bar bracket 15 frictionally engaged with the ball plunger assembly 21 of the ball catch base 17 to hold the door open. The ball catch base 17 is shown with mounting portion extending perpendicularly upward and downward for additional support. This configuration allows the ball catch base 17 to be fully supported in either the upward facing or downward facing direction. In FIGS. 47-48 , where the door catch 10 is mounted at the bottom of the door, the slot 27 of the ball plunger assembly 21 is facing upward for easy adjustment with a screwdriver or the like from above. As the ball plunger assembly is rotated so it screws downward and into the ball catch base 17 , the ball plunger assembly 21 and catch bar bracket 15 become more frictionally engaged. As the ball plunger assembly is rotated so it screws upward and out of the ball catch base 17 , the ball plunger assembly 21 and the catch bar bracket 15 become less frictionally engaged. Also shown in FIGS. 47-48 are the threaded fasteners 25 and aperture 23 for receiving the threaded fasteners 25 into either the door 11 or wall 13 . In FIG. 48 , both the wall 13 and the door 11 are shown as wood. The door 11 or wall 13 can also be any combination of standard door and wall materials. For example, the wall 13 can be drywall, metal, or concrete or a fiberglass frame and the door can include a fiberglass or metal frame structure in addition to the illustrated wood structure. Those skilled in the art will readily recognize other suitable door and wall materials.
[0087] The door catch thus far described has been applied to frictionally hold a door in an open position. It may also be desirable to frictionally hold a door in a closed position. For example, local fire and safety codes may require certain exit door include a crash bar or “panic bar” where a simple push on the bar releases the door for easy egress during an emergency. Many historical buildings require that their facade be maintained including the original doors and these may not suitable or adaptable for integration of a panic bar. In this situation it may be possible to adapt the door catch 10 described thus far to function in the closed position. For example by extending perpendicular brackets outward from the inside of the door and the wall to provide suitable mounting surfaces for the catch bar bracket 15 and ball catch base 17 while the door is in the closed position.
[0088] A novel door catch has been described. It is not the intent of this disclosure to limit the claimed invention to the examples, variations, and exemplary embodiments described in the specification. Those skilled in the art will recognize that variations will occur when embodying the claimed invention in specific implementations and environments. As an example, while the catch bar bracket is shown in specific examples mounted to a door and in others mounted to a wall, those skilled in the art will readily recognize from the disclosure that the catch bar bracket can be mounted on either the door or the wall in any of the examples. The same can be said for the ball catch base. In addition, various materials, for example, wood, metal, fiberglass, or drywall has been shown for the wall material in specific examples. Similarly, various material variations have been shown for the door. It should be understood, that the choice of material is simply as an aid in understanding the broad scope for which the disclosed door catch can be utilized. In each example, any of the other disclosed materials as well as any standard material for commercial or residential door and wall construction can be used to mount the door catch.
[0089] It is possible to implement certain features described in separate embodiments in combination within a single embodiment. Similarly, it is possible to implement certain features described in single embodiments either separately or in combination in multiple embodiments. It is the intent of the inventor that these variations fall within the scope of the claimed invention. While the examples, exemplary embodiments, and variations are helpful to those skilled in the art in understanding the claimed invention, it should be understood that, the scope of the claimed invention is defined solely by the following claims and their equivalents. | Disclosed is a door catch that can help to prevent door sag, especially for heavy or tall residential or commercial doors, and provides for post-installation catch tension adjustment without removal or adjustment of mounting members. In one aspect, the door catch can include a ball catch base, a threaded ball plunger assembly, a catch bumper, and a bumper base. In another aspect, the catch bumper and the bumper base can optionally be combined into a single catch bar bracket. The ball plunger assembly is adjustably mounted within a threaded aperture of ball catch base. A ball captive in one end of the ball plunger assembly engages a detent in the catch bumper, or catch bar bracket, providing friction to hold the door open. The position of the ball plunger assembly can be adjusted vertically to increase or decrease the tension between the detent and the ball plunger assembly. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 11/566,676, filed Dec. 4, 2006, and entitled “DEVICE FOR ISOLATION OF ELECTRICAL COMPONENTS” which claims priority to U.S. Provisional Patent Application No. 60/597,461, “DEVICE FOR ISOLATION OF ELECTRICAL COMPONENTS” filed on Dec. 4, 2005, each of which is hereby incorporated by reference.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to apparatus for isolation of cables, adapters, power sources, and electronics.
[0004] 2. Background Art
[0005] Electrical devices have become nearly ubiquitous in modern society. As technology continues to evolve, more and more electrical devices are purchased and used by consumers in homes, offices, and other environments. By definition, such devices require an electrical power source to operate. Typically the electrical power source will provide power to electrical devices through one or more cables.
[0006] Furthermore, many of today's electrical devices will also be configured to communicate with other devices. This communication is also typically achieved through the use of cables.
[0007] Although cables are an effective means of transmitting power and/or data signals, they are also vulnerable and hazardous. For instance, where cables are disposed in areas in which contact with an individual or creature or possible, the cable, individual or creature, and connected equipment are all subject to damage due to potential interactions. Furthermore, signal and power transmission through cables may adversely affect nearby equipment. Finally, unintended interactions with cables and other electrical components may result in loss of power to one or more components, with possible undesirable consequences. Accordingly, there is exists a need for a cost-effective device that can provide a desired degree of isolation for such cables, adapters, power sources, and other electrical devices.
SUMMARY OF INVENTION
[0008] In one embodiment, the invention comprises a device for providing a degree of isolation for one or more electrical components and/or other potentially hazardous and/or fragile objects. The device includes a front and base member and may also include one or more side members, as well as retaining elements disposed for retaining the electrical components in a desired location within the device.
[0009] In one embodiment, the invention comprises a method for manufacturing a device for providing a degree of isolation for one or more electrical components and/or other potentially hazardous and/or fragile objects.
[0010] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 shows one embodiment of the invention, including retaining elements disposed within an internal environment thereof.
[0012] FIG. 2 shows one embodiment of the invention, wherein the front member comprises multiple sub-members.
[0013] FIG. 3 shows one embodiment of the invention, wherein the front member comprises multiple sub-members.
[0014] FIG. 4 shows one embodiment of the invention, wherein the front member comprises multiple sub-members, one of which has a curved configuration.
[0015] FIG. 5 shows one embodiment of the invention in use with a plurality of electric components.
[0016] FIG. 6 shows one embodiment of the invention in use with a plurality of electric components.
[0017] FIG. 7 demonstrates how one embodiment of the invention might be used to provide relative isolation to a wall outlet.
[0018] FIG. 8 shows one embodiment of the invention wherein a front member is movable relative to a base member.
[0019] FIG. 9 shows one embodiment of the invention, comprising a plurality of openings.
[0020] FIG. 10 shows one embodiment of the invention, comprising at least one side member.
[0021] FIG. 11 shows one embodiment of the invention, comprising a plurality of slots for the passage of cables and other objects.
[0022] FIG. 12 shows one embodiment of the invention, configured to be operatively connected to a wall or other partition.
DETAILED DESCRIPTION
[0023] As used herein, the term “isolation” means an increased state of physical, thermal, magnetic, and/or other form of separation between an object and another object or an environment. Isolation may occur through the provision of a physical barrier and/or the provision of a magnetic, thermal, and/or electrical barrier. “Relative isolation” refers to any change in a level of isolation. Other meanings of the term “isolation” which are not incompatible with the spirit of the invention may also apply. Furthermore, other meanings of the term “isolation” may be implicit in the following description.
[0024] As used herein, “electrical component” means any thing known in the art to carry and/or utilize an electrical signal. Thus, anything that conveys, stores, and/or utilizes electrical power, data, and/or other signals falls within the scope of this term. Such things include, but are not limited to, power outlets, surge protectors, adapters, modems, computers, and cables. Other definitions which do not depart from the spirit of the invention may also apply.
[0025] As shown in FIG. 1 , in one embodiment the invention comprises a front member 102 and a base member 104 . The front member 102 is operatively connected to the base member 104 . The operative connection between the front member 102 and base member 104 may be of any type known in the art, and the two members 102 , 104 may be formed as a single unitary body. The operative connection between the front member 102 and base member 104 may be configured such that the front member 102 is disposed at any desired angle with respect to the base member 104 , and furthermore may be configured to provide a variable angle (e.g., hinged, etc.) or to be reversible.
[0026] The base member 104 may be of any desired configuration, and need not conform with the front member 102 in terms of depth, width, material, thickness, and/or any in any other fashion. In one embodiment, the base member 104 will have an increased weight to provide an increased stability. In one embodiment, the base member comprises an outlet strip, surge protector, or other electrical component.
[0027] In one embodiment, a bottom surface of the base member 104 will be configured to provide an increased stability on a predetermined substrate. For example, the bottom surface may be coated with a non-skid or cushioning material to prevent undesired displacement.
[0028] In one embodiment an upper surface of the base member 104 will be configured to retain, stabilize, and/or protect one or more objects expected to be disposed thereupon. For example, such a surface may be coated with or comprise a non-skid material, cushioning material, magnetically and/or electrically -shielded material, etc., and may also include one or more retaining elements or connectors therefore, for maintaining a desired position or configuration of objects disposed thereupon. Such objects may include electrical equipment, cables, surge protectors, electrical outlets, modems, and/or any other items.
[0029] The base member 104 may also include one or more holes, which may be threaded to operatively connect a retaining element. As used herein, “retaining element” is used generically to mean any element that is used to fix a component to a surface or to support a component in a relatively fixed location relative to an operatively connected surface. Retaining elements may include, but are not limited to, screws, bolts, clips, supports, slots, flexible ties, adhesives, and any other elements or combinations thereof having a similar functionality. Other members may also be configured to operatively connect to retaining elements.
[0030] Furthermore, it may be desirable in certain embodiments to configure a bottom surface of the base member 104 such that it is easily slideable, such that when placed on a substrate it may be more easily positioned. One or more wheels may be operatively connected to the base member 104 to facilitate positioning In one embodiment, the base member 104 may comprise and/or be coated with a material which will facilitate sliding on a predetermined surface. One or more edges of the base member 104 may also be tapered or otherwise configured such that objects may be disposed upon an upper surface thereof by sliding the base member 104 under any such objects. For instance, the base member 104 may include a tapered edge for sliding under objects disposed on a surface along which the base member 104 is moved.
[0031] In one embodiment, it may also be desirable to dispose one or more feet or other such elements on a bottom surface of the base member 104 such that it is elevated and/or stabilized. Elevation of the base member 104 may advantageously allow for greater ventilation, particularly if one or more openings are included in the base member 104 . Such openings, in addition to providing ventilation, may advantageously function as points for operatively connecting retaining elements 107 .
[0032] As shown in the embodiments of FIGS. 2-3 , the front member 102 may comprise any number of facets and/or sub-members 106 . Any number of sub-members 106 may be used and the operative connection between sub-members 106 , and between sub-members 106 and other members, may be of any type known in the art. Furthermore, The operative connections between sub-members 106 may be of any type known in the art, including but not limited to, formation as a unitary body and hinged and/or reversible connections. Furthermore, each sub-member 106 may be disposed at any angle relative to any other sub-member 106 .
[0033] As shown in the embodiment of FIG. 4 , sub-members 106 may also have curved surfaces (in any desired dimension). The surfaces of any one or more members 102 , 104 and/or sub-members 106 may also include a decorative design and/or may include openings for ventilation, for operatively connecting retaining elements, and/or for entry and/or egress of desired objects.
[0034] In various embodiments, one or more desired members 102 , 104 , and/or sub-members 106 , may include heating and/or cooling elements. Such elements include, but are not limited to, fans. For example, in one embodiment, a fan may be operatively connected to an inner surface of a front member 102 , such that warm or cool air may be displaced by the fan through one or more openings in the front member 102 . Such a configuration advantageously provides heating or cooling to the external environment, and may also advantageously provide ventilation to components located within the internal environment.
[0035] An outer surface of a front member 102 or any sub-member 106 may also include “comfort elements” such as protrusions, dimples, rollers, cushions, or other elements known in the art such that, if positioned in front of a chair, such a surface may advantageously function as a comfortable footrest.
[0036] As shown in the embodiment of FIG. 5 , in use the invention provides a barrier between an internal environment 108 , to provide a desired type and degree of isolation from an external environment 110 . This isolation advantageously permits the placement of relatively delicate and/or potentially hazardous objects in the internal environment 108 to protect them from factors in the external environment 110 and/or minimize hazardous interactions between them and objects and/or creatures in the external environment 110 . Electrical components, such as electrical outlets, outlet strips, surge protectors, modems, adapters, and/or other electrical devices 112 and/or cables 114 may benefit from such isolation. In use, disposing embodiments of the invention near a wall 116 or other partition, advantageously provides greater isolation of the internal environment 108 .
[0037] As used herein, inner surfaces will face the internal environment 108 , in use. As shown in the embodiment of FIG. 6 , one or more inner surfaces of any member may be configured to retain one or more objects in a desired position. Any approach known in the art may be used to retain such objects in any one or more desired locations. Such approaches include, but are not limited to, retaining elements 117 .
[0038] As shown in the embodiment of FIG. 7 , the invention may be advantageously used to provide relative isolation of cables 114 , wall outlets 118 , and/or other potentially fragile and/or hazardous things regardless of whether anything is placed on the base member 104 .
[0039] As shown in the embodiment of FIG. 8 , the operative connection between the front member 102 and base member 104 may include a hinge. Any type of hinge known in the art may be utilized, as well as any configuration which provides the same or a similar function. Such a configuration advantageously permits access to the internal environment 108 . The operative connection may allow any desired range of rotation of the front member 102 relative to the base member 104 . In one embodiment, this range of will be such that the front member 102 may be stabilized by a nearby wall 116 or similar partition when in a raised position, thereby increasing the isolation of the internal environment 108 . In one embodiment, the operative connection between the front member 102 and base member 104 is reversible.
[0040] As shown in the embodiment of FIG. 9 , the invention may be disposed such that gaps will exist along the top 120 and/or side 122 permitting the passage of cables 114 and/or other objects, as well as ventilation. Ventilation may also be provided by the disposition of one or more openings 124 in any one or more members. The openings 124 may also advantageously provide attachment points for stabilizing or retaining elements. Furthermore, in one embodiment a top member (not visible in FIG. 9 ) may be configured to include slots and/or holes such that cables 114 and/or other objects may pass therethrough.
[0041] Although not required in various embodiments, as shown in the embodiment of FIG. 10 , the invention may include side members 126 to further isolate an internal environment 108 . One or more edges 128 of the side members 126 may extend rearwardly (relative to the front member 102 ) to any desired extent. In one or more embodiments, it may be advantageous to extend any such edges 128 at least as far as the rearward edge of the base member 104 , thereby providing an increased isolation of the internal environment 108 .
[0042] As shown in the embodiment of FIG. 11 , one or more slots 130 , holes, and/or other openings may be provided in any member of the invention to provide for the passage of cables 114 and other objects, as well as to provide a desired ventilation. Such slots 130 and/or holes may be configured to frictionally retain an object, such as a cable 114 , thereby advantageously providing for an increased organization and separation of such objects and furthermore facilitating the placement and retention of unneeded lengths of cable within the internal environment 108 .
[0043] As shown in the embodiment of FIG. 12 , the invention may be operatively connected to a wall 116 or other partition such that it is supported in an elevated location, and such that it will provide support for any objects placed on a base member 104 thereof, and/or provide a desired degree of isolation of any cables 114 and/or other objects from an external environment 110 . In one embodiment, operative connection of the front member 102 to base member 104 may be reversible or include a hinge to permit access to an internal environment 108 thereof without requiring detachment from the wall 116 or other partition. In one embodiment, such an operative connection will occur by connecting only the base member 104 to the wall 116 or other partition. In one embodiment, the base member 104 may be operatively connected to one or more suspension members 132 , which in turn may be operatively connected to the wall 116 or partition by any means known in the art. Embodiments of the invention may also be operatively connected to any suitable surface of any desired object.
[0044] The various members described herein may comprise any material or combination thereof known in the art. Any desired member may also comprise an insulating material to provide sound and/or thermal insulation to components disposed within the internal environment. Furthermore, such members may be of any size and/or configuration known in the art, and need not conform in terms of size, configuration, style, dimension, composition, or any other variable, with adjacent members. One skilled in the art will understand that a degree of variability is permitted for aesthetic/decorative and/or design purposes, without departing from the spirit of the invention. In one or more embodiments, members or parts thereof may be transparent or partially transparent to allow for the viewing of objects disposed within the internal environment. In one or more embodiments, members may be configured and/or colored to match a wall or partition so as to be less visibly obtrusive. One advantage of embodiments of the invention is the ability to conceal electronic components which might otherwise be visually displeasing. Accordingly, configuration, coloration, and other aspects of embodiments of the invention may be selected to match those of a nearby wall or partition to more effectively conceal both the electronic components, and the embodiment.
[0045] Embodiments of the invention advantageously decrease the risk of injury from electric components and other objects, while also providing a degree of protection for any such objects from the surrounding environment. Although embodiments may be used in a variety of locations, one particularly advantageous location might be under a desk, where cables and various other electric components are often disposed and may be damaged or rendered inoperative by an individual's feet, or possibly harm an individual who makes contact with them. Embodiments will also be advantageous in areas where pets and/or children may contact electric components, thereby injuring themselves.
[0046] 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. | A device for creating a relatively isolated environment for protecting dangerous and/or fragile components, particularly electrical components, from the surrounding environment. The device will typically include a front member and base member which may be formed as a unitary body. A relatively isolated environment will be formed in the area behind the front member and above the base member and the isolation may be enhanced by placing the device near a wall or partition. The device may also include side members for enhancing the isolation of the internal environment. Openings or slots may be located in any of the members to permit the passage of cables or other tubular objects and also to provide ventilation. Retaining elements disposed on the inside of the base member or front member may be used to retain various components in a desired position. The front member may also include a fan or comfort elements for use as a footrest or cooling device. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority of U.S. Provisional Application No. 60/417,800, filed on Oct. 3, 2002, the entire disclosure of which is incorporated by reference.
FIELD OF THE INVENTION
The invention generally relates to methods for fabricating integrated circuits (ICs) and semiconductor devices and the resulting structures. More particularly, the invention relates generally to the packaging used for semiconductor devices and methods for making such packaging.
BACKGROUND OF THE INVENTION
Semiconductor processing builds hundreds of individual IC chips on a wafer. These individual chips are then cut, tested, assembled, and packaged for their various uses. The packaging step in this processing can be an important step in terms of costs and reliability. The individual IC chip must be connected properly to the external circuitry and packaged in a way that is convenient for use in a larger electrical circuit or system.
There are a number of different types of packages for semiconductor device (“semiconductor packages” or “packages”). One type of semiconductor package is called a flip chip in a leaded molded package (FLMP). This package is described in detail in U.S. patent application Ser. Nos. 09/464,885 and 10/413,668, the disclosures of which are incorporated herein by reference. The FLMP contains a leadframe structure that has a die attach pad and leads that extend away from the die attach pad. The die attach pad is coupled to the front side of a semiconductor die with solder. A molding material covers the die attach pad and the front side of the semiconductor die, while the back side of the semiconductor die is exposed through the molding material. The leads extend laterally away from the molding material and are substantially co-planar with the back side of the semiconductor die and a surface of the molding material. The front side of the semiconductor die may contain the gate region and the source region of a MOSFET (metal oxide semiconductor field effect transistor) in the semiconductor die. The back side of the semiconductor die may contain the drain region of the MOSFET. When the semiconductor package is mounted to a circuit substrate, the back side of the die and the leads are connected to conductive lands on the circuit substrate. The circuit substrate may be a printed circuit board.
Such a semiconductor package has a number of advantages. First, because there is a substantially direct electrical connection between the back side of the semiconductor die and the circuit substrate. Because there are short, low-resistance conductive paths between the source and gate regions in the semiconductor die as well as the circuit substrate, the die package resistance is nearly eliminated. This results in one of the industry's lowest R DS(ON) based on the size of the footprint. R DS(ON) is the on-resistance that is associated with turning a MOSFET in the die package on from an off-state.
The second advantage of the above-described semiconductor package is the reduced thickness. For example, compared to a conventional wire bonded SOIC-8 package, which is about 1.6 mm tall, a FLMP can have a height of less than about 1.0 mm. The FLMP can have the same or better electrical and thermal performance while also being smaller than a standard SOIC-8 package. And thinner semiconductor packages are especially desirable as the size of portable electronic devices (such as wireless phones and laptop computers) continue to decrease.
While the above-described semiconductor package has a number of advantages, a number of improvements could be made. When mass producing semiconductor packages of the type described above, a number of problems can occur. The problems include, for example, silicon cracks that form because of an uneven die standoff from the die attach region of the leadframe structure; moisture seepage into the semiconductor package; delamination between the leadframe structure and the molding material; and finally molding material bleed on an exposed die surface and leads (that can hinder the package from functioning efficiently or potentially fail during device applications). Other problems include poor solder adhesion between the circuit board bonding pads and the semiconductor die, as well as uneven cutting during the singulation process.
In one improvement of this method, a Pb-based solder bump has been used to serve as a stress absorber, thereby protecting the silicon die from cracking when a compressive or a thermal stress is applied. See U.S. patent application Ser. No. 10,413,668, the disclosure of which is incorporated herein by reference. However, Pb is an undesirable material to be used in bumps for two reasons. First, it is a hazardous material. Second, the existing electroplated Pb-based solder bumping process is relatively expensive when compared to direct metal bumping processes.
SUMMARY OF THE INVENTION
The invention provides a packaging assembly for semiconductor devices and a method for making such packaging. The invention provides a non-Pb bump design during a new flip-chip method of packaging. The design uses special conductive materials in a stud form, rather than a solder ball containing Pb. This configuration maintains a desirable solder thickness between the die and the leadframe and forms a high standoff by restricting solder wettabilty on the leadframe side. This configuration also absorbs any stress and protects the die from cracking. The invention also provides methods for making such semiconductor packages.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description of the invention can be understood in light of FIGS. 1-10 , in which:
FIGS. 1 and 2 illustrate a die used in one aspect of the invention;
FIGS. 3-4 illustrate leadframe structures used in one aspect of the invention;
FIGS. 5-9 illustrate methods for making the semiconductor packages in one aspect of the invention;
FIG. 10 depicts the semiconductor package in one aspect of the invention;
FIGS. 11-13 are SEM photographs illustrating various aspects and advantages of the invention.
FIGS. 1-13 illustrate specific aspects of the invention and are a part of the specification. Together with the following description, the Figures demonstrate and explain the principles of the invention. In the drawings, the thickness of layers and regions are exaggerated for clarity. It will also be understood that when a layer is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. The same reference numerals in different drawings represent the same element, and thus their descriptions will not be repeated.
DETAILED DESCRIPTION OF THE INVENTION
The following description provides specific details in order to provide a thorough understanding of the invention. The skilled artisan, however, would understand that the invention can be practiced without employing these specific details. Indeed, the invention can be practiced by modifying the illustrated method and resulting product and can be used in conjunction with apparatus and techniques conventionally used in the industry. For example, while the semiconductor packages described herein are “single-sided,” the invention could be easily modified for semiconductor packages that are “double-sided”. Indeed, as described briefly below, the invention can be adapted for packaging systems for electronics devices other than just ICs, such as silicon MEMS or optoelectronic devices.
The invention includes packaging assembly for integrated circuit and semiconductor devices that contains non-Pb stud bumps in place of Pb solder balls, including those illustrated in the Figures and described below. The invention also includes any method(s) for making such semiconductor packages, including the methods illustrated in the Figures and described below.
In one aspect, as shown in FIG. 10 , the invention includes a semiconductor package 1000 comprising a leadframe structure (or leadframe) 100 and a semiconductor die (or die) 10 attached to the leadframe structure 100 . An array of bump structures 36 is contained between the semiconductor die 10 and the leadframe structure 100 . The leadframe structure 100 and the semiconductor die 10 can be partially or fully encapsulated by a molding material 40 .
The semiconductor die 10 in the semiconductor package 1000 often contains a transistor, such as a vertical power transistor. Exemplary vertical power transistors are described, for example, in U.S. Pat. Nos. 6,274,905, and 6,351,018, the entire disclosures of which are herein incorporated by reference. Vertical power transistors include both VDMOS transistors and/or vertical bipolar power transistors.
When the semiconductor die 10 comprises a vertical transistor (i.e., a vertical MOSFET), the source region and the gate region (not shown) of the vertical transistor can be located on a first side 14 and the drain region can be located on a second side 15 of the semiconductor die 10 . In this aspect of the invention, the second side 15 of the die 10 can be coated with gold or any other solder-wettable material. The drain region on the second side can be coupled to a substrate (i.e., a circuit board) as known in the art.
As shown in FIGS. 1 and 2 , the semiconductor die 10 contains bond pads 11 . The bond pad is that portion of the die 10 through the die is attached to the leadframe structure 100 via bump structures 36 . To enhance the bond between the semiconductor die 10 and the leadframe structure 100 (described below), the bond pads 11 in the semiconductor die 10 may be formed with uneven surfaces so that the metal stud 20 on the bond pads tightly adheres thereto.
The semiconductor package 1000 also contains leadframe structure 100 . The leadframe supports the die 10 , serves as a fundamental part of the I/O interconnection system, and also provides a thermally conductive path for dissipating the majority of the heat generated by the die. The leadframe generally contains an interconnected metallized pattern containing first, a centrally located support to which the die will later be attached and second, a network of leads. As known in the art, the leadframe structure may be one of many leadframe structures in a leadframe carrier, which can be in the form of a strip. During processing, the leadframe structures may be present in a leadframe carrier if multiple leadframe structures are processed together.
As known in the art, the leadframe structure generally contains a die attach region, and two or more leads. The leads extend away from the die attach region. A leadframe structure may include a gate lead structure with a gate attach region and a gate lead and a source lead structure with a plurality of source leads and a source attach region. The source lead structure and the gate lead structure are electrically isolated from each other in the semiconductor package that is eventually formed.
FIGS. 3 and 4 show a leadframe structure 100 according to one aspect of the invention. The leadframe structure 100 comprises a gate lead structure 22 including a gate attach region 23 and a gate lead 28 , and a source lead structure 25 including a source attach region 26 and five source leads 27 . The gate attach region 23 and the source attach region 26 can form a die attach region 21 of the leadframe structure 100 , where the semiconductor die (not shown) is usually attached. The die attach region 21 is “downset” with respect to the ends of the gate lead 24 and the source leads 27 .
The metal of the leadframe structure 100 may comprise any metal, such as copper or a copper alloy. In one aspect of the invention the leadframe structure 100 can contain a layer of metal plating (not shown), if desired. The layer of metal plating may comprise an adhesion sublayer such as nickel or chromium; a conductive sublayer such as copper or palladium; and/or an oxidation resistant layer such as gold. For example, the leadframe structure 100 may include a leadframe plating containing an adhesion sublayer and a wettable/protective sublayer. In another example, an exemplary leadframe plating may comprise at least a nickel sublayer and a palladium sublayer. The plating may also comprise a gold sublayer as an outer, solder-wettable sublayer.
The leadframe structure 100 may be configured for additional functionality. In one aspect of the invention, an aperture 29 can be contained in the die attach region 21 . The aperture 29 can be in the form of an elongated slot or other shapes (e.g., circular, square, polygonal, etc.). The aperture 29 may be formed in the leadframe structure 100 by any suitable method including photolithography followed by etching, and stamping. Instead of, or in addition to the aperture 29 , the die attach region 21 of the leadframe structure 100 may comprise a number of dimples in it to improve adhesion to the molding material. Dimples may be formed in the die attach region 21 of the leadframe structure 100 using any known process such as partial etching. The molding material (not shown) may flow over and attach to the dimples, thus improving the bond between the molding material and the leadframe structure.
In another aspect of the invention, the leadframe structure 100 can be configured with depressions as shown in FIG. 4 . Providing depressions 24 in the leadframe structure 100 has a number of advantages. For example, the depressions 24 can restrict the flow of solder paste as a result of capillary action during reflow, thereby restricting the flow of the solder paste towards the lead bends. By restricting the flow of solder paste towards the lead bends, the likelihood of die edge shorting is reduced. There may be up to one depression 24 per lead in the leadframe structure 100 . The depressions 24 may have any suitable width and depth.
The die 10 and the leadframe 100 are attached to each other using bump structures 36 . Each bump structure 36 comprises a metal stud 20 and reflowed solder paste 103 . The array of bump structures 36 results in smaller inductances than, for example, wire bonds.
The metal stud 20 can comprise any conductive material(s) that has a melting temperature greater than the melting temperature of the solder paste 103 . In one aspect of the invention, the metal stud 20 may comprise any conductive material or combination of material containing no Pb or containing only negligible amounts of lead. Generally, the material used for the metal stud contains less than about 1 ppm of Pb.
The semiconductor package 1000 also comprises a molding material 40 as an encapsulant. The molding material 40 covers the inner portion (including the die attach region) of the leadframe structure 100 , the plurality of solder structures 36 , and at least the first side 14 of the semiconductor die 10 . The molding material 40 can also fill the spaces between the bump structures 36 . As shown in FIG. 10 , the bottom surface of the molding material 40 is substantially co-planar with the ends of the leads of the leadframe structure 100 , and is also substantially co-planar with the second surface 15 of the semiconductor die 10 . As shown, the ends of the leads of the leadframe structure 100 extend laterally away from the molding material 40 . Thus, the illustrated semiconductor package 100 has a low profile and is thin.
The molding material 40 can comprise any molding material known in the art that flows well and therefore minimizes the formation of any gaps. In one aspect of the invention, the molding material is an epoxy molding compound such as an epoxy material with the following properties: (a) low thermal expansion (a low CTE), (b) fine filler size (for better flow distribution of the molding material in between small spaces, thus reducing the likelihood of forming voids in the formed semiconductor package), (c) a glass transition temperature of about 146° C., (d) a 10 second Ram Follower gel time at 175° C., and (e) high adhesion strength to pre-plated leadframe structures. A preferred epoxy molding material is Plaskon AMC-2RD molding compound, which is commercially available from Cookson Semiconductor Packaging Materials, of Singapore.
The semiconductor package 1000 can also contain other components, such as metal clips, heat sinks, or the like.
The above semiconductor packages can be made using any suitable method that forms the structures illustrated and described above. In one aspect of the invention, the various IC chips are manufactured, cut, tested, and die-bonded to a substrate as known in the art to form a semiconductor die 10 containing the internal circuitry of the IC.
As shown in FIG. 2 , the semiconductor die 10 is provided with an array of I/O points containing bond pads 11 . The I/O points are the location where the internal circuitry of the IC will communicate with the external circuitry (i.e., of a circuit board). The bond pads 11 can be provided using any known mechanism in the art.
Then, as known in the art, the die 10 is provided with metal stud 20 on the bond pad 11 . Metal stud 20 serves as the main part of the bump structure 36 connecting the die 10 and the leadframe 100 . Thus, any metal stud 20 that operates in this manner can be used in the invention.
The metal stud 20 can contain any suitable conductive material known in the art. Examples of such conductive materials include Cu, Au, Pd & their alloys. n one aspect of the invention (as described above), the metal stud 20 does not comprise Pb or contains only negligible amounts of Pb. Pb-based solder bumps are very expensive to manufacture and so are not used in this aspect of the invention. The metal stud 20 can be provided by any process known in the art, including thermosonic bonding, thermocompression bonding, ultrasonic bonding, and the like.
The leadframe structure 100 may then be formed in any suitable manner that makes the leadframe structure described above. For example, the base metal structure of the leadframe structure 100 may comprise copper, and may be formed by stamping or etching a copper sheet. When used, a layer of metal plating may be formed on the base metal structure by processes such as electroless plating, sputtering, or electroplating. A pre-plated leadframe can be used and advantageously eliminates post plating processes, and provides wettable surfaces for solder paste on the conductive lands of a circuit substrate.
When present, the depressions 24 in the leadframe structure 100 may be formed using any suitable process. For example, in some aspects, stamping or a half-etching process can be used to form the depressions. In another examples, a leadframe structure without depressions could be patterned with a photoresist, and then partially etched in those areas where the depressions are to be formed.
The leadframe structure 100 is then provided with a plurality of solderable areas 101 as shown in FIG. 7 . The solderable areas 101 are those portions of the leadframe 100 where the bump structures 36 (and solder paste) will be located. Thus, the solderable areas 101 will be formed where the bump structures 36 will be located.
The array of solderable areas 101 can be formed by any suitable method which provides them with the characteristics described herein. In one aspect of the invention, the solderable areas 101 are formed by a selective plating method (SP Method). In another aspect of the invention, the solderable areas 101 are formed by a polymeric method (P method).
In the SP method, the solderable areas 101 can be formed by one of two variations. In the first variation of the SP method, and as shown in FIGS. 5 and 7 , the solderable areas 101 are formed by first forming a metal coating 111 on the die attach region 21 of the leadframe 100 . This metal coating is formed to substantially cover the entire portion of the leadframe that will contain the bump structures 36 . The metal coating can be made of any metal or metal alloy that can be oxidized, such as Cu, Ag or Ni. The metal coating can be formed by any method known in the art, such as electroplating, electroless plating or sputtering. In one aspect of the invention, such as when Ni is used, the thickness of the metal coating can range from about 20 to about 80 microinches.
Then, a selective coating 112 is formed on the metal coating 111 . The selective coating is formed only on certain areas of the metal coating 111 , i.e., those areas where bump structures 36 will be formed and on the external leads. The selective coating can be made of any metal or metal alloy that is not easily oxidized, such as Pd or PdAu, Ag, or noble metals and its alloys, like Pd or PdAu. The selective coating can be formed by any method known in the art, e.g., mask electroplating or depositing a full coating and then using a masking and etching process to define the areas of the selective coating that are to remain. In one aspect of the invention, such as when Pd or PdAu are used, the thickness of the selective coating can range from about 20 to about 90 microinches.
Next, after forming the selective coating 112 , the resulting structure is then oxidized. During this oxidation, the metal coating not covered by the selective coating is oxidized to form a metal oxide (i.e., NiO) layer 113 . The selective coating 112 does not oxidize during this stage because of the materials it contains. In one aspect of the invention, the thickness of the metal oxide layer 113 should be sufficient to prevent the solder from wetting the oxidized area and/or act as a solder dam for the solder paste. In one aspect of the invention, such where the metal oxide is NiO, the thickness of the metal oxide layer must be at least about 100 Angstroms. Thus, the oxidation is performed for a time and at a temperature sufficient to form the desired thickness.
In the second variation of the SP method, and as illustrated in FIG. 6 , a metal (i.e., Cu) leadframe is provided with a selective coating 114 . The selective coating 114 is formed only on certain areas of the leadframe 100 , i.e., those areas where bump structures 36 will be formed and on external leads. The selective coating can be made of any metal or metal alloy that is not oxidized (such as Pd or PdAu). As well, the selective coating can be made from metals and their alloys that act as barrier metal for migration of the leadframe metal and/or that prevent IMC formation (such as NiPd or NiPdAu). The selective coating 114 can be formed by any method known in the art, e.g., mask electroplating or depositing a full coating and then using a masking and etching process to define the areas of the selective coating that are to remain. In one aspect of the invention, such as where the selective coating is NiPd or NiPdAu, the thickness of this layer can range from about 20 to about 90 microinches.
Next, the exposed areas of the metal leadframe 100 are then oxidized to form a metal oxide coating 115 on the leadframe. The thickness of the metal oxide (CuO) coating should be sufficient to prevent the solder from wetting the oxidized area and/or act as a solder dam for the solder paste. In one aspect of the invention, such where the metal oxide coating is CuO, the thickness of the metal oxide coating 115 can be greater than about 100 Angstroms. Thus, the oxidation is performed for a time and at a temperature sufficient to form the desired thickness.
In the P method, a similar process is used. Rather than forming a metal oxide through an oxidation process, however, a polymer coating is selectively formed to define the solderable areas 101 . The polymer selected can be any polymer known in the art that does not char or decompose during the temperature excursions. The polymer can also be photosensitive or not. Examples of the polymers include solder masks, polyimide, BCB (benzocyclobutene), and the like. The thickness of the polymer can be greater than about 2 micrometers.
The polymer can be selectively formed by depositing the polymer and removing portions of the polymer layer. In another aspect of the invention, the polymer can be selectively formed by any screen printing process known in the art. After screen printing, the resulting structure is then placed in a reflow furnace for curing the polymer. If necessary, downsetting can be carried out on the leadframe after the curing,
As illustrated in FIG. 7 , the resulting structure after the SP or P method comprises a lead frame structure 100 with an array of solderable areas 101 . The substantially remainder of the surface of the die attach region 21 of the leadframe structure contains non-solderable areas 102 .
Then, solder paste 103 is placed on the solderable areas 101 , as shown in FIG. 8 . When the leadframe structure 100 and the die 10 are later combined (as described below), the solder paste acts as a stress absorber. The solder paste can be placed on or in the solderable areas 101 using any known process in the art. For example, solder paste 103 can be dispensed using an array of multiple nozzles. The solder paste 103 may be made of ordinary solder material known in the art.
Next, as illustrated in FIG. 9 , the leadframe 100 and the die 10 are then joined using any suitable flipchip process. In this process, the bumped semiconductor die 10 is flipped over and aligned with the dispensed array of solder paste 103 on the die attach region 21 of the leadframe structure 100 . The die 10 and the leadframe structure 100 are then pressed together.
After attaching the leadframe and die, the solder is reflowed as known in the art to obtain the structure in FIG. 10 . The solder-reflow process is performed by heating at a temperature sufficient to reflow the solder paste. When the paste is in this re-flowed state, it contacts the bumps 20 and due to capillary action, “flows” around the bumps and is limited to selective solderable area 101 on the die attach region 21 as shown in FIG. 10 . Thus, the solder paste 103 is kept to a desired thickness “T” of about 50 to about 100 micrometers between the metal stud 20 and die attach region 21 .
After reflowing, the bump structures 36 provide a mechanical and an electrical connection between the leadframe structure and the semiconductor die. During reflow, the solder paste melts and solidifies, while the metal stud adheres to the solder without melting. This keeps the semiconductor die 10 and the die attach region 21 of the leadframe structure 100 spaced at a uniform distance and keeps the back side 15 of the semiconductor die aligned with the ends of the leads of the leadframe structure.
After the semiconductor die is attached to the leadframe structure, the molding material 40 is molded around the desired portions of the semiconductor die and the leadframe structure. The solder paste between the metal stud 20 and die attach region 21 absorbs the mechanical stress during mold clamping. In one aspect of the invention, a film assisted molding process is used. In this process, a film is used between molding dies of a mold tool. The film serves as a cushion for the semiconductor die during molding, thus absorbing the stress and preventing die cracks too. The use of a film also allows a smaller clamping force to be used. Any films serving these functions can be used in the invention. In one aspect of the invention, the film is an adhesive-free film, which protects the exposed die back side and the leads from mold bleed that can prevent solderability during board mounting. An exemplary adheseive-free film is a fluoropolymer film that has a matted surface finish on one side and a glossy finish on the other side, such as that sold under the tradename AFLEX 50KN.
After the molding process, the gate lead structure of each leadframe structure can be electrically isolated from its corresponding source lead structure by severing the electrical connection between them. Then, the non-singulated semiconductor packages may be electrically tested. Parametric testing is performed while the semiconductor packages are in the form of a strip. After electrical testing, the molded molding material in the semiconductor packages may be laser marked.
After laser marking, the semiconductor packages in the array of semiconductor package are singulated using any suitable process. In one aspect of the invention, the singulation process is a tapeless singulation process. A tapeless singulation process uses a metal saw jig instead of commonly used dicing tapes to hold the semiconductor packages in place during sawing. A strip of molded packages can be loaded onto a jig with recesses that are arranged in a layout similar to the layout of the molded packages in the leadframe carrier, while the back sides of the semiconductor die face upward. The leadframe carrier orientation is chosen to minimize vertical burr formation in the direction of the flat side of the package (which can cause mounting problems). The recesses and vacuum hold the molded packages in place during sawing.
EXAMPLE 1
The advantages of the invention can also be seen in FIGS. 11-13 .
Having described the preferred aspects of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are possible without departing from the spirit or scope thereof. | A packaging assembly for semiconductor devices and a method for making such packaging is described. The invention provides a non-Pb bump design during a new flip-chip method of packaging. The design uses special conductive materials in a stud form, rather than a solder ball containing Pb. This configuration maintains a desirable solder thickness between the die and the leadframe and forms a high standoff by restricting solder wettabilty on the leadframe side. This configuration also absorbs any stress and protects the die from cracking. The invention also provides methods for making such semiconductor packages. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application No. 62/151,202 filed on Apr. 22, 2015. The disclosures of the above application are incorporated herein by reference.
FIELD OF THE INVENTION
The field of the present invention is that of protectors for scopes and other gun accessories such as laser aiming modules, night vision devices, reflex sites and tactical lights and other like gun accessories. More particularly the present invention relates to protectors for scopes and other gun accessory devices for rifles and shotguns that are positioned on top of a gun stock or barrel.
BACKGROUND OF THE INVENTION
To increase accuracy in shooting, many guns have a scope or other auxiliary device. Many of these devices are more fragile than the gun and therefore need to be protected against physical damage. Damage can easily occur if the gun is inadvertently dropped or entangled by brush or other vegetation in a forest or jungle environment.
It is desirable to provide a scope protector which in at least one preferred embodiment is easily and readily attachable to a gun. It is desirable to provide a scope protector which in at least one preferred embodiment attachment is so simple that attachment can be accomplished in darkness in a combat environment. It is desirable to provide a scope protector that can be easily modified for a variety of guns. It is desirable to provide a scope protector that can be easily modified for a variety of scopes or other auxiliary devices. It is desirable to provide a scope protector, that when removed from a gun, is a single unitary member.
SUMMARY OF THE INVENTION
To make manifest the above delineated and other desires, a revelation of the present invention is brought forth. In a preferred embodiment, the present invention endows a freedom of a scope protector that includes a front and rear hinged arch for encircling the scope. The hinged arches are connected by a plurality of protector rods. In a preferred embodiment, the scope protector can be attached to a gun rail such as a PICATINNY RAIL commonly found on modern firearms.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
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 perspective view of a scope protector according to the present invention;
FIG. 2 is a side elevational view of the scope protector shown in FIG. 1 ;
FIG. 3 is a front elevational of a hinged arch of scope protector shown in FIG. 1 ;
FIG. 4 is a side elevational view of the hinged arch shown in FIG. 3 ;
FIG. 5 is a perspective view of the hinged arch shown in FIGS. 3 and 4 ;
FIG. 6 is a front elevational view of a portion of the hinged arch shown in FIGS. 3 and 4 ;
FIG. 7 is a side elevational view of the portion of the hinged arch shown in FIG. 6 ;
FIG. 8 is a partial perspective view of the hinged arch shown in FIG. 6 ;
FIG. 9 is a front elevational view of another portion of the hinged arch shown in FIGS. 3 and 4 ;
FIG. 10 is a side elevational view of the hinged arch shown in FIG. 9 .
FIG. 11 is a front elevational view of a protector rod shown in FIG. 1 ;
FIG. 12 is a side elevational view of the protector rod shown in FIG. 1 ;
FIG. 13 is a perspective view of the protector rod shown in FIG. 1 ;
FIG. 14 is a partial perspective view of a protector rod extension;
FIG. 15 is a side elevational view of a protector rod extension;
FIG. 16 is a front elevational view of the protector rod extension shown in FIG. 15 ;
FIG. 17 is a perspective view of the scope protector installed on a semi-automatic rifle; and
FIG. 18 is an alternate preferred embodiment hinged arch to the hinged arch shown in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to FIGS. 1 through 17 , a scope protector 7 for guarding a scope 8 of a gun 10 is provided. The scope protector 7 includes a rear hinged arch 12 and a front hinged arch 14 . The hinged arches 12 and 14 are typically identical to each other and are therefore interchangeable. The hinged arch 12 is typically elliptical, almost circular in its cross-sectional shape being slightly greater in its width dimension than in its vertical dimension to allow it to encircle the scope 8 .
The hinged arch 12 has 4 cross bores 20 allow for insertion of protector rods 22 . The protector rods 22 are affixed to the hinged arches 12 , 14 via threaded set screws that are inserted in set screw bores 26 . Typically the set screws 23 are drivable by a blade drive or Allen wrench. Set screw bores 26 are drilled to be generally parallel with each other and are horizontal. Since the protector rods 22 are connected with the hinged arches 12 , 14 by set screws, the axial length between the hinged arch 12 and 14 can be adjusted for the particular application that the scope protector 7 is being utilized for. A cross-sectional angle 70 between the top protector rods 22 is designed so that there is no less than 90° unobstructed area between the protector rods to allow a gun operator easy access for any fine adjustments needed be made to the scope 8 .
The hinged arch is fabricated from arcuate members 30 and 32 and are hingeably connected along their top ends by a hinge pin 34 . Arcuate member 30 has a floor piece 40 attached thereto. Floor piece 40 abuts a stud 42 that is connected with arcuate member 32 . The stud 42 and floor piece 40 have cam faces 45 and 47 to allow them to be attached to a Picatinny mounting rail 51 of the gun 10 . A through bore 48 that extends through the cam faces 45 and 47 allows the hinged arch 12 be fixedly connected with the mounting rail by a set screw. Attachment is relatively easy, which allow for attachment in non-lighted environments. When the scope protector 7 is removed from the gun 10 , the scope protector is a single unitary member.
The protector rods 22 along their forward end have a threaded bore 62 to allow a threaded stud 64 of a protector rod extension 66 to be a threadably attach thereto. The hinged arches and protective rods 22 are typically fabricated from aluminum, titanium or other light strong metal or from a fiber reinforced polymeric material.
FIG. 18 provides a hinged arch 112 . The hinged arch 112 has a side dimension 171 from a center line 173 that is approximately 9 to 10% larger than side dimension 175 . The larger dimension 171 in the arch 112 accommodates additional space for adjustment knobs on the scope. Hinged arch 112 also has flange area 180 around the holes for the protector rods, allowing the hinges' main radial body 181 to have a radial thickness less than that of the reinforcement rod.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited, since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims. | A scope protector is provided that includes a front and rear hinged arch for encircling the scope. The hinged arches are connected by a plurality of protector rods. The scope protector can be attached to a gun rail such as a PICATINNY RAIL commonly found on modern firearms. | 5 |
FIELD OF THE INVENTION
The present invention generally relates to the field of lighting devices having a circuit board for controlling the lighting device. In particular, the present invention relates to arrangements for mounting such a circuit board in the lighting device.
BACKGROUND OF THE INVENTION
Non-incandescent lighting devices generally require driving electronics including a circuit board, such as a printed circuit board, PCB, for driving and controlling the lighting device. For example, lighting devices based on light emitting diodes, LEDs, requires a PCB for driving and controlling the LEDs.
In such non-incandescent lighting devices, the base of the lighting device typically comprises metal. For example, the base may be a metal screw base (cap) adapted to fit and be in electrical contact with a light fitting, and, in particular in LED based lighting devices, the base may comprise a metal heat sink for cooling the LEDs and the driving electronics. The cooling is necessary for maintaining a sufficiently low operating temperature, which extends the life time of the lighting device. Conventionally, to electrically insulate the PCB from any metal parts in the base of the lighting device, potting is used to encapsulate the PCB. The potting is also used to secure the PCB to the base of the lighting device and to conduct heat from the PCB to the heat sink. The potting may e.g. comprise epoxy or silicone. Without the use of potting, the PCB gets thermally insulated and heat dissipation from the PCB is reduced, thereby deteriorating the thermal performance of the lighting device and limiting the maximal output power.
US 2008/0232199 shows an LED lamp having a metal screw base. The screw base is filled with thermally conductive epoxy that secures the PCB and thermally conducts heat away from the LED and the ballast circuit mounted on the PCB to the metal screw base which also forms a heat sink. A drawback with such an arrangement is that thermally conductive epoxy is relatively expensive, and since the base needs to be filled with such epoxy, material costs are high.
SUMMARY OF THE INVENTION
Thus, there is a need for providing alternatives and/or new devices that would overcome, or at least alleviate or mitigate, at least some of the above mentioned drawbacks. An object of the present invention is to provide an improved alternative to the above mentioned technique and prior art. More specifically, it is an object of the present invention to provide a lighting device with an improved thermal performance and a reduced manufacturing cost in comparison with the prior art.
These and other objects of the present invention are achieved by means of a lighting device with the features defined in the independent claim. Preferable embodiments of the invention are characterized by the features set forth in the dependent claims.
Hence, according to the present invention, a lighting device is provided. The lighting device comprises a light source, a circuit board configured to control (or power or drive) the light source, and a circuit board frame comprising a slot. Further, an edge of the circuit board is mounted in the slot such that the circuit board is in thermal contact with the circuit board frame, thereby enabling heat to be conducted from the circuit board to the circuit board frame. Preferably, heat is subsequently dissipated from the circuit board frame onwards to the surroundings e.g. via a heat sink (or heat dissipating component).
The present invention is based on the insight that encapsulating the circuit board with potting (as in prior art techniques) reduces reworkability and makes recycling more complicated as the potting material adheres to the circuit board. Further, in such prior art techniques, the base needs to be filled with potting material, thereby increasing the weight and material cost of the lighting device.
The present invention is based on the idea of instead using a circuit board frame to retain the circuit board in the lighting device. The mounting of the circuit board in the slot of the circuit board frame provides heat dissipation from the circuit board as heat can be conducted from the circuit board, via the circuit board frame, to for instance a heat sink of the lighting device or the ambient air. As the slot clasps (or snugly surrounds) the edge of the circuit board, an increased thermal contact area is provided by the overlap between the circuit board and the circuit board frame (preferably on the two opposite sides of the circuit board), which is advantageous in that an improved cooling of the driving electronics of the lighting device is obtained, thereby extending the life time of the lighting device. Hence, an improved thermal performance of the lighting device is obtained. Optionally, the circuit board may be fastened in the slot by means of gluing or soldering in addition to the clamping that the slot may provide.
Further, the present invention is advantageous in that assembly of the lighting device is facilitated as the circuit board may simply be slid (or inserted) into the slot of the circuit board frame. Consequently, also recycling of the lighting device is facilitated, as the circuit board easily may be separated from the circuit board frame by pulling it out of the slot. The lighting device is preferably designed to allow insertion and removal of the circuit board along the direction of the slot, rather than by urging the circuit board edge into the slot along the normal direction, which may require harmful bending of the circuit board. Further, with the present invention, less material is needed for securing the circuit board to the lighting device, which is advantageous in that the weight of the lighting device as well as material costs are reduced. In addition, a lower weight facilitates logistic handling of the lighting device products.
According to an embodiment of the present invention, the circuit board frame may comprise an electrically insulating material (such as plastics) for electrically insulating the circuit board. The electrically insulating material may for example be provided along the slots and/or as a coating of the circuit board frame. Preferably, most or all the circuit board frame may be made of an electrically insulating material. The present embodiment is advantageous in that the circuit board is electrically isolated from its surroundings, such as from a metal heat sink, a metal screw base or any other component of the lighting device made of an electrically conductive material, thereby reducing the risk of electrically charging parts of the lighting device that are reachable for humans. Alternatively, or as a complement, a separate insulating member may be provided in the lighting device for electrically insulating the circuit board from its surroundings.
In an embodiment of the present invention, the circuit board frame may be at least partly made of thermal plastic, which is advantageous in that the thermal plastic provides electrical insulation and an improved thermal conductivity. In the present disclosure, the term “thermal plastic” refers to a plastic material with a filler which increases the thermal conductivity of the plastic. Hence, the circuit board may be electrically, but not thermally, insulated from its surroundings (including metallic parts, such as the heats sink, in the base of the lighting device), whereby the thermal performance of the lighting device is further improved while reducing the risk of electricity to be conducted to parts of the lighting device reachable for humans.
According to an embodiment of the present invention, the slot may be straight and the circuit board slightly curved, thereby improving the physical contact between the circuit board and the circuit board frame and further securing the circuit board to the circuit board frame. Generally, circuit boards naturally get slightly curved during manufacture due to warpage as a consequence of component soldering. Since the slot is straight, a slight mechanical stress is provided as the circuit board is slid into the slot, which will cause the circuit board to be frictionally retained in the circuit board frame. Advantageously, the slot is sufficiently narrow that the circuit board can only be received therein when the circuit board is urged into a slightly flattened shape. The greater and/or tighter physical contact area in turn improves the thermal contact between the circuit board and the circuit board frame. Alternatively, a straight PCB may be combined with a slightly warped slot to obtain similar results.
According to an embodiment of the invention, the circuit board frame may further comprise a rib in which the slot extends. The slot may be defined by one or more inner surfaces of the rib. In the present disclosure, the term “rib” refers to an elongated, preferably protruding member. The rib may protrude from a supporting member, which e.g. may be the base of the lighting device or a ring-shaped element adapted to support the ribs in the lighting device. The slot may extend in the longitudinal direction of the rib. Further, the rib may be either freestanding or integral with a straight or curved surface which is tangential to the rib. The rib may e.g. extend along the inside of a housing enclosing the circuit board or along the inside of the heat sink. The present embodiment is advantageous in that material consumption and costs can be reduced, in particular if the rib is freestanding and no additional material is used to enclose the circuit board. Further, by virtue of the design freedom regarding thickness and the like, the rib may provide a rigid support for the circuit board, an improved clasping of the circuit board edge and an increased overlap, i.e. an increased thermal contact area, between the circuit board and the circuit board frame.
In an embodiment of the present invention, the circuit board frame may further comprise an electrically insulating housing enclosing (or surrounding) the circuit board, thereby protecting the circuit board and electrically insulating it from its surroundings, such as the heat sink. Further, the housing increases the heat dissipating area of the circuit board frame as heat can be conducted from the slot walls/area to the housing. The electrically insulating housing may for instance be essentially tube shaped and surround the circuit board. The slots may be provided at the inner walls of the housing, e.g. extending in the longitudinal direction of the tube-shaped housing. The housing may be made of thermal plastic, thereby increasing the heat dissipation from the circuit board frame. In an embodiment, the rib may be integral with the housing enclosing the circuit board, thereby increasing the thermal contact area between the circuit board frame and the circuit board.
According to an embodiment of the present invention, the circuit board frame further may comprise an electrically insulating foil, such as a polyimide film, wherein the foil and the rib together enclose (or surround) the circuit board. For example, the foil may, together with the rib, be essentially tube-shaped and the rib may extend along the longitudinal direction of the tube shape. The present embodiment is advantageous in that protection and electrical insulation of the circuit board is enhanced. Further, material costs may be reduced since the foil may be fabricated from a cheaper material than the ribs (and the electrically insulating housing) which may be fabricated from thermal plastic.
Alternatively, no housing or foil to enclose the circuit board may be used if the distance from the electric components of the circuit board to the inner wall of the heat sink (or any other metal part in the base) is long enough to reduce the risk of sparking between the electric components and the heat sink.
In an embodiment of the present invention, the lighting device may further comprise a base, wherein the circuit board frame is integral with an external portion of the base. The present embodiment is advantageous in that the heat dissipating area of the circuit board frame is increased, in particular if the base is made of thermal plastic. Further, as the circuit board frame is integral with the base of the lighting device, the number of components in the lighting device is reduced, thereby facilitating manufacture as well as recycling. It will be appreciated that the base of the lighting device may be the part that is arranged to support the light source and its driving electronics, and support the lighting device in a light fitting.
According to an embodiment of the present invention, the lighting device may further comprise a heat sink (preferably made of metal) arranged in thermal contact with the circuit board frame, which is advantageous in that heat can be conducted away from the circuit board, via the circuit board frame, to the heat sink, thereby further improving the cooling of the circuit board.
In an embodiment of the present invention, the slot may at least 1 mm deep, preferably at least 2 mm deep and even more preferably at least 4 mm deep. A deeper slot provides an increased overlap and thus increases the size and thermal conductivity of the contact area between the circuit board and the circuit board frame. Further, the slot may not be deeper than, but rather essentially correspond to (or be slightly more shallow than), the shortest distance from the electric components of the circuit board to the edge of the circuit board. The overlap may preferably be as large as possible while not obstructing the other components of the lighting device.
In an embodiment of the present invention, self-heating components of the circuit board may be arranged in proximity of the edge of the circuit board, thereby reducing the distance between those components and the circuit board frame, which improves the cooling of the components. Further, by increasing the percentage of the circuit board area covered with electrically conductive material, such as Ag or Cu and extending (or localizing) such coverage towards the edge mounted in the circuit board frame, the cooling of the circuit board is further improved.
According to an embodiment of the present invention, the circuit board frame may comprise an additional slot in which another edge of the circuit board may be mounted such that the circuit board also is in thermal contact with the circuit board frame in the additional slot. To receive a substantially straight circuit board, the slots may be located such that they are facing each other. The present embodiment is advantageous in that the thermal contact area between the circuit board and the circuit board frame is enlarged and the fastening of the circuit board to the circuit board frame is enhanced. Preferably, the two slots of the circuit board frame may be arranged opposite each other, such that two opposing edges of the circuit board may be mounted in (and slid into) the slots of the circuit board frame.
According to an embodiment of the present invention, the ribs may be moulded onto the inside of the heat sink. The ribs may then solidify on the inside of the heat sink during the manufacturing process, which improves thermal contact between the ribs and the heat sink. Hence, the metal heat sink acts as a mould during the plastic injection moulding process. Furthermore, the outside of the lighting device, such as the metal heat sink, may be overmoulded with a (preferably thermo) plastic material for improving the electrical safety of the lighting device. The plastic overmould may e.g. be 1 mm thick and cover at least a part of the metal heat sink. Advantageously, the circuit board frame may be moulded in the same processing step as the overmould.
Further objectives of, features of and advantages with the present invention will become apparent when studying the following detailed disclosure, the drawings and the appended claims. Those skilled in the art realize that different features of the present invention can be combined to create embodiments other than those described in the following or the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiments of the invention.
FIG. 1A shows a lighting device according to an embodiment of the present invention;
FIG. 1B is an exploded view of the lighting device shown in FIG. 1A ;
FIG. 2A shows a circuit board frame according to an embodiment of the present invention;
FIG. 2B is a cross-sectional view of a rib of the circuit board frame taken along the line A-A in FIG. 2A , wherein a circuit board is inserted in the rib;
FIG. 3A shows a circuit board frame according to another embodiment of the present invention;
FIG. 3B is a top view of the circuit board frame shown in FIG. 3A ;
FIG. 4A shows a circuit board frame according to yet another embodiment of the present invention;
FIG. 4B is a top view of the circuit board frame shown in FIG. 4A ; and
FIG. 5 is a cross-sectional view of a base of a lighting device according to an embodiment of the invention.
All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the invention, wherein other parts may be omitted or merely suggested.
DETAILED DESCRIPTION
A lighting device according to an embodiment of the present invention will now be described with reference to FIGS. 1A and 1B .
FIGS. 1A and 1B show a lighting device 1 comprising a base 2 at which light sources 3 , such as LEDs, are arranged. The light sources 3 may be covered with a protective screen 6 optionally including lenses or scattering optics. Alternatively, the light sources 3 may be enclosed in a bulb-shaped envelope (not shown). The base 2 comprises a metal heat sink 4 , for cooling the light sources 3 and their driving electronics, and a portion 5 adapted for connection to a light fitting. The lighting device 1 further comprises a printed circuit board, PCB 7 , for controlling and driving the light sources 3 . The PCB 7 is mounted in a circuit board frame 10 , or a PCB frame 10 , which secures the PCB 7 to the base 2 of the lighting device 1 . At least one edge 8 of the PCB 7 , but preferably two opposite edges 8 of the PCB 7 , are held by the PCB frame 10 . Preferably, the PCB frame 10 is in physical contact with the heat sink 4 , which is arranged to surround (or enclose) the PCB 7 and the PCB frame 10 , thereby facilitating heat conduction therebetween. The lighting device 1 further comprises a connector 9 arranged at said portion 5 of the base 2 , to electrically connect the lighting device to a light fitting.
With reference to FIGS. 2A and 2B , the PCB frame 10 according to an embodiment of the present invention will be described in more detail.
FIG. 2A shows the PCB frame 10 , in which for the sake of clarity, no PCB 7 is inserted. The PCB frame 10 comprises at least one, but preferably two, ribs 11 provided with slots 12 extending along the longitudinal direction of the ribs 11 . The slots 12 are arranged opposite each other, such that two opposing edges of the PCB 7 can be slid into the slots 12 . The slots 12 are straight and their width is adapted to be slightly wider than the thickness of the PCB 7 . The PCB 7 in turn is slightly curved (or warped) due to the component soldering. FIG. 2B shows a cross sectional view of the rib 11 taken along the line A-A in FIG. 2A , but with the PCB inserted in the slot 12 . As the slightly curved PCB 7 is inserted in the straight slots 12 , the mechanical stress will press portions 21 of the PCB edges 8 against portions of the inside of the slot 12 in the rib 11 , as shown in FIG. 2B . The mechanical stress frictionally secures the PCB 7 to the slot 12 and provides physical contact between the PCB 7 and the rib 11 facilitating heat conduction therebetween. The small air gaps between those portions of the PCB edge 8 that are not in direct physical contact with the rib 11 are small enough to still enable some thermal contact between the PCB 7 and the rib 11 .
The PCB frame 10 extends to form a part of, or connects to, the lower portion 5 of the base 2 . In other words, the ribs 11 protrude from the portion 5 of the base 2 . Preferably, the ribs 11 protrude from the portion 5 of the base 2 in the longitudinal direction of the lighting device, i.e. in a direction essentially parallel with the optical axis of the lighting device. Hence, the PCB 7 may be slid into the slots 12 (towards the portion 5 of the base 2 ) with a sliding movement in a direction parallel with the longitudinal direction of the slots 12 . As the PCB frame 10 forms a part of the portion 5 of the base 2 , the heat dissipating area of the PCB frame 10 is enlarged since heat may not just be conducted from the ribs 11 to the heat sink 4 , but also to the portion 5 of the base 2 , which in turn dissipates the heat to the ambient air.
The PCB frame 10 is partly or (at least almost) entirely made of an electrically insulating material for electrically insulating the PCB 7 from the heat sink 4 . For example, the PCB frame 10 may be made of ceramics, but more preferably of plastics, which is a cheaper alternative to ceramics. The plastic may e.g. be a thermoplastic, such as polycarbonate (PC), which is generally used for injection molding. Such common thermoplastic typically has a thermal conductivity of about 0.2/m·K and is advantageous in that it is relatively cheap. Alternatively (or in combination with a common thermoplastic), the PCB frame 10 may be partly or (at least almost) entirely made of thermal plastic. The filler of the thermal plastic may e.g. be ceramic filler or graphite filler in particulate of fibre form. The thermal conductivity of the thermal plastic may range from about 1 up to 15 W/m·K. Thermal plastics with ceramic fillers typically has a thermal conductivity in the range from 1 to 8 W/m·K, and thermal plastics with graphite fillers has a thermal conductivity of up to 15 W/m·K. The thermal plastic is more costly than a common thermoplastic such as PC, but offers a better thermal conductivity, which enhances the thermal path between the PCB 7 and the heat sink 4 . However, materials with a thermal conductivity in the range from 0.4 to 1.0 W/m·K may also applicable to the present invention.
The slots 12 may preferably be at least 1 mm deep, and more preferably at least 2 or 4 mm deep.
With a conventional LED lamp, experiments have shown that after filling the heat sink with potting material having a thermal conductivity of 0.5 W/m·K, the average temperature difference is 8° C. between the PCB and the heat sink. In experiments without potting material (and no PCB frame), the average temperature difference is 20° C.
In experiments without potting, but with the application of a PCB frame with ribs made of a thermal plastic having a thermal conductivity of about 2 W/m·K and 2 mm deep slots, an average temperature difference of 14° C. between the PCB and the heat sink is measured. For a PCB frame made of polycarbonate plastic with a thermal conductivity of 0.2 W/m·K, an average temperature difference of 17° C. is found. Hence, the PCB frame according to an embodiment of the invention provides competitive heat dissipation compared to potting techniques.
With reference to FIGS. 3A and 3B , a PCB frame 30 according to another embodiment of the invention will be described. FIG. 3B shows a top view of the PCB frame 30 shown in FIG. 3A .
The PCB frame 30 comprises ribs 31 protruding from the portion 35 which forms a part of the base of the lighting device, and in particular, the portion 35 forms an external portion of the base. Preferably, the ribs 31 and the portion 35 are molded in the same piece, and/or in the same material, to enhance heat conduction from the ribs to the portion 35 . Slots 32 extend in the ribs 31 , which slots 32 are adapted to receive the edges of the PCB (not shown for the sake of clarity). The PCB frame 30 further comprises an electrically insulating foil 33 , wherein the foil 33 and the ribs 31 are adapted to together enclose the PCB. The ribs 31 extend along the longitudinal direction of the essentially tube shaped foil 33 , thereby facilitating insertion of the PCB into the PCB frame 30 . The slots 32 are arranged opposite each other, such that two opposing edges of the PCB can be slid into the slots 32 . The foil may be formed of two rectangular foil portions fastened in the ribs 31 . The foil 33 reduces the risk of sparks between the PCB and the heat sink and may for instance be a Kapton® foil.
With reference to FIGS. 4A and 4B , a PCB frame 40 according to yet another embodiment of the invention will be described. FIG. 4B is a top view of the PCB frame 40 shown in FIG. 4A .
The PCB frame 40 comprises an electrically insulating housing 43 adapted to enclose the PCB (not shown for the sake of clarity). Ribs 41 extend on the inside of the housing 43 along the longitudinal direction of the essentially tube-shaped housing 43 . In the ribs 41 , slots 42 are arranged to receive the PCB. The slots 42 are arranged opposite each other in the housing 43 , such that two opposing edges of the PCB can be slid into the slots 42 . As shown in FIGS. 4A and 4B , the ribs 41 may be integral with the housing 43 . Alternatively, the slots 42 may be arranged as recesses 42 provided directly in the housing 43 , which may lack any ribs. The housing 43 reduces the risk of sparks being produced between the PCB and the heat sink and may for instance be made of plastics, such as thermal plastics or any other electrically insulating material. The housing 43 also enlarges the heat dissipating area of the PCB frame 40 as heat may be conducted from the slots 42 to the housing 43 and subsequently to a heat sink if such is provided around the housing 43 .
With reference to FIG. 5 , another embodiment of the invention will be described. FIG. 5 is a cross-sectional view of a base 50 of a lighting device. In the present embodiment, the PCB frame comprises ribs 51 , in which slots 52 extends, being attached, and preferably moulded (or glued), onto the inside of a heat sink 58 of the lighting device. Further, an overmould 56 is attached, and preferably moulded, onto the outside of the heat sink 58 . The overmould 56 may for instance be about 1 mm thick. A portion of the over mould 56 may extend (or protrude) into a screw base 57 (or lower portion) of the base 50 . A PCB 7 may be inserted in the base 50 , e.g. by sliding the edges 8 of the PCB into the slots 52 . When the lighting device is operated, heat may be conducted from the PCB to the ribs 51 and then further to the heat sink 58 . The tight fitting of the ribs 51 to the inside of the heat sink 58 achieved by the moulding or gluing improves the heat conduction therebetween.
While specific embodiments have been described, the skilled person will understand that various modifications and alterations are conceivable within the scope as defined in the appended claims. For example, the materials, slot dimensions and PCB frame location and orientation described with reference to FIGS. 2A and 2B are applicable also to the embodiments described with reference to FIGS. 3A , 3 B, 4 A, 4 B and 5 . Further, it will be appreciated that the invention is applicable not only to LED-based lighting devices, but any lighting device comprising a PCB or circuit board with components requiring cooling for driving/controlling the lighting device. | The present invention relates to a lighting device ( 1 ). The lighting device comprises a light source ( 3 ), a circuit board ( 7 ) configured to control the light source, and a circuit board frame ( 10 ) comprising a slot ( 12 ). Further, an edge ( 8 ) of the circuit board is mounted in the slot such that the circuit board is in thermal contact with the circuit board frame, thereby enabling heat to be conducted from the circuit board to the circuit board frame. The present invention is advantageous in that the thermal performance of the lighting device is improved and manufacturing costs are reduced. | 5 |
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. provisional patent application No. 60/266,579 filed on Feb. 5, 2001, the entirety of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a safety improvement for use in connection with fittings, and more specifically, a fitting restraint device for a liquid cylinder.
BACKGROUND OF THE INVENTION
[0003] The improvement relates to the industrial gas industry. The Compressed Gas Association (CGA) publishes a wide variety of standards for the industrial gas industry. The publications provide standards for compressed gas cylinder valve outlet and inlet connections. The primary services for liquid cylinders are liquid nitrogen, oxygen, argon, carbon dioxide and nitrous oxide, which are very dangerous when mishandled.
[0004] Hoses for filling and discharging a product are frequently attached to and removed from the CGA fittings. It is possible for an untrained or uninformed user to change valve connections by simply unthreading the exit fitting and threading in a different fitting. For example, it is possible to remove an oxygen service fitting and replace it with an nitrogen service fitting. The consequence of this incorrect fitting replacement is the supply of oxygen to an nitrogen application.
[0005] The CGA has revised Safety Bulletin 26 (SB-26-2001) so that tamper-resistant devices are required on medical gas cylinders and tamper-evident devices are required on industrial gas cylinders. Tamper-resistant devices can be silver brazed, welded or attached by other methods in a manner that prevents removal or would render the connection or valve body outlet unusable if removal was attempted. The current industry standard fitting restraint device is a cable that wraps around the valve body and attaches to a ring with a plastic clasp. This device is more tamper-evident and not tamper-resistant as required by the CGA.
[0006] As compared to the prior art, a significant difference between the present invention and the prior art is the type of attachment to the valve body. The present invention device is installed in a secure manner and includes devices such as rivets which allow disassembly of the invention, but only with a great degree of effort.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a safety bracket system involving fittings and liquid cylinders that satisfies the need to prevent against mixing gases.
[0008] In one aspect, the invention provides a bracket for preventing undesired movement of a storage cylinder fitting which includes a lower section permanently mounted to a storage cylinder, an upper section affixed to the lower section where the upper section defines an interference surface for abutting against the storage cylinder fitting to prevent rotational movement thereof.
[0009] In another aspect, the invention provides a bracket for preventing undesired manipulation of a storage cylinder fitting attached to a storage cylinder valve, the bracket including a horizontal section defining an opening through which a valve body of the storage cylinder valve extends, a vertical section including an interference surface for abutting against the storage cylinder fitting to prevent rotational movement thereof; and locking means for restraining lateral movement of the vertical section.
[0010] In yet another aspect, the invention provides a bracket for preventing undesired manipulation of a storage cylinder fitting attached to a storage cylinder valve, the bracket includes a vertical section with an exterior plate and an interior plate and means for attaching the two. The exterior plate includes an interference surface for abutting against the storage cylinder fitting to prevent rotational movement thereof, and a horizontal section integrally formed with the interior plate wherein the horizontal section circumscribes a valve body of the storage cylinder valve.
[0011] The present invention provides may advantages over what is known. The bracket described is difficult to tamper with, but may be removed with the right tools and patience. The bracket described is also reusable by installing new locking devices into the existing bracket pieces. The invention is provided in both an original equipment version where a weld joint to a storage cylinder is used and a retrofit version where contact with the storage cylinder is not required. The invention provides a bracket which minimizes the ability tamper with a storage cylinder by removing its fitting, and also prevents normal loosening and/or unthreading of the fitting which may occur in normal usage. Thus, the potential for leaks is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a perspective view of the first embodiment of the present invention;
[0013] [0013]FIG. 2 is an exploded view of the first embodiment;
[0014] [0014]FIG. 3 is a perspective view of a variation of the first embodiment;
[0015] [0015]FIG. 4 is a front view of a portion of the first embodiment;
[0016] [0016]FIG. 5 is an exploded view of a fitting and a valve;
[0017] [0017]FIG. 6 is a perspective view of a second embodiment of the present invention;
[0018] [0018]FIG. 7 is a side view of the second embodiment;
[0019] [0019]FIG. 8 is a perspective view of a part of the second embodiment; and
[0020] [0020]FIG. 9 is a perspective view of a part of the second embodiment.
DETAILED DESCRIPTION
[0021] The invention will now be described with reference to the drawings. FIG. 1 shows a piping connection 15 for a tank or cylinder 11 with a bracket 40 which protects the piping connection from undesired manipulation. The piping connection 15 has a first pipe 13 with one end attached to the cylinder 11 . The opposite end of the first pipe 13 is attached to a valve 25 . The valve contains a removable handle 27 to open and close the valve 25 .
[0022] Referring to FIG. 5, a fitting 30 with external threads 34 fits into the valve 25 with internal threads 26 . The fitting 30 is specific as to the type of gas or liquid which is to be transferred in or out of the cylinder. The fitting 30 is cylindrical in shape with a first end 31 , a second end 32 , and a midsection 33 . The first end 31 is externally threaded in order to attach to the valve 25 . This first end 31 has the same thread type for all the different fittings. The midsection 33 is preferably shaped like a hexagonal nut, including wrench flats, in order for a wrench to grasp the fitting 30 and twist the fitting 30 on or off the valve 25 . The second end 32 is externally threaded, but the type varies depending upon which type of gas is distributed from the cylinder.
[0023] Referring to FIGS. 1 and 2, a first embodiment of the bracket 40 comprises a lower section 42 and an upper section 46 . The lower section 42 contains slotted holes 44 and is welded to the top of the cylinder 11 in order to prevent easy removal of the bracket 40 and manipulation of the storage cylinder fitting 30 . The holes 44 may also be circular as opposed to slotted.
[0024] The upper section 46 includes two holes 48 to facilitate attachment to the lower section 42 . Rivets 50 or a other fastening devices which are not easily removed secure the upper section 46 to the lower section 42 by penetrating the holes 48 which are aligned with the slotted holes 44 . As a result easily manipulation of the storage cylinder fitting 30 by removal of the upper section 46 of the bracket 40 is not possible. However, the upper section 46 of the bracket 40 may be removed by a time-consuming process of drilling out the rivets 50 . Bolts may also be used to hold the upper section 46 and lower section 42 together.
[0025] The upper section 46 defines an interference surface 54 . The interference surface 54 abuts against the midsection 33 or wrench flats of the storage cylinder fitting 30 to prevent rotational movement of the fitting 30 . The interference surface 54 may be a single face abutting a single flat portion of the midsection of the fitting 30 . Alternatively, the interference surface 54 may be two or more surfaces. As shown in FIGS. 1 and 2 the upper section 46 is a plate and the interference surface 54 is multiple surfaces, defining an aperture, which completely circumscribes the midsection 33 of the fitting 30 .
[0026] Referring to FIGS. 3 and 4, a variation of the first embodiment is shown where the lower section 42 has an extended height. The upper section 46 is shortened. The lower section 42 defines an aperture which circumscribes the cylinder fitting. The aperture in the lower section does not restrict rotation of the fitting 30 . An advantage to this variation is the ability to use a common upper plate in both the first embodiment of the invention and the second embodiment described below.
[0027] A second embodiment of the bracket 60 is shown in FIGS. 6, 7, 8 and 9 . The second embodiment of the bracket 60 does not require attachment to a cylinder itself. The bracket 60 includes a generally vertical section 62 and a generally horizontal section 74 . The generally vertical section comprises two vertical plates, an exterior plate 64 and an interior plate 66 . The exterior plate 64 and interior plate 66 may have substantially equal heights and widths. The exterior plate 64 includes one or more interference surfaces 68 , similar to those in the first embodiment of the bracket. These surface(s) 68 prevent rotational movement of the fitting 30 . The exterior plate 64 abuts and is attached to the interior plate 66 . The interior plate defines an aperture 78 through which the fitting 30 may pass, but does not interfere with the rotational movement of the fitting 30 . The interior plate 66 is attached to the exterior plate 64 using a locking device which is difficult to remove such as rivets 70 or a lock. As a result, lateral movement of the vertical section 62 is restrained. It is difficult for an unauthorized person to detach the exterior plate 64 and manipulate or remove the fitting 30 . If rotation of the fitting 30 is not prevented, the fitting 30 may leak and result in lost product. However, it is possible to remove the exterior plate 64 by drilling out the rivets 70 or unlocking the lock. As shown in FIG. 7, the interior plate 66 may be positioned along the lengthwise axis of the piping connection in a position which is beyond the valve body. Thus, upon removal of the exterior plate 64 , unscrewing the fitting 30 , and removal of the handle 27 the interior plate 66 and horizontal section 74 can be easily removed. The interior plate 66 may be part of a common piece which includes the horizontal section 74 .
[0028] Referring to FIGS. 7 and 8, the horizontal section 74 of the bracket 60 defines an opening 76 through which the valve body 25 may protrude before a handle 27 is attached to the valve body 25 . In an embodiment of the invention the horizontal section 74 fully circumscribes the valve body 25 . The interference caused by the horizontal section 74 against the valve body 25 , in combination with the means of locking the bracket 60 results in a system which cannot be easily disengaged from the valve 25 . As a result this bracket 60 prevents fitting 30 removal in addition to locking the fitting 30 in place and preventing rotation. | A bracket assembly for securing a fitting to a liquid cylinder within the Compressed Gas Association standards for the industrial gas industry. The tamper resistant bracket prevents a fitting from being removed from and an incorrect fitting from being attached to a liquid cylinder so as to not to provide the wrong product for a given application. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to apparatus for detection of the proper function of an electric fence and/or a fence charger intended to maintain charge on the fence. More particularly, the invention relates to a compact and durable sensing device which can be readily mounted to an electric fence for detecting proper operation of the fence and of a charging device intended to maintain a charge on the fence.
2. Description of the Prior Art
The imposition of an electrical charge on fencing intended to maintain livestock within a specified area has become well known as an alternative or addition to the fencing of livestock or the like by means of conventional fencing intended to retain such stock by virtue of the strength of the fencing rather than by an electrical charge which causes the stock to avoid the fencing. Electric fencing is charged to an appropriate voltage by means of fence charging apparatus which typically apply either continuous or pulsed current to at least one electrical conductor comprising the fencing. Examples of presently available electric fence chargers include the random pulse charging apparatus of Phillips et al which is disclosed in U.S. Pat. No. 4,316,232. McKissack, in U.S. Pat. No. 4,859,869, discloses the use of transformers for applying a continuous charge for energization of an electric fence. Standing, in U.S. Pat. Nos. 4,394,583 and 4,691,084, describe electrical fence chargers as does Shaw et al in U.S. Pat. No. 5,381,298.
While electric fence and fence charger combinations usually provide satisfactory operation, certain circumstances can occur whereby a fence can lose its electrical charge either by failure of the fence charger or by damage to the fence itself such as by cutting of the fence or other circumstance which causes an open circuit or “short” condition. While fence charging apparatus may employ visual or audible signals on the apparatus itself to indicate failure or incipient failure of the fence charger, it is not possible to determine these conditions unless personnel are deployed in the area of the fence chargers per se in order to detect such indications. Accordingly, a need has been felt in the art to provide a simple and inexpensive means by which an observer at essentially any location along an electric fence can be informed of the operational state of the electric fence so that a determination can be made in the event of an indicated failure as to whether a failure of the fence charger exists or whether conductive elements of the electric fence have been breached such as by cutting or other separation thus causing an open or short circuit. The art has previously provided monitoring an alarm system used in association with electric fences and fence chargers. Begg, in U.S. Pat. No. 4,523,187, provides one such alarm while Pope et al, in U.S. Pat. No. 4,220,949, provides a fence monitor as does Hamm in U.S. Pat. No. 5,550,530. McCutchan et al, in U.S. Pat. No. 4,297,633, provides remote devices on electric fence sections whereby the devices transmit signals to a central control location. Although the art has provided monitoring and alarm systems such as are represented by the United States patents cited herein, the art continues to feel the need for a compact and inexpensive device which can be placed on a conductive element of an electric fence and which provides a signal, particularly a visual signal in the form of a flashing light, in the event of the inability of a fence charger to maintain an electric charge on the fence or the lack of a charge on the fence such as can occur due to a separation of the electrical conductor of the fence such as by cutting or any separation causing an open or short circuit. The present invention provides in a compact, inexpensive and exceptionally durable apparatus circuitry for sensing the operational state of an electric fence and thus an electric fence charger intended to maintain an electric charge on the fence and in the several embodiments thereof finds compatibility with known fence chargers whether pulse or continuous and in supply voltage ranges of at least 3 to 15 volts DC while being operable within a wide range of temperatures at least from −40° C. to 85° C.
SUMMARY OF THE INVENTION
The invention provides a compact, inexpensive and exceptionally durable device which can be simply hung at a multiplicity of locations on a conductive portion of an electric fence with immediate electrical contact thus being provided between the fence and circuitry internal of the device, any desired number of the present devices being usable without drawing down voltage. The device of the invention in its several embodiments includes a self-contained power source such as batteries of appropriate size and voltage, a circuit board carrying circuitry elements, a source of illumination disposed within the device and a shock-resistant “plastic” lens which forms at least a part of a housing within which components of the device are disposed and interrelated for appropriate function.
Circuitry suitable to an appropriate operation of the invention can take a variety of forms according to the invention with that part of the circuitry causing communication with the electric fence and/or with the fence charger being a clip or mounting arrangement which simply and readily fits over an electrical conductor of the electric fence at any location of the fence, the clip being directly connected electrically to circuitry internal of the device, which circuitry causes operation of the device to provide an appropriate visual signal in the event of the failure of the fence to exhibit an appropriate charge or the failure of the fence charger to appropriately charge the fence. The circuitry can also sense voltage drops below a predetermined value and provides a signal indication of such a voltage drop. A particularly useful circuit defined according to the invention includes an integrated circuit as a part of the circuitry providing control, an output from the integrated circuit causing a transistor to oscillate, oscillation of the transistor controlling a light source carried by the device. It should be understood that the light source is preferably carried within the device in order to prevent damage to the light source. In this preferred circuit, the integrated circuit functions essentially as a timer and further provides means for adopting other functions to the circuitry as desired. For example, self-test functions or the like can be incorporated into the preferred circuitry due to the presence within the circuitry of the integrated circuit comprising the timer function. In a similar vein, auxiliary subsystems can be connected into the circuitry through the integrated circuit to provide other functions without any real modification of the original circuit.
The invention further contemplates provision of a control and/or timing function by means of the operation of discrete circuit elements including at least one resistor and at least one transistor which function to control the oscillation of a transistor and thus control of the light source. It is to be understood that the light source in the several embodiments of the invention can take several forms including low voltage DC lamps of the incandescent types as well as light emitting diodes of various description, it being desirable to utilize light emitting diodes having the capability of flashing operation.
In the several embodiments of the present circuitry, it is to be noted that the circuitry is not grounded to earth ground and that the electrical reference is at the battery negative terminal. Accordingly, it is thus seen that the impedance of air at the connection of the circuit to the fence conductor is used to prevent lowering of the voltage of the fence charger.
The invention in its several embodiments will be seen to be compatible with all types of fence chargers whether pulse or continuous and will accept wide ranges of supply voltages such as from 3 to 15 volts DC. The present devices function within a wide range of temperatures and within a wide range of weather conditions. The devices of the invention further will not drop the voltage of the fence charger, a clip connecting the device to the fence further connecting directly to circuitry within the device and providing input from the fence charger to such circuitry. The clip provides a means for hanging the devices of the invention on a high voltage fence wire without danger of shock. The illumination source of the several devices of the invention only flashes when a fence charger is not working properly or when the fence has an open or short circuit.
Accordingly, it is a primary object of the invention to provide a detection apparatus in several embodiments for sensing the operational state of an electric fence and thus an electric fence charger intended to maintain an electric charge on the fence, the detection apparatus being of compact, inexpensive and durable construction and housing circuitry and an illumination source driven by the circuitry, whereby the circuitry detects charge on the electric fence at any location thereof and provides an indication of malfunction when such charge does not exist due either to fence charger failure or the presence of an open circuit or short in the fence.
It is another object of the invention to provide compact and inexpensive detection devices capable of sensing the operational state of an electric fence including operation at a reduced voltage below a predetermined level at any location thereof as well as the appropriate function of an electric fence charger, the devices of the invention being usable at multiple locations and simply being clipped to or hung on electrically conductive fence elements of an electric fence at any location of the electric fence to provide an indication of the appropriate functioning of the fence and fence charger without drawing down the voltage imposed on the fence by the charger.
It is a further object of the invention to provide detection apparatus for sensing the operational state of an electric fence and thus an electric fence charger whereby an illumination source carried by the apparatus will be caused to flash in the event of a failure of the fence charger or the existence of an open circuit such as can be caused by a separated fence wire.
Further objects and advantages of the invention will become more readily apparent in light of the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an idealized perspective view illustrating a detection device configured according to the invention and including a housing carrying a power source, an illumination source, controlling circuitry and a clip or similar mechanism for hanging the assembly to a portion of an electric fence in order to effectively communicate the condition of the fence and of a fence charger intended to charge the fence to circuitry contained within the apparatus of the invention;
FIG. 2 is a circuit diagram illustrating a preferred embodiment of the circuitry of the invention; and,
FIG. 3 is a block diagram illustrating an alternative circuit which can be used in the device of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIG. 1, a detector configured according to the invention is seen generally at 10 to comprise a housing 12 formed of a lens element 14 and a back plate 16 . A power source such as batteries 18 is mounted in any convenient fashion to an inner surface of the back plate 16 , the back plate 16 then being mounted either directly to the lens element 14 or to a rear housing element 17 in any convenient fashion. For example, the back plate 16 can be provided with screw threads (not shown) which mate with threads formed about an opening in the element 17 so that the back plate 16 can be conveniently and positively attached to the housing 12 . The lens element 14 and the rear housing element 17 can be permanently attached to each other or can be integrally formed, it only being necessary for the lens element 14 to be formed of a clear, “plastic” material having sufficient durability to withstand the rigors of the outdoor environment within which the detector 10 is intended to function.
Interiorly of the housing 12 and in a position to direct light through the lens element 14 is disposed a light source 22 , the operation of which is controlled by circuitry 26 mounted on a circuit board 20 , the circuit board 20 being mounted in any convenient fashion within the interior of the housing 12 . It is to be understood that reflector elements can be provided within the interior of the housing in order to efficiently reflect light through the lens element 14 . Further, the lens element 14 can preferably be formed of a material having a color tint which would cause illumination of the light source 22 , especially flashing illumination, to be more readily observed. In practice, an amber light emitting diode coupled with yellow reflective materials or yellow-tinted materials is preferred.
A connector 24 is mounted to the housing 12 and has conductive elements (not shown) which extend into electrical contact with the circuitry 26 mounted on the circuit board 20 . Electrical connection between this connector 24 and the circuitry 26 is illustrated in FIGS. 2 and 3.
The connector 24 not only provides a mechanism by which the detector 10 can be mounted to, that is, “hung” onto an electrically conductive fence element (not shown in FIG. 1 ), the connector 24 also couples the circuitry 26 of the detector 10 to an electrically conductive fence element and therefore a fence charger (shown in FIGS. 2 and 3) without providing a shock risk. In particular, the circuitry 26 of the detector 10 is not grounded to earth ground, the electrical reference of the detector 10 thus being at the negative terminal of the battery or batteries 18 . Accordingly, the impedance of the air in the vicinity of the hanging connection acts to prevent lowering of the voltage of the fence charger. This grounding of the detector 10 to the negative terminal of the battery 18 rather than to earth ground is of very substantial importance in that any number of the detectors 10 can be hung onto an electric fence without drawing down voltage on the fence, thereby allowing detection of the operational state of the fence charger 30 and of the fence at any desired number of locations by any desired number of the detectors 10 at any given time. Further, a voltage drop on the fence of a predetermined degree, such as 1000 volts, can be detected by the detector 10 with a resulting visual indication being provided by said detector.
A consideration of the structure of the detector 10 as seen in FIG. 1 reveals alternatives as to the construction thereof. For example, a light emitting diode can be utilized as the light source 22 and particularly a light emitting diode capable of flashing operation. While a DC-driven light source such as an incandescent bulb can be utilized, power drain on the batteries 18 will be substantially reduced through use of a light emitting diode as the light source 22 . The light source 22 is connected into the circuitry 26 in a manner as is disclosed in the discussion of FIGS. 2 and 3 as provided hereinafter. It is further to be understood that the batteries 18 could take the form of disc-type batteries which could be mounted within circular depressions formed in the back plate 16 , for example. Such batteries are usually slotted to allow removal from circular depressions which are threaded to mate with threads formed on the batteries themselves.
Referring now to FIG. 2, a preferred circuit is seen as comprising the circuit 26 . The circuit 26 of FIG. 2 includes a light emitting diode 48 having flashing capability as the light source 22 . The batteries 18 of FIG. 1 are seen to also be a part of the circuit 26 and are described as battery 55 in the circuitry of FIG. 2 .
FIG. 2 illustrates an electrically conductive fence element 28 in schematic fashion, such a fence element 28 being typically formed of wire and being that portion of an electric fence on which the connector 24 is hung in order to mount the detector 10 to the electric fence. The fence element 28 is shown in a schematic fashion to be connected to a fence charger 30 which may essentially comprise a charger of any known type whether continuous or pulse and within the usual voltage ranges of such chargers, that is, having a supply voltage of between 3 and 15 volts DC. When the fence charger 30 is operable to charge the fence element 28 on which the detector 10 is mounted through the connector 24 , resistors 32 and 34 sense the voltage provided by the fence charger 30 . The fence charger 30 causes a small current to be fed from junction 33 of the resistors 32 and 34 , this current flowing to the base of transistor 36 and thereby turning the transistor 36 on. Activation of the transistor 36 charges capacitor 38 with a resultant activation of the transistor 40 . When the transistor 40 is thus activated or caused to be in an “on” condition, capacitor 42 is discharged through the transistor 40 , thus causing output of timer 44 to go “high”. When the output of the timer 44 goes high, transistor 46 turns off and the light source in the form of the light emitting diode 48 is also “off”. Accordingly, in the condition whereby the fence charger 30 is properly operating and causing a charge to be imposed upon the fence element 28 , the detector 10 senses the charge imposed upon the fence element 28 and thus senses that the fence charger 30 is performing properly and that a charge exists as is expected on the fence element 28 . In this condition, the light source, that is, the light emitting diode 48 , is inoperative.
In the condition whereby the fence charger is in the “off” condition for any reason such as by actual failure, the charge in the capacitor 38 slowly drops to zero volts, thus preventing the capacitor 42 from being discharged. It is thus seen that the capacitor 42 charges through resistor 50 and resistor 52 , a network 54 being essentially formed by the resistors 50 , 52 and the capacitor 42 . Once the capacitor 42 has charged up to approximately one-third of the supply voltage, the output of the timer 44 will go “low” and the capacitor 42 will slowly discharge through resistor 52 . When the capacitor 42 is discharged below approximately one-third of the supply voltage, the output of the timer 44 will go “high” and the capacitor 42 will be recharged again. This charge/recharge cycle of the capacitor 42 causes the timer 44 to oscillate the transistor 46 since the gate of the transistor 46 is controlled by the output of the timer 44 . The rate of oscillation is determined by the product of the resistor 50 , the resistor 52 and the capacitor 42 which form the network 54 as indicated previously. The light source, that is, the light emitting diode 48 , is controlled by the oscillation of the transistor 46 . Accordingly, failure of the fence charger to maintain the appropriate charge on the fence element 28 causes the light emitting diode 48 to flash and thus provide a visual failure indication. The detector 10 thus only provides a visual failure indication when the fence charger 30 is not working properly or when the electric fence has an open or short circuit such as can be caused by cutting of the fence or by a separation occurring due to the other causes.
Referring again to FIG. 2, it is seen that the timer 44 takes the form of an integrated circuit, the output of which at 3 controlling the gate of the transistor 46 to thereby oscillate the transistor 46 . The integrated circuit comprising the timer 44 provides flexibility to the circuit 26 when considered relative to discrete element circuitry since options can be connected to the circuit 26 through the integrated circuit comprising the timer 44 with minimum or no modification to the circuit 26 . Such modifications can include circuit subsystems providing other alarm indicators, self-test functions, etc. The integrated circuit of the circuit 26 , that is, the timer 44 , can be provided with GND at 1, a TRIGGER function at 2, an OUTPUT function at 3, a RESET function at 4, a THRESHOLD function at 6, a DISCHARGE function at 7 and a VCC function at 8. A control function could be provided at a position such as the 5 position (not shown). The circuit 26 can otherwise be provided with conventional discrete circuit elements. However, it is to be understood that the resistors can preferably be carbon film of ⅛ watt or better while capacitors are all 15 V. The light emitting diode 48 must have high MCD. Further, all transistors must have a gain of a minimum of 200 while the integrated circuit taking the form of the timer 44 is preferably of the CMOS type. The resistor 50 can be 1 M or 2 M and potted for flash rate setting. All electrical components can be surface mounted or through-hole mounted on the circuit board 20 . The detector 10 functions maximally with all types of fence chargers and especially where pulses are less than 0.5 Hz or once every two seconds. The flash rate of the detector 10 is approximately once every three seconds. It is further to be noted that the transistors 36 and 40 are NPN type transistors while the transistor 46 is a PNP transistor. The capacitors are typically 1 microfarad, 15 V electrolytic devices. The integrated circuit, that is, the timer 44 , is chosen to be a TC 555 CMOS timer.
Referring now to FIG. 3, an alternative circuit is seen at 57 and comprises a number of discrete circuitry elements which are present in the circuit 26 of FIG. 2, these elements functioning in essentially the same manner. However, the timer 44 has a transistor 56 and a resistor 58 substituted therefor. In operation, the resistors 32 and 34 sense voltage when the fence charger 30 is operating appropriately, the fence charger 30 feeding a small current from the junction 33 of the resistors 32 , 34 , this current flowing to the base of the transistor 36 with the result that the transistor 36 is turned on. The capacitor 38 is charged through the transistor 36 and turns on the transistor 40 . When the transistor 40 is in the “on” condition, the capacitor 42 is discharged through the transistor 40 causing the transistor 56 to turn off, the transistor 46 also being caused to turn off so that the light emitting diode 48 is also off. When the fence charger 30 is not functioning, the charge in the capacitor 38 slowly drops to zero volts thus preventing the capacitor 42 from being discharged. As with the circuit 26 of FIG. 2, the capacitor 42 charges through the resistors 50 and 52 . When the capacitor 42 has charged up to a value of approximately 0.7 V, which is the saturation point of most transistors, and thus causing the transistor 56 to turn on, the transistor 56 simultaneously turns the transistor 46 on, thus causing the light emitting diode 48 to flash. The flash rate of the light emitting diode 48 is determined by the inherent rate of the LED itself.
As is the case with the circuit 26 of FIG. 2, the circuit 57 is not grounded to earth ground, the electrical reference being at the negative terminal of the battery 55 . Accordingly, the impedance of the air functions to prevent lowering of the voltage of the fence charger 30 . The transistor 46 of the circuit 57 of FIG. 3, is an NPN transistor rather than the PNP transistor of the circuit 26 of FIG. 2 .
While the detector 10 including the circuits 26 and 57 have been described as explicit embodiments of the inventive concept disclosed herein, it is to be understood that the conformation of the detector 10 and particular circuit elements can be configured other than as explicitly shown and described herein without departing from the scope of the invention as defined by the appended claims. | Detection apparatus for sensing the operational state of an electric fence and thus an electric fence charger intended to maintain an electric charge on the fence, the invention and the several embodiments thereof find compatibility with known fence chargers whether pulse or continuous in appropriate supply voltage ranges. The detection apparatus of the invention includes a power supply such as a battery to drive a light source such as a light emitting diode which is caused to flash by circuitry carried by the apparatus, the apparatus being clipped to the fence at any location thereof to connect the circuitry to the electrical load on the fence. The light source operates in the event of a failure of the fence charger to perform properly including conditions ranging from complete failure to voltage drops of a predetermined degree or in the event of an open circuit such as can be caused by a separated fence conductor such as a fence wire. The circuitry of the invention includes in the several embodiments thereof control functions based on the operation of an integrated circuit or a transistor in combination with other circuit elements. | 6 |
TECHNICAL FIELD
[0001] The present disclosure relates generally to information handling systems and, more particularly, to optimizing power delivery and signal routing in information handling system printed circuit boards.
BACKGROUND
[0002] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
[0003] As the performance requirements of information handling systems continue to increase, costs associated with printed circuit board (PCB) fabrication also increase. One reason for this increase in costs can be attributed to an increase in PCB complexity. As more signals are added to PCB designs, additional PCB layers are typically required to route those signals and deliver sufficient power to support their functionality. Some high performance system designs have resorted to routing signals on layers that are typically devoted to delivering power. The resulting reduction in available area on these power layers generally yields diminished power delivery performance which, under electrically stressful conditions, may compromise functionality of the entire system. In addition, validating the PCB power delivery, typically a time consuming process, is made considerably more difficult with marginal power delivery designs. As a result, if signal routing must be included on the power delivery layers of a PCB, novel approaches must be devised to mitigate the detrimental effect such routing typically has on power delivery performance.
SUMMARY
[0004] In accordance with teachings of the present disclosure, an information handling system for optimizing power delivery and signal routing on printed circuit board power planes is provided. The information handling system preferably includes a printed circuit board having first and second cores, at least one processor and a memory operably coupled to the processor and the printed circuit board. The printed circuit board preferably further includes a dielectric including glass particles disposed in a portion thereof, where the dielectric is operable to couple the first and second cores substantially parallel one another.
[0005] In addition, a printed circuit board for optimizing power delivery and signal routing is also provided. The printed circuit board preferably includes a first core, a second core and an insulating material having regions of increased permittivity. The insulating material is preferably operable to couple the first core to the second core where the regions of increased permittivity are disposed proximate at least one power plane defined between the first and second cores.
[0006] Further, a method for manufacturing an optimized power delivery and signal routing printed circuit board is provided. The printed circuit board preferably includes a first and a second core. The method for manufacturing the printed circuit board preferably includes integrating an insulating material having a first permittivity into at least a portion of a dielectric layer having a second permittivity. The method preferably also includes coupling the first and second cores together about the dielectric layer such that the insulating material integrated portions substantially align with a power delivery plane defined by at least a portion of the first and second cores.
[0007] In one aspect, teachings of the present disclosure provide the technical advantage of permitting regions of a printed circuit board to be optimized for power and signal routing.
[0008] In another aspect, teachings of the present disclosure provide the technical advantage of enabling more complex printed circuit board implementations by facilitating an increase in area available for signal routing without compromising effective power delivery.
[0009] Further, teachings of the present disclosure provide the technical advantages of a low-cost, efficient alternative to printed circuit board fabrication where regions of the circuit board may be selectively optimized for power delivery and signal routing.
[0010] In addition, teachings of the present disclosure provide the technical advantage of enabling variable capacitance power delivery planes, the capacitance of a selected power delivery plane determined by materials, spacing of materials, as well as other factors controlled by a multilayered printed circuit board fabricator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
[0012] FIG. 1 is a block diagram showing an information handling system including a hybrid printed circuit board power delivery plane, according to teachings of the present disclosure;
[0013] FIG. 2 is a top view showing a woven fiberglass mesh, according to teachings of the present disclosure;
[0014] FIG. 3 is a side view of the woven fiberglass mesh of FIG. 2 , according to teachings of the present disclosure;
[0015] FIG. 4 is a side view of an exemplary embodiment of a prepreg sheet, according to teachings of the present disclosure;
[0016] FIG. 5 is a side view showing an exemplary embodiment of a multilayered printed circuit board incorporating a hybrid power delivery plane and at least one signal trace, according to teachings of the present disclosure; and
[0017] FIG. 6 is an exploded view of an exemplary embodiment of multilayer printed circuit board fabrication, according to teachings of the present disclosure.
DETAILED DESCRIPTION
[0018] Preferred embodiments and their advantages are best understood by reference to FIGS. 1 through 6 , wherein like numbers are used to indicate like and corresponding parts.
[0019] For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
[0020] Referring first to FIG. 1 , a block diagram of an information handling system is shown, according to teachings of the present disclosure. Information handling system or computer system 10 preferably includes at least one microprocessor or central processing unit (CPU) 12 . CPU 12 may include processor 14 for handling integer operations and coprocessor 16 for handling floating point operations. CPU 12 is preferably coupled to cache 18 and memory controller 20 via CPU bus 22 . System controller I/O trap 24 preferably couples CPU bus 22 to local bus 26 and may be generally characterized as part of a system controller.
[0021] Main memory 28 of dynamic random access memory (DRAM) modules is preferably coupled to CPU bus 22 by a memory controller 20 . Main memory 28 may be divided into one or more areas such as system management mode (SMM) memory area (not expressly shown).
[0022] Basic input/output system (BIOS) memory 30 is also preferably coupled to local bus 26 . FLASH memory or other nonvolatile memory may be used as BIOS memory 30 . A BIOS program (not expressly shown) is typically stored in BIOS memory 30 . The BIOS program preferably includes software which facilitates interaction with and between information handling system 10 devices such as a keyboard (not expressly shown), a mouse (not expressly shown), or one or more I/O devices. BIOS memory 30 may also store system code (note expressly shown) operable to control a plurality of basic information handling system 10 operations.
[0023] Graphics controller 32 is preferably coupled to local bus 26 and to video memory 34 . Video memory 34 is preferably operable to store information to be displayed on one or more display panels 36 . Display panel 36 may be an active matrix or passive matrix liquid crystal display (LCD), a cathode ray tube (CRT) display or other display technology. In selected applications, uses or instances, graphics controller 32 may also be coupled to an integrated display, such as in a portable information handling system implementation.
[0024] Bus interface controller or expansion bus controller 38 preferably couples local bus 26 to expansion bus 40 . In one embodiment, expansion bus 40 may be configured as an Industry Standard Architecture (“ISA”) bus. Other buses, for example, a Peripheral Component Interconnect (“PCI”) bus, may also be used.
[0025] In a portable information handling system embodiment, Personal Computer Memory Card International Association (PCMCIA) controller 42 may also be included and is preferably coupled to expansion bus 40 as shown. PCMCIA controller 42 is preferably coupled to a plurality of information handling system expansion slots 44 . Expansion slots 44 may be configured to receive one or more PCMCIA expansion cards such as modems, fax cards, communications cards, and other input/output (I/O) devices.
[0026] Interrupt request generator 46 is also preferably coupled to expansion bus 40 . Interrupt request generator 46 is preferably operable to issue an interrupt service request over a predetermined interrupt request line in response to receipt of a request to issue interrupt instruction from CPU 12 .
[0027] I/O controller 48 , often referred to as a super I/O controller, is also preferably coupled to expansion bus 40 . I/O controller 48 preferably interfaces to an integrated drive electronics (IDE) hard drive device (HDD) 50 , CD-ROM (compact disk-read only memory) drive 52 and/or a floppy disk drive (FDD) 54 . Other disk drive devices (not expressly shown) which may be interfaced to the I/O controller include a removable hard drive, a zip drive, a CD-RW (compact disk-read/write) drive, and a CD-DVD (compact disk-digital versatile disk) drive.
[0028] Communication controller 56 is preferably provided and enables information handling system 10 to communicate with communication network 58 , e.g., an Ethernet network. Communication network 58 may include a local area network (LAN), wide area network (WAN), Internet, Intranet, wireless broadband or the like. Communication controller 56 may be employed to form a network interface for communicating with other information handling systems (not expressly shown) coupled to communication network 58 .
[0029] As illustrated, information handling system 10 preferably includes power supply 60 , which provides power to the many components and/or devices that form information handling system 10 . Power supply 60 may be a rechargeable battery, such as a nickel metal hydride (“NiMH”) or lithium ion battery, when information handling system 10 is embodied as a portable or notebook computer, an A/C (alternating current) power source, an uninterruptible power supply (UPS) or other power source.
[0030] Power supply 60 is preferably coupled to power management microcontroller 62 . Power management microcontroller 62 preferably controls the distribution of power from power supply 60 . More specifically, power management microcontroller 62 preferably includes power output 64 coupled to main power plane 66 which may supply power to CPU 12 as well as other information handling system components. Power management microcontroller 62 may also be coupled to a power plane (not expressly shown) operable to supply power to an integrated panel display (not expressly shown), as well as to additional power delivery planes preferably included in information handling system 10 .
[0031] Power management microcontroller 62 preferably monitors a charge level of an attached battery or UPS to determine when and when not to charge the battery or UPS. Power management microcontroller 62 is preferably also coupled to main power switch 68 , which the user may actuate to turn information handling system 10 on and off. While power management microcontroller 62 powers down one or more portions or components of information handling system 10 , e.g., CPU 12 , display 36 , or HDD 50 , etc., when not in use to conserve power, power management microcontroller 62 itself is preferably substantially always coupled to a source of power, preferably power supply 60 .
[0032] In a portable embodiment, information handling system 10 may also include screen lid switch or indicator 70 which provides an indication of when an integrated display is in an open position and an indication of when the integrated display is in a closed position. It is noted that an integrated panel display may be located in the same location in a lid (not expressly shown) of the computer as is typical for clamshell configurations of portable computers such as laptop or notebook computers. In this manner, the integrated display may form an integral part of the lid of the system, which swings from an open position to permit user interaction to a closed position.
[0033] Computer system 10 may also include power management chip set 72 . Power management chip set 72 is preferably coupled to CPU 12 via local bus 26 so that power management chip set 72 may receive power management and control commands from CPU 12 . Power management chip set 72 is preferably connected to a plurality of individual power planes operable to supply power to respective components of information handling system 10 , e.g., HDD 50 , FDD 54 , etc. In this manner, power management chip set 72 preferably acts under the direction of CPU 12 to control the power supplied to the various power planes and components of a system.
[0034] Real-time clock (RTC) 74 may also be coupled to I/O controller 48 and power management chip set 72 . Inclusion of RTC 74 permits timed events or alarms to be transmitted to power management chip set 72 . Real-time clock 74 may be programmed to generate an alarm signal at a predetermined time as well as to perform other operations.
[0035] Referring now to FIGS. 2 and 3 , a top view and a side view of an exemplary embodiment of a woven fiberglass mesh are shown, respectively. As indicated generally in FIG. 3 , fiberglass mesh 100 is preferably a woven fiberglass mesh and typical of an FR4-based prepreg sheet used in the manufacturing of printed circuit boards (PCB). In a preferred embodiment, the woven, fiberglass-based construction of a prepreg sheet results in an effective prepreg sheet dielectric constant based on the dielectric constants of both the selected woven fiberglass mesh and the resin or other adhesive material disposed on one or more sides thereof.
[0036] Referring now to FIG. 4 , a side view of an exemplary embodiment of a prepreg sheet incorporating woven fiberglass mesh 100 of FIGS. 2 and 3 is shown, according to teachings of the present disclosure. As illustrated, prepreg sheet 102 preferably includes woven fiberglass mesh 100 as well as adhesive layers 104 and 106 on respective sides of woven fiberglass mesh 100 . The material chosen for adhesive layers 104 and 106 may be varied, and may include, but is not limited to, one or more types of resin or resin compounds. According to teachings of the present disclosure, prepreg sheet 102 is one example of a dielectric or insulator operable to couple together a plurality of cores to form a multilayered printed circuit board.
[0037] As discussed above, prepreg sheet 102 may be constructed from woven fiberglass mesh 102 and adhesive layers 104 and 106 . Also as mentioned above, adhesive layers 104 and 106 may be formed from resin or another adhesive material according to teachings of the present disclosure. In one embodiment, adhesive layers 104 and 106 are preferably reprocessed such as by heating the prepreg sheet, such that one or more materials or compounds, such as a material component or compound having an increased or high permittivity, may be integrated, embedded, infused or otherwise incorporated therein. In an alternate embodiment, adhesive layers 104 and 106 preferably include an outer layer or surface subject to reprocessing and operable to receive and adhere one or more layers of one or more components or materials thereon. Alternate embodiments of a PCB hybrid power delivery plane disclosed in teachings of the present disclosure may employ dielectrics of other materials. Examples of dielectric materials include, but are not limited to, polyimide, Teflon, Kevlar, Kapton and Pyralux flexible laminates.
[0038] Referring now to FIG. 5 , a side view of an exemplary embodiment of a multilayered printed circuit board incorporating teachings of the present disclosure is shown. As illustrated in FIG. 5 , multilayered PCB 108 preferably includes cores 110 and 112 coupled to adhesive layers 104 and 106 of prepreg sheet 102 , respectively. As shown, core 110 preferably includes insulator or dielectric 114 disposed between copper layers 116 and 118 . Similarly, core 112 preferably includes insulator or dielectric 120 disposed between copper layers 122 and 124 . In some instances, the combination of prepreg sheet 102 with cores 110 and 112 may be referred to as a panel. Depending on the complexity of PCB to be designed, copper layers 116 and 122 of cores 110 and 112 , respectively, may be coupled to one or more additional cores using one or more additional prepreg sheets.
[0039] Multilayer printed circuit boards, such as multilayered PCB 108 , are often used to implement and support complex information handling system or computer designs. In such implementations, the various copper layers are typically etched, patterned or otherwise subdivided to serve varying purposes throughout the multilayered PCB. Typically, the copper layers of a multilayered printed circuit board are often divided into one or more powered delivery planes as well as into a plurality of signal routing traces. For example, as illustrated in FIG. 5 , copper layer 124 is divided into a region defined by power delivery plane section 126 and first and second signal routing traces 128 and 130 , respectively. In general, those portions dedicated to power delivery planes are typically employed to distribute power from a power source coupled to the multilayered printed circuit board, such as power source 60 of FIG. 1 , to the various components mounted or included thereon. Also in such implementations, the plurality of signal routing traces included in one or more copper layers of a multilayered printed circuit board may be employed to communicate signals generated or received by one or more components between the various components included or integrated thereon.
[0040] According to teachings of the present disclosure, power delivery planes and signal routing traces of a multilayered printed circuit board may be optimized such that the availability of signal routing traces may be maximized while the amount of a given copper layer necessary for proper or appropriate power delivery planes may be minimized. A hybrid power delivery plane incorporating teachings of the present disclosure will generally increase power delivery performance while retaining an area for signal routing traces. According to teachings of the present disclosure, power delivery plane performance can be enhanced by increasing the capacitance between adjacent power and ground regions of a multilayered printed circuit board power delivery plane. An exemplary embodiment of a PCB hybrid power delivery plane board is shown generally in FIG. 5 .
[0041] According to teachings of the present disclosure, a hybrid power delivery plane of multilayered PCB 108 is indicated generally at 132 and may be described as that area between and including copper layer 118 of core 110 and power delivery plane copper layer section 126 of core 112 . Prior to infusion, incorporation, mixing, embedding or otherwise implanting higher increased permittivity material 134 substantially within power plane region 132 , prepreg sheet 102 possesses a permittivity generally defined by the combination of its respective components, the permittivity of woven fiberglass mesh 100 and the permittivity of adhesive layers 104 and 106 here. As a result of infusing higher or increased permittivity material 134 substantially within power plane 132 , the overall permittivity of prepreg sheet 102 may be increased. As a result, with copper layer 118 serving as a ground plane and power delivery plane copper layer section 126 serving as the positive power plane, for example, the capacitance measure within power delivery plane 132 may be increased. As a result of this increased permittivity and corresponding increase in capacitance between the power and ground planes, the power delivery performance of power plane 132 is ultimately enhanced.
[0042] A variety of methodologies may be employed, according to teachings of the present disclosure, for increasing the permittivity and corresponding capacitance substantially within a power delivery plane of a multilayered PCB. In one embodiment, adhesive layers 104 and/or 106 may be reprocessed such that a selected amount of increased permittivity material 134 , such as glass particles, may be infused, embedded, incorporated, or combined therewith in selected regions. In another embodiment, increased permittivity material 134 may be adhered to a surface of one or more of adhesive layers 104 and 106 substantially within the desired power delivery plane regions prior to coupling prepreg sheet 102 with cores 110 and 112 . By selectively increasing the permittivity and capacitance in limited regions of a multilayered PCB, those regions designed for power delivery, such as power delivery plane 132 , may be reduced yet optimized while those areas designed for signal routing, such as the region embodying signal routing traces 128 and 130 , may be expanded and optimized.
[0043] In an embodiment of a multilayered PCB which couples cores 110 to 112 together with a dielectric or insulator other than prepreg sheet 102 , such a dielectric or insulator may also have desired regions thereof receive higher increased permittivity material 134 . Similar to the methodologies described above, such a dielectric or insulator may be reprocessed, heating for example, such that higher increased permittivity material 134 may be infused or incorporated therein. Such a dielectric or insulator material may also or alternatively be capable of having higher increased permittivity material 134 adhered to one or more exterior surfaces of the dielectric or insulator prior to combination of the dielectric or insulator with cores 110 and 112 .
[0044] As disclosed herein, a multilayered PCB having a plurality of power delivery planes optimized through varying the capacitance therebetween is contemplated. According to teachings of the present disclosure, the capacitance of a selected power delivery plane may be controlled by, at least, the selection of materials used to form the multilayer and PCB. As such, according to teachings of the present disclosure, a multilayered PCB having a plurality of power delivery planes and where one or more of the power delivery planes possesses a capacitance or permittivity value different from that of the other power delivery planes is contemplated. In one respect, teachings of the present disclosure provide for controlling and varying the capacitance in selected regions of a multilayered printed circuit board through, at least, controlling and varying the spacing between respective cores and copper layers, controlling and varying the materials used to join together cores and the materials selected for increasing the capacitance or permittivity in selected areas or regions of the multilayered PCB design, e.g., one or more power delivery planes.
[0045] Referring now to FIG. 6 , an exploded view of an exemplary embodiment of a multilayered printed circuit board incorporating teachings of the present disclosure is shown. As illustrated in FIG. 6 , multilayered PCB 150 preferably includes cores 152 , 154 , 156 and 158 . Core 152 preferably includes copper layers 160 and 162 coupled together using insulator or dielectric 164 . Core 154 preferably includes copper layers 166 and 168 coupled together using insulator or dielectric 170 . Core 156 preferably includes copper layers 172 and 174 coupled together using insulator or dielectric 176 . Similarly, core 158 preferably includes copper layers 178 and 180 coupled together using insulator or dielectric 182 .
[0046] Copper layer 162 of core 152 is preferably coupled to copper layer 166 of core 154 using prepreg sheet 184 . Copper layer 168 of core 154 is preferably coupled to copper layer 172 of core 156 using prepreg sheet 186 . Similarly, copper layer 174 of core 156 is preferably coupled to copper layer 178 of core 158 using prepreg sheet 188 . In one embodiment, preparing sheets 184 , 186 and 188 are similar in composition and makeup to prepreg sheet 102 of FIG. 4 . In addition, varying embodiments of multilayered PCB 150 may subject one or more of prepreg sheet 184 , 186 and 188 to reprocessing such that one or more selected regions thereof may be optimized for power delivery planes and/or signal routings as desired.
[0047] As illustrated, multilayered PCB 150 is preferably manufactured as a hybrid power delivery plane printed circuit board. Beginning with prepreg sheet 184 , regions 190 and 192 , between copper layer 162 of core 152 and copper layer 166 of core 154 , are preferably included to create power planes 194 and 196 , respectively. Similarly, regions 198 and 200 of prepreg sheet 186 having high or increased permittivity material included therein preferably cooperate with copper layer 168 of core 154 and copper layer 172 of core 156 to create optimized hybrid power delivery planes 202 and 204 , respectively. Likewise, regions of increased permittivity 206 , 208 and 210 of prepreg sheet 188 preferably cooperate with copper plate 174 of core 156 and copper plate 178 of core 158 to form optimized hybrid power delivery planes 212 , 214 and 216 , respectively.
[0048] It should be noted that detail regarding the numerous signal pathways or signal routing traces component connection points, etc., of multilayered PCB 150 have been omitted from portions of the various FIGURES referenced above to avoid confusion and to focus discussion on concepts of the present disclosure. For example, one or more of the various copper layers of FIG. 6 may typically include complex patterns of copper signal routing traces, power delivery planes, etc., prior to assembly of multilayered PCB 150 , such as signal routing traces 128 and 130 . Following assembly of a multilayered PCB incorporating teachings of the present disclosure, the multilayered PCB may have one or more vias disposed therein, be subject to more etching, copper deposition, tin sealing, lithographing, etc.
[0049] Although the disclosed embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope. | A system, method and apparatus for providing a printed circuit board having optimized power delivery planes and signal routing regions are disclosed. In one aspect, the present disclosure teaches a printed circuit board having two or more cores coupled together using a prepreg sheet having selected regions of increased permittivity. In combining the cores with the prepreg sheet, the regions of increased permittivity are preferably aligned with power delivery planes defined between respective cores. By increasing the permittivity within the power delivery planes, the greater the reduction in area of the cores needed for power delivery and the greater the area retained on the cores for providing signal routing. As a result, a printed circuit board incorporating teachings of the present disclosure may support more advanced and complex information handling system implementations. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of German application No. 10 2007 032 082.7 filed Jul. 9, 2007, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for correcting truncation artifacts in a reconstruction method for computed tomography recordings.
BACKGROUND OF THE INVENTION
[0003] Such a correction method for truncation artifacts can be deployed with an x-ray diagnostic facility for angiography as known from US 2006/0120507 A1, which is shown by way of example in FIG. 1 . The x-ray diagnostic facility has a C-arm 2 supported in a rotatable manner on a stand 1 , at the end of which C-arm 2 an x-ray radiation source, for example an x-ray emitter 3 , and an x-ray image detector 4 are positioned.
[0004] The x-ray image detector 4 can be a rectangular or square, flat semiconductor detector, which is preferably made of amorphous silicon (aSi).
[0005] In the beam path of the x-ray radiation source 3 is a patient support table 5 for recording for example the heart of a patient to be examined. Connected to the x-ray diagnostic facility is an image system 6 , which receives and processes the image signals from the x-ray image detector 4 . The x-ray images can then be viewed on a monitor 7 .
[0006] The movable components 2 to 5 can also be supported individually or in a common manner on robot arms.
[0007] To create 3D data sets the C-arm 2 , which is supported in a rotatable manner, is rotated with the x-ray emitter 3 and x-ray image detector 4 in such a manner that, as shown schematically in the top view of the axis of rotation in FIG. 2 , the x-ray radiation source 3 moves on one circumferential path 7 and the x-ray image detector 4 moves on one circumferential path 8 around an examination object 9 . The circumferential paths 7 and 8 can be traveled wholly or partially to create a 3D data set.
[0008] The examination object 9 can be for example an animal or human body or even a phantom body.
[0009] The x-ray radiation source 3 emits an x-ray beam bundle 6 , which leaves a beam focus of the x-ray radiation source 3 and strikes the x-ray image detector 4 .
[0010] The x-ray radiation source 2 and the x-ray image detector 4 move respectively around the examination object 9 in such a manner that the x-ray radiation source 2 and the x-ray image detector 4 are located facing each other on opposite sides of the examination object 9 .
[0011] A significant processing step for the 3D reconstruction by means of filtered backprojection (FBP) is the filtering of the projection data along predefined lines in the x-ray image detector. The non-local nature of the filter core, for example the ramp filter or Hilbert filter, means that the filter lines have to run through the entire projection of the examination region and cannot be cut off, even if only part of the body region, for example the so-called region of interest (ROI), is to be reconstructed. The limited detector width however results in cut off projections of the examination region in many recordings, in particular when using the above-mentioned C-arm system, as this cannot be covered completely by the field of view (FoV). This results in cut-off filter lines in these projections. This produces pronounced reconstruction artifacts, which falsify the result and hinder, complicate or render impossible its qualified diagnosis. One example of this is an examination of the abdomen or thorax. A distinction can be made between two types of truncation:
[0000] (1) transaxial truncation and
(2) axial truncation.
[0012] Transaxial truncation is produced by examination objects that are cut off along the horizontal detector axis.
[0013] Axial truncation is produced by examination objects that are cut off along the vertical detector axis. Therefore in the case of the Feldkamp algorithm described in [1], with which filtering operates along horizontal lines in the x-ray image detector, only transaxial truncation of the filter lines is possible. However the development of new approximative and exact reconstruction algorithms and the use of novel scanning paths, such as circle and line, circle and arc, saddle, means that non-horizontal filter lines have also been introduced, as described for example in Pack et al. [2] and [6], Katsevich [3] and [4] as well as Nett et al. [5]. This means that both transaxial truncation and axial truncation can occur (see also FIG. 3 ). Such algorithms therefore require a new method, which is able to correct both types of truncation effectively. Since the algorithms promise a very high image quality, the solution to the truncation problem would be an important and central contribution to the resolution of reconstruction problems in computed tomography.
[0014] FIG. 3 shows possible truncations for non-horizontal filter lines by way of example. The contours of the examination object are mapped on the x-ray image detector 4 . One filter line F 1 is cut off transaxially on both sides. One filter line F 2 is cut off axially on both sides. One filter line F 3 is cut off axially on the left and transaxially on the right. One filter line F 4 has no truncation. Truncation always occurs when a filter line exits from the x-ray image detector 4 before it exits from the examination object 9 . Significant reconstruction artifacts result for every point on a truncated filter line. This can be the case for the majority of points in the case of non-horizontal filter lines.
[0015] In the case of C-arm systems, until now 3D reconstruction was carried out using the Feldkamp algorithm, which manages with a planar, circular scanning path. It uses only horizontal filter lines, so that only transaxial filter line truncation can occur. A hybrid solution has proven very effective for correcting transaxial truncation. Hybrid correction is made up of the so-called water cylinder correction and a Gaussian extrapolation, as described by way of example in Hsieh et al. [7], Zellerhoffet al. [8] or Scholz [9]. The method is implemented row by row. It is first checked in each instance using a threshold value whether truncation is present. If so, either water cylinder correction or Gaussian extrapolation is used, depending on the gradient of the (truncated) projection profile at the edge of the detector row in question (see FIG. 4 ). If the gradient at the left detector edge is positive or the gradient at the right detector edge is negative, water cylinder correction is deployed (see FIG. 5 ). With water cylinder correction it is assumed that the examination object can be approximated very closely by a water cylinder. To this end the center point and radius of the water cylinder are first determined. The missing projection values are then generated artificially by computer-simulated x-ray beams, which pass through the water cylinder. The detector row is continued with the projection values thus generated. If the gradient at the left detector edge 35 is negative or the gradient at the right detector edge 36 is positive, Gaussian extrapolation is deployed (see FIG. 6 ). With Gaussian extrapolation the missing projection values are approximated by a Gaussian curve. This produces the absent projection values, as with water cylinder correction.
[0016] A Feldkamp based reconstruction algorithm is also used with CT systems. However filtering takes place along non-horizontal lines in the x-ray image detector 4 , with the gradients of the filter lines having very low values. With CT systems transaxial truncation cannot take place due to the size of the detector. Therefore only axial truncation has to be dealt with. To this end the x-ray image detector 4 is constantly continued in the axial direction, by repeatedly copying and adding the first and/or last detector row (see FIG. 7 ) as for example with Flohr et al. [10] or Kachelrieβ et al. [11].
[0017] FIG. 4 shows a projection profile p(u) along a cut off detector row. Either water cylinder correction (a) or Gaussian extrapolation (b) is used depending on the gradient of the measured projection values 11 at the edge of the row.
[0018] FIG. 5 shows an example of a water cylinder correction for the right detector edge 36 . The missing projection values are generated by computer-simulated x-ray beams by means of a water cylinder 12 and used as artificially generated projection values 13 to continue the profile.
[0019] FIG. 6 shows an example of Gaussian extrapolation for the right detector edge 36 . The missing projection values are approximated by a Gaussian curve 14 and used as artificially generated projection values 15 to continue the profile.
[0020] With CT systems truncation correction is carried out by constant axial continuation 16 of the x-ray image detector 4 in the axial direction, as shown in FIG. 7 . The sizes of the extension regions are selected here in such a manner that no further filter lines are cut off.
[0021] [12] and DE 103 45 704 A1 and U.S. Pat. No. 5,640,436 do not describe any truncation corrections in the axial direction. Roughly speaking the patient can be seen as a cylinder of almost infinite length. With truncation in the transaxial direction a part close to the edge of the object is missing. Corrections try to estimate the edge of the object and to extrapolate the data. This truncation correction is well known in the literature.
[0022] With truncation in the axial direction the majority of the object is essentially missing. Close object edges are not present, being estimated and extrapolated. Such extrapolation methods for correcting axial truncation are not known.
[0023] DE 103 45 704 A1 and U.S. Pat. No. 5,640,436 deal only with transaxial truncation.
[0024] [12] describes the “long object problem”, in other words axial truncation, where iterative methods are examined. Axial truncation is therefore not corrected by data extrapolation but by appropriate selection of data in the reprojection and correction of the intermediate result. Section 2.D deals with an extrapolation method, which supplements missing data (see FIG. 5 , mask 1 ). The missing data at the start and end of the scanning path is the result of data sorting from fan-beam to parallel-beam geometry regardless of the shape of the object and the size of the detector. The resulting truncation problem is however equivalent to transaxial truncation and is corrected accordingly.
SUMMARY OF THE INVENTION
[0025] The invention is based on the object of configuring a correction method for truncation artifacts of the type mentioned in the introduction, such that truncation correction can also be carried out even with filter lines of any orientation.
[0026] The method corrects truncation artifacts in a reconstruction method for computed tomography recordings with truncated projection data in the reconstructed computed tomography images, wherein a radiation source emits divergent radiation, an object to be examined is transilluminated in different projection directions with said divergent radiation, the radiation penetrating the object to be examined is detected by an x-ray image detector and a filtered backprojection is carried out filtering the projection data along predefined non-horizontal lines in the x-ray image detector, with projection images recorded by the x-ray image detector being extended by determining the attenuation of the radiation outside the projection image for pixels.
[0027] According to the invention the object is achieved in that for the purposes of truncation correction non-horizontal filter lines are extended by a transaxial and axial artificial extension of the x-ray image detector, with the truncation correction for non-horizontal filter lines being carried out according to a method from at least one of the following groups:
[0000] I) Truncation correction takes place regardless of the specific location and orientation of the filter lines.
II) Truncation correction takes place as a function of the specific position and orientation of the filter lines, with the filter lines themselves being retained.
III) Truncation correction takes place by introducing new modified filter lines, with filtering taking place along offset artificially extended filter lines.
[0028] According to the invention the truncation correction methods for non-horizontal filter lines are divided into three groups. The methods in group I carry out the correction regardless of the specific position and orientation of the filter lines. They can therefore be applied regardless of the reconstruction algorithm used. The methods in group II carry out the correction as a function of the specific position and orientation of the filter lines. The filter lines themselves are retained. With the method in group III new filter lines are introduced during the course of truncation correction.
[0029] The x-ray image detector according to group I) can advantageously be artificially extended transaxially and axially, with the extensions being based on hybrid correction or the transaxial extension being based on hybrid correction and it being possible for the axial extension to take place by means of constant continuation of the x-ray image detector in the axial direction by repeatedly copying and adding the first and last detector rows.
[0030] It has proven advantageous, if the filter lines according to group II) are extended artificially, by carrying out a hybrid correction not along the detector rows but along the filter lines.
[0031] Alternatively the filter lines according to group II) can be artificially extended by constant continuation of the x-ray image detector in the axial direction followed by hybrid correction along the filter lines or a modified water cylinder correction along the filter lines.
[0032] Advantages?
[0033] The new methods allow an artifact-free ROI reconstruction within larger body regions such as the abdomen or thorax, which was not possible until now due to the restricted detector surface (in particular with C-arm systems). Moreover the methods can expediently be combined with all FPB algorithms, with which cut off projections cause artifacts. The methods hereby principally aim toward novel approximative and exact FBP algorithms, having non-horizontal filter lines. Methods 1 and 2 are independent of the reconstruction algorithm and can be seen as a preprocessing step before reconstruction. They are therefore generally valid. Methods 3 to 6 are a function of the specific reconstruction algorithm but can however be integrated effectively herein. Moreover the new methods allow an enlargement of the FoV and therefore the reconstruction of larger body regions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The invention is described in more detail below with reference to exemplary embodiments illustrated in the drawings, in which:
[0035] FIG. 1 shows an x-ray diagnostic facility for implementing the method,
[0036] FIG. 2 shows a view of the path of an x-ray image detector and a radiation source around an object to be examined in an axial viewing direction,
[0037] FIG. 3 shows an overview to explain transaxial and axial truncation and possible types of filter line,
[0038] FIG. 4 shows a projection profile p(u) along a cut off detector row,
[0039] FIG. 5 shows a projection profile p(u) with a water cylinder correction for the right detector edge,
[0040] FIG. 6 shows a projection profile p(u) with a Gaussian extrapolation at the right detector edge,
[0041] FIG. 7 shows a truncation correction by constant continuation of the x-ray image detector in the axial direction,
[0042] FIG. 8 shows an original projection with axial and transaxial truncation as a basis for explaining method 1,
[0043] FIG. 9 shows transaxial extension of the x-ray image detector according to FIG. 8 by means of hybrid correction,
[0044] FIG. 10 shows axial extension of the x-ray image detector according to FIG. 9 by means of hybrid correction,
[0045] FIG. 11 shows an original projection with axial and transaxial truncation as a basis for explaining method 2,
[0046] FIG. 12 shows transaxial extension of the x-ray image detectors according to FIG. 11 by means of hybrid correction,
[0047] FIG. 13 shows axial extension by means of constant continuation of the x-ray image detector according to FIG. 12 in the axial direction,
[0048] FIG. 14 shows an original projection and a filter line according to method 3 with associated projection profile,
[0049] FIG. 15 shows an original projection and filter line according to method 4 with associated projection profile,
[0050] FIG. 16 shows an original projection and filter line according to method 5 with associated projection profile und
[0051] FIG. 17 shows an original projection and the original and modified filter line according to method 5 with associated projection profile.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Method 1 (Group I)
[0052] FIG. 8 shows the original projection with axial and transaxial truncation. In FIG. 9 the x-ray image detector 4 has first been extended transaxially with the aid of hybrid correction, so that extension regions with attenuated transaxial continuation 17 result on both sides. In FIG. 10 the x-ray image detector 4 has then been extended axially with the aid of hybrid correction, so that extension regions with attenuated transaxial continuation 18 result on both sides. The size of the extension regions can be configured freely in each instance and can be selected so that it is different for each detector side (left, right, top, bottom). Further flexibility of the method means that steps b) and c) can be interchanged.
Example 2
Method 2 (Group I) FIGS. 11 - 13
[0053] FIG. 11 shows the original projection with axial and transaxial truncation. In FIG. 12 the x-ray image detector 4 has first been extended with the aid of hybrid correction so that extension regions with attenuated transaxial continuation 17 result on both sides. In FIG. 13 the x-ray image detector 4 has then been extended axially by repeatedly copying and adding the first and last detector rows, so that extension regions with constant axial continuation 19 result on both sides. The size of the extension region can be configured freely in each instance and can be selected so that it is different for each detector side (left, right, top, bottom). The axial extension regions 19 should hereby be set so that no further filter lines are cut off. Further flexibility of the method means that steps b) and c) can be interchanged.
Example 3
Method 3 (Group II) FIG. 14
[0054] FIG. 14 shows the original projection and a filter line F 3 , which is cut off axially on the left and transaxially on the right. Curve 20 shows the corresponding projection profile p(u) for this filter line F 3 . In the supplemented curve 21 the profile has been continued on both sides by artificially generated projection values 22 by means of hybrid correction. The size of the extension region can be configured freely in each instance and can be selected so that it is different for each side of a filter line F 3 .
Example 4
Method 4 (Group II) FIG. 15
[0055] FIG. 15 shows the original projection, which has already been supplemented by extension regions with constant axial continuation 23 in the axial direction. In the curve 24 the projection profile p(u) of the filter line F 3 therefore only shows transaxial truncation. In the supplemented curve 25 the profile has been continued by artificially generated projection values 26 with the aid of hybrid correction. Continuation 27 of the supplemented curve 25 results in the region of constant axial continuation 23 . The sizes of the extension regions for the x-ray image detector 4 and filter lines F 3 can be freely configured in each instance and can be selected so that they are different for each detector side (top, bottom) and for each side of a filter line F 3 .
Example 5
Method 5 (Group II). FIG. 16
[0056] FIG. 16 shows the original projection together with the projection of a water cylinder 28 . In the curve 29 the projection profile p(u) of the filter line F 5 only has transaxial truncation in this example. In the supplemented curve 30 the profile of the filter line F 5 has been continued by means of artificially generated projection values 31 , in that the filter line F 5 has been evaluated in this region along the projection of the water cylinder 28 . The corresponding projection values are artificially generated by computer-simulated x-ray beams. The center axis (or rotation axis) of the cylinder is oriented parallel to the z-axis of the reference coordinate system. The height of the cylinder is assumed to be infinite, so that only the point of intersection (x,y,0) of the center axis of the cylinder with the xy-plane and the radius R of the cylinder have to be determined. The three parameters (x,y,R) can be determined in that for example the measured projection values p(u) along the filter line F 5 and their first and second derivation in relation to u, p′(u) and/or p″ (u) at a point u=u 0 are determined. This gives the following equations for calculating (x,y,R):
[0000] d ( u 0 ,x,yR )*μ w =p ( u 0 ) (1)
[0000] d ′( u 0 ,x,y,R )*μ w =p ′( u 0 ) (2)
[0000] d ″( u 0 ,x,y,R )*μ w =p″ ( u 0 ). (3)
[0057] Here d refers to the sectional length of the x-ray beam with the water cylinder, d′ and d″ its first and second derivation in relation to u and μ w the attenuation coefficient of water. The procedure should be applied anew for each side of a filter line F 5 . The modified water cylinder correction differs from the original water cylinder correction in the use of cone-beam geometry. In the original method parallel beam geometry is used to generate the projection values, even though the original projections are acquired using cone-beam geometry.
Example 6
Method 6 (Group III) FIG. 17
[0058] FIG. 17 shows the original projection together with the original filter line F 3 and the modified filter line F 6 shown with a broken line. The curve 32 of the projection profile p(u) of the modified filter line F 6 only has transaxial truncation. In the curve 33 the profile has been continued with artificially generated projection values 34 with the aid of hybrid correction. The sizes of the extension regions for the filter lines can be freely configured in each instance and can be selected so that they are different for each side of a filter line. As a further variant it would be possible also to modify the filter line F 6 in the transaxial direction before the hybrid correction, for example by continuing this likewise horizontally as soon as it leaves the x-ray image detector 4 .
[0059] The following method variants result from the inventive embodiment:
[0060] Group I, Method 1:
[0061] The x-ray image detector 4 is artificially extended transaxially and axially. The extension is based on hybrid correction in each instance (see example 1).
[0062] Group I, Method 2:
[0063] The x-ray image detector 4 is artificially extended transaxially and axially. The transaxial extension is based on hybrid correction. The axial extension happens by means of constant continuation of the x-ray image detector 4 in the axial direction (see also FIG. 5 ), by repeatedly copying and adding the first and last detector rows (see example 2).
[0064] Group II, Method 3:
[0065] The filter lines are artificially extended in that the hybrid correction is carried out not along the detector rows as in the original method (see also image 2 ) but along the filter lines (see example 3).
[0066] Group II, Method 4:
[0067] The filter lines are artificially extended, by constant continuation of the x-ray image detector 4 in the axial direction (see also FIG. 5 ) followed by hybrid correction along the filter lines (see example 4).
[0068] Group II, Method 5:
[0069] The filter lines are artificially extended, by carrying out a modified water cylinder correction along the filter lines (see example 5).
[0070] Group III, Method 6:
[0071] The filter lines are modified in such a manner that filtering takes place along offset filter lines. These are then artificially extended, by carrying out the hybrid correction along the offset filter lines (see example 6).
[0072] The filter part of the filtered backprojection consists of a one-dimensional linear filtering of the detector data. The data can be filtered by means of a convolution operation in real space. Alternatively a convolution operation in real space can be replaced by a multiplication in reciprocal space. With single-row detectors it is clear that the whole detector row is dealt with in one filter step. In the case of multi-row detectors (surface detectors) data has to be found for the one-dimensional filter step. The data to be filtered is collected along one filter line. The data along one filter line can either be convoluted in real space or multiplied in reciprocal space. It should be noted that only the part of real space along a filter line is transformed to reciprocal space with a one-dimensional Fourier transformation. These relationships are basic knowledge in specialist circles, so they have not been explained in the application.
[0073] The selection of the filter lines is a function of the reconstruction problem and the reconstruction algorithm used. The frequently applied Feldkamp algorithm described in [1] filters the detector data one-dimensionally row by row, i.e. the filter lines are oriented along the detector rows. In the case of the algorithms for an exact reconstruction of cone-beam data filter lines are generally not arranged along the detector rows, as described for example in [2] to [6].
LITERATURE
[0000]
[1] L. A. Feldkamp, L. C. Davis, J. W. Kress. “Practical Cone-Beam Algorithm”. J. Opt. Soc. Am. A, 1(6): pages 612-619, 1984.
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[3] A. Katsevich. “Image reconstruction for the circle-and-line trajectory”. Physics in Medicine and Biology, 49(22): pages 5059-5072, 2004.
[4] A. Katsevich. “Image reconstruction for the circle-and-arc trajectory”. Physics in Medicine and Biology, 50(10): pages 2249-2265, 2005.
[5] B. E. Nett, T. Zhuang, and G.-H. Chen. “A cone-beam fbp reconstruction algorithm for short-scan and super-short-scan source trajectories”. In Fully 3D Image Reconstruction in Radiology and Nuclear Medicine, Salt Lake City, Utah, USA, Jul. 6-Jul. 9, 2005.
[6] J. Pack and F. Noo. Cone-beam reconstruction using 1D filtering along the projection of m-lines. Inverse Problems, 21(3): pages 1105-1120, 2005.
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[8] M. Zellerhoff, B. Scholz, E.-P. Rührnschopf and T. Brunner. Low contrast 3D-reconstruction from C-arm data. SPIE Medical Imaging 2005, 5745: pages 1605-7422, 2005
[9] Bernhard Scholz, Fächerstrahlbasierte Wasserzylinderextrapolation von abgeschnittenen Projektionen zur Behandlung von Trunkierungsartefacten (Fan-beam based water cylinder extrapolation from cut-off projections for dealing with truncation artifacts), former patent application DE 10 2006 014 629.8 dated 29.03.2006.
[10] T. Flohr, K. Stierstorfer, H. Bruder, J. Simon, A. Polacin, and S. Schaller. Image reconstruction and image quality evaluation for a 16-slice CT scanner. Medical Physics, 30(5): pages 832-845, 2003
[11] M. Kachelrieβ, M. Knaup, and W. A. Kalender. Extended parallel backprojection for standard three-dimensional and phase-correlated four-dimensional axial and spiral cone-beam CT with arbitrary pitch, arbitrary cone-angle, and 100% dose usage. Medical Physics, 31(6): pages 1623-1641, 2004
[12] Magnusson et al., “Handling of Long Objects in Iterative Improvement of Nonexact Reconstruction in Helical Cone-Beam CT”, IEEE Trans. Med. Imaging Vol. 25, NO. 7, July 2006, pages 935-940 | The invention relates to a method for correcting truncation artifacts in a reconstruction method for computed tomography recordings. The projection images are recorded by an x-ray image detector being extended by determining the attenuation of the radiation outside the projection image for pixels. Non-horizontal filter lines are extended by transaxial and axial artificial extension of the x-ray image detector for the purposes of truncation correction. The truncation correction for non-horizontal filter lines being carried out according to a method from at least one of the following groups: truncation correction takes place regardless of the specific location and orientation of the filter lines; truncation correction takes place as a function of the specific position and orientation of the filter lines, with the filter lines themselves being retained; and truncation correction takes place by introducing new modified filter lines, with filtering taking place along offset artificially extended filter lines. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to jewelry and more particularly to a magnetic jewelry clasp with a safety catch. While the jewelry clasp is magnetic, the catch may or may not be magnetic. The clasp may include a retaining wall or other device to help retain the safety catch in a closed position.
[0003] 2. Discussion of Related Art
[0004] A conventional jewelry clasp is connected to links of a necklace, bracelet, ankle bracelet or belly chain. By opening or closing the mechanical clasp, the jewelry can be either removed from or secured on the wearer. A second clasp or “safety catch” is sometimes provided. This is especially true for more expensive jewelry. A conventional safety catch is also a mechanical connection.
[0005] A magnetic jewelry clasp includes two bodies that are held together by magnetic attraction and released from each other by pulling them apart to break the magnetic attraction. Thus, the bodies are movable between a connected condition (when together) and a separated condition (when pulled apart).
[0006] The inventor is unaware of a magnetic jewelry clasp which also employs a safety catch. This is probably due to the fact that conventional magnetic clasps do not limit the position for connecting the two sides of the clasp. Thus, while employing a safety catch with conventional magnetic jewelry clasps would add the benefit of added security, it would also eliminate an advantage offered by such clasps by requiring a user to properly align the sides of the clasp for the clasp to be closed. The inventor is also unaware of any magnetic safety catches.
[0007] The making and breaking of a magnetic attraction force between the two portions of the clasp renders the magnetic jewelry clasp easy to use. However, it would be beneficial to make the clasp more secure by adding a safety clasp (magnetic or mechanical). Additionally, it would be desirable to make the safety catch easier to use and yet still resist forces that might otherwise break the magnetic attraction force between the two sides of the clasp.
SUMMARY OF THE INVENTION
[0008] To improve upon the conventional jewelry clasp, the invention provides a magnetic jewelry clasp with a safety catch. The clasp includes two bodies movable between a separated condition and a connected condition. Each of the two bodies has at least one magnetically attractive surface that is attracted to the other in the connected condition. At least one of the magnetically attractive surfaces is formed by a magnet. The other may be a magnet or a magnetically attracted material. The two bodies are arranged to move into the separated condition in response to manual forces that pull the two bodies apart to break the magnetic attraction between the surfaces. The invention also includes a safety catch, connected to one of the two bodies, that includes an arm movable between a catch position and a release position. The safety catch may be magnetic or conventional.
[0009] The arm is hinged to one of the bodies and has a free end that may be moved between a catch position and a release position. In the catch position, the arm may be in magnetic attraction with one of the two bodies in accordance with one embodiment or with the magnetic connection between the two bodies in accordance with another embodiment. The arm may be in magnetic attraction with one of the magnets in one of the bodies in an embodiment and/or the arm may be conventionally connected to one of the bodies.
[0010] While the arm is in the release position, there may be blocking surfaces that no longer abut even though the two bodies are still magnetically connected to each other. While the arm is in the catch position, the blocking surfaces abut to resist forces that otherwise would tend to pull the bodies apart and break the magnetic attraction between the bodies. These blocking surfaces may also be magnetically attracted to each other.
[0011] The arm may enter the release position from the catch position by using the user's fingernail to flick a free end of the arm in a direction that breaks the magnetic attraction between the arm and the one of the two bodies. Once the safety catch is released, the two bodies may be pulled apart by breaking the magnetic connection between the surfaces that face each other. To close the jewelry clasp, the two bodies are brought together so as to establish the magnetic connection and then the safety catch is secured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 shows a side elevation view of a jewelry clasp in accordance with the present invention with a safety catch secured with its arm in a closed position;
[0013] [0013]FIG. 2 shows a bottom plan view of FIG. 1;
[0014] [0014]FIG. 2 a shows a side elevation view of an additional embodiment;
[0015] [0015]FIG. 2 b shows a top plan view of the arm in accordance with the additional embodiment of FIG. 2 a;
[0016] [0016]FIG. 2 c shows a bottom plan view of another embodiment with a safety catch in an open condition;
[0017] [0017]FIG. 2 d shows the embodiment of FIG. 2 c , but with the arm of the safety catch secured in a closed condition;
[0018] [0018]FIG. 2 e shows a top plan view of an alternate embodiment of the arm of FIG. 2 c in accordance with a further embodiment in which the side elevation view of this further embodiment with the arm of the safety catch secured in a closed condition would be identical to FIG. 2 d;
[0019] [0019]FIG. 3 shows a side elevation view as in FIG. 1, but with the safety catch released with its arm in an open position;
[0020] [0020]FIG. 4 shows a top plan view of the safety arm of FIG. 1;
[0021] [0021]FIG. 5 shows a bottom plan view of one of the two bodies of FIG. 1 with a magnet on the bottom surface;
[0022] [0022]FIG. 6 shows a side elevation view of the two bodies separated from each other, but without showing the safety catch;
[0023] [0023]FIG. 7 shows a front plan view of either of the bodies of FIG. 6, as viewed when looking at the magnet;
[0024] [0024]FIG. 8 shows a rear plan view of either of the bodies of FIG. 6, as viewed when looking at the half ring to attach to necklace or other jewelry chain links;
[0025] [0025]FIG. 9 shows a side elevation view of an alternate embodiment of a jewelry clasp in accordance with the present invention with a safety catch secured with its arm in a closed position;
[0026] [0026]FIG. 10 shows a bottom plan view of FIG. 9;
[0027] [0027]FIG. 11 shows a top plan view of the safety arm of FIG. 9;
[0028] [0028]FIG. 12 shows a bottom plan view of one of the two bodies of FIG. 9 with a magnet on the bottom surface;
[0029] [0029]FIG. 13 shows a side elevation view of another alternate embodiment of a jewelry clasp in accordance with the present invention with a safety catch released with its arm in an opened position;
[0030] [0030]FIG. 14 shows a bottom plan view of FIG. 13;
[0031] [0031]FIG. 15 shows a top plan view of the safety arm of FIG. 13;
[0032] [0032]FIG. 16 shows a bottom plan view of one of the two bodies of FIG. 13 with the magnet open to the bottom surface; and
[0033] [0033]FIG. 17 shows a front plan view of either of the bodies of FIG. 13, as viewed when looking at the magnet.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Turning to the drawings, FIGS. 1, 2, 2 a , 2 c , 2 d , 3 , 6 , 9 , 10 , 13 and 14 show two bodies 10 , 12 of a jewelry clasp. The main bodies have connection surfaces 14 , 16 , that face each other and have opposite surfaces 18 , 20 that face away from each other. As seen in FIGS. 1, 2, 2 a , 2 c , 2 d , 3 , 6 , 9 , and 13 each of the connection surfaces 14 , 16 is shown with a magnet 22 , 24 so that the connection surfaces 14 , 16 of the bodies 10 , 12 are magnetically attracted to each other when brought together face to face. Those skilled in the art will recognize that only 1 of the magnets is necessary and that the other magnet may be eliminated if the other face is made of a magnetically attracted material. They will also recognize that if both connection surfaces 14 , 16 include magnets that the magnets could be configured with north and south poles such that when the two surfaces are brought together they align to the same orientation every time. As seen in FIGS. 1, 2 a , 3 , 6 , 8 , and 9 each of the opposite surfaces 18 , 20 has a half ring 26 , 28 that is used to connect with a necklace or a bracelet or other jewelry chain links (not shown) in a conventional manner.
[0035] [0035]FIGS. 1, 2 a , 2 b , 3 , 4 and 9 show a safety catch 30 , which includes an arm 32 , a hinge 34 , a retaining wall 36 , a ball 38 , a magnet holder 40 and a magnet 42 . The hinge 34 is secured to body 10 . The arm 32 is connected to the hinge 34 at one end, and also has a free end at which is located the ball 38 . The arm 32 is rotatable about the hinge 34 between a release position clear of the body 12 , as shown in FIG. 3, and a catch position adjacent bottom surfaces 44 , 46 of bodies 10 , 12 , as shown in FIGS. 1 and 2. The arm may be considered to be a thin and narrow paddle with flat opposite sides. Rotation of the arm 32 may be to the extent necessary (i.e., up to and including 360 degrees) to the particular design. FIG. 13 illustrates an alternate design for the safety catch 30 . This design includes the retaining wall 36 (*also referred to as a blocking surface) but not the magnet 42 or magnet holder 40 . However, those skilled in the art will recognize that retaining wall 36 could be replaced by magnet 42 and magnet holder 40 without departing from the scope of the invention.
[0036] The bottom surface 46 of the body 12 has a magnet 48 . When the arm 32 is in the catch position, the magnet 42 and the magnet 48 have faces that contact each other and are magnetically attracted. The magnet 42 is held in a holder 40 , which is secured to a flat side of the arm 32 at a location so that when the arm 32 is rotated about the hinge 34 to be neighboring the bottom surfaces 44 , 46 , faces of the magnets 42 , 48 contact each other. Those skilled in the art will recognize that the holder may not be required and that one of the magnets could be replaced by a metal such as steel, iron or the like.
[0037] The retaining wall 36 extends from the arm 32 , preferably in a direction perpendicular thereto, to lie against a rear surface 20 of the body 12 when the arm 32 is in the catch position, as shown in FIG. 3. When the arm 32 is in such a catch position, the retaining wall 36 is in the most likely path that the body 12 would travel to separate from the body 10 . Also, magnetic attractive surfaces 42 , 48 of the arm 32 and the body 12 are in contact with each other to effect a magnetic connection therebetween. The retaining wall 36 blocks the two bodies 10 , 12 from inadvertently moving apart from each other. The blocking force exerted resists such movement because the opposite end of the arm 32 is secured by the hinge connection 34 to the body 10 . Such a blocking force is in addition to the magnetic attraction afforded by the magnets 42 , 48 , 22 and 46 that also resist movement of the bodies 10 , 12 away from each other.
[0038] In addition, when the arm 32 is in the closed or catch position, the ball 38 is beyond a periphery of the body 12 . To open the safety catch 30 from the position shown in FIGS. 1 and 2 , one need only place one's fingernail against the ball 38 and move the ball 38 in a direction away from the body 12 that will separate the magnets 42 , 48 from each other. Thus, the two bodies 10 , 12 are grasped in one hand while the ball is moved with the other hand. In other words, the safety catch 30 may be released by moving the arm 32 from a catch position to the release position. In the release position, the retaining wall 36 is clear of the path and the magnetic connection is broken between the magnetically attractive surfaces 42 , 48 of the arm 32 and the body 12 . Once the safety catch is open, pulling apart the two bodies 10 , 12 to break the magnetic attraction between them will result in a separated condition of the bodies, as shown in FIG. 6.
[0039] While the two bodies 10 , 12 are shown to have cubic shapes in the drawings, they may be configured instead to have any other geometric shape. For instance, instead of having a circular cross-section, it may be rectangular, square, trapezoidal, pentagonal, hexagonal, octagonal or any other polygonal shape. The shape of the magnet 48 may be changed accordingly to suit. Further, while the arm 32 is magnetically attracted to the clasp it need not be.
[0040] The magnets 22 , 24 and the magnets 42 , 48 each may be cylindrical with a circular cross-section, as shown in FIG. 7, or may have any other geometric shape needed to best accomplish closure of the jewelry clasp. The clasp may be made out of any material or combination of materials so long as the connection surfaces 14 , 16 of the two bodies 10 , 12 are magnetically attracted to each other. The arm 32 may also be magnetically attracted to the bottom surface 46 of at least one of the bodies 10 / 12 . For example, if the jewelry clasp is made of an expensive metal, i.e., gold, silver, platinum or titanium, then both pairs of magnets 22 , 24 and 42 , 48 may be employed for additional protection. If, however, the clasp is made of fashion metals, each of the pairs of magnets 22 , 24 and 42 , 48 on their respective connection surfaces may be replaced by one magnet, on one of the connection surfaces, provided the other of the connection surfaces to which the magnet contacts in the closed position is made of a magnetically attractive metal itself, such as iron, steel, etc.
[0041] The magnet 42 may be secured to its magnet holder 40 with an adhesive. Likewise, the magnet 48 may be secured to the body 12 with an adhesive. It may also be secured within a recess 50 formed in the body 12 . To help keep the magnets from dislodging over time due to the adhesive losing its adhesive strength, the outer periphery of the recess 50 and the magnet holder 40 may be bent inwardly or a metal rim added to extend inwardly from the outer peripheries. Preferably, at least one half of the outer peripheries will have this inward bend or metal rim, under which is placed the respective magnet edge. Such a configuration prevents dislodgment of the magnet 42 from the magnet holder 40 or the magnet 48 from the recess 50 . Likewise, the peripheries of recesses that contain the magnets 22 , 24 may be bent in the same manner or a metal rim added to protrude inwardly. Preferably, at least one half of the periphery has the metal rim or bent portions.
[0042] Instead of rotating the arm 32 about a hinge 34 connection, provision may be made to replace the hinge 34 connection by a guide groove to permit the arm 32 to slide between the catch and release positions (not shown). In such a construction, outwardly directed projections may be provided on the arm 32 spaced from either end of the guide groove to prevent the arm 32 from sliding entirely out of the guide groove. Further, the guide grooves may each have a lip that extends toward each other to either cover the arm 32 or define a gap therebetween that is smaller in dimension that the width of the arm 32 .
[0043] As an alternative, the hinge 34 connection may remain, but the hinge 34 may be modified to allow the arm 32 to rotate in a plane parallel to the adjacent surface of the body 10 as opposed to rotating in a plane transverse thereto (FIG. 2 c ).
[0044] While the retaining wall 36 provides advantages in preventing the two bodies 10 , 12 from inadvertently separating from each other, the magnetic attraction between the magnets 42 , 48 alone may suffice, so that the retaining wall 36 may be dispensed with. Alternatively, the retaining wall 36 may be used in tandem with complementary male and female connectors 52 , 54 provided on the arm 32 and the body 12 to engage each other when the magnets 42 , 48 contact each other. The male connector 52 preferably is an oblong peg attached to the bottom surface 44 of the body 12 . The female connector 54 preferably is a complementary shaped orifice passing through the arm 32 at a location in alignment with the male connector 52 when the safety catch is in the closed position.
[0045] The male connector 52 and the female connector 54 are sized relative to each other so that the male connector 52 fits without tension within the female connector 54 in the catch position. This contrasts with conventional catch devices where pressure must be exerted to force a male connector into a female connector. This also contrasts with conventional catch devices that lock the male connector and the female connector together. Although such conventional catch devices may be employed if no magnetic attraction is used to maintain the catch in the catch position.
[0046] As an alternative, the female connector may be formed as a recess instead of an orifice. If desired, the male connector may be configured into a different shape other than as an oblong peg, provided the recess or orifice is configured to accommodate its insertion. Also, the female connector may be on the body 10 and the male connector may be on the arm 32 .
[0047] FIGS. 9 - 12 show a further embodiment that is identical to the embodiment of FIGS. 1 - 8 except that the male connector 52 and the female connector 54 of FIGS. 1 - 6 are omitted.
[0048] As a further alternative to the embodiment of FIGS. 1 - 8 , the retaining wall 36 may be dispensed with, but the complementary male and female connectors 52 , 54 of FIGS. 1 - 8 remain together with the magnet pairs 22 , 24 and 42 , 48 . As still a further alternative, only the magnet pairs 22 , 24 and 42 , 48 remain to enable opening and closing of the clasp, which means that both the retaining wall 36 of FIGS. 1 - 12 and the complementary male and female connectors 52 , 54 are omitted.
[0049] The embodiment of FIGS. 2 a and 2 b differs from that of the embodiment of FIG. 1 by dispensing with the magnet 48 and arranging the magnet 55 and its holder 55 a in a different position on the arm 32 than was the case for magnet 42 and holder 40 , such that the magnet 55 aligns with the edges of the magnets 22 , 24 to effect magnetic attraction when the arm 32 is moved from its release position to the catch position. Also, the arm 32 has a step 60 , which may be curved as shown in FIGS. 2 b , to abut a peg 52 a from the body 12 . Thus, any tendency to pull the bodies 10 , 12 apart while the arm is in the catch position will be resisted by the peg 52 a acting against the body 12 , while the magnet 55 keeps the arm in the catch position by magnetic attractive forces between the magnet 55 and the edges of the magnets 22 , 24 . If desired, magnet 55 may be replaced by a magnetically attracting surface.
[0050] The embodiment of FIG. 2 c differs from the embodiment of FIG. 1 in that the arm 32 of FIG. 1 moves away from and toward the faces of bodies 10 , 12 while the arm 32 a of FIG. 2 c moves sideways across the faces of the bodies 10 , 12 . Also, the hole 54 of FIG. 2 is replaced by a cut-out 54 a that opens to the side. The embodiment of FIGS. 2 d and 2 e differ from the embodiment of FIG. 2 c by eliminating the need for the magnet 48 . Instead, the magnet 55 is moved on the arm to align with the edges of the magnets 22 , 24 when the arm is in the closed condition. While the magnets 22 , 24 need not have their sides exposed for the embodiment of FIG. 2 c , exposure is necessary for the embodiment of FIGS. 2 d and 2 e to enable magnetic attraction with the magnet 55 .
[0051] FIGS. 13 - 17 show another alternate embodiment of the invention. Instead of the retaining wall 36 being positioned to lie against the rear surface 20 of the body 12 when the arm 32 is in the catch position, the retaining wall 36 is positioned to lie within the body 12 . Accordingly, body 12 includes a recess 60 that extends from the bottom surface 46 to the magnet 24 . The recess 60 may be a hole in a portion of the body such that the two bodies 10 , 12 would need to be properly oriented for the arm to be placed into the catch position, or it may be a groove extending around the entire body 12 such that the arm could be placed into the catch position regardless of the orientation of the bodies 10 , 12 . Those skilled in the art will recognize that if retainer wall 36 is replaced by a magnet or includes an additional magnet (not shown) that the recess 60 need not extend all the way to magnet 24 , although it still could, so long as the body 12 is a magnetically attractive material such as iron, steel etc, or such a metal is located within the recess 60 . As with the other embodiments, the retaining wall 36 may be any shape so long as it is capable of mating with recess 60 . Further, while it is preferred that retaining wall 36 and recess 60 have the same general shape, it is not necessary.
[0052] When the arm 32 is in a catch position, the retaining wall 36 is in the most likely path that the body 12 would travel to separate from the body 10 . The retaining wall 36 blocks the two bodies 10 , 12 from inadvertently moving apart from each other. The blocking force exerted resists such movement because the opposite end of the arm 32 is secured by the hinge connection 34 to the body 10 . Such a blocking force is in addition to the magnetic attraction afforded by the magnets 22 and 24 that also resist movement of the bodies 10 , 12 away from each other. Also, the magnetic attraction between retaining wall 36 and magnet 24 oppose movement of the clasp in any less likely path that the body 12 would travel to separate from the body 10 .
[0053] The foregoing specific embodiments of the present invention as set forth in the specification herein are for illustrative purposes only. Various deviations and modifications can be made within the spirit and scope of this invention, without departing from the main theme thereof. | A jewelry clasp is provided with two bodies, each having a surface magnetically attracted to the other. The clasp has a safety catch that includes an arm hinged to one of the bodies. The arm may be swung about the hinge between an open position and a closed position. A further magnetic attraction keeps the arm in the closed position until opened with a fingernail. A retaining wall may extend generally perpendicular to a direction of elongation of the arm to block a path that the other of the bodies could travel if the bodies were to separate from each other while the safety catch is in the closed position. If desired, a male connector may be inserted into a female connector to prevent separation of the bodies from each other. The male connector and female connector are usable in tandem with the retaining wall, or in lieu thereof. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a housing with a central retaining device for at least two information discs, for example CDs, lying one above the other and each having a central opening, which retaining device is arranged on a base plate.
2. Description of the Related Art
Such a housing is known from, for example, published German application DE-GM 87 11 339. The known housing has a bottom part, a lid hinged thereto, and a moulded part which can be inserted into the bottom part and which has a circular depression and a projection which enters the central holes of information discs. The depth of the circular depression in the known construction and the length of the projection are a multiple of the thickness of an information discs. Furthermore, the circular depression is provided with an edge support which is raised above the bottom of the bottom part or of the moulded part and which adjoins the wall of the circular depression. The projection passing through the central holes of the discs lying on top of one another in the known construction is of a rigid construction and has surfaces which extend perpendicularly to the surface of the bottom part. Accordingly, there is no possibility of fastening the stacked discs by means of the rigid projection through clamping or a similar action in this known construction.
SUMMARY OF THE INVENTION
The invention has for its object to improve the known construction by providing a special arrangement of the central retaining device which renders possible an individual clamping of the stacked information carriers.
According to the invention, this object is achieved in a housing of the kind mentioned in the opening paragraph in that
a) the retaining device is built up from clamping studs which are arranged in a circle, grip into the central openings, and are resilient in the radial direction, and
b) at least two groups of independent clamping studs are provided, each group with clamping surfaces arranged in a different plane for clamping a respective information disc.
It is possible in this manner to fasten each of the stacked, disc-shaped information carriers individually by the clamping action of the specially designed clamping studs without the clamping studs of the one group detracting from or interfering with the clamping action of another group. Dropping out of the information carriers when the lid is opened is avoided thereby, while in addition the individual clamping of the information carriers substantially prevents a circular movement of the information carriers during transport such as is possible, for example, in the known construction mentioned above where the information carriers are passed loosely over the projection. Sticking together of several stacked discs is prevented, when the information carriers used are, for example, commercially available CDs, in that the commercially available CDs are at present each provided with a projecting ring adjoining the central opening at their laser read-out sides. The interspacings of the planes comprising the clamping surfaces are then adapted to the thickness of the information carriers to be clamped, i.e. inclusive of any rings which may be present.
To prevent sagging of the bottom information disc provided with such a ring in one arrangement of several information discs, an embodiment of the invention the otherwise planar lower support surface of the base plate is provided with an elevation in its edge region whose height is equal to the height of the ring present on the information carrier.
A chamfer-type clamping between the information disc and the clamping studs is achieved in a further embodiment of the invention in that the clamping surfaces each lying in an individual plane are given a tapering shape in the direction of the base plate such that the greatest outer diameter of the clamping surfaces arranged in a circle is slightly greater than the diameter of the central opening of the relevant clamped information disc.
To prevent the clamping studs of the individual groups from influencing one another, a further embodiment of the invention is characterized in that the surfaces of the clamping studs adjoining the clamping surfaces of a group extend perpendicularly to the base plate, and the outer diameter of the former surfaces is somewhat smaller than the diameter of the central opening of the information discs.
An improved separation between the individual clamping planes is in addition achieved in that radial ridges of a diameter somewhat greater than the diameter of the central openings of the information carriers are provided at the ends of the clamping surfaces of a group of clamping studs. When an information disc is passed over the clamping studs, these ridges cause the relevant clamping studs to be pressed somewhat inwards, whereupon they spring back into their clamping position after the information carrier has reached its clamping position.
A further embodiment of the invention is characterized in that the clamping studs of the individual groups from among two or more groups of different clamping studs are arranged in alternation one after the other distributed over the circular circumference. At least three clamping studs regularly distributed over the circumference are necessary for each group in order to achieve an effective clamping. For example, if there is a total of twelve clamping studs, a maximum of four disc-shaped information carriers can be securely clamped and held each by means of three clamping studs exclusive to the relevant disc and evenly distributed over the circumference. If three information discs are to be accommodated by means of a total of twelve clamping studs, four clamping studs will be available for each disc, while in the case of two information discs each disc will have six clamping studs at its disposal.
The invention may be used to advantage in a commercially available housing with a bottom part, a lid hinged thereto, and a tray which can be inserted into the bottom part and which is shaped so as to form the base plate with the central retaining device according to the invention as defined above, while the housing remains unchanged in other respects. Depending on the construction of the known tray, it is now possible to accommodate a maximum of three disc-shaped information carriers in the housing without the necessity of changing the exterior dimensions thereof, the bottom part and the lid of the known commercially available housing remaining of the same construction. This constitutes a major space saving compared with the known housing which is capable of accommodating only one information carrier.
In a first embodiment thereof, the known tray is provided with a plane support surface for the bottom information carrier and an also plane outer surface for resting against the bottom part of the housing, while a raised central support surface is dispensed with. Space is thus gained without further changes in the tray or the housing, so that two information carriers can be individually and securely clamped, while at the same time the space available for a booklet above the retaining device can be maintained unrestricted.
A second embodiment is characterized in that in addition to the above changes in the tray the clamping studs of the retaining device are lengthened in the direction of the lid. Three information discs can be securely clamped in this embodiment, but the space for accommodating the booklet between the clamping studs and the lid is reduced here if the exterior dimensions of the housing remain unchanged.
A further application of the invention is found in a commercially available housing with a bottom part and a lid hinged thereto, where the bottom part is arranged so as to form the base plate with the central retaining device according to the invention described above, the other dimensions of the housing remaining the same, and where the clamping studs starting from the bottom part extend to just below the lid. In such an embodiment of the invention, a maximum of four information carriers can be accommodated one above the other, individually clamped, in a housing which was originally capable of holding only one information carrier, without the dimensions of the outer housing, i.e. of the bottom part or the lid, having to be changed. Such an embodiment of the invention is favourable, for example, as a bulk packing for data carriers which do not require a special text booklet, since such a text booklet can no longer be accommodated because of the reduced space between the lid and the upper edge of the retaining device.
Impact loads cannot be avoided, however, in the transport of such housings with, for example, four information carriers on one and the same clamping device, so that the uppermost information carrier could possibly become detached from the retaining device. It may also happen that one or several clamping elements break off in the case of multiple impacts. This means that the information carriers can no longer be securely held under certain circumstances.
Published German application DE 34 25 579 C2 discloses a storage cassette for disc-shaped information carriers, for example for CDs, in which the central retaining device comprises radially resilient clamping studs which are designed for holding a single CD. To prevent the CD getting loose, for example owing to an impact, the ends of the clamping studs are fixedly interconnected by a pressure plate such that the retaining device of this construction has a reduced diameter in the case of a pressure load on the pressure plate in dependence on its elastic deformation, while the clamping studs are provided with retaining or positioning projections by means of which the retaining device fixes the deposited information carrier into place by interlocking with its central hole edge region. Such a construction renders it possible for the retaining device gripping into the central hole of the information plate to be easily reduced in diameter. The information carrier may thus be pushed home on the retaining device with a slight pressure, whereupon a secure fixation between the retaining device and the information disc can be achieved owing to their interlocking shapes. Conversely, the information disc can only be detached through the exertion of a slight pressure on the pressure plate, whereby the diameter of the retaining device is reduced and the disc can be subsequently removed. This effect can be further improved in the known construction by fastening the clamping studs to the pressure plate via connection bridges which have an undulating pattern.
To avoid a possible detachment of an information disc from the retaining device in such housings, in an embodiment of the invention at least part of the clamping studs are fixedly interconnected at their free ends while retaining their radial resilience. This is in principle the application of the construction described above and known per se to a housing in which the retaining device is capable of accommodating at least two information discs. This is particularly favourable in such retaining devices because these retaining devices in general comprise fewer clamping elements for retaining each of the information discs to be retained, and are accordingly more prone to failure than retaining devices which retain only a single information disc and accordingly comprise more clamping elements for this information disc. The construction according to the invention also reduces the risk of fracture of the clamping studs in the case of impacts.
Since the uppermost information disc is most at risk of being detached from the retaining device, an embodiment of the invention is characterized in that those clamping studs of the group are interconnected whose clamping surfaces lie farthest to the outside. This means that the uppermost information disc is particularly well secured and thus also constitutes a stop device for the lower information discs.
An embodiment of the invention is characterized in that the clamping studs are connected to a plate via elastic connection bridges. These elastic connection bridges render possible a simple placement of the information discs, during which the clamping studs give way radially inwards and snap back again after the placement has been completed, so that the radially outermost clamping surfaces bear on the inside walls of the central hole of each information disc. Detaching is done in reverse order, a slight pressure on the plate being exerted. A ring may be used instead of the plate.
An embodiment of the invention is characterized in that the elastic connection bridges have an undulating profile or S-profile. These profiles can be simply manufactured and also render possible an elastic connection between the clamping studs and the plate or ring in a simple manner.
A simple manufacture is achieved in a further embodiment of the invention in that the clamping studs, possibly in conjunction with the elastic connection bridges, are integral with the plate.
An improvement in the quality of the retaining device is achieved in that at least the clamping studs of one group are interconnected. Such a construction already gives the total retaining device the required stability. This group preferably is, as stated above, that group whose clamping surfaces lie axially farthest away from the base surface of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view of a tray with a central retaining device for several CDs, without CDs being inserted,
FIG. 2 is a cross-section taken on the line A--A in FIG. 1 on an enlarged scale, with two CDs being retained,
FIGS. 3A and B are two enlarged diagrammatic pictures of the clamping region for clamping two CDs,
FIG. 4 shows in cross-section a side of a housing for accommodating two CDs,
FIG. 5 shows the same housing as FIG. 4, but now accommodating three CDs,
FIG. 6 shows the same housing as FIG. 4, now accommodating four CDs,
FIGS. 7 to 9 show clamping studs as used in FIGS. 4 to 6 arranged in circle,
FIG. 10 is a cross-section of a housing for accommodating six CDs, and
FIG. 11 shows the complete housing of FIG. 10,
FIG. 12 shows a retaining device according to FIG. 1 on a larger scale, with a plate arranged between clamping studs, and
FIG. 13 is a cross-section taken on the line B--B in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The tray 10 shown in FIG. 1 is normally inserted into a bottom part of a housing which may subsequently be closed with a lid hinged to the bottom part. Such housings are diagrammatically shown further down in FIGS. 4 to 6. The tray 10 of FIG. 1 has a side grip 11 and a central retaining device 12. The retaining device 12 in FIGS. 1 and 2 comprises two groups of clamping studs arranged in a circle, i.e. a first group of six clamping studs 13 for holding and clamping a first CD 14 and a second group of six clamping studs 15 for holding and clamping a second CD 16. The clamping studs 13 and 15 alternate along the circumference of the retaining device 12.
FIG. 3A shows a cross-section, not true to scale, of two mutually opposed clamping studs 13 from the first group. These studs have clamping surfaces 13a adjacent the surface 17 of the tray 10 and narrowing conically towards the surface 17. The maximum outer diameter D 1 of these clamping surfaces 13a in the non-clamped state is a little greater than the diameter 18a of the central opening 18 of the CDs 14 or 16. By contrast, the outer diameter D 2 of the straight surfaces 13b of the clamping studs 13 situated above the clamping surfaces 13a is smaller than the diameter 18a of the central opening 18, so that said surfaces 13b do not interfere with the clamping of the second CD 16. A radial ridge 13c is provided between the surfaces 13a and 13b of a diameter greater than the diameter of the central opening 18. This ridge 13c serves to provide a better seat for the CD 14.
FIG. 3B is a diagrammatic cross-section of two mutually opposed clamping studs 15 from the second group. The radially resilient clamping studs 15 also have clamping surfaces 15a which narrow conically towards the surface 17 of the tray 10, and surfaces 15b adjoining the former surfaces and directed perpendicularly to the surface 17. The clamping surfaces 15a here serve to clamp the CD 16 which lies on the CD 14. The same holds for the dimensions of the diameters of the conical clamping surfaces 15a and the straight surfaces 15b as discussed for the surfaces 13a and b described above, i.e. the greatest outer diameter D 3 of the clamping surfaces 15a is a little greater than the diameter 18a of the central CD opening 18. Furthermore, the outer diameter D 4 of the straight surfaces 15b is a little smaller than the diameter 18a. The clamping studs 15 have a radial ridge 15c above the CD 16, which serves to secure the CD 16 passed over the ridge 15c in its position. The tray 10 shown in FIGS. 1 to 3 has no elevation on its surface 17 for supporting CDs as was usual in prior art trays. Instead, the bottom CD 14 rests with its ring 14a directly on the surface 17 and the CD 16 rests with its ring 16a on the CD 14.
FIGS. 4, 5 and 6 show three embodiments of a single housing with the same external dimensions, comprising an identical bottom part 20 and a lid 21 hinged thereto, as evidenced by FIGS. 4 and 5. The bottom part 20' of FIG. 6 has a modified interior (see further below). The housing of FIGS. 4 to 6 has outer dimensions which correspond to those of commercially available CD packagings for holding a single CD. The embodiment of FIG. 4 differs from the commercially available embodiment of the housing in that the tray 22 arranged in the bottom part has a plane support surface 22a for a CD 23 while a raised central support is omitted, whereby space is gained for accommodating two CDs 23 and 24 which have respective raised rings 23a, 24a. A further space gain is achieved when the tray 22 bears with a flat surface 22b directly on the bottom part 20, in contrast to the prior art. The space for a text booklet 25 is sufficiently large. The retaining device 12 is constructed in accordance with the invention as shown in FIGS. 1 to 3, which is not depicted in detail here. The height of the retaining device 12 has not been changed compared with the known embodiment of the commercially available housing.
The embodiment of FIG. 5 differs from the known commercially available construction of the housing in that the tray 22 without a raised central support, as in FIG. 4, is given a plane support surface 22a for the bottom CD 23 and also bears with a plane outer surface 22b directly on the bottom part 20, as in FIG. 4. In this construction, moreover, the retaining device 12' has been lengthened in upward direction towards the lid 21, so that space is now available for accommodating a further CD 26, which, however, has reduced the space available for holding a booklet 25', which has been made thinner.
The embodiment of FIG. 6 again does not differ from the commercially available housing in its outer dimensions, but no separate tray is provided in this embodiment; instead, the bottom part 20' itself is provided with the retaining device 12", which here projects to immediately below the lid 21. This provides sufficient space for holding four CDs 23, 24, 26, 27 in one housing which had originally been designed for a single CD. The retaining device 12" is again provided with resilient clamping studs according to the invention, as shown in FIGS. 1 to 3, i.e. in this embodiment with four groups of at least three clamping studs each.
FIGS. 7 to 9 diagrammatically show the clamping devices 12, 12', 12" from FIGS. 4 to 6, each with twelve clamping studs. The construction of FIG. 7 comprises two groups of six clamping studs 28, 29, each for holding two CDs, corresponding to the embodiment of FIGS. 3A and B. The construction of FIG. 8 comprises three groups of four clamping studs 30 . . . 32 each for holding three CDs, and the construction of FIG. 9 comprises four groups of three clamping studs 33 . . . 36 each for holding four CDs.
FIG. 10 shows the right-hand side of a housing for a total of six CDs. The housing has a central part 37 and two identical lid parts 38 which are hinged to the central part. The hinges for the lids 38 are arranged, as in the embodiments of FIGS. 4 to 6, in the left-hand part of the housing as shown in FIG. 11. The external dimensions of the housing of FIG. 10 correspond exactly to those of the similar commercially available housing which is suitable for holding no more than four CDs, i.e. one CD on each lid part 38 and two CDs on the central part 37. According to the invention, this housing is now so constructed that the two identical lid parts 38 are formed so as to correspond to the construction of FIG. 4. This means that the two lid parts 38 each accommodate a tray 39 which has a plane support surface 39a without a raised central support and which rests on the relevant lid part 38 also with a plane support surface 39b. So much space is gained thereby that two CDs 40, 41; 42, 43 can be accommodated in each lid part 38. Two further CDs 44, 45 can be accommodated on the central part 37 in conventional manner, as in the known housing, so that the housing can now hold a total of six CDs. The centrally arranged clamping device 12 of each lid part is constructed in accordance with the embodiment of FIGS. 4 and 7, i.e. each clamping device 12 comprises two groups of clamping studs 28, 29 for retaining two CDs.
FIG. 11 shows the construction of FIG. 10, the left-hand part of the housing with the two hinges 46 for the lids 38 being drawn here. The housings of FIGS. 4, 5, 6 are of the same construction on the left-hand side.
In FIG. 12, the clamping studs 15 of the second group are interconnected by a rigid plate 19, S-shaped connection bridges 47 (see FIG. 13) being provided between the free ends of the clamping studs 15 and the plate 19 for providing a degree of elasticity.
When the first CD 14 is inserted, the clamping elements 15 are first pressed together, and subsequently the CD 14 is held by the clamping surfaces 13a of the clamping elements 13. Then the second CD 16 is inserted, which does not affect the clamping elements 13, but only bends the clamping elements 15 inwards, so that the CD 16 after being inserted will be held by the clamping surfaces 15a. | A housing for storing a stack of at least two information discs such as CDs includes a central retaining device for engaging and securely fastening each of the discs. The retaining device consists of a plurality of clamping studs arranged in a circle, and with respective groups of studs being in respective planes, each such plane being for a respective disc. The studs are resilient in the radial direction and those in a given group engage the central opening of the disc to be stored in the relevant plane. | 6 |
[0001] This application is a utility application based on U.S. Provisional patent application Ser. No. 62/279,073, filed Jan. 15, 2016, from which priority is claimed.
BACKGROUND OF THE INVENTION
[0002] This invention deals with compositions of matter that are antifreeze compositions, coolants, heat transfer fluids, and de-icing fluids. For purposes of discussion in this specification, all of the afore-mentioned materials are referred-to as “antifreeze” compositions.
[0003] NFPA 13, Standard for the Installation of Sprinkler Systems, has included guidance on the use of antifreeze compositions in fire sprinkler systems. Antifreeze compositions may be used in fire sprinkler systems where the piping system, or portions of the piping system, may be subjected to freezing temperatures.
[0004] The term “antifreeze” refers to a composition which reduces the freezing point of an aqueous solution, or is an aqueous solution with a reduced freezing point with respect to water, for example, a composition comprising a freezing point depressant.
[0005] The term “coolant” refers to a category or liquid antifreeze compositions which have properties that allow an engine to function effectively without freezing, boiling, or corrosion. The performance of an engine coolant must meet or exceed standards set by the American Society for Testing and Materials (ASTM) and the Society of Automotive Engineers (SAE).
[0006] The term “heat transfer fluid” refers to a fluid which flows through a system in order to prevent it from overheating and transferring the heat produced within the system to other systems or devices that can utilize or dissipate the heat.
[0007] The term “de-icing fluid” refers to a fluid which makes or keeps a system, a device, or a part of a device free of ice, or a fluid that melts ice.
[0008] The term “ultra-pure water” as used herein refers to the water obtained by the process as set forth in U.S. patent Publication 2010/0209360, published Aug. 19, 2010 entitled “Method for making a Gas from an Aqueous Fluid, Product of the Method and Apparatus Therefor.
[0009] The term “non-flammable” as used herein refers to the standard for flammability set forth in UL Test Standard 2901.
[0010] “Coalescence” for purposes of this invention means similar or like properties as a group.
[0011] These compositions (hereinafter “antifreeze compositions”) have multiple uses, as they can be used to prevent freezing of certain systems, but can also be used as additives for certain applications in which heat control is an issue.
[0012] It is known to use antifreeze compositions in heat exchanger systems, de-icing applications, for example, on airplane wings and fuselage, radiators in automobiles, automobile and truck batteries and other vehicles, such as armored tanks, and the like.
[0013] Currently the only antifreeze which is approved for use in CPVC fore sprinkler piping by NFPA 13 is glycerin. Ethylene glycol and propylene glycol have been used for hard piped sprinkler systems. All of these antifreeze materials are flammable. Flammability and a variety of other issues have created a need for a non-flammable antifreeze materials for sprinkler piping. A variety of “compounds” and additives have been evaluated in the prior art without any success.
[0014] In such applications, the antifreeze composition must be contained, and the materials of the containment system must come in contact with the antifreeze compositions. Such systems are manufactured from metals, alloys of metals and other components forming the different parts of the systems.
[0015] Thus, one of the major issues in using antifreeze compositions is the prevention of corrosion in such materials. Another issue is flammability of the antifreeze compositions, especially when such antifreeze compositions are used in fire sprinkler systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1A is a graph showing conductivity end freezing points of aqueous solutions without potassium formate. FIG. 1B is a graph of various properties of aqueous solutions without potassium formate.
[0017] FIG. 1C is a graph of conductivity and freezing point of aqueous solutions with potassium formate.
[0018] FIG. 1D is a graph of various properties of aqueous solutions with potassium formate.
[0019] FIG. 1E is a graph of freezing point comparison with and without potassium formate.
[0020] FIG. 2A is a comparison of samples 130 , 131 , and 132 , initial properties compared to commercial antifreeze.
[0021] FIG. 2B is a comparison of sample 130 , 131 , and 132 , at 30 days at high ambient temperature stability 70° C. for 30 days.
[0022] FIG. 2C is a comparison of sample 130 , 131 , and 132 , at 90 days at high ambient temperature stability 70° C. for 90 days.
[0023] FIG. 2D is a comparison of sample 130 , 131 , and 132 , at 40 cycles high ambient temperature stability 66° C.
[0024] FIG. 3A is a graph of corrosion rate at 30 days.
[0025] FIG. 3B is a graph of weight loss rate at 30 days.
[0026] FIG. 3C is a graph of corrosion rate for 60 days.
[0027] FIG. 3D is a graph of weight loss for 60 days.
[0028] FIG. 3E is a graph of corrosion for 90 days.
[0029] FIG. 3F is a graph of weight loss for 90 days.
[0030] FIG. 4A is a table showing corrosion rate and weight loss data at 30 days
[0031] FIG. 4B is a table showing corrosion rate and weight loss date at 60 days
[0032] FIG. 4C is a table showing corrosion rate weight loss data at 90 days
[0033] FIG. 5A is a graph showing % volume changes for formulation 130 and various rubbers and plastics.
[0034] FIG. 5B is a graph showing % weight change for formulation 130 and various rubbers and plastics.
[0035] FIG. 5C is a graph showing % volume change for formulation 131 and various rubbers and plastics.
[0036] FIG. 5D is a graph showing % weight change for formulation 131 and various rubbers and plastics.
[0037] FIG. 5E is a graph showing % volume change for formulation 132 and various rubbers and plastics.
[0038] FIG. 5F is a graph showing % weight change for formulation 132 and various rubbers and plastics.
[0039] FIG. 6A is a table showing data for formulation 130 and various rubbers and plastics.
[0040] FIG. 6B is a table showing data for formulation 131 and various rubbers and plastics.
[0041] FIG. 6C is a table showing data for formulation 132 and various rubbers and plastics.
DETAILED DESCRIPTION OF THE INVENTION
[0042] It has now been discovered that antifreeze compositions can be formulated that are essentially low cost, non-flammable, have very low freezing points, and are essentially non-corrosive to metal components of systems used for handling such antifreeze compositions.
[0043] What is disclosed herein are non-flammable antifreeze compositions comprising the incipient materials, water; a coalescent efficient glycol ether selected from a group of materials having the general formula:
[0000] RO(CH 2 CH 2 O) y R′ or,
[0000]
[0044] In the first formula, RO is selected from a group consisting of an alkoxy group of 1 to 6 carbon atoms or phenoxy; R′ is H, or —C(O)CH 3 , and y has a value of 1 to 6. In the second formula, RO is an alkoxy group of 1 to 4 carbon atoms, the phenoxy group or acetoxy group; is R′ or —C (O)CH 3 , and y has a value of 1 to 3, wherein the boiling point of the coalescent efficient glycol ether is 190° C. or greater at 760 mm Hg.
[0045] A third component is a non-flammable compound selected from the group consisting of sodium formate, potassium formate, lithium formate, rubidium formate, cesium formate, beryllium formate, magnesium formate, calcium formate, strontium formate, barium formate, and mixtures of these components.
[0046] In addition, it is contemplated within the scope of this invention to use one or more additional adjuvants and materials in the formulation. Such materials comprise such materials as waxes, silicate stabilizers, thickeners, dyes, and the like. It is also contemplated within the scope of this invention to use mixtures of these materials with the basic formulation.
[0047] Another embodiment is the use of the basic formula set forth Supra in conjunction with other sources of carbinol, such as sugar, glycerin, polyethylene glycol, polypropylene glycol, diethylene glycol, and, salts such as sodium chloride and sea salt. Also contemplated within the scope of this invention are mixtures of these materials.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0048] Thus what is disclosed and claimed herein are non-flammable antifreeze compositions based on water. the amount of each of the components here is based on the total weight of the components, and the amount of water that can be used herein is 0.1 to 95% weight percent. A preferred amount of water is from about 15 weight percent to about 75 weight percent and the most preferred embodiments is water at 40 weight percent to 65 weight percent.
[0049] A second component of the antifreeze composition is a group of materials that are coalescent efficient glycol ethers having the general formula RO(CH 2 CH 2 O) y R′ or,
[0000]
[0000] wherein in the first formula, RO is selected from a group consisting of an alkoxy group of 1 to 6 carbon atoms or phenoxy; R′ is H, or —C(O)CH 3 , and y has a value of 1 to 6, and in the second formula, RO is an alkoxy group of 1 to 4 carbon atoms, the phenoxy group or acetoxy group; R′ is H or —C(O)CH 3 , and y has a value of 1 to 3.
[0050] These materials can be used singularly or combined in two or more combinations. They are used in this composition at from 0.1 to 85 weight percent, based on the total weight of the composition. Preferred is from 20 to 60 weight percent and most preferred is from 40 to 55 weight percent based on the total weight of the final composition.
[0051] A third component of the antifreeze composition is a non-flammable compound selected from group consisting of sodium formate, rubidium formate, cesium formate, beryllium formate, magnesium formate, calcium formate, strontium formate, barium formate, potassium formate, lithium formate, and, mixtures of these compounds. These compositions are used in the antifreeze compositions at from 0.1 to 85 weight percent of the total composition. Preferred is a weight of from 0.1 weight percent to 70 weight percent and most preferred is the use at 0.1 to 50 weight percent based on the weight of the final composition.
[0052] In addition, it is contemplated within the scope of this invention to use corrosion inhibitors, such as, for example, sodium silicate, potassium silicate, and sodium trihydroxysilylpropyl methylphosphonate. The corrosion inhibitors are used at 0.1 to 10 weight percent based on the weight of the total composition. Preferred is from about 3 percent to about 8 percent and most preferred is from about 5 percent to 7 percent by weight based on the total weight of the final composition.
[0053] Other adjuvants include waxes, such as carnauba, paraffin, polyethylene wax or polypropylene wax, PTFE, microcrystalline waxes and blends of waxes which are used primarily at about 0.2 weight percent to about 10.0 weight percent based on the total weight of the final composition. Such waxes can be obtained from a variety of commercial sources such as Michelman, INC. Cincinnati, Ohio.
[0054] In addition, there can be used thickeners or rheology modifiers, for example for use on de-iceing airplanes wings. Any conventional thickener can be used. Cellulosics such as CMC, HMC, HPMC, and others, that are chemically substituted cellulose macromolecules, polyvinyl alcohol, metal oxides such as silica, clays: attapulgite which also disperses suspensions, bentonite (both flocculating and non-flocculating), and other montmorillonite clays. Preferred for this invention is carboxymethylcellulose which is used primarily at about 0.2 weight percent to about 5.0 weight percent based on the total weight of the final composition.
[0055] As indicated Supra, ultra-pure water can be used in this invention and it can be used is conjunction with other water, such as well water, city water, river, lake and pond water.
[0056] When the coalescent efficient glycol ethers are mixed with the other carbinol materials, the ratio of the other carbinol materials to the coalescent efficient glycol ethers is in the range of from 0.1:99.9 to 25:75. The salts can be managed in the same manner.
[0057] The compositions of the invention are easily prepared by simple mixing of the ingredients at room temperature and, the compositions can be stored indefinitely at room temperature.
[0058] The following examples illustrate the disclosure.
Examples
[0059] In accordance with UL 2901: Outline of Investigation for Antifreeze Solutions for Use in Fire Sprinkler Systems initial testing on potential solutions includes Pour Point—ASTM D97, Standard Test Method for Pour Point of Petroleum Products Viscosity—ASTM D2983, Standard Test Method for Low-Temperature Viscosity of Lubricants Measured by Brookfield Viscometer; Specific Gravity—ASTM D1429, Standard Test Methods for Specific Gravity of Water and Brine; pH—ASTM D1293, Standard Test Methods for pH of Water; Freeze Point—ASTM D6660, Standard Test Method for Freezing Point of Aqueous Ethylene Glycol Base Engine Coolants by Automatic Phase Transition Method or equivalent differential scanning calorimetric methods. All of these methods were used in acquiring the data in the following examples.
[0060] After these required tests are met and quantified, the following further testing is required: High Ambient Temperature Stability; Temperature Cycling Stability; Electrical Conductivity; Corrosion Rate; Exposure to Elastomeric Materials; Compatibility with Polymeric Materials, and Exposure to Fire.
[0061] In these examples, all data is in grams; Temperatures are measured in Centigrade (degrees C); Freeze Point at −20° C. was determined by placing samples in a refrigerated chamber for 24 hours at a constant −20° C. After 24 hours the sample was evaluated for flow; pH was tested using the Standard Methods for examination of water and wastewater standard 4500-H.
[0062] Exotherm or endotherm was measured using a NIST certified thermometers; Viscosity was tested using ASTM D2983, Standard Test Method for Low-Temperature Viscosity of Lubricants Measured by Brookfield Viscometer Model DV-II; Spindle 2 @100 rpm or Ubbleode tubes for low viscosity measurements.
[0063] Freeze Point at −40° C. (or lower) was determined by placing samples in a bath of Dow Corning® 10 cst 200 fluid chilled to temperature using either a bath of dry ice in acetone or a Neslab Bath Cooler Model PBC 2-II; Pour point was determined by placing samples in a bath of Dow Corning® 10 cst 200 fluid™ chilled to temperature using either a bath of dry ice in acetone or a Neslab Bath Cooler Model PBC 2-II and observing the temperature at which the sample was no longer fluid.
[0064] Corrosion rate was determined by placing pre-weighed samples into the test solution, aged at 49° C., and re-weighed at the prescribed times; Exposure to Elastomeric Materials was determined by placing pre-weighed samples into the test solution, aged at 70° C., and reweighed at the prescribed times, and, Unless specified otherwise all raw materials were purchased form Aldrich Chemical Company.
[0065] Tables 1 and 2 represent the development work done to arrive at the lowest freezing point achievable. This effort centered on dissociative salts trying to achieve a freezing point of at least −40° C.
[0066] The compositions of this invention can have conductivity properties that can be manipulated at will as will be obvious from the data infra. For example, city water, in the inventor's laboratory, has a conductivity of 300 μS. A requirement for the materials used for antifreeze for outdoor file suppression systems is 1000 μS or less. Table 3 sets forth conductivity for the various components and combinations useful in this invention. H+H 2 O is ultra-pure water. “Water” indicates tap water.
[0000]
TABLE 1
sample No.
A
B
C
D
E
F
G
Water
100
100
100
100
100
100
100
KC 2 H 3 O 2
269
201
135
70
269
NaC 2 H 3 O 2
94.9
Glycerol,
100
25
50
75
100
pure
FPt, −20 C.
OK
SOLID
OK
OK
OK
OK
OK
initial pH
8.5
7
4.5
final pH
7
7
7
7
7
7
7
Exotherm, @
mix
Init temp
23
23
23
final temp
9
20
23
pour point
, −52 C.
, −52 C.
FPt, −40 C.
solid
solid
OK
OK
, −48 C.
OK
OK
[0000]
TABLE 2
Sample No.
H
K
L
M
O
P
Water
100
100
100
100
100
KC 2 H 3 O 2
269
33.7
Glycerol,
100
50
10
100
raw
S.G.
1.55
1.2
1.25
FPt, −20 C.
OK
Slice
2
solid
solid
v
phase
thick
initial pH
9
7.5
4.5
5
final pH
8
7
5
5
4.53
Exotherm, @
mix
Init temp
22
22
22
22
final temp
11
21
22
22
Viscosity,
32
5
20
3
cps
Sp 2 @ 100 rpm
Freezing
, −40 C.
point
[0000]
TABLE 3
Sample
9
10
11
12
13
H + H 2 O
100
50
50
Glycerin
50
DPM
100
50
TPNB
100
Conductivity uS
1.8
3.6
4.5
0.08
1
FPt, −20 C.
solid
OK
<−75
−83
OK
Flash Pt
126
75
Density
0.93
0.95
[0000]
TABLE 4
Sample
I
J
K
L
Water
100
90
45
49
KC2H3O2
135
10
5
1
Glycerol
50
50
Wt. % KCHO
57
11
5
3.6
Conductivity, uS
76000
14400
8500
3600
[0067] Table 4 contains data regarding the level of Potassium Formate as it relates to the conductivity vs concentration in solution. Tables 5 and 6 illustrate conductivity as it relates to three lower levels of Potassium Formate, no Potassium Formate, and the addition of specialty fluids to lower the freezing point of the formulation. The formulations in Table 7 contain date regarding the levels of water in the formulation and its effect on conductivity and pH.
[0000]
TABLE 5
Sample
15
16
17
H + H 2 O
50
50
50
DPM
47.75
47.75
47.75
TPNB
2.25
2.25
2.25
KCHO
1
0.6
0.2
% H 2 O
50
50
50
Conductivity uS
3600
1955
785
[0000]
TABLE 6
Sample
15
16
17
14
18
19
H + H 2 O
50
50
50
50
50
50
DPM
47.75
47.75
47.75
47.75
40
30
TPNB
2.25
2.25
2.25
2.25
10
20
KCHO
1
0.6
0.2
0
Conductivity
3600
1955
785
2.5
5.4
2
uS
phase
FPt, −20 C.
OK
OK
OK
OK
OK
[0000]
TABLE 7
Sample
20
21
22
14
23
24
25
H + H 2 O
450
150
100
50
25
10
5
DPM
47.75
47.75
47.75
47.75
47.75
47.75
47.75
TPNB
2.25
2.25
2.25
2.25
2.25
2.25
2.25
% H 2 O
90
75
66
50
36
16
9
Conductivity
13.9
8.01
5.07
2.5
6.2
5.81
5.51
uS
pH
7.57
7.3
7.02
6.6
6.2
5.8
5.5
[0068] Tables 8 and 9 are miscellaneous salt additives as they relate to freezing point while Table 10 shows the optimum formulations that have resulted in low conductivity and low freezing point depression. Additionally an added corrosion inhibitor to further improve the formulation was incorporated, i. e. CH 3 COOK and/or CH 3 COONa.
[0000]
TABLE 8
Sample
20
21
22
Water
100
100
100
CH 3 COOK
200
CH 3 COONa
125
NaCl
35
ppt
FPt, −20 C.
OK
solid
some ice
initial pH
9
9
6.8
final pH
9
8
6.8
Exotherm, @ mix
Init temp
21
21
21
final temp
26
32
19
[0000]
TABLE 9
Sample
a-13
a-14
a-20
a-21
a-3
a-4
a-7
Water
100
100
100
100
100
100
KC 2 H 3 O 2
269
135
269
33.7
prop glycol
100
100
50
Na Lactate
100
100
Na Silicate
26.9
13.5
FPt, −20 C.
Solid
Solid
OK
OK
OK
OK
OK
[0000]
TABLE 10
Sample
29
30
17
15
H + H 2 O
50
50
50
50
DPM
47.75
47.75
47.75
47.75
TPNB
2.25
2.25
2.25
2.25
DCC 6083
1
0.5
KCHO
0.1
0.2
1
% H 2 O
50
50
50
50
Conductivity uS
967
857
785
3600
FPt, −20 C.
OK
OK
OK
OK
FPt, −C.
−20
R.I.
1.3907
1.4255
pH
11.5
10.7
[0000]
TABLE 11
Aging Study
Formulations
130
131
132
same as
30
24
32
H + H 2 O
50
10
10
DPM
47.5
47.75
47.75
TPNB
2.25
2.25
2.25
DCC 6083
0.5
0.5
KCHO
0.1
0.1
% H 2 O
50
16.7
16.5
[0069] High Ambient Temperature Stability at 70° C. for 90 days . The Pour Point, Viscosity, Specific Gravity, pH and Freeze Point will remain stable within 10 percent of the initial properties (FIG. 2). Temperature Cycling Stability at 66° C. for 40 cycles. One cycle was equal to 24 hours at 66° C. and 24 hours at room temperature. The Pour Point, Viscosity, Specific Gravity, pH and Freeze Point will remain stable within 10 percent of the initial properties (FIG. 2). Corrosion Rate. The corrosion rate should not exceed 1.0 mils/year. Corrosion rate was tested according to NFPA 18A-2011. Metal alloy samples were submerged in the test solutions and incubated at 45° C. for 30, 60 and 90 days. The corrosion rate (Cr) was calculated using the following equation:
[0000]
Cr
=
weight
loss
(
g
)
×
K
alloy
density
×
exposed
area
×
exposure
time
[0000] where K=5.34*10 5
Percent Weight Loss was also calculated for these samples where:
[0000]
%
Weight
Loss
=
initial
weight
-
final
weight
×
100
initial
weight
See FIG. 3 .
[0070] Exposure to Elastomeric Materials: A volume change of minus 1 to plus 25 percent and a maximum loss of weight of 10 percent (See the Figures).
[0071] Tables 12 , 13 , and, illustrate a few of the compositions of this disclosure.
[0000]
TABLE 12
sample No.
A
B
C
D
E
F
G
Water
100
100
100
100
100
100
100
KC 2 H 3 O 2
269
201
135
70
269
NaC 2 H 3 O 2
94.9
Glycerol, pure
100
25
50
75
100
Freeze Pt,
OK
SOLID
OK
OK
OK
OK
OK
−20 C.
initial pH
8.5
7
4.5
final pH
7
7
7
7
7
7
7
Exotherm,
@ mix
Init temp
23
23
23
final temp
9
20
23
Ratio
100/0
0/100
75/25
50/50
25/75
100/100
Viscosity
S.G.
pour point
−52 C.
−52 C.
R.I.
Freeze Pt,
solid
solid
OK
OK
−40 C.
−48 C.
OK
OK
[0000]
TABLE 13
Sample No.
H
K
L
M
O
p
Water
100
100
100
100
100
KC 2 H 3 O 2
269
33.7
Glycerol, raw
100
50
10
100
S.G.
15.5
1.2
1.25
Freeze Pt, −20 C.
OK
Slice
2
solid
solid
v
phase
thick
initial pH
9
7.5
4.5
5
final pH
8
7
5
5
4.53
Exotherm, @ mix
Init temp
22
22
22
22
final temp
11
21
22
22
Viscosity
32
5
20
3
[0000]
TABLE 14
a = 8
a-9
a-10
a-13
a-14
Water
100
100
100
100
KC 2 H 3 O 2
269
135
135
prop glycol
eth glycol
Glycerol
50
Corr. In @ 43%
26.9
13.5
13.5
Na Lactate
100
100
S.G.
FPt, −20 C.
OK
OK
OK
Solid
Solid
initial Ph
Corrosion inhibitor = sodium trihydroxysilylpropyl methylphosphonate | Compositions of matter that are antifreeze composition, coolants, heat transfer fluids, and de-icing fluids based on the use of coalescent efficient glycol ethers. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of previously filed Provisional Patent Application, Ser. No. 62/055,770 filed on Sep. 26, 2014.
FIELD OF THE INVENTION
This invention describes a synchronization method for over air interfaces. More specifically this invention describes a partial-band interference tolerant multi-band synchronizer for a typical OFDM system employing antenna diversity.
BACKGROUND OF THE INVENTION
In modern communication systems, coherent detection is usually employed, which requires a receiver to be very accurately synchronized with the transmitter in both time and frequency. In most systems, key elements of the synchronization scheme are designed with only additive white Gaussian noise (AWGN) in mind. However, many emerging devices operate in unlicensed spectrum, e.g., the 902-928 Industrial Scientific and Medical (ISM) band, where many unpredictable forms of interference are consistently present. In such devices, these commonly-used synchronization schemes, designed for best operation under AWGN conditions only, may vastly under-perform in strong interference environments. Furthermore, modern air interfaces, e.g., those employing Orthogonal Frequency Division Multiplexing (OFDM), often lend themselves to powerful detection techniques that potentially provide extreme resilience against the most powerful of interferers. This potential immunity to interference, however, will never be harnessed unless the receiver is able to acquire and maintain synchronization in the presence of such interference. The invention described herein pertains to receivers, in general, and is described within the context of, but not limited to, an OFDM system employing antenna diversity. Furthermore, the invention is primarily directed to partial-band interference, which is the most-common form of interference encountered when operating in unlicensed spectrum such as the 902-928 MHz ISM band.
In order to demonstrate the problem solved by this invention, along with the capability of the invention itself, we first provide a basic description of the system model and its key components, as illustrated in the block diagram of FIG. 1 . Note that the ideas disclosed within this document are not strictly limited to the system under consideration as those skilled in the art can easily realize after review of this disclosure.
In FIG. 1 data packets are generated and encoded into channel bits. An OFDM symbol mapper converts the encoded channel bits into N streams of complex channel symbols, where N is the number of transmit antennas, and maps them onto the OFDM time-frequency grid, while merging them with known channel symbols used for synchronization and channel estimation/training. An OFDM modulator converts the N streams of complex time-frequency symbols into N complex time-domain waveforms, using an inverse fast Fourier transform (IFFT) with cyclic prefix insertion. A channel function generates time-dispersive channel fading, which exhibits a frequency-selective gain, for the OFDM and interfering signals, producing an output consisting of M waveforms, where M is the number of receive antennas. The interfering signal is modeled as either a continuous wave (CW), or a complex Gaussian signal of specified bandwidth, center frequency, starting point, and duration. Note that each of the bandwidth, center frequency, starting point, and duration may be specified as random. A receiver filter removes out-of-band noise from the noisy received signal, before splitting the filtered signal off into two branches. In the diagram, the upper branch is the synchronization block, which is the primary focus of this disclosure. The synchronizer generates time and frequency offset information, which is essential for proper operation of the OFDM demodulator and ensuing blocks. The OFDM demodulator performs a fast Fourier transform (FFT) on blocks of samples that have been time and frequency corrected by the synchronizer. The FFT output is fed to a channel estimation block, which estimates the channel gains for the desired signal, as well as any other important characteristics of the received signal, which are then fed, along with the FFT output, to the detector block. Note that the channel estimator may be particularly sensitive to synchronization error, depending on its design. The detector block uses the M branches of the FFT output, and channel estimation information, to form a best estimate of the complex transmitted symbols. These complex symbol estimates are sent to a de-mapping function, which may make further measurements pertaining to the received signal, along with its primary function of converting the complex symbol estimates to bit-level estimates for the purpose of channel decoding.
A traditional synchronizer correlates against a known sync waveform embedded within the waveform, and adjusts symbol timing and sometimes frequency offset based on the results of this correlation. Another very commonly used form of coarse sync acquisition for OFDM, e.g. that proposed by Schmidl, embeds a repeated pattern into the OFDM waveform at the transmitter, and in the receiver, correlates the received signal against a delayed version of itself, in an attempt to detect this repetition. This method is very effective under AWGN conditions, since it allows a very wide frequency offset capture range, offers good initial frequency offset estimation, and is computationally very simple. In such traditional schemes, the fine timing sync is then achieved by correlating the received signal against the known sync waveform, after initial acquisition and frequency offset correction. While this method is effective under AWGN conditions, these typical methods perform very poorly under interference conditions, and in this case, are, by far, the limiting factor in determining the receiver's ability to reject partial-band interference.
In the case of frequency offset estimation, these common methods, which correlate the received signal against a delayed version of itself when estimating offset, are very easily thrown off frequency by any noise or interference which are colored. In addition, this correlation method is easily fooled into false detection when in the presence of colored noise or interference, potentially leaving the receiver in a perpetual state of confusion if colored noise is continuously present. Furthermore, the fine sync correlation against the known sync waveform is rendered ineffective and therefore useless whenever strong partial-band interference is present, since the desired signal is very easily over-powered.
BRIEF SUMMARY OF THE INVENTION
This invention describes a multi-band synchronizer, which performs robustly in the presence of partial-band interference, by breaking down the correlation of a sync waveform, at a plurality of times, with one or more received signal branches, into a multitude of sub-band correlations, and combining the sub-band correlations such that the impact of partial-band interference on synchronization performance is significantly mitigated.
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the accompanying drawings, in which:
FIG. 1 is a diagram showing an over air interface system model and it's key components; and,
FIG. 2 is a diagram showing frequency response of 4 sub-bands.
DETAILED DESCRIPTION OF THE INVENTION
The disclosed synchronization method will now be described in mathematical detail. The typical sync word correlation is here modified, and presented in the form of a multi-band synchronizer, which uses intelligent signal processing to combine sub-band correlations into a single correlation waveform which performs robustly in the presence of partial-band interference.
In the preferred embodiment of the invention we let r m,n be the complex received time sample n of receive branch m. We define a set
{h n (i) }| i=1 N b
of N b complex filter impulse responses, each of length N h , where each complex impulse response {h n (i) } has a passband frequency response which covers a portion, or sub-band, of the OFDM signal band. FIG. 2 shows the frequency responses for the case of N b =4 sub-bands, with the property that the sum of these responses produces a flat passband that covers the entire OFDM signal band.
Next we let
x m , n ( i ) = ∑ k = 0 N h - 1 h k ( i ) r m , n - k
be the output of sub-band filter i for receive branch m at sample time n. With complex input samples {r m,k } and a complex sub-band filter impulse response {h n (i) }, this filtering function is potentially expensive if implemented as stated, using brute-force convolution. It should be appreciated by one well-versed in the art of signal processing that this operation can be performed equivalently and more efficiently in the frequency domain, using, for instance, the FFT overlap-and-add method. From these sub-band filter outputs, we compute the following two signal sequences
y m , n ( i ) = ∑ k = 0 N w - 1 w k * x m , n + k ( i ) e n ( i ) = ∑ m = 1 M ∑ k = 0 N w - 1 x m , n + k ( i ) 2
where {w n }| n=1 N w is the known, complex OFDM sync waveform of length N w in samples, with the general property
∑ n = 0 N w - 1 w n 2 = 1
The sub-band sync correlation sequence {y m,n (i) } is the sliding correlation between the known, complex conjugate sync sequence and sub-band i of the received signal on branch m, and the sequence {e n (i) } is sum total of received signal energy for sub-band i, over the same moving time interval as that used for the sub-band sync correlation.
We then form N c combinations of the sub-band sync correlations, where lε[1,N c ] denotes the combination index. The sub-band indices used to form combination l are denoted {i l,p }| p=1 P l , where P l is the number of sub-bands used in combination l. The complex sync correlation for combination l at sample time n on receive branch m is
z l , n , m = ∑ p = 1 P l y m , n ( i l , p )
with scaled, net correlation energy
C l , n = ( N b P l ) ∑ m = 1 M z l , n , m 2
and corresponding signal energy
E l , n = ∑ p = 1 P l e n ( i l , p )
A sync correlation “hit” is said to have occurred, for combination l and sample time n, whenever
C l,n >η h,l E l,n
where η n,l is a pre-determined, fixed detection threshold for combination l, which is always less than unity. Upon sync detection, frame and symbol timing estimation may be performed using techniques known by those well-versed in the art, thus providing symbol timing estimate {circumflex over (n)} 0,l for combination l. Furthermore, within the embodiment of this disclosure, in addition to symbol timing information, we wish to obtain frequency offset information from the sync word as well. To this end, the sync word is specified to be transmitted twice within an appropriate time span, thereby providing the opportunity to measure phase changes in the sync correlations between the two transmissions, which translate to frequency offset. It must be noted that, for each sync word transmission, multiple sync correlation hits may be observed, due to multipath fading. Let {n h,l } be the set of sample time indices at which sync hits occur for combination l on each of the two sets {n h,l } and {n h,l +N Δ }, where N Δ is the time difference, in samples, between the two sync words. In other words, {n h,l } are the sample phases at which multipath sync hits occur for combination l on each of the two transmissions. Within the embodiment of this invention, the frequency offset, in Hz, for combination l is
f ^ 0 , l = ( f s 2 π N Δ ) ∅ ( ∑ n ∈ { n h , l } ∑ m = 1 M z l , n + N Δ , m z l , n , m * )
where ƒ s is the sampling frequency, in Hz, and Φ(•) represents the four-quadrant angle, in radians, of a complex number. These are quality estimates, since we only use correlations where sync hits occur on each of the two sync transmissions, and also, since the phasors of each receive branch m are weighted according to the sync correlation levels.
We have now established a multi-band sync correlator and combiner which provides, for each combination l of N c combinations, an event of sync detection, a symbol timing estimate {circumflex over (n)} 0,l , and a frequency offset estimate {circumflex over (ƒ)} 0,l . We will now describe the method for selecting which combination to use when updating the system symbol timing and frequency synchronization. It should be pointed out that we do not actually need to compute the offset estimates for each combination l, and that it is only necessary to compute the offsets for the chosen combination l 0 , after the selection process, which will now be described.
In order to qualify each combination l, let n 0,l be the sample index, among the samples within the search window of the two sync words, where a sync hit occurs, and where the sequence {C l,n } is maximum. In addition, let I l be the integer peak resolution for combination l, which is usually a multiple of an integer over-sampling factor relative to the signal bandwidth. Next, define the peak sample set {n p,l } as those samples, within the search window of the two sync words, where a sync hit for combination l occurs, and which are offset from n 0,l by integer multiples of the peak resolution I l .
We then define the following qualifiers for combination:
Γ C , l = ( 1 E l , n 0 , l ) ∑ n ∈ { n p } C l , n Γ E , l = ( N b P l ) E l , n 0 , l
where Γ C,l can be thought of as the normalized energy accumulated in all of the sync correlation peaks, which will be close to unity in good signal conditions, and Γ E,l is the corresponding received signal energy, time-aligned with Γ C,l , and scaled inversely by the number of sub-bands used for combination l. In addition, we order the combinations such that, as l increases, the number of sub-bands P l used to form combination l is non-increasing. With this arrangement, when there is no partial-band interference present, we would not expect the quality of the sync correlation to improve with increasing l.
We then perform the following algorithm:
1. Initialize Γ C,0 =Γ E,0 =0
2. Set l=1
3. If combination l has a sync hit and a valid frequency offset estimate:
a. If (Γ C,l >η 1,l Γ C,0 ) or ((Γ C,l >η 2,l Γ C,0 ) and (Γ E,0 >η 3,l Γ E,l ))
i. Set Γ C,0 =Γ C,l ii. set Γ E,0 =Γ E,l iii. Set l 0 =l
4. Increment l=l+1
5. If (l≦N c ) then go back to Step 3.
The explanation of the algorithms is as follows. The first condition in Step 3a demands that the net normalized sync correlation energy Γ C,l exceed the maximum previously stored quantity Γ C,0 by a healthy margin. To this end, the first threshold η 1,l is typically greater than unity. A second alternate condition leading us to replace the best stored combination with the current combination has two conditions of its own, the first of which demands that the net normalized sync correlation energy Γ C,l exceed the maximum previously stored quantity Γ c,0 using a second threshold η 2,l , which is more relaxed and therefore lower than the first threshold η 1,l . However, in addition, we require that the previously-stored quantity Γ E,0 exceed the signal energy metric Γ E,l using a third threshold η 3,l which is meant to be greater than unity.
The reason for this second alternate condition is, while the net normalized sync correlation energy Γ C,l may not be sufficiently stronger than the maximum previously stored quantity Γ C,0 using threshold η 1,l , if it is adequately stronger, based on the relaxed threshold η 2,l , even though its energy Γ E,l appears to be significantly lower than the best previously-stored energy Γ E,0 , then the current combination l is likely less interfered with than the previously-stored best combination. This is a sound method that has been shown to significantly improve an interference-aware receiver's ability to maintain synchronization and reject strong partial-band interference.
Since certain changes may be made in the above described method for a interference-tolerant multi-band synchronizer for over air interfaces without departing from the scope of the invention herein involved, it is intended that all matter contained in the description thereof or shown in the accompanying figures shall be interpreted as illustrative and not in a limiting sense. | A multi-band synchronizer that performs robustly in the presence of partial-band interference by breaking down the correlation of a sync waveform at a plurality of times, with one or more received signal branches into a multitude of sub-band correlations, and combining the sub-band correlations such that the impact of partial-band interference on synchronization performance is significantly mitigated is disclosed. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a composition exhibiting Giant Magneto-Impedance (GMI) properties. The present invention also relates to a giant magneto-impedance (GMI) based sensing device for detection of carburization in austenitic stainless steel.
BACKGROUND OF THE INVENTION
[0002] Damage assessment of structural components used in industries like power, petrochemical, steel etc. is required for prevention of premature failure. Carburization is one of the causes for the failure of steel components in petrochemical industries. Carburization occurs at elevated temperature in the presence of carbon rich gases. Associated phenomenon such as metal dusting, microstructure alteration and brittleness reduce the service life of the industrial components. Thus, evaluation and monitoring of carburization is necessary to avoid catastrophic failure of components. The process of high temperature carburization involves the steps of formation of carbon layer on the surface, inward diffusion of dissolved carbon into the metal, reaction of carbon with carbide forming elements to form carbides of the type Cr 23 C 6 and C 7 C 3 . The carbides and the austenitic steel are paramagnetic in nature. However, the formation of these chromium carbides leads to depletion of chromium in the matrix. Consequently there is enrichment of Fe and Ni in the matrix and the material becomes ferromagnetic in nature. PZT-based sensors are widely used to determine the flaws in structural components. Inductive sensors using ferrite cores are also extensively used for nondestructive testing (NDT). Magnetic sensors with high sensitivity have been investigated for some years to improve the performances of sensing device. Anisotropic magneto-resistance (AMR), giant magneto-resistance (GMR), fluxgate and SQUID sensors have been explored not only for the flaw identification but also evaluation of damages that occur prior to the formation of cracks. Attempts have been made to develop sensing devices using GMI materials.
[0003] Austenitic stainless steel have high amount of chromium (16 to 20%) and nickel (8 to 10%). Due to high nickel and chromium content the steel remains in austenitic phase even in the room temperature. Hence the material exhibits paramagnetic property. Carburization results in the formation of chromium carbides in the austenitic stainless steel. Chromium carbides are formed because chromium has more affinity to form Carbides than nickel and iron which are present in the material. The carbides generally formed are Cr 23 C 6 and Cr 7 C 3 . Due to the formation of these carbides small chromium depleted areas is formed near to carbide sites. These chromium depleted areas will have high relative concentration of iron and nickel. Due to the increase in the concentration of iron and nickel these areas will transform from paramagnetic to ferromagnetic state.
[0004] GB 1517096 discloses a device for monitoring carburization by measuring permeability in which the energizing coil is excited at a certain frequency and the e.m.f induced in detecting coil coupled to the energizing coil is measured. The method is not suitable as the ferromagnetic oxides formed in outer surface of tubes also influence the measurement. EP 81304158.9 discloses measurement of carburization in furnace tubes using the method of differential permeability technique. However, such technique has limitation owing to frequency selection criteria to meet the desired penetration depths.
[0005] Ferromagnetic behavior of stainless steel due to carburization is studied by various authors. In these studies, the level of carburization of the samples was determined by nondestructive magnetic flux density measurements before they were removed from the tubes. This technique measures the magnetic flux density near the external surface of the tubes by means of a magnetoresistive sensor biased by a small ferrite magnet.
SUMMARY OF INVENTION
[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.
[0007] According to one aspect of the invention, a compound of following chemical formula is provided: (Fe X Co 100-X ) 100-(α+β+γ) Cr α Si β B γ , characterized in that α<β and α<γ, wherein α may preferably be in the range of 2 to 4% by weight, β may preferably be in the range of 11.5% to 13% by weight, γ may preferably be in the range of 11% to 13% by weight. Further, γ may preferably be about (15−α)% by weight and X may preferably be about 6% by weight. More preferably, the chemical formula is (Fe 6% Co 94% ) 72.5% Cr 2% Si 12.5% B 13% .
[0008] According to another aspect of the invention, a nanostructured wire is provided, which is made of a compound of chemical formula (Fe X Co 100-X ) 100-(α+β+γ) Cr α Si β B γ , characterized in that α<β and α<γ. The compound comprises about 72.5% Iron Cobalt alloy (FeCo), about 2% Chromium (Cr), about 12.5% Silicon (Si), and about 13% Boron (B). Further, the Iron Cobalt alloy comprises about 6% Iron (Fe) and about 94% Cobalt (Co). The diameter of the nanostructured wire may be in a range of 90 to 110 μm.
[0009] According to another aspect of the invention, a giant magneto-impedance (GMI) based sensing device is provided for detection of carburisation in austenitic stainless. The device comprises: a hand-held sensor probe having a nanostructured wire as a sensing transducer, the nanostructured wire comprising a compound of chemical formula (Fe X Co 100-X ) 100-(α+β+γ) Cr α Si β B γ , characterized in that α<β and α<γ. One end of the hand-held sensor probe may be pointed in shape. The device can operate in a frequency of 200 K Hz to 1.5M Hz. The diameter of the nanostructured wire is about 100 μm±10%. The device further comprises: a crystal oscillator and an amplifier for providing control signals to the sensing transducer through a bridge circuit, a digital display to show output of the device and waveforms thereof, and an interface to communicate with a data acquisition and/or control system.
[0010] The advantages of the present invention include, but are not limited to that the compound and the nanostructured wires made thereof exhibit superior Giant magneto-impedance properties that in one example can be utilized for detecting carburization in austenitic stainless steel samples, even having irregular surfaces. The device allows non-destructive contactless on-site testing of such samples. The device also allows contact based testing of the sample without penetration. The device is hand-held and light weight, and hence portable.
[0011] The details of one or more embodiments are set forth in the accompanying drawings and description below. Other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. It is to be understood that the following detailed description is explanatory only and is not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0012] To further clarify the advantages and features of the invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings in which:
[0013] FIG. 1 illustrates an exemplary graph pertaining to boosting and diffusion cycle followed for the supplied SS321.
[0014] FIG. 2 illustrates an exemplary scheme of working principle and data flow during test of a carburized steel specimen.
[0015] FIG. 3 illustrates an exemplary schematic presentation of detection of carburization in SS321 plate using a computer controlled Giant magneto-impedance device.
[0016] FIG. 4 illustrates an exemplary practical use of the Giant magneto-impedance device.
[0017] FIG. 5 illustrates an exemplary Giant magneto-impedance sensor output for the 321SS plate carburized for different cycles and aged for different durations at 800° C. (#2B, #4B) and 780° C. (#12B).
[0018] FIG. 6 illustrates an exemplary chart for variation of GMI max with frequency for as-spun wires.
[0019] FIG. 7 illustrates an exemplary chart for variation of GMI max with frequency for wires annealed at 300° C.
[0020] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawings. Further, those of ordinary skill in the art will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of aspects of the invention. Furthermore, the one or more elements may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefits of the description herein.
DESCRIPTION OF THE INVENTION
[0021] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof. Throughout the patent specification, a convention employed is that in the appended drawings, like numerals denote like components.
[0022] Reference throughout this specification to “an embodiment”, “another embodiment” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0023] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of other devices or other sub-systems.
[0024] Various embodiments of the invention will be described below in detail with reference to the accompanying drawings.
[0025] The present invention discloses composition exhibiting Giant Magneto-Impedance (GMI) properties. Further, the present invention also discloses a device for detecting carburization in austenitic steel. Particularly, the present invention discloses a Giant magneto-impedance (GMI) based sensor for detection of carburization in austenitic steel. The present invention also discloses a method for detection of carburization in austenitic stainless steel using a GMI based sensing device.
[0026] In the Fe—Cr—Ni alloy system, the austenitic stainless steel lies in the paramagnetic state. The change in the concentration of chromium, nickel and iron, changes the austenitic stainless steel to ferromagnetic steel. The SS321 plate during carburization transforms from paramagnetic state to ferromagnetic state. For this, transformation, the steel has been subjected to different durations (boosting) of carburization, diffusion ( FIG. 1 ) and subsequent heat treatment at different temperatures and ageing times to induce variations in carburization so that such para-ferro transformation occurs. The regions with Cr-carbide precipitates formed during carburization have depleted Cr content. As a result the adjoining areas become ferromagnetic domains rich in FeNi content.
[0027] In an aspect of the present invention, a composition exhibiting GMI properties is disclosed, such composition comprising:
a. 72.5% Cobalt-Iron alloy, said Cobalt Iron alloy having 94% Cobalt (Co) and 6% Iron (Fe); b. 12.5% Silicon (Si); c. 13% Boron (B); and d. 2% Chromium (Cr).
[0032] In accordance with the present invention, a device for detecting carburization in austenitic steel is disclosed, such device comprising of a hand-held probe, wherein a nanostructured rapidly solidified wire of a GMI material as a sensing transducer, and wherein the GMI material comprises a nominal composition of (Co 94% Fe 6% ) 72.5% Si 12.5% B 13% Cr 2% . In an embodiment, diameter of the wire is in a range of 90 to 110 μm. In another embodiment, the device operates in a frequency of 200 K Hz to 1.5M Hz.
[0033] In accordance with the present invention, the device further comprises a crystal oscillator and amplifier for providing control signals to the sensing transducer through a bridge circuit. In another embodiment, the device comprises a digital display to show output of the device and waveforms. The device further comprises an interface to communicate with a data acquisition and/or control system.
[0034] Having described the basic aspects of the present invention, the following non-limiting examples illustrate specific embodiment thereof.
[0035] The present invention provides a Giant Magneto-Impedance (GMI) based magnetic sensing device for detection of carburization in SS321 in non-invasive way. The SS321 plate during carburization transforms from paramagnetic state to ferromagnetic state. For this, transformation, the steel has been subjected to different durations (boosting) of carburization, diffusion ( FIG. 1 ) and subsequent heat treatment at different temperatures and ageing times to induce variations in carburization so that such para-ferro transformation occurs. The GMI based sensing device comprises of a computer controlled system with display of the sensor signal. The GMI based sensing transducer 201 can be triggered on using an external programmable system and simultaneously the data can be displayed on a computing device 202 ( FIG. 2 ). As shown, the sensing transducer 201 is coupled with a bridge circuit 203 . The bridge circuit 203 is communicatively coupled with a crystal oscillator and amplifier 204 that generates a sufficiently large electrical signal even for small values of carburization. All the sensed data is sent to the data acquisition system 205 that can be shared with the computing device 202 for display and further analysis. The sensor transducer 201 includes a sensor probe 301 , which can be placed in contact mode or at close proximity (2-3 mm) above the carburized steel sample 206 ( FIG. 3 ). The regions with Cr-carbide precipitates formed during carburization have depleted Cr content. As a result the adjoining areas become ferromagnetic domains rich in FeNi content. Consequently, the emanated flux from these ferromagnetic regions is picked up by the sensor probe 301 . The emanated and subsequently received flux is converted to secondary voltage by the GMI sensor unit 302 and displayed in the form of a waveform with a corresponding display of the peak or rms voltage quantitatively on the computer 303 having sensor driving module and data logging system.
[0036] FIG. 4 illustrates an exemplary practical use of the device as per the present invention. The device uses a compound exhibiting Giant Magneto Impedance (GMI) properties as the basic sensing element for detection of carburization in 321SS austenitic stainless steel. The sensing element is prepared from a rapidly solidified nanostructured wires of said compound having Giant Magneto Impedance properties. In-water quenching system may be used for preparation of rapidly quenched cast wire. During tests, the 321 SS plate has been carburized and aged at various temperatures (750° C., 800° C.) for different durations for the formation of carbides. The material which was initially non-magnetic in nature became ferromagnetic on carburisation. The GMI based sensing device showed increase in output voltage with increase in carbutisation duration. The developed device also indicated the change in amplitude of the real time waveform when the probe is placed in different carburised test pieces. As shown, the sensor probe which is pointed in shape at one end can be used to check carburization in the 321 SS plate having irregular surface 401 , such as Johnson screen. Due to this pointed shape and non-contact non-penetration sensing ability, the sensor probe 301 can be used on difficult surfaces in the field thanks to portability and light weight of the device. That is really advantageous over state of the art techniques as they utilize destructive testing, i.e., the sample has to be destructed in order to detect carburization. On the other hand, the present invention allows non-destructive testing even on difficult surfaces in the field.
Example-1
[0037] The response of Giant magneto-impedance (GMI) based sensing device was observed on carburized samples which have been initially generated through a boosting cycle of 2½ hours and diffusion cycle for 2 hours at a temperature of 925° C. The samples mentioned in this example have been subjected to twice (designate Sample #2B) of such combined cycles (boosting+diffusion) of 4½ hours leading to a total exposure time of 9 hours. For further enhancement of diffusion, controlled heat treat schedule was followed for 1 hours at different temperatures ranging from 700° C. to 900° C. displayed in table-I. The GMI based sensing device showed an increasing output voltage from 20 mV to a maximum value of 84 mV with the increase in heat treatment temperature also signifying enhancement of ferromagnetism in the material with the increase in carburization.
[0000]
TABLE 1
Sample #2B
Heat treatment
Heat treatment
GMI voltage
Sl. No
Duration (hrs)
temperature (° C.)
(mV)
1.
1 hour
700
20
2.
750
20
3.
800
84
4.
850
56
5.
900
37
Example-2
[0038] The response of Giant magneto-impedance (GMI) based sensing device was observed on carburized samples which have been subjected to different heat treatment duration at a constant temperature. A set of samples mentioned in Example-1 subjected to twice (designate Sample #2B) of combined cycles (boosting+diffusion) of 4½ hours leading to a total exposure time of 9 hours was used. For further enhancement of diffusion, controlled heat treat schedule was followed for different hours at a constant temperature of 750° C. displayed in Table-2. The GMI based sensing device showed an increasing output voltage from 15 mV to a maximum value of 233 mV with the increase in heat treatment duration also signifying enhancement of ferromagnetism in the material with the increase in carburization.
[0000]
TABLE 2
Sample #2B
Heat treatment
Heat treatment
GMI voltage
Sl. No
temperature (° C.)
Duration (hours)
(mV)
1.
As-carburized
15
2.
750° C.
1
20
3.
24
230
4.
48
233
5.
70
225
Example-3
[0039] The response of Giant magneto-impedance (GMI) based sensing device was observed on carburized samples which have been subjected to different heat treatment duration at a constant temperature. A set of samples mentioned in Example-1 subjected to twice (designate Sample #2B) of combined cycles (boosting+diffusion) of 4½ hours leading to a total exposure time of 9 hours was used. For further enhancement of diffusion, controlled heat treat schedule was followed for different hours at a constant temperature of 800° C. displayed in table-3. The GMI based sensing device showed an increasing output voltage from 15 mV to a maximum value of 302 mV ( FIG. 5 ) with the increase in heat treatment duration also signifying enhancement of ferromagnetism in the material with the increase in carburization.
[0000]
TABLE 3
Sample #2B
Heat treatment
Heat treatment
GMI voltage
Sl. No
temperature (° C.)
Duration (hours)
(mV)
1.
As-carburized
15
2.
800° C.
1
84
3.
12
302
4.
48
190
5.
72
141
Example-4
[0040] The response of Giant magneto-impedance (GMI) based sensing device was observed on carburized samples which have been subjected to different heat treatment duration at a constant temperature. A set of samples mentioned in Example-1 subjected to four times (designate Sample #4B) of combined cycles (boosting+diffusion) of 4½ hours leading to a total exposure time of 18 hours was used. For further enhancement of diffusion, controlled heat treat schedule was followed for different hours at a constant temperature of 800° C. displayed in table-4. The GMI based sensing device showed an increasing output voltage from 52 mV to a maximum value of 90 mV ( FIG. 5 ) with the increase in heat treatment duration also signifying enhancement of ferromagnetism in the material with the increase in carburization.
[0000]
TABLE 4
Sample #4B
Heat treatment
Heat treatment
GMI voltage
Sl. No
temperature (° C.)
Duration (hours)
(mV)
1.
As-carburized
52
2.
800 ° C.
90
90
4.
270
62
5.
370
64
Example-5
[0041] The response of Giant magneto-impedance (GMI) based sensing device was observed on carburized samples which have been subjected to different heat treatment duration at a constant temperature. A set of samples mentioned in Example-1 subjected to twelve times (designate Sample #12B) of combined cycles (boosting+diffusion) of 4½ hours leading to a total exposure time of 54 hours was used. For further enhancement of diffusion, controlled heat treat schedule was followed for different hours at a constant temperature of 800° C. displayed in table-5. The GMI based sensing device showed an increasing output voltage from 15 mV to a maximum value 213 mV ( FIG. 5 ) with the increase in heat treatment duration also signifying enhancement of ferromagnetism in the material with the increase in carburization.
[0000]
TABLE 5
Sample #12B
Heat treatment
Heat treatment
GMI voltage
Sl. No
temperature (° C.)
Duration (hours)
(mV)
1.
As-carburized
15
2.
800° C.
90
38
4.
180
58
5.
270
213
6.
370
42
[0042] The sensing device utilizes the Giant magneto-impedance property of rapidly quenched materials obtained in the form of nanostructured wires with a typical diameter of about 100 micrometer. The Giant magneto-impedance (GMI) based sensing device with the nanostructured wire as the core material, exhibits lowest field sensitivity of about 300 mOe. The quenching apparatus, such as a wire caster may be used to prepare said nanostructured wires, wherein the molten metal of suitable composition is quenched by rapidly rotating water stream. The parameters, such as ejection pressure, nozzle diameter, superheat temperature can be adjusted in such a way that the wire diameter is around 100 μm±10. Table 6 given below lists the as cast properties of two prepared samples obtained at driving frequency 1 MHz and 2 mA driving current.
[0000]
TABLE 6
Peak value of GMI Ratio,
GMI max (%) at 1 MHz frequency
Sample Composition
As-prepared
Annealed at 300° C. for 30 min
(Co 94 Fe 6 ) 72.5 Si 12.5 B 13 Cr 2
246
500
(Co 94 Fe 6 ) 72.5 Si 12.5 B 11 Cr 4
357
375
[0043] Frequency variation of the peak value of GMI signal, GMI max for as cast materials is shown in FIG. 6 . This shows that the materials will be suitable for working in the frequency range of 500 kHz to 5 MHz. Above that frequency range the materials property deteriorate. To enhance the property further, the developed wires were annealed at different temperatures for 10 minutes. The variation of the peak value of GMI signal, GMI max measured at 1 MHz and 2 mA current for annealed wires (annealed at 300° C.) of both the alloys is shown in FIG. 7 . It clearly shows that the (Co 94 Fe 6 ) 72.5 Si 12.5 B 13 Cr 2 alloy exhibited superior properties after annealing at 300° C. Thus the material in the form of wire of diameter 100 μm±10 μm and having composition (Co 94 Fe 6 ) 72.5 Si 12.5 B 13 Cr 2 (at %) was used for the proposed sensing device to monitor carburization in SS321.
[0044] Embodiments of the invention have been described in detail for purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims. Thus, although the invention is described with reference to specific embodiments and figures thereof, the embodiments and figures are merely illustrative, and not limiting of the invention. Rather, the scope of the invention is to be determined solely by the appended claims. | The present invention relates to a compound exhibiting Giant Magneto-Impedance (GMI) properties. The general chemical formula of the compound is (Fe X Co 100-X ) 100-(α+β+γ) Cr α Si β B γ , characterized in that α<β and α<γ, wherein α is preferably in the range of 2 to 4% by weight, β is preferably in the range of 11.5% to 13% by weight, and γ is preferably in the range of 11% to 13% by weight, and X is preferably about 6% by weight. The chemical formula more preferably is (Fe 6% Co 94% ) 72.5% Cr 2% Si 12.5% B 13% . The present invention also relates to a giant magneto-impedance (GMI) based sensing device for non-destructive contactless detection of carburization in austenitic stainless steel samples in field. | 6 |
CROSS-REFERENCE TO RELATED INVENTIONS
[0001] This is a continuation-in-part of U.S. Application Ser. No. 11/177,009, filed Jul. 7, 2005, the disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to fall protection devices and systems which are attached to roofs of structures under construction. More particularly, this invention relates to fall protection devices and systems which are mounted on trusses or rafters of structures under construction, but are not attached to the fascia of such structures.
[0004] 2. Description of the Background Art
[0005] The Occupational Safety and Health Act mandates that every trade who must build or stand on a roof surface should have fall protection. At the very minimum a slide guard should be in place to protect the worker. The minimum slide guard is described as a two by four nominal dimension member secured on its edge to the roof below the worker to arrest his possible slide. Many trades must stand on a sloped roof to accomplish their work. Tradesmen include framing carpenters and roofers. For multi-storied structures, other tradesmen may include window installers, house wrap installers, siding installers, exterior trim carpenters, soffit installers, lathers and stucco crews.
[0006] In practice, the framing carpenter installs a slide guard on the roof surface, but it is often promptly removed when the framing is finished since it becomes an obstacle to some subsequent trades. Moreover, the guards are seldom replaced. There therefore exists a need to overcome the shortcomings of conventional fall protection devices.
[0007] Prior art include stanchions which attach to a truss below the roof line and to the fascia to dip down below the fascia and then up above the roof. Thus, the prior art cannot be employed in buildings designed with no fascia. Further, even though the buildings are designed with fascia, damage may occur where the fascia is the finished product. Still further, where the roofing requires a metal eave drip to the fascia to be installed before roofing, the connection to the fascia may have to be removed, thus rendering the prior art inoperable. Finally, the prior art cannot be properly attached until the fascia is constructed. Hence, there has existed a need for a fall protection device that does not require a mechanical attachment to fascia.
[0008] Representative prior art include U.S. Pat. Nos. 6,345,689; 5,221,076; 5,353,891; 5,573,227; 5,570,559; 4,666,131; 5,067,586; 4,669,577; 3,901,481; and 4,359,851.
[0009] Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the fall protection art.
[0010] Another object of this invention is to provide a fall protection system that attaches to a roof truss at a single point in such a manner as to extend below the fascia and return up above the roof surface such that the carpenters may attach the stanchions prior to hoisting the trusses onto the roof-bearing walls, or immediately thereafter, and then install the guardrails such that the workers are protected throughout the entire construction process.
[0011] Another object of this invention is to provide a fall protection system having various constructions for connecting the J-shaped stanchions to a roof truss, optionally including a separate attachment bracket that may be pre-installed onto the truss during fabrication of the truss at the factory to which the J-shaped stanchion is then removably connected during assembly on the job site.
[0012] Another object of this invention is to provide a fall protection system which is economical to manufacture while supporting the minimum impact of two hundred pounds (200 lbs.) required by OSHA for a slide guard or guard rail.
[0013] Another object of this invention is to provide a fall protection system including a J-shaped stanchion that is extendible to allow additional rows of guard rails to be installed.
[0014] The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
[0015] For the purpose of summarizing this invention, this invention comprises a fall protection system including a J-shaped stanchion which attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The J-shaped stanchion is designed to exceed the 200 pound minimum impact currently required by OSHA for a slide guard or guardrail. The J shape of the stanchion is configured to extend below the fascia and return up above the roof surface. During assembly, a plurality of stanchions is attached along the roof line. Horizontal fall protection guardrails are then connected to the upstanding stanchions thereby providing fall protection for workers. Notably, the single point of attachment to the trusses along the roof line allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and installed. Furthermore, the trusses may optionally be fabricated with a separate attachment bracket to which the J-shaped stanchion is removably connected. This feature of the preferred embodiment has the potential of protecting workers during the entire construction process of the structure which involves working on the roof. When all workers are safely off the roof, the stanchions may be easily removed and reused.
[0016] The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
[0018] FIG. 1 is a perspective view of the fall protection system of the invention including a J-shaped stanchion guardrail member and attachment bracket;
[0019] FIG. 2 is a side view of FIG. 1 attached to a truss of a building with a square cut fascia;
[0020] FIG. 3 is a side view of FIG. 1 attached to a truss of a building with a plumb cut fascia;
[0021] FIG. 4 is a perspective view of three stanchion guardrail members shown in FIG. 1 attached to the trusses of a building with the horizontal guardrail installed;
[0022] FIG. 5 is a perspective view of another embodiment of a the fall protection system of the invention with a removable extended stanchion;
[0023] FIG. 6 is a perspective view of another embodiment of the fall protection system of the invention with a permanent extended stanchion;
[0024] FIG. 7 is a perspective view of a lock bracket that may be employed in combination with the fall protection system of the invention to more securely lock the attachment bracket to the truss;
[0025] FIG. 8 is a perspective view of the fall protection system of the invention shown in phantom with the lock bracket mounted in position on the attachment bracket for locking the attachment bracket into position with the truss;
[0026] FIG. 9 is a side elevational view of another embodiment of the invention employing another type of coupler allowing a stanchion extension composed of a plank to be connected to the end of the stanchion; and
[0027] FIG. 10 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket composed of a center web with a multiplicity of punched barbs extending therefrom (preferably on both sides), that dig into the truss when the attachment bracket is installed;
[0028] FIG. 11 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket with pointed upper members to facilitate insertion between the rafter and the already-installed plywood;
[0029] FIG. 12 is a perspective view of another embodiment of the invention in which the attachment bracket is removably connected to the J-shaped stanchion allowing the attachment bracket to be first installed to the truss, the truss erected, and the J-shaped stanchion connected thereto;
[0030] FIG. 13 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention having a multiplicity of barbs formed in its center web for connection to the truss;
[0031] FIG. 14 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention particularly designed to be pre-installed at the during factory fabrication of the truss;
[0032] FIG. 15 is a perspective view of a J-shaped member employed as a support for another device such as a satellite dish;
[0033] FIG. 16 is a perspective view of a J-shaped member having a hook at its end which may be employed for supporting objects such as Christmas ornaments, plants, etc.;
[0034] FIG. 17 is a perspective view of a J-shaped member having an upstanding member serving as a flag pole; and
[0035] FIG. 18 is a side view of a J-shaped member which may be employed as a support for an object such as a basketball hoop.
[0036] Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Referring to the drawing of FIG. 1 , a J-shaped stanchion 1 includes a truss attachment bracket 2 in a preferred J shape comprised of center web 2 C to which an upper rear flange 2 A, upper front flange 2 B and lower flange 2 D, formed of flat stock steel are secured by weld 16 . The J-shaped formed of square stock tubing and bent 180 degrees is preferably affixed to the lower flange 2 D by weld 16 . Also preferably, two slide arrest guardrail brackets 3 , formed of flat stock steel and bent so as to accept a nominal 2′×4″ plank (or higher) horizontal slide arrest guardrail 5 (see FIG. 4 ) is affixed to the stanchion 1 by weld 16 on the upper portion thereof above the roof line at its side 17 to face roof-ward.
[0038] Referring next to FIG. 2 , the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with square cut fascia 6 . The attachment bracket 2 is preferably fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent to either side of the truss 11 . Where nails, bolts, screws, bolts, and their fastener equivalents are used to secure the attachment bracket 2 to the roof truss 11 , they are inserted through the orifices 4 in the center web 2 C of the attachment bracket 2 and into the adjacent truss 11 .
[0039] Stanchions 1 are respectively installed on respective roof trusses 11 along the horizontal roof edge 18 . The strength of this attachment is due to the envelopment of the roof truss 11 between the upper rear flange of attachment bracket 2 A, the upper front flange of attachment bracket 2 B and the lower flange of attachment bracket 2 D adjacent the center web 2 C causing the entire truss 11 to react as one with stanchion 1 on impact. The lower portion of the stanchion 1 is bent 180 degrees from its end 17 such that the guardrail brackets 3 are perpendicular to the plane of the roof regardless of the roof pitch.
[0040] Referring next to FIG. 3 , the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with plumb cut fascia 6 . Note that the J shape of the stanchion 1 provides adequate clearance for the fascia 6 .
[0041] Referring next to FIG. 4 , the stanchions 1 are installed along horizontal roof edge 18 and then the guardrails 5 are installed into the respective guardrail brackets 3 . As shown, when two stacked guardrail brackets 3 are employed on the stanchion 1 , the guardrails 5 overlap adjacent guardrails 5 at their ends.
[0042] Referring next to FIG. 5 , the stanchion 1 is extendable by a removable stanchion extension 1 A coupled to the stanchion by a coupler 20 . Guardrail brackets 19 , similar in construction to brackets 3 , comprise flat stock steel bent so as to accept a nominal 2×4 plank (or higher) slide arrest guardrail 5 (see FIG. 4 ), and are welded 16 to the upper portions of the extension 1 A to face roof-ward.
[0043] FIG. 6 illustrates an alternative embodiment of the invention illustrated in FIG. 5 in which the stanchion extension 1 A is integrally formed with the stanchion 1 .
[0044] Referring now to FIG. 7 , the invention also comprises a lock bracket 21 composed of a strip of steel bent in a generally L-shaped configuration. The shorter leg 21 A of the L-shaped configuration comprises an inwardly turned end 22 that defines space 23 between it and the balance of the shorter leg 21 A.
[0045] As shown in FIG. 8 , the lock bracket 21 is dimensioned to be installed after the attachment bracket 2 is mounted to the truss 11 whereby the lock bracket 21 more securely holds the attachment bracket 2 in position. More particularly, as shown in FIG. 8 , once the attachment bracket 2 is affixed to the end of the truss 11 with, for example, nails through orifices 4 , the space 23 of the lock bracket 21 allows it to be slid onto the lower flange 2 D from the inward side of the mounting bracket 2 to the underside of the lower flange 2 D with the end 22 overlapping one side thereof. When slid downwardly to meet the stanchion 1 , the 2×6 plank of the truss 11 is captured between the web member 2 C and the longer side 21 B of the L shape of the lock bracket 21 . The lock bracket 21 fully captures the truss 11 to prevent any loosening of the fasteners that secure the attachment bracket 2 to the truss 11 .
[0046] Referring now to FIG. 9 , in lieu of the stanchion extension 1 A previously described above, another type of extension may comprise a wood plank 25 such as a 2×4 plank which is coupled to the end of the stanchion 1 by a tubular coupler 26 that conforms at its one end to the outer circumference of a nominal sized plank 25 and its other end to the upper end of the stanchion 1 . As shown in FIG. 9 , the horizontal guardrails 5 may be connected to the stanchion extension 25 by conventional nailing 27 or other techniques for fastening wood components.
[0047] The operation of the preferred embodiment of the invention is as follows. Referring to FIG. 3 , the stanchion 1 is attached only to the rafter, roof truss, or roof member 11 and is attached up to two inches from horizontal roof edge 18 . The attachment bracket 2 is comprised of the upper rear flange 2 A, the upper front flange 2 B, the securing plate 2 C, and the lower flange 2 D. Working in concert with its comprised parts, the attachment bracket 2 , envelopes the girth of rafter, roof truss, or roof member 11 , and once stanchion 1 is attached at securing plate 2 C, by means of nailing, and or screwing, welding, strapping, gluing, bolting, or any known equivalent, no additional points of attachment are necessary. Since this is the only necessary connection to the rafter, roof truss, or roof member 11 , it becomes evident that the ideal location for this connection is on the ground before the rafter, roof truss, or roof member 11 is hoisted onto the wall 14 . Ground level installation has many advantages. The installation can be more precise, is easy to install, and due to the firm footing of ground level installation, the occurrences of injury from heights (ladders, scaffolding, lift equipment, etc.) is eliminated. Lock bracket 21 may be installed while still on the ground or after the trusses are hoisted and seated on the wall 14 .
[0048] The lock bracket 21 may be tethered to the attachment bracket 2 by a chain or other member to minimize the possibility of it being lost and inadvertently not used. Furthermore, to assure that the lock bracket 21 may not slide off, a headed stop pin 24 may be inserted into a hole in the lower plate 2 D to block the lock bracket 21 from being removed. The stop pin 24 may likewise be tethered to the attachment bracket 2 to prevent inadvertent loss or nonuse.
[0049] Ground level installation of the fall protection device stanchion 1 greatly reduces the work time involved in assembly, and allows the system to be substantially assembled prior to the workman being in peril. Immediately after the rafter, roof truss, or roof member 11 is hoisted onto structure 15 , the horizontal slide arrest guardrail 5 can be hoisted up and secured. Therefore, fall protection can be in position prior to the installation of the first sheathing/roof decking and if used until all roof operations are complete, it will provide the absolute time maximum uninterrupted fall guard protection possible.
[0050] The process of ground level installation, although preferred, does not limit the attachment of the fall protection stanchion 1 in other situations, such as existing structures, or in conventional framing, i.e., framing in which the construction of the structure must be built in the field, on the job site, such as hips, dormers, or any other roof or balcony configuration as is known to one of ordinary skill in the art. Such alternative attachments may require the use of additional equipment (ladders, scaffolding, lift equipment, etc.).
[0051] Optional dimensions of attachment bracket 2 are available to accommodate other nominal sizes of rafters, roof trusses, roof members 11 , or for any architecturally specified size rafter, roof truss, or roof member 11 .
[0052] Once stanchion 1 is properly attached to the rafter, roof truss, or roof member 11 , and the rafter, roof truss, or roof member 11 is properly affixed to building 15 and the slide arrest guardrails 5 are installed, a continuous barrier around the perimeter of the roof is formed. Such guardrails 5 may be composed of a nominal 2×4 or greater wood plank, a metal member, a crossbar, a rope, a strap, mesh netting or any known equivalent. The slide arrest guardrail 5 may be strung or inserted through the slide arrest guard bracket 3 and may be optionally fixed in place by means of nailing, screwing, welding, strapping, gluing, or bolting the strap to the bracket 3 , such nails, screws, bolts and equivalents, passing through the orifices 4 in the bracket 3 .
[0053] The stanchions 1 are secured to adjacent manufactured rafter, roof trusses or roof member 11 at horizontal roof edge 18 , they extend down below the fascia 6 location and up above the horizontal roof edge 18 where the 2×4 wood plank, metal member, crossbar, mesh netting or any known equivalent, horizontal slide arrest guardrail 5 is attached to the guard rail bracket 3 by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent and thus becomes the barrier which a sliding workman would contact thus preventing the workman from sliding off of the roof.
[0054] This fall protection device stanchion 1 attaches directly to the truss tail, and does not touch the fascia 6 ; therefore there is no interference with the process of snapping a line from the first rafter, roof truss, or roof member 11 , to the last rafter, roof truss, or roof member 11 , for the purpose of determining which horizontal roof edges 18 , do not line up. At this point the roof edge 18 can be saw cut straight for a square cut 6 , or plumb cut 6 , fascia without interference from the fall protection device stanchion 1 , thus allowing the attachment of the fascia 6 . Due to the encompassing features of the attachment bracket 2 , fascia optional architecture (open design with no fascia) still allows continuous fall protection for workman.
[0055] The continuous row of the J shaped stanchions 1 mounted along the horizontal roof edge 18 , allows a useful area in their inner radii for the temporary support of long stock materials, (i.e., fascia stock material or sub fascia stock material) thus providing a safer environment for the installation of the fascia 6 . Once the fascia 6 is attached and horizontal slide arrest guardrail 5 is properly fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent; the sheathing process may begin. Therefore the safety of workers is enhanced even before stanchion 1 begins providing fall protection.
[0056] Depending on the pitch and or overall size of a roof, OSHA requires additional slide guards at specific intervals going up the roof. As the sheathing or roofing progresses the stanchion 1 can be used as a brace against which a grid of additional 2×4 supports and slide guards can be constructed with ininimal or no penetration of the roofing surface.
[0057] The fall protection device stanchion 1 remains attached to the rafter, roof truss, or roof member 11 thus allowing all trades which may have to work on the roof surface, such as framers, roofers, plumbers, HVAC, electricians, window installers, siding installers, soffit installers, etc. to complete all work necessary while assuring continuous fall protection for all workman.
[0058] The attachment bracket 2 encompasses the rafter, roof truss, or roof member overhang 11 , in such a manner as to allow the girth of the rafter, roof truss, or roof member 11 to support the fall protection device stanchion 1 . This strong connection is suitable for attachment of additional devices such as stanchion extensions with additional guard rails, proprietary or others, and may be fastened by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent.
[0059] The fall protection device stanchion 1 attaches only to the rafter, roof truss, or roof member 11 and therefore does not interfere with the exterior finishes such as siding, lath, stucco, paint, trim, or other exterior claddings.
[0060] The fall protection stanchion 1 becomes suitable for additional devices such as bracket arm extensions 21 with additional nets, rope, cables, straps or any known equivalents. Additional ropes, cables, straps, harnesses or any known equivalent may be attached tied, strapped, clamped or any known equivalent to the fall protection stanchion 1 or harness ropes may be placed over the crown of the roof to a stanchion on the opposing side for support of the workers on the roof.
[0061] The fall protection stanchion 1 can be used to support any number of other devices such as Jacob's ladders, swings, swinging scaffolds, roof jacks, safety harnesses (for workman and materials) ropes, pulleys, beams, and cables upon which to hang lights, drapes or any known equivalent.
[0062] The attachment bracket 2 is preferably double-sided and can be used on either side of any given roof truss, rafter, or roof member 11 . Furthermore, the fall protection system is economical, has little or no moving parts, is sturdy, requires nominal if any maintenance, and provides value far beyond the cost to build install and maintain. Lastly, the device easily and safely removed and is fully reusable.
[0063] Referring now to FIG. 10 , as noted above, the attachment bracket 2 may be affixed to the end of the truss 11 by any suitable means. As shown in FIG. 10 , one method may comprise forming a multiplicity of barbs 30 in the center web 2 C, preferably extending on both surfaces thereof to engage into the surface of the truss 11 during assembly. Due to the engagement of the barbs 30 into the wood of the truss 11 , the attachment bracket 2 is firmly secured to the truss 11 .
[0064] It is noted that in re-roofing applications, the roofing plywood is already nailed to the trusses 11 and therefore, it would be difficult to force the upper rear and front flanges 2 A and 2 B therebetween. Accordingly, in order to facilitate forcing the flanges 2 A and 2 B between the roofing plywood and the truss 11 , as shown in FIG. 11 , the ends of the upper rear and front flanges 2 A and 2 B may comprise points 32 and be beveled. In this manner, the points 32 along with their bevels form a web shape that can be more easily driven between the roofing plywood and the truss 11 .
[0065] It is noted that in some applications, it may be desirable to have the J-shaped stanchion removably connected to the attachment bracket 2 . For example, as shown in FIG. 12 , the attachment bracket 12 may comprise a boss 34 formed on the underside of the lower flange 2 D which comprises a configuration and is properly dimensioned to fit into the tubular stanchion 1 . Aligned holes 36 and 38 formed in the stanchion 1 and the boss 34 allows a fastener 40 to be inserted therethrough to removably interconnect the bracket 2 to the stanchion 1 . During installation, the attachment bracket 2 may be installed to the end of the truss 11 whereupon the truss may then be hoisted onto the wall and, once secured, the stanchion 1 may then be connected to the bracket 2 by means of the boss 34 and fastener 40 . The removability of the stanchion 1 from the bracket 2 allows more convenient installation and erection of the fall protection system of the invention.
[0066] FIG. 13 illustrates still another method for attaching the attachment bracket 2 to the end of a truss 11 . More specifically, a plurality of barbs 30 are punched into the center web 2 C so as to engage into the wood of the truss 11 as described previously in connection with FIG. 10 . The embodiment of FIG. 13 , however, comprises a one-sided bracket, as opposed to the double-sided brackets described above. This one-sided bracket 2 is particularly adaptable to be installed at a truss factory during the fabrication of the truss itself. Indeed, it is contemplated that brackets 2 would be customarily installed at the fabrication plant during fabrication of the trusses whereupon, on the job site, the trusses would be erected onto the walls and the stanchions 11 then connected to the brackets by means of the removable connection composed of the boss 34 and fastener 40 that engages through hole 38 .
[0067] FIG. 14 illustrates still another embodiment of a one-sided bracket 2 intended to be factory-installed during fabrication of the trusses. More particularly, in this embodiment, in lieu of the center web 2 C, the bracket 2 includes two upstanding webs 2 W, each having inwardly facing barbs 30 . During assembly, the truss 11 is placed within the U-shaped channel formed by the lower flange 2 D and the upstanding flanges 2 W whereupon the barbs 30 of the upstanding flanges 2 W are then pressed into the wood of the truss 11 for assuring a secure connection.
[0068] As noted above, the attachment bracket 2 may be factory-installed or installed on the job site. In either case, the attachment bracket 2 with a removable connection may be used as a way of removably connecting modified stanchion members 42 to the attachment bracket 2 via the boss 34 and fastener 40 that engages into corresponding holes 36 and 38 . More particularly, as shown in FIG. 15 , the stanchion member 42 may comprise a support for a satellite dish 44 . In FIG. 16 , it is seen that the stanchion member 42 may be provided with an ornament hook 46 for connecting Christmas ornaments, plants, or any other object along the roof line of the structure. Indeed, the hook 46 with its bracket 46 B may be directly connected to the boss 34 . In FIG. 17 , it is seen that the stanchion member 42 may be fitted with a flag pole 48 for supporting a flag, pennant or other object 50 . Finally, FIG. 18 illustrates a stanchion member 42 having an elongated length to which is mounted a conventional basketball assembly 52 having a backboard 52 rigidly connected to the stanchion member 42 by brackets 54 .
[0069] Without departing from the spirit and scope of the invention it should be appreciated that FIGS. 15 through 18 are exemplary and that stanchion member 42 may be used to support many other objects along the roof line of a structure.
[0070] The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A J-shaped stanchion which attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The stanchion is designed to bend below the fascia and return up above the roof surface where successive stanchions similarly attached are connected via a fall protection guardrails providing fall protection for all workers. This single point of attachment allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and secured. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved concrete railroad grade crossing, and more particularly to an improved railroad grade crossing comprising concrete gauge panels which extend between the rails and further comprising concrete field panels which extend between each rail and the roadway. Even more particularly, the invention relates to improved elastomeric gauge seals which are attached to the sides of the gauge panels and relates to improved elastomeric field seals which are attached to the inner ends of the field panels. More particularly, the invention relates to the means for securing the seals to the panels through the use of bolts which extend through the metal edge protector of the panel and into the side of the seal for connection to an elongated member channel positioned in an elongated channel-shaped cavity in the seal.
2. Description of the Prior Art
Frequently, a railroad track crosses a roadway which necessitates that the space between the rails be filled with a material which brings that space up to grade. It is also necessary to bring the approaches on either side of the rails up to grade. In the past, precast concrete panels, or gauge panels, have been positioned between the rails and precast concrete panels, or field panels, have been positioned on the approach sides of the track. The prior art railroad grade crossings have also used elastomeric seals on the sides of the concrete gauge panels to fill the space between the gauge panels and the rails to prevent foreign materials from entering and filling the space between the gauge panels and the rail. The prior art railroad grade crossings have also used elastomeric seals on the inner ends of the concrete field panels to prevent foreign materials from entering and filling the space between the field panel and the associated rail. In some cases, the upper inner ends of the field panels and the upper outer ends of the gauge panels were chamfered or beveled to prevent portions of the concrete field panels and gauge panels from chipping off and filling the spaces between the panels and the rails. In other cases, angle irons or edge protectors have been used as edge protectors to prevent the chipping problem.
In later years, the gauge seals and field seals have been partially embedded in the concrete panels to aid in attaching the seals to the panels. However, even where the seals are partially embedded in the prior art concrete panels, it is believed that the prior art devices experience some attachment problems of the seals. Assignee's co-pending application, Ser. No. 10/268,398 filed Oct. 10, 2002, is believed to solve at least some of the attachment problems. The instant invention is believed to represent a further advance in the art.
SUMMARY OF THE INVENTION
A railroad grade crossing for extending a roadway across a pair of parallel spaced-apart rails is disclosed. The railroad grade crossing includes one or more concrete gauge panels which extend substantially between the rails. Each of the gauge panels has a top surface which is substantially coplanar with the roadway with the bottom surface of the gauge panel being supported upon the ties. Each of the gauge panels has an elongated elastomeric gauge seal on each side thereof which is positioned adjacent the rails. The upper ends of the gauge seals are positioned downwardly from the top surface of the gauge panel with the upper ends of the gauge seals having arcuate recessed portions formed therein adjacent the outer ends thereof. The inner ends of the gauge seals are attached to the gauge panels by a bolt and channel member assembly. Concrete field panels are positioned between each rail and the roadway associated therewith. Each of the concrete field panels has a top surface which is substantially coplanar with the roadway and a bottom surface which is supported upon the ties. The field panels have elastomeric field seals at their inner ends thereof with the upper ends of the field seals being preferably positioned downwardly from the top surface of the field panels. The inner ends of the field seals are attached to the inner ends of the field panels by a bolt and channel member assembly.
Elongated, metal angle members (edge protectors) are cast in the upper outer edges of the gauge panels and the upper inner edges of the field panels and are maintained therein by horizontally disposed DBAs (deformed bar anchors) and by vertically disposed headed studs. The bolt and channel member assembly which connects the seals to the panels comprises a plurality of horizontally spaced-apart bolts extending outwardly through slots formed in the vertical legs of the edge protectors with the heads of the bolts being positioned at the inner surface of the vertical legs. The bolts extend through openings formed in the inner sides of the seals with the openings communicating with an elongated channel-shaped cavity formed in the seal. One or more channel members are positioned in the channel-shaped cavity and have nuts welded thereto which are positioned thereon in register with openings formed in the web of the channel member. The threaded inner ends of the bolts extend through the openings formed in the web of the channel member and are threadably attached to the nuts on the channel member to secure the seal to the panel.
It is therefore a principal object of the invention to provide an improved concrete railroad grade crossing.
A further object of the invention is to provide an improved concrete railroad grade crossing comprising concrete gauge panels and concrete field panels wherein elastomeric seals are bolted to the panels and extend therefrom so as to be positioned adjacent the rails.
Still another object of the invention is to provide an improved method of attaching elastomeric gauge and field seals to gauge panels and approach panels, respectively.
Still another object of the invention is to provide an improved railroad crossing which has greater durability than the railroad grade crossings of the prior art.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial top plan view of the concrete railroad grade crossing of this invention;
FIG. 2 is a partial vertical sectional view of the concrete railroad grade crossing of this invention;
FIG. 3 is a partial exploded perspective view of one of the field panel seals of this invention;
FIG. 4 is a partial exploded perspective view of one of the gauge panel seals of this invention;
FIG. 5 is a partial vertical sectional view of the concrete railroad grade crossing of this invention; and
FIG. 6 is a partial exploded perspective view of one of the field seals of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the numeral 10 refers to a railroad track including rails 12 and 14 which are supported upon a plurality of spaced-apart ties 16 by means of tie plates 18 which are secured to the ties 16 in conventional fashion such as by spikes, clips or bolts. In many cases, the railroad track 10 must cross a roadway which is generally referred to by the reference numeral 20 .
Normally, a plurality of precast concrete approach or field panels 22 will be positioned between the roadway 20 and the rails 12 and 14 with the field panels 22 being supported upon the outer ends of the ties 16 . Normally, the field panels 22 will be positioned between the roadway 20 and one of the rails in an end-to-end fashion, the number of which will depend upon the width of the roadway and the length of the field panels. The numeral 24 refers to precast concrete gauge panels which are positioned between the rails 12 and 14 and which are supported upon the ties 16 . The gauge panels 24 are supported upon the ties 16 in an end-to-end fashion, the number of which will depend upon the width of the roadway and the length of the gauge panels.
Each of the approach or field panels 22 is comprised of a precast concrete material and includes top surface 26 , bottom surface 28 , and opposite sides 30 and 32 . Field panel 22 is provided with a recessed portion 34 formed therein at each of the opposite sides thereof to provide a clearance space for the spikes, bolts, clips, etc., which secure the tie plates 18 to the ties 16 and which secure the rail to the tie plate 18 in conventional fashion.
An elongated, metal angle member 38 (edge protector) is cast in the field panel 22 at the upper inner side thereof, as illustrated in the drawings, and which is held in place in the concrete by horizontally disposed and horizontally spaced retainers, rods or bars 40 secured thereto which are commonly referred to as DBAs (deformed bar anchors). The angle member 38 is also held in place by a plurality of vertically disposed and horizontally spaced retainers or studs 41 secured thereto having enlarged head portions at their lower ends. As will be explained in more detail hereinafter, a field seal 42 is secured to the inner end of each of the field panels 22 .
Each of the gauge panels 24 is comprised of a precast concrete material and includes top surface 44 , bottom surface 46 , and opposite sides 48 and 50 . Gauge panel 24 is provided with a recessed portion 52 at side 48 and is provided with a recessed portion 54 at its side 50 , as seen in FIG. 2 , to provide a clearance space for the spikes, bolts, clips, etc., which secure the tie plates 18 to the ties 16 and which secure the rails to the tie plates 18 in conventional fashion.
Elongated, metal angle members (edge protectors) 56 and 58 are cast in the gauge panel 24 at the upper outer sides thereof, as illustrated in the drawings, and which are held in place by horizontally disposed and horizontally spaced retainers, rods or bars 60 (DBAs) secured thereto. The angle members 56 and 58 are also held in place by a plurality of vertically disposed and horizontally spaced retainers or studs 61 secured thereto having enlarged head portions at their lower ends. As will be explained in more detail hereinafter, gauge seals 62 and 64 are secured to the outer sides of each of the gauge panels 24 . Inasmuch as gauge seals 62 and 64 are identical, only gauge seal 62 will be described in detail.
As seen in FIGS. 3 and 6 , field seal 42 is preferably comprised of an elastomeric material generally having an outer end 66 and an inner end 68 . The upper end 70 of seal 42 is preferably ribbed, as illustrated in FIG. 6 , with upper end 70 being preferably positioned below the top surface of the panel 22 and below the upper end of the associated rail (FIG. 2 ).
Elongated voids 72 and 74 are formed in the seal 42 to reduce the amount of material required to fabricate the seal. Additional voids may be utilized if so desired. Seal 42 is provided with an elongated channel-shaped cavity 76 formed therein which extends between the ends of the seal. Although other configurations of the cavity 76 may be used, it is preferred that the cavity 76 be channel-shaped in cross-section. For purposes of description, cavity 76 will be described as including an upper cavity portion 78 , intermediate cavity portion 80 , and lower cavity portion 81 . A plurality of horizontally spaced-apart openings 82 extend inwardly from the inner end 68 of seal 42 into the cavity 76 . One or more channel members 84 are positioned in cavity 76 as seen in the drawings. For purposes of description, each of the metal channel members 84 will be described as having an upper flange 86 , web 88 and lower flange 90 . The web 88 is provided with a plurality of horizontally spaced-apart openings 92 formed therein. Flange nuts 94 are welded to web 88 as seen in the drawings at each of the openings 92 . Edge protector 38 has a plurality of horizontally spaced-apart slots 96 formed therein. Bolts 98 extend outwardly through slots 96 in edge protector 38 , through openings 82 , and through openings 92 in channel member 84 for threadable connection to the nuts 94 to secure the seal 42 to the panel 22 .
The gauge seals 62 and 64 have elongated channel-shaped cavities 76 ′ formed therein which are identical to the cavities 76 of seal 42 and which receive channel members identical to channel members 84 . The edge protectors 56 and 58 have slotted openings 96 ′ formed therein which are identical to slots 96 .
The gauge seals 64 are secured to the opposite sides of the gauge panel 24 in a manner identical to that just described. Bolts 98 ′ extend through slots 96 ′ in the vertical leg portion of edge protectors 56 and 58 through openings 82 ′ in seals 62 and 64 , through openings 92 ′ in channel members 84 ′ for threadable connection to the nuts 94 ′ which are welded to the channel members 84 ′.
The bolts 98 and 98 ′ are positioned in the edge protectors during the assembly of the panels prior to concrete being placed into the form. The seals are also attached to the bolts 98 and 98 ′ before concrete is placed into the form. The slots 96 and 96 ′ permit the bolts 98 and 98 ′ to be brought into alignment with the openings 92 and 92 ′. The bolts are threadably received by the nuts 94 and 94 ′ to securely fasten the seals to the panels. The channel-shaped cavities in the seals help to maintain the channel members 84 and 84 ′ in the seals in the proper position while the seals are being attached to the panels so that the openings 92 will be in alignment with the openings 82 .
The invention herein ensures that the seals will be securely attached to the panels and will not become detached therefrom during or after installation. The invention herein also provides a method of attaching the seals to the panels which facilitates rapid assembly of the structure.
Thus it can be seen that the invention accomplishes at least all of its stated objectives. | A concrete railroad grade crossing comprised of a precast concrete gauge panel extending between the rails and precast concrete field panels which extend between each rail and the roadway. Elastomeric gauge seals are provided on the opposite sides of the gauge panels for sealing the space between the sides of the gauge panels and the rails. Elastomeric field seals are provided on the inner ends of the field panels for engagement with the outer sides of the rails. The seals are secured to the panels by bolt and channel member assemblies. | 4 |
FIELD OF THE INVENTION
[0001] The present invention regards a technique for engrafting plants and a tool for implementing the technique. The technique and instrument are suitable for engrafting plants in a vegetative pickup step or not, for fruit trees or ornamental plants already well established after transplant, where the graft-holder and the graft have a diameter at least close to that of a vine shoot or rose stem variable in the range of 6-12 mm, and on branches, especially of fruit trees, obviously even of a diameter exceeding 12 mm.
STATE OF THE ART
[0002] The use of engrafting in agriculture has been known for centuries and both the techniques and tools for implementing them, range from the knives appropriate for producing “split” grafts, “near” grafts by an English double split or an “eye”, up to the latest pedal-actuated bench-scale machines and known tools operating with milling cutters for producing the indented grafts known as of a “tenon-mortise” types and the so-called “omega” grafts.
[0003] At present, the grafts on transplanted plants must still be manually produced by an expert grafter using an appropriate knife or special tongs as used for the “omega” graft.
DRAWBACKS IN THE STATE OF THE ART
[0004] The use of an engrafting knife and tongs implies above all that the grafter be an expert in his technique, and also involves a considerable amount of time, especially when the operation is to be performed on a substantial number of plants with a highly compact fibro-vascular structure. It must further be added that with the known techniques and means the engrafting requires a binding or wrapping of a very accurate and long-lasting type.
SUMMARY OF THE INVENTION
[0005] The invention comprises a technique for preparing the graft exchanging surfaces and a portable tool for implementing the technique.
[0006] It should be premised that the term “perpendicular cut” is used to mean that the cut is done at 90° from the longitudinal axis which the portion (graft holder or graft) presents in the engrafting zone, and that the terms “axial” and “longitudinal” are used to designate the coincidence with the central longitudinal axis of the portion in the engrafting zone and with a direction parallel to the longitudinal axis of said portion, respectively; the term “transversal axis” of a graft holder or graft is used to designate any of the axes passing through the centre and set perpendicular to the longitudinal axis.
[0007] It is also made clear that in the inventive technique the longitudinal hollow seats and longitudinal extensions of the two portions are well defined and matching each other, which means that the portions are worked with the same tool, with the same milling cutters mounted on the tool and with the same reciprocal position of the milling cutters. After axially rotating one portion 180° with respect to the other, the longitudinal extensions of one portion end up to be exactly facing the longitudinal hollow seats of the other, and the grafting is done by inserting the longitudinal extensions into the hollow seats.
[0008] It is further clarified that the term “inner face” of a milling cutter designates the face lying opposite the inner face of the other milling cutter.
[0009] It is finally clarified that the term “inner face” of a hollow seat indicates the face adjacent to the inner face of the other hollow seat.
[0010] The technique according to the invention comprises the steps of:
i) perpendicularly cutting the graft holder and the graft in the respective areas chosen for the engrafting, ii) mechanically removing material from the cut-out extremities of the graft holder and of the graft by using a milling machine fitted with two parallel milling cutters of different thickness, where the inner face of the milling cutter of smaller diameter lies in the plane passed by the central longitudinal axis of the graft holder and of the graft, so as to create longitudinal hollow seats and longitudinal extensions matching each other, while the extensions of one portion are exactly interpenetrating the hollow seats of the other portion, and the longitudinal central axes of the graft holder and of the graft end up to be coincident. iii) alternatively, mechanically removing material from the cut-out extremities of the graft holder and of the graft by using a milling machine fitted with two parallel milling cutters, so as to create longitudinal hollow seats and longitudinal extensions matching each other, where the extensions of one portion end up to be exactly interpenetrating the hollow seats of the other portion; and iv) coupling the extremities of the graft holder and of the graft rotated 180° around its longitudinal axis, so that the longitudinal extensions of one portion enter into the hollow seats of the other portion.
[0015] As a whole, the tool according to the invention comprises the following:
a) a fork-shaped element essentially in the shape of a V, in whose cavity the graft holder and the graft are held fast by hand one after the other, regardless of the steps ii) or iii) of the technique, while one central transversal axis of the same passes through the apex of the fork-shaped element; b) two parallel milling cutters of different thickness held apart by a distancing element of a thickness equal to the thickness of the smaller milling cutter where the inner face of the latter milling cutter lies in the plane passed by the central longitudinal axis of the graft holder and of the graft, are moved by an electrical motor designed to remove two longitudinal portions of the graft holder, and two equal longitudinal portions of the graft held fast in the fork-shaped element (the term “equal” stands to mean that the longitudinal portions carved out in the graft holder are equal to the longitudinal portions carved out in the graft), thus creating hollow seats and longitudinal extensions matching each other; c) alternatively, two milling cutters set up in parallel and separated from each other by a distancing element moved by an electric motor designed to remove at least two longitudinal portions of the graft holder and at least two equal portions of the graft held fast in the fork-shaped element, thus creating hollow seats and longitudinal extensions matching each other; d) a battery powering the electric motor; e) alternatively, an electrical cable connecting the electrical motor with a remote source of electrical power being a battery separated from the body of the tool, a portable current generator or a current outlet of a stationary electrical power plant connected to the motor by an electrical cable and a suitable interposed electrical transformer; f) as a result of the solution illustrated at the preceding point, an extension of the motor shaft in the rear portion, for the mounting of an auxiliary pair of milling cutters; and g) a kit of milling cutters of various diameter and thickness, a kit of spacers of different thicknesses to separate the two chosen milling cutters to be mounted on the tool, and a device to vary the transversal and longitudinal positions, respectively, of the fork-shaped element so as to adapt it to the milling cutters eventually mounted on the tool and to hold it close to the cutting-out line of the milling cutters during the operation.
[0023] It is understood that the diameter, the thickness and the reciprocal distance of the milling cutters are chosen depending on the dimensions and botanical characteristics of the portions to be grafted. It is likewise understood that the milling cutters already known in the field have two, three or more teeth, or are milling cutters in the shape of a disc for circular saws with a high number of teeth.
[0024] It is also understood that the tool can be realized with the shaft on which the milling cutters are mounted being coincident with or parallel to the motor shaft or set an angle of up to 90° with respect to the motor shaft, in order to facilitate the work under certain conditions, such as when it is necessary to operate on the extremity of a graft-holder after transplant.
ADVANTAGES OF THE INVENTION
[0025] The main advantages of the technique and of the tool of the invention are in allowing the production of small grafts (vine shoots, rose stems, and the like) by using a single portable and lightweight tool, so portable and lightweight as to be capable of being kept in a pocket or in a grafter's bag, in its operating speed and in the precision and strength of the achieved graft. The graft achieved by interpenetrating the matching and closely coupled portions can in fact simplify the binding and wrapping step. A further advantage is represented by the fact of also allowing the production of large-size grafts (branches of trees and the like). Another, certainly not secondary advantage is represented in that the tool, being lightweight, portable and versatile in its general application, facilitates and encourages experiments and research studies aimed at producing new hybrids and plant varieties.
[0026] Other advantages are given by the fact of allowing interchanges between pairs of milling cutters and spacers of various diameters and thicknesses depending on the characteristics of the graft to be carried out, the penetrating depth of the milling cutters and the fact that the milling cutters, while sliding over the fork-shaped element, shave off the bark of the graft holder and of the graft at the level of the exchanging surfaces, thus producing very “clean” surfaces. Finally, the possibility of mounting, on the rear portion of the tool, a pair of milling cutters differing from that mounted on the front portion offers the advantage of quickly producing grafts of an unusual or unexpected kind, without having to remove the milling cutters that have been pre-arranged on the front side for the purpose of producing the grafts commonly employed by a user.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The invention will now be described in detail through an example of an embodiment and with the aid of the simplified enclosed drawings, wherein the dimensions of the milling cutters and of the fork-shaped element are enlarged with respect to their real size, so as to render the drawings more effective and where
[0028] FIG. 1 is a first partially sectionalized view,
[0029] FIG. 2 is first prospective view,
[0030] FIG. 3 is a vertical section,
[0031] FIG. 4 is a first overall view,
[0032] FIG. 5 is a side view, and
[0033] FIG. 6 is a second overall view.
[0034] FIG. 1 shows a side view of the upper extremity of a graft holder 1 constituted of a vine shoot after transplanting, which has been cut-out perpendicularly along the chosen section S-S, and worked by the milling cutters 3 , 4 . This extremity is held fast in the fork-shaped element 2 of the tool, an element that is shown as being far removed from its working position so as to clearly illustrate this exposure, as can be seen in the transversal view of the lower portion of the figure. The longitudinal central axis X-X of the graft holder passes through the apex V of this fork-shaped element. The milling cutters 3 , 4 have shaped two longitudinal hollow seats 5 , 6 and the longitudinal extensions 7 , 8 which are better visible in FIG. 2 . The milling cutters 3 , 4 are appropriately spaced apart from each other by a suitable axial spacer 9 , so as allow the longitudinal central axis X-X of the graft holder 1 to be contained in the inner face of the milling cutter 3 , whose thickness coincides with the thickness of the spacing element 9 . The two milling cutters are mounted on the shaft 10 of an electrical motor 11 powered by a battery 12 and are contained in the handle of the tool (not shown). The axial spacer 9 is part of a kit of axial spacers of different thicknesses, so as to allow the grafter to set the milling cutters at their most appropriate reciprocal distance, on a case-by-case basis. For convenience in the current description, the graft 13 is also aligned with the graft holder 1 , so as to allow understanding the way the milling cutters are used to create the longitudinal extensions 14 , 15 destined to couple with the axial hollow seats 5 , 6 . It should be observed that the same couple of milling cutters is used to work the extremity of the graft holder 1 and the extremity of the graft 13 , and that in reality the graft 13 will be milled by holding it in the fork-shaped element 2 (as the graft holder 1 was held fast) and will then be rotated 180° to graft itself onto the graft holder, as shown in FIG. 2 . The number 16 designates the teeth of the milling cutters. The fork-shaped element 2 , whose walls are grazed by the teeth of the milling cutters during the operation, acts so that the bark of the graft holder and of the graft are shaved-off at the level of the exchange surfaces, thus producing very “clean” cuts.
[0035] FIG. 2 shows the extremity of a graft holder 1 worked according to the technique and the tool of the invention. The extensions 7 , 8 , the hollow seat 5 and the lateral seat 6 can be seen.
[0036] FIG. 3 shows the two portions 1 and 13 in their initial engrafting step: the extensions 14 , 15 of the graft 13 are penetrating into the seats 5 , 6 of the graft holders 1 . The longitudinal central axes of the two portions coincide with the axis X-X passing the inner face of the longitudinal extension 8 . The width of the hollow seat 5 coincides with the width of the extension 15 .
[0037] FIG. 4 shows the tool 20 as a whole. The handle of the tool contains a battery 11 that powers an electrical motor 12 whose shaft 10 mounts two milling cutters 3 , 4 that are spaced apart by the spacer 9 and set in a radial direction partially protected by the cover 21 and in the front by the shield 22 . At the level of the exposed portions of the two milling cutters, there is a fork-shaped element 2 fastened to the handle of the tool so as to receive a graft holder 1 to be worked in its hollow. It can be seen that the axis X-X passes through the inner face of the milling cutter 3 , the centre of the graft holder 1 and the apex V of the fork-shaped element 2 . The fork-shaped element 2 slides perpendicularly to the axis Y-Y along a guide G, and parallel to the axis Y-Y along another guide, not shown.
[0038] FIG. 5 shows the profile generally used for the milling cutters of a conventional mechanical engrafting machine. The milling cutter 3 partially covers the milling cutter 4 , and 16 indicates the teeth of the milling cutters.
[0039] FIG. 6 shows a tool 20 a that carries the pair of milling cutters described in FIG. 1 and a pair of auxiliary milling cutters 30 , 40 mounted on the rear extension 10 aa of the motor shaft 12 a. It shows that the rotating shaft 10 b of the milling cutters 3 a and 4 a is set up perpendicular to the rotating shaft 10 a of the motor 11 a. The transmission between the shafts 10 a and 10 b is conventionally realized by two conical gears 25 and 26 . This tool is also fitted with a fork-shaped element 2 a, whose apex V lies in the plane of the internal surface of the milling cutter 4 a. It will be grasped that whenever the size of the milling cutter changes, the fork-shaped element 2 must be shifted in a transversal direction. This element will also be endowed with the possibility of shifting in a longitudinal direction, so as to make it possible to appropriately approach it to the cutting-out edge of the milling cutters during the material removing operation. This version of the tool does not contain a battery in its housing. The power supply to the motor 12 a occurs through the electrical cable 13 that connects it to a suitable battery carried by the grafter in a shoulder bag. The rear extension 10 aa of the motor shaft carries a square terminal section, so as to receive and hold the extremity of an auxiliary shaft 32 fast on the same, in which two auxiliary milling cutters 30 , 40 are mounted and spaced apart by a spacing element 33 . This assembly of auxiliary milling cutters comprises milling cutters of a size larger than that of the milling cutters 3 , 4 , so as to allow the engrafting of graft holders and grafts of a larger size or of a different consistency from those workable by using the milling cutters 3 , 4 , and a fork-shaped element 2 aa is mounted with the same criteria shown in FIG. 1 .
[0040] It is understood that the tool may be constructed to contain the portions mentioned above, except for the battery, which is to be kept separate as stated. | Material is mechanically removed from the cut-out extremities of the graft holder ( 1 ) and graft ( 13 ) by a tool fitted with two parallel milling cutters ( 3, 4 ) of different thickness, in which the inner face of the milling cutter of smaller thickness ( 3 ) lies in the plane passed by the longitudinal central axis (X-X) of the graft holder and of the graft, so as to create two matching longitudinal hollow seats ( 5, 6 ) and longitudinal extensions ( 14, 15 ), where the extensions of one portion end up being exactly capable of interpenetrating the hollow seats of the other portion, and the longitudinal central axes (X-X) of the graft holder and of the graft turn out to be coincident. | 0 |
BACKGROUND OF THE INVENTION
This invention generally relates to puzzles that are assembled by matching assembly information on adjacent cards and, more particularly, to the type of puzzle in which a picture is formed through the correct responses to a quiz or set of quiz-like associations.
Numerous puzzles and games provide people of all ages with many hours of entertainment, but provide very little if any educational experience. However, educational experience gained from memorizing facts, reading flash cards or rote learning of any kind often involves mind-numbing drill which can destroy interest and motivation for learning. Furthermore, educational experience of this type usually requires outside assistance for direction, encouragement and grading.
Although teachers have long recognized the usefulness of drill, drill as such has been downgraded in many educational circles because it is associated with old-style, authoritarian methods, and because it often fails to stimulate interest in the learner. This invention takes into account both the usefulness of drill and the importance of interest arousal. This invention can serve the repetitive function of drill, but it can also serve to stimulate and to motivate the learner by providing a sense of accomplishment and pleasure as the picture takes shape and finally is completed when all the correct associations have been made.
The principal object of this invention is to provide a novel puzzle that has the combined benefits of being educational, entertaining, self-teaching and self-correcting. The puzzle can be made to give educational experience on any subject such as math, history, language, sports, literature, etc. and on any achievement level. The formation of a picture through the correct responses to a quiz or matching of quiz-like associations provides entertainment. Self-teaching is achieved through the process of reading, thinking, searching among alternatives and responding without outside assistance. Self-correction occurs when the incorrect formation of the picture is observed, thus indicating incorrect responses to the educational material.
Several known picture and quiz-type puzzles require apparatus to accommodate part of the quiz and response information, in addition to the puzzle pieces. U.S. Pat. No. 1,701,557 (D. Clinch et al, Feb. 12, 1929) requires a column of questions or instructions on a separate folder, in addition to the puzzle pieces. U.S. Pat. No. 2,481,109 (M. C. Grace, Sept. 6, 1949) requires a set of cards that contain information, in addition to the puzzle pieces. Tray Puzzles (currently manufactured by Ideal School Supply Co.) require an answer tray, in addition to the puzzle pieces.
Accordingly, one object of this invention is to provide apparatus which incorporates all quiz and response information or quiz-like information on the puzzle pieces. This has the advantage of simplifying the apparatus over these previously known puzzles.
U.S. Pat. No. 3,171,214 (A. Sutherland, Mar. 2, 1965) describes a method that includes all quiz and response information on the puzzle pieces, but this method provides an area no larger than the picture segments. This greatly restricts the amount of quiz and response information necessary for educational value, particularly for puzzles comprising a large number of pieces.
Accordingly, another object of this invention is to provide a considerably larger area on each puzzle piece than the picture segment; the area does not decrease for puzzles comprising a large number of pieces. This enables the quiz and response information or quiz-like information to be in the form of pictures, sentences, paragraphs and brief stories, which can greatly expand and improve the educational value.
Still another object of this invention is to provide a puzzle that is simple and economical to produce. This makes it possible for more people to afford this type of educational puzzle over other known educational puzzles.
Another important advantage of this invention is the ease of handling and storing the puzzle pieces, since they are in the form of cards (similar to ordinary playing cards). This would appeal to the people who enjoy the manipulating of playing cards.
Although this puzzle is ideally suited for one person, several people can play as a cooperative or competitive game. Each player can be assigned to assemble a particular portion of the puzzle or points can be awarded to the player who finds the correct match.
These and other objects and advantages of this invention will be more readily apparent from a consideration of the summary and the description of the several forms of this invention.
SUMMARY OF THE INVENTION
One form of apparatus based on this invention comprises a plurality of cards and a card holder. The cards are designed to partially overlap each other, when placed on the card holder, so that exposed portions of the cards form a picture. The cards also contain assembly information which is used as a guide to assemble the puzzle.
The card holder provides a series of open slots to receive the cards individually. The slots and the cuts extending from the slots are designed to position and releasably hold the cards substantially flat against each other so that exposed picture segments can be easily viewed. The lower edge of each slot is also the upper edge of a tab which is forced to raise slightly when a card is inserted. The pressure of the tab against the inserted card acts to hold the position of the card. Cuts extending from both sides of the base of each tab automatically provide a stop as each card is inserted.
The cards can be made similar to ordinary playing cards as to size, material and thickness. A tab is provided at the bottom of each card as a means to insert the card into a slot in the card holder.
The cards can be divided into three classes: the "beginning cards," the "middle cards" and the "end cards." The face of each card displaying the picture segment will hereafter be referred to as the top side.
The top side of each "beginning card" is divided into two areas; one area contains the picture segment and the other area contains the assembly information. The underside of each "beginning card" contains start information.
The top side of each "middle card" is also divided into two areas; one area contains the picture segment and the other area contains the assembly information. The underside of each "middle card" contains assembly information.
The entire top side of each "end card" contains a picture segment and the underside contains assembly information.
The inspection of the picture segments is not intended to be used as a means to assemble the puzzle, but only to indicate mistakes. The puzzle is to be assembled by matching assembly information located on the cards, which can be in the form of any suitable associations of letters, words, phrases, sentences, paragraphs, brief stories, pictures, symbols, numerals, clues and any combination thereof. For example, in the brief story and picture categories, the descriptions of various species of birds as to size, color, habits, locale, etc. can be matched to pictures in color of the various birds.
Picture segments that do not visually align, in form and color, to adjacent picture segments, indicate that an improper association between the assembly information has been made. A mistake can be immediately noted so that one will not assume a correct response has been made. This will prevent confusion that can result from discovering errors after a period of time, and then unlearning what was thought to be true.
The puzzle is assembled as follows:
The "beginning cards" are inserted into the top row of slots of the card holder. The marking "START 1," "START 2," "START 3," etc. on the underside of each "beginning card" is matched to the marking "START 1," "START 2," "START 3," etc. on the face of the card holder respectively. The picture segment and assembly information on the top side of each "beginning card" is now displayed.
The remaining "middle cards" and "end cards" are now shuffled to minimize logical order.
The assembly information on the underside of each card is now read and compared to the assembly information displayed on the "beginning cards". When a likely match is found, the "middle card" is inserted into the slot immediately below the slot occupied by the "beginning card." This "middle card" covers the assembly information on the "beginning card," and now displays new assembly information. If a correct match has been made, the form and color of the picture segments will align. The assembly information on the top side of a correctly positioned "middle card" can now be used.
As the assembly information is matched, the cards are inserted into the card holder, one immediately below the other, until all cards are in place.
In another form, based on this invention, the apparatus comprises only a plurality of cards. The cards are designed to partially overlap each other, when attached to each other, so that exposed portions of the cards form a picture. The cards also contain assembly information which is used as a guide to assemble the puzzle, exactly as described in the first form of this invention.
A tab is provided at the top of each "middle card" and each "end card" for a means to insert the card into an opening in any "beginning card" or other "middle card". Cuts formed in the face of each "beginning card" and each "middle card" provide the means for forming the opening during assembly of the puzzle. The cuts are also designed to position and releasably hold the cards substantially flat against each other so that exposed picture segments can be easily viewed.
A tab immediately above the opening in each "beginning card" and each "middle card" is forced to raise slightly when a card is inserted. The pressure of the tab against the inserted card acts to hold the position of the cards with respect to each other.
The puzzle is assembled in columns, starting with each "beginning card." As described in the first form of this invention, it is intended for the puzzle to be assembled only by matching related assembly information. When all columns are completely assembled, they are placed next to each other to form the entire picture.
In one modification, the widths of several cards can be increased so that they are common to two or more columns. This will hold the columns together and provide increased areas for the assembly information. This would be particularly useful for assembly information consisting of pictures.
A modification can also be made to the tab at the top of each "middle card" and each "end card". This will lock the cards together to prevent the cards from slipping with respect to each other while the puzzle is being assembled. Each tab is also designed to enable the cards to be easily unlocked from each other.
In the drawings:
FIG. 1 is a front view of the card holder.
FIG. 2 is a side view of the card holder.
FIG. 3 is a perspective view of a portion of the card holder.
FIG. 4 is a perspective view of a portion of a modified form of the card holder.
FIG. 5 is a front and rear view of a "beginning card."
FIG. 6 is a front and rear view of a "middle card."
FIG. 7 is a perspective view of two cards inserted into a portion of the card holder.
FIG. 8 is a front and rear view of an "end card."
FIG. 9 is a perspective view of a partially assembled puzzle.
FIG. 10 is a perspective view of several loose cards to complement the puzzle in FIG. 9.
FIG. 11 is a front and rear view of a "beginning card" for a puzzle consisting only of cards.
FIG. 12 is a front and rear view of a "middle card" for a puzzle consisting only of cards.
FIG. 13 is a perspective view of three cards attached to each other for a puzzle consisting only of cards.
FIG. 14 is a front and rear view of an "end card" for a puzzle consisting only of cards.
FIG. 15 is a front view of a modified form of several attached cards.
FIG. 16 is a front view of two cards having modified tabs for locking the cards together.
FIG. 17 is a front view of two cards being unlocked from each other.
DESCRIPTION OF THE INVENTION
A front view on the entire card holder is shown in FIG. 1. The card holder consists of a front layer 10 which is bonded to a rear layer 11 as shown in FIG. 2. Heavy paper, cardboard, plastic or the like are suitable materials for both layers 10 and 11. The cards are held entirely by the front layer 10. The front layer 10 is relatively thin which can be approximately twice the thickness of ordinary playing cards. The rear layer 11 provides a space directly below each slot and adds strength to the card holder.
All cuts made in the face of the card holder which include the formation of the slots and the cuts extending from the slots will hereafter be referred to as face cuts.
The front layer 10 provides a series of identical slots and face cuts extending from the slots which are arranged in five columns and six horizontal rows. Face cuts 12 and 13 represent the upper edge and the lower edge of any slot in the front layer 10. "START 1," "START 2," "START 3," "START 4" and "START 5" are printed over the columns as shown in FIG. 1.
The number of columns and rows can vary according to the intended difficulty of the puzzle. For preschool children, a card holder providing only one column of three slots can be sufficient. For adults, a card holder providing 10 columns and 10 rows of slots would make a challenging puzzle.
The construction of a typical slot and the face cuts extending from the slot is best shown in FIG. 3. All face cuts are entirely through the front layer 10. Face cuts forming the left edge 14 and the right edge 15 of a typical slot extend to meet perpendicular face cuts 16 and 17 respectively. The lower edge 13 of a typical slot is also the upper edge of a tab formed by face cuts 13, 14 and 15.
All tabs formed from face cuts 13, 14 and 15 will hereafter be referred to as face tabs. The point where face cuts 14 and 16 meet and the point where face cuts 15 and 17 meet define the base of a typical face tab. Thus, face cuts 16 and 17 are located on each side of the base of a typical face tab and extend away from each other.
A tab located on the bottom edge of each card, hereafter referred to as an edge tab, will fit between face cuts 14 and 15. In assembling the puzzle, this will provide a guide to accurately locate the inserted card horizontally, and face cuts 16 and 17 automatically provide a stop to accurately locate the inserted card vertically. This facilitates the accurate locating of the cards, so that the picture segments will properly align.
The construction of the rear layer 11 is best shown in FIG. 3, where a portion of the front layer 10 is graphically cut away. A rectangular space 18 is provided directly below each slot to provide space for the edge tab while the card is being inserted into the slot.
Since the cards are held entirely by the front layer 10, it is possible to eliminate the rear layer 11 with some sacrifice to the rigidity of the card holder. Simply holding the card holder in one hand will provide space below the slots. Resting the card holder on a soft surface, such as a rug, will permit the insertion of the edge tabs.
In many instances it is convenient to assemble the puzzle on a smooth hard surface, such as a table top. A card holder formed of a single layer 19 can be designed to provide space below the slots as shown in FIG. 4. Space is provided below all slots by raising the sheet material 19 above the table top. A tab 20 above each slot is curved to extend below the plane of the sheet material 19. This will maintain the necessary space below all slots.
Another modification to the cuts is also shown in FIG. 4. The face cuts forming the left edge and the right edge of the slot can be extended below the perpendicular face cuts as shown by face cuts 21 and 22. These face cuts act to hold the center position of the inserted card.
The cards can be made similar to ordinary playing cards as to size, material and thickness. All cards are identical in shape, including the edge tab at the bottom of each card. The edge tabs provide the means to insert the cards into the slots in the card holder.
The cards can be divided into three classes: the "beginning cards," the "middle cards" and the "end cards." Only one side of each card displays a picture segment. The face displaying the picture segment is referred to as the top side.
FIG. 5 shows both the top side and the underside of a typical "beginning card" 23. The top side of "beginning card" 23 is divided into two areas; the area in the top portion contains the picture segment 24 and the area in the lower portion contains the assembly information 25. The underside of the "beginning card" 23 contains information 26 which says "START 3." In assembling the puzzle, this card should be placed in the third column and top row to cover the information "START 3" printed on the card holder. The edge tab 27 is shown at the bottom of the card.
FIG. 6 shows both the top side and the underside of a typical "middle card" 28. The top side of the "middle card" 28 is divided into two areas; the area in the top portion contains the picture segment 29 and the area in the lower portion contains the assembly information 30. The edge tab 32 is shown at the bottom of the card. In assembling the puzzle, the assembly information 31 on card 28 can be correctly matched to the assembly information 25 on card 23; card 28 is then placed in the third column and second row to cover the assembly information 25 on card 23. Assembly information 30 on card 28 is now displayed.
FIG. 7 shows how the form of the picture segment 24 aligns with the form of the picture segment 29 when card 28 is positioned on the card holder immediately below card 23. The face tab formed by the edges 13, 14 and 15 is forced to raise to a distance no greater than the thickness of the inserted card 28. The pressure of the face tab against the inserted card 28 acts to hold the position of the card 28 substantially flat against card 23. The edges 16 and 17 connect the raised face tab to the plane of the front layer 10 of the card holder. This automatically provides a stop to accurately locate the inserted card 28.
FIG. 8 shows both the top side and the underside of a typical "end card" 33. The entire top side of the "end card" 33 contains a picture segment 34 and the underside contains assembly information 35. The edge tab 36 is shown at the bottom of the card.
The start information printed on the card holder and the underside of the "beginning cards" is used as a guide to correctly locate the first card of each column on the card holder. A plurality of puzzles can be made to have the same start information contained on the "beginning cards," but having different assembly information contained on the "middle cards" and "end cards." In this way one card holder can be standard for a plurality of puzzles with assembly information covering a plurality of subjects. Thus, additional puzzles can be purchased without the expense of additional card holders. If the manufacture and sale is not intended to include additional puzzles, then assembly information consistent with the assembly information on the "middle cards" and "end cards" can be used as the start information.
The overall formation of a partially solved puzzle is best shown in FIG. 9. Several loose cards not yet placed on the card holder in FIG. 9 is shown in FIG. 10. This puzzle is designed for 30 cards: five "beginning cards," 20 "middle cards" and five "end cards." There are five "beginning cards", fourteen "middle cards" and three "end cards" correctly in place. The assembly information displayed on the underside of card 38, shown in FIG. 10, can be correctly matched to assembly information on the top side of card 37, shown in FIG. 9. In assembling the puzzle, card 38 should now be turned over to expose the top side, and then placed on the slot immediately below the slot already occupied by card 37. Card 38 will then display new assembly information and add a picture segment to the overall formation of the picture.
As the assembly information is matched, the cards are inserted into the card holder, one immediately below the other. An "end card" in the bottom row indicates that a column is complete. There is no definite order as to which column is completed first, second, third, etc. When all cards are correctly in place, the picture will be complete and no assembly information will be exposed.
Although the card holder facilitates the positioning of cards, particularly for children under the age of ten years old, I have found that the card holder can be completely eliminated by attaching the cards to each other. This will reduce the manufacturing cost, since the entire puzzle comprises only a plurality of cards. FIGS. 11 through 14 shows one form of puzzle designed for attaching the cards to each other.
The cards can be made similar to ordinary playing cards as to size, material and thickness. With respect to the picture segments and the assembly information, the cards can be divided into three classes, exactly as described in the form consisting of a plurality of cards and a card holder.
FIG. 11 shows both the top side and the underside of a typical "beginning card" 39. The top side contains a picture segment 40 and the assembly information 41. The underside contains start information which says "START 3". In assembling the puzzle on a table top, card 39 will be the first card of the third column. It is not necessary to place the columns next to each other until all columns are completely assembled.
All "beginning cards" and "middle cards" are provided with cuts identical to cuts 42, 43, 44, 45 and 46. These cuts will also be referred to as face cuts. Face cuts 42, 43 and 44 are provided to form a face tab. The point where face cuts 43 and 45 meet and the point where face cuts 44 and 46 meet define the base of a typical face tab. Face cuts 45 and 46 are located on each side of the base of a typical face tab and extend away from each other.
An edge tab located on the top edge of each "middle card" and "end card" will fit between face cuts 43 and 44. In assembling the puzzle, this will provide a guide to locate the inserted card horizontally, and face cuts 45 and 46 automatically provide a stop to accurately locate the inserted card vertically. This facilitates the accurate locating of the cards with respect to each other, so that the picture segments will properly align.
FIG. 12 shows both the top side and the underside of a typical "middle card" 47. The top side contains a picture segment 48 and assembly information 49. The underside contains the assembly information 50. Edge tab 51 is shown at the top of card 47.
FIG. 13 shows how the form of the picture segments align when three cards are attached to each other. The "middle card" 52 shows the typical face cuts 42 through 46. When attaching the next card to the column, the three cards can be held in one hand; then by bending the lower portion of card 52 downward, the edges formed by face cut 42 will separate. This will provide an opening to insert an edge tab under the face tab formed by face cuts 42, 43 and 44.
FIG. 14 shows both the top side and the underside of a typical "end card" 53. The entire top side contains a picture segment 54 and the underside contains assembly information 55. The edge tab 56 is shown at the top of card 53.
Starting with each "beginning card," the puzzle is assembled in columns. If several people participate, each person can be assigned to assemble one or more columns. When all columns are completely assembled, they are placed next to each other to form the entire picture.
FIG. 15 shows a modified form of four attached cards. Cards 57 and 58 are twice the width of card 5, and card 60 is three times the width of card 59. An entire row can consist of only one extended card. By extending the width of several cards to be common to two or more columns, the columns will be held together. The area provided for the assembly information is increased proportionally to the increased width of each card.
For puzzles comprizing a large number of cards, it is helpful to lock the cards together. This will prevent the cards from separating from each other while adding additional cards to a column.
FIG. 16 shows a modified form of the edge tab 67 designed for locking the cards 61 and 62 together. The width A of the edge tab 67 located at the top of card 62 is greater than the width B of the face tab 68 in card 61. Cuts 63 and 64 are extended inwardly from the ends of edge tab 67 and will be referred to as edge cuts.
When the edge tab 67 at the top of cards 62 is fully inserted beneath the face tab 68 of card 61, the cards will lock together. Edge cut 63 will coincide with face cut 65 and edge cut 64 will coincide with face cut 66. The stresses within the material surrounding these cuts, cause the edges formed by these cuts that coincide to partially overlap each other -- thus, locking the cards together.
Cards 61 and 62 can be easily unlocked from each other by sliding card 62 to the left and then rotating card 62 clockwise as shown in FIG. 17. The two cards can now be separated by sliding card 62 to the right and downward.
As can be seen, an educational puzzle is provided which allows each participant to apperceive new knowledge as well as delight in an entertaining experience. A picture is formed as cards with picture segments thereon are correctly matched with other cards by an existing informational relationship. Although general assembly information in many forms can be used in assembling the puzzle, this invention contemplates the use of educational information as a preferred form of assembly information. In such case, the correct relationships must be determined between cards having educational information thereon in order to correctly assemble the puzzle.
In one form of the invention, the cards have a tab formed on one edge that allows placement of the cards in a card holder to thus hold the cards in the correct position. In another form, the cards have a tab and cuts formed therein so that the cards may be interfitted to form the completed picture. The disclosed puzzle will provide hours of entertainment as well as affording an educational experience without outside assistance. | A puzzle is disclosed that is comprised of a plurality of cards that partially overlap each other so that, when completely assembled, the combined exposed portions provide a picture; the non-exposed portions provide areas for assembly information. The matching of the assembly information is a guide to assemble the puzzle. In one form, a card holder can be used to facilitate the positioning of the cards. In another form, the cards simply attach to each other. | 0 |
This application relies for priority on U.S. Provisional Patent Application Ser. No. 60/416,534, filed on Oct. 8, 2002, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to snow grooming vehicles that use winches to assist in climbing steep inclines. The invention is also directed to level winding systems for winch assemblies.
2. Description of Related Art
Tracked vehicles used in rugged terrain often employ winch assemblies to assist in maneuvering steep inclines. Snow grooming vehicles, for example, are sometimes equipped with winches that have cables that attach to fixed points on the incline to allow the vehicle to be anchored to the fixed point while sweeping up or down the slope. The cable anchor prevents the vehicle from turning over or sliding down the slope, which could occur on very steep inclines.
A winch-equipped vehicle typically carries a cable that extends outwardly through a rotatable boom. The boom is an elongated metal arm that guides the cable through a series of pulleys. Depending on the direction of intended travel, the boom is rotated to extend forwardly over the cab or to extend rearwardly away from the cab. The cable is typically carried on a drum, preferably a grooved drum, that is driven to control outlay and intake of the cable. A guide, preferably a level winder, is provided at the base of the boom to assist in aligning the cable as it is fed to and from the drum to prevent twisting of the cable.
Most prior art winches use vertical guides and worm gears that follow a linear path parallel to the drum's axis of rotation to align the cable with the drum grooves. As the load on the cable in such a system can be up to 10,000 lbs., the guide assembly must be constructed to accommodate such forces. These assemblies require a large degree of maintenance to prevent the guides and gears from rusting and breaking. However, constant lubrication is necessary. Additionally, these guide assemblies consume a large amount of space, which leaves limited space for the pulleys and rollers associated with the cable system. As a result, the diameter of the pulleys and rollers are often smaller than the minimum recommended cable bending radius. Bending cable about a radius less than the recommended bending radius shortens the life and reliability of the cable.
Some prior art systems use capstan systems to address the problems associated with the prior art guide assemblies described above. FIG. 5 illustrates a capstan system 100 that utilizes a linear guide system 110 . The torque applied to the guide system 110 is reduced by winding cable 120 around a capstan 130 . As a result, the force at the exit of the capstan 130 is a fraction, 1,000 lbs. for example, of the force in a conventional guide system. The cable 120 is guided from the capstan 130 through a sliding component 140 to a drum 150 . However, the capstan 130 itself occupies a great deal of space and is complex, due in large part to the motors required for driving the capstan. Further, maintenance for a capstan is complicated as changing a cable requires a large investment of labor. Moreover, the sliding component 140 must be constantly lubricated.
Thus, there is a need for a less complex and more compact guide assembly associated with such a winch, especially a level winder assembly.
SUMMARY OF THE INVENTION
An aspect of embodiments of the invention is to provide a winch assembly that has a relatively compact and simple design.
Another aspect of embodiments of the invention is to provide a winch assembly suitable for use on a snow grooming vehicle and further to provide a snow grooming vehicle equipped with such a winch.
A further aspect of embodiments of the invention is to provide a winch that is relatively easy to operate, may allow an operator to observe operation, and may extend the useful life of the wound cable.
Among other things, the invention is directed to a winch assembly that includes a drum, a driver, and a level winder. The drum carries a length of cable. The driver is coupled to the drum and rotates the drum to wind and unwind the cable. The level winder is disposed adjacent to the drum to guide the cable with respect to the drum, and is supported to move in an arc shaped path.
The invention is also directed to a winch assembly that includes a drum, a driver, and a level winder. The drum carries a length of cable. The driver is coupled to the drum and rotates the drum about a generally horizontal axis to wind and unwind the cable. The level winder is disposed adjacent to the drum to guide the cable with respect to the drum. The level winder is also supported to pivot about a generally vertical axis.
The invention is also directed to vehicle that includes a frame, an engine that is supported by the frame, a drive mechanism that is operatively connected to the engine, and a winch assembly that is supported by the frame. The winch assembly includes a drum that carries a length of cable. A driver is coupled to the drum for rotating the drum to wind and unwind the cable. A level winder is disposed adjacent to the drum to guide the cable with respect to the drum. The level winder is supported to move in an arc shaped path.
These and other aspects of embodiments of the invention will become apparent when taken in conjunction with the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Features of the invention are shown in the drawings, which form part of this original disclosure, in which:
FIG. 1 is a partial view of a tracked vehicle having a winch assembly in accordance with embodiments of the invention;
FIG. 2 is an enlarged side view of the level winder illustrated as a part of the tracked vehicle shown in FIG. 1 ;
FIG. 3 is a top schematic view of the level winder of FIG. 2 ;
FIG. 4 is a side perspective view of the level winder of FIG. 2 ; and
FIG. 5 is a view of a prior art capstan cable winding system.
DETAILED DESCRIPTION OF THE INVENTION
This invention is described for use on a tracked vehicle, particularly a snow grooming vehicle, for purposes of illustration only. However, the winch and level winder in accordance with embodiments of this invention may be used in any cable winding system. Further, the winch may be used on any type of vehicle, especially vehicles driven by rotatable tracks that may be driven over rugged terrain, such as steep inclines on mountains or ravines.
Throughout this description, reference is made to vertical and horizontal axes. It is understood that these axes are intended to refer to a vehicle position in which the vehicle is supported on a substantially horizontal surface.
FIG. 1 illustrates a vehicle 10 of the present invention. The vehicle 10 includes a frame 12 , an engine 14 supported by the frame 12 , a drive mechanism 16 operatively connected to the engine 14 , a winch assembly 24 supported by the frame 12 , and a boom 18 supported by the frame 12 . A cab 15 for having an operator and vehicle control elements is also supported by the frame 12 . In the illustrated embodiment, the engine 14 is not illustrated, but its location is indicated on the frame 12 . As would be appreciated by those skilled in the art, the engine 14 need not be positioned in the area indicated. Instead, the engine 14 may be located on the vehicle 10 in any alternative, suitable location.
The frame 12 can be fabricated from materials well known in the art, including but not limited to steel. Fabrication techniques well known in the art can be used to form and assemble the frame 12 .
The engine 14 can be any engine typically used in such vehicles. The size of the engine 14 will depend on the size and specific demands of the vehicle 10 . Preferably, the engine 14 is an internal combustion engine that can generate a high horse power.
The drive mechanism 16 is operatively connected to the engine 14 so as to move the vehicle 10 across a surface. The drive mechanism 16 allows for the vehicle 10 to move across land, ice, or water. The drive mechanism 16 may comprise an endless track, as illustrated by FIG. 1 , wheels, or any component that will allow the vehicle 10 to travel.
The winch assembly 24 is supported on a winch frame 19 that is coupled to the frame 12 . The winch assembly 24 includes a drum 26 that carries a length of cable 28 , a driver 30 coupled to the drum 26 for rotating the drum 26 to wind and unwind the cable 28 , and a level winder 32 disposed at a base portion of the boom 18 and adjacent to the drum 26 to guide the cable 28 with respect to the drum 26 .
It is contemplated that the driver 30 is a hydraulic motor that is operatively connected to the engine 14 via a suitable hydraulic system. Of course, as would be appreciated by those skilled in the art, the driver 30 may be mechanically driven by the engine. Alternatively, the driver 30 my be an electrically-driven motor. It should be understood that the driver 30 may be of any type suited for this purpose without departing from the scope and spirit of the invention.
The boom 18 has a guide system that guides the cable 28 outward from (or inward to) the vehicle 10 . The guide system includes a series of pulleys 20 , a series of rollers 22 , or any combination of pulleys 20 and rollers 22 . The pulleys 20 are disposed on the boom 18 , and the cable 28 is fed around the pulleys 20 . The rollers 22 are disposed on the boom 18 , and the cable 28 is fed over the rollers 22 . The boom 18 is preferably formed of metal and may comprise a pair of parallel beams with the guide system supported therebetween. Alternatively, the boom 18 may be formed of a series of rigid members fixed together as an integral cantilever support. It is noted that the boom 18 may have any other suitable construction without departing from the invention.
As seen in FIG. 1 , the boom 18 is supported for movement on a support platform 21 that is supported by the vehicle frame 12 , at least in part, via the winch frame 19 . Preferably, the boom 18 is supported for rotatable movement with respect to the platform 21 on the winch frame 19 . With this arrangement, the boom 18 can be oriented at various directions with respect to the drive mechanism 16 to accommodate different directions of travel. The direction of the boom 18 may be controlled by the operator or may be preset. Alternatively, other mounting structures may be implemented that allow for directional adjustment. It is also possible to use a fixed boom depending on the intended use of the vehicle 10 .
The cable 28 is typically metal, such as steel, but may be any material suitable for the intended purpose of the invention. Any known cable 28 capable of withstanding a large load is suitable. The diameter of the cable 28 and type of material are chosen to ensure that the load requirements of the vehicle 10 may be tolerated.
The drum 26 is mounted on the winch frame 19 such that it rotates about a longitudinal axis. The longitudinal axis is generally horizontal (when the vehicle 10 is supported on a horizontal surface). The drum 26 is sized to ensure that the appropriate amount of cable 28 can be completely wound onto the drum 26 . The cable 28 is wound across an outer circumferential surface of the drum 26 . The outer circumferential surface of the drum 26 may be smooth or grooved. In the preferred embodiment, the drum 26 is grooved, as illustrated in FIG. 3 .
Grooves with the appropriate radius may be formed in the circumferential surface of the drum 26 so that when the cable 28 wraps around the drum, the cable 28 lies in what is essentially one continuous groove. The grooves may be added to the drum 26 by standard fabrication techniques, including but not limited to machining. Spaced grooves around the circumference of the drum 26 allow the cable 28 to be retained in the grooves during winding and unwinding. The grooves provide a tighter, neater, and more compact wind as compared to drums with a smooth surface. This provides for smoother operation and may enhance the life of the cable 28 .
The driver 30 is coupled to the drum 26 and rotates the drum 26 . The drum 26 rotates in one direction to wind the cable 28 and in the opposite direction to unwind the cable 28 . As mentioned above, the driver 30 may be an electric or hydraulic motor, for example. The driver 30 may be operatively connected to the vehicle engine 14 and/or electrical system or may be an independent component. The driver 30 preferably is sized to handle the load created by the drum 26 and the cable 28 .
The level winder 32 is disposed adjacent to the drum 26 to guide the cable 28 from the boom 18 with respect to the drum 26 . The level winder 32 is supported to move in an arc shaped path and is preferably supported to pivot about a generally vertical axis. The arc shaped path is largely defined by the pivoting of the level winder 32 about the generally vertical axis.
As illustrated in FIG. 2 and FIG. 3 , the level winder 32 includes a rotatable support 34 , a cable support frame 36 that is connected to the rotatable support 34 , and a pair of rotatable pulleys 38 carried by the cable support frame 36 . The cable support frame 36 pivots with the rotatable support 34 . By this, the pair of pulleys 38 pivot with respect to the drum 26 .
The rotatable support 34 is mounted on the winch frame 19 . The rotatable support 34 is preferably operatively connected to a pair of rotatable support bearings 58 . The rotatable support bearings 58 are fixedly attached to the winch frame 19 . The rotatable support bearings 58 are connected to opposite ends of the rotatable support 34 so that the rotatable support 34 can freely rotate about a generally vertical axis, while being fixed in the other two directions. The rotatable support 34 is substantially the shape of a hollow cylinder with at least one slot 35 along the longitudinal length of the cylinder. Of course, any suitable support assembly may be used to allow the level winder 32 to pivot with respect to the drum 26 .
The winch assembly 24 further includes a rotatable pulley 60 that is disposed adjacent to the rotatable support 34 such that an outer edge of the rotatable pulley 60 lies within the slot 35 of the rotatable support 34 . The rotatable pulley 60 is disposed between two substantially parallel support plates 37 . The support plates 37 are fixedly attached to the rotatable support 34 such that the support plates 37 rotate with the rotatable support 34 about a generally vertical axis. The rotatable pulley 60 is mounted to the support plates 37 such that the rotatable pulley 60 can freely rotate about its generally horizontal axis. The rotatable pulley 60 directs the cable 28 from the boom 18 to the level winder 32 . The rotatable pulley 60 has a radius greater than or equal to the minimum recommended bending radius of the cable 28 .
The level winder 32 further includes at least one actuator 40 that is coupled to the rotatable support 34 . In the preferred embodiment, one upper bracket 39 is mounted to each support plate 37 , preferably above the axis of the rotatable pulley 60 . One end of the actuator 40 is pivotally attached to the upper bracket 39 . The opposite end of the actuator 40 is pivotally attached to the winch frame 19 , as seen in FIG. 1 , and is in communication with a proximity switch 56 . Preferably, the actuator 40 is a hydraulic or pneumatic cylinder. Upon activation, the actuator 40 extends or retracts to push or pull the support plates 37 , which in turn rotates the rotatable pulley 60 , the rotatable support 34 , and the cable support frame 36 . As will be discussed below, this causes the pair of pulleys 38 to pivot with respect to the drum 26 to maintain the cable 28 in a predetermined position relative to the drum 26 . The desired predetermined position relative to the drum 26 is generally perpendicular, in this case.
Referring to FIGS. 2-4 , the cable support frame 36 includes an upper plate 41 and a lower plate 43 that are substantially parallel to one another. The cable support frame 36 has a longitudinal centerline CL that extends in a direction from the rotatable support 34 towards the drum 26 . Each support plate 37 further includes a pair of lower brackets 45 that are fixedly attached to the support plate 37 below the axis of the rotatable pulley 60 . The lower brackets 45 in each pair are spaced such that the cable support frame 36 can be disposed therebetween. A pair of level winder ball bearings 62 are disposed within the cable support frame 36 on opposite sides of the longitudinal centerline CL. The level winder ball bearings 62 are mounted and oriented in such a way as to create a generally horizontal axis. The level winder ball bearings 62 allow the cable support frame 36 to rotate within a fixed range about a generally horizontal axis.
A biasing mechanism 42 is coupled between the cable support frame 36 and the top of the support plates 37 , preferably at the upper brackets 39 . The biasing mechanism 42 maintains the cable support frame 36 in a predetermined position relative to the rotatable support 34 . The predetermined position relative to the rotatable support 34 is generally perpendicular. The biasing mechanism 42 can include a spring that retains the cable support frame 36 in a relatively horizontal position. Of course, any biasing mechanism can be used, including a resilient cable or hydraulic or pneumatic cylinder. By this construction, the cable support frame 36 can move slightly up or down with respect to the surface of the drum 26 to accommodate the thickness of the cable 28 wound on the drum 26 .
At the opposite end of the cable support frame 36 , the pair of pulleys 38 are disposed between the upper plate 41 and the lower plate 43 on opposite sides of the longitudinal centerline CL of the cable support frame 36 . The pair of pulleys 38 are connected to the cable support frame 36 with pulley bearings 47 . The pulleys 38 are generally oriented in the same plane and are spaced so that the cable 28 can pass between them. The centers of the pulleys 38 are aligned on an axis that is generally perpendicular to the longitudinal centerline CL of the cable support frame 36 .
The level winder 32 further includes a feeding mechanism 44 that is pivotally supported by the cable support frame 36 . The feeding mechanism 44 controls the tension and direction of the cable 28 as the cable 28 is fed from the pulleys 38 to the drum 26 . An embodiment of the feeding mechanism 44 is illustrated in detail in FIG. 4 . The feeding mechanism 44 includes a pivot arm 55 , a pair of guiding rollers 46 , and a pair of tensioning rollers 49 .
In the preferred embodiment, the pivot arm 55 is disposed above the upper support plate 41 of the cable support frame 36 such that the pivot arm 55 and the cable support frame 36 extend in substantially parallel planes to one another. The pivot arm 55 is pivotally connected to the cable support frame 36 with a bearing 59 and a fastener 61 at a position along the longitudinal centerline CL of the cable support frame 36 . The pivot arm 55 has a first end and a second end. The first end of the pivot arm 55 extends beyond the cable support frame 36 in the direction towards the drum 26 .
The guiding rollers 46 are attached between a pair of roller support brackets 53 with bearings and fasteners. The roller support brackets 53 are fixedly attached to the first end of the pivot arm 55 and extend generally downward in such a manner that they do not interfere with the pair of pulleys 38 . The guiding rollers 46 are generally aligned in a vertical plane and are spaced and shaped such that the cable 28 can fit snugly between them.
The pair of tensioning rollers 49 are disposed at one end of a pair of cantilever brackets 51 . The cantilever brackets 51 each have a first end and a second end. The first ends of the cantilever brackets 51 are pivotally connected to the first end of the pivot arm 55 with bushings and fasteners. The second ends of the cantilever brackets 51 extend away from the pivot arm 55 and cable support frame 36 towards the drum 26 . The tensioning rollers 49 are connected to the second ends of the cantilever brackets 51 with bearings and fasteners. Preferably, the tensioning rollers 49 and the guiding rollers 46 are oriented such that their axes of rotation are perpendicular to one another. For example, in the preferred embodiment, the guiding rollers 46 rotate about generally horizontal axes and the tensioning rollers 49 rotate about generally vertical axes (when the vehicle 10 is supported on a horizontal surface). Alternatively, the guiding rollers 46 may rotate about generally vertical axes and the tensioning rollers 49 may rotate about generally horizontal axes (when the vehicle 10 is supported on a horizontal surface).
The feeding mechanism 44 further includes a pressure controller 48 . The pressure controller 48 is coupled to the tensioning rollers 49 to control the pressure between the tensioning rollers 49 to control feeding of the cable 28 . Preferably, the pressure controller 48 includes a hydraulic cylinder. Alternatively, the pressure controller 48 may include a pneumatic cylinder or any other resilient device. In the preferred embodiment, the pressure controller 48 includes a pair of hydraulic cylinders, as illustrated in FIG. 4 .
The feeding mechanism 44 further includes a sensitivity controller 50 . The sensitivity controller 50 is coupled to the tensioning rollers 49 to adjust the distance between the tensioning rollers 49 . Preferably, the sensitivity controller 50 includes a first plate 64 mounted to one of the cantilever brackets 51 and a second plate 66 mounted to the other cantilever bracket 51 . A third plate 68 is disposed in between the cantilever brackets 51 and is fixedly attached to the pivot arm 55 . The sensitivity controller 50 further includes a pair of adjustment screws 52 . The adjustment screws 52 are used to set a gap between the first plate 64 and the third plate 66 and a gap between the second plate 68 and the third plate 66 .
As the adjustment screws 52 are tightened, the cantilever brackets 51 are pushed away from each other, thereby increasing the gap between the tensioning rollers 49 , which decreases the sensitivity to changes in the position of the cable 28 . Conversely, as the adjustment screws 52 are loosened, the cantilever brackets 51 will by drawn towards each other due to the pressure exerted by the pressure controller 48 . This in turn will decrease the gap between the tensioning rollers 49 , which increases the sensitivity to changes in the position of the cable 28 .
The feeding mechanism 44 further includes a position actuator 54 that is operatively coupled to the proximity switch 56 that activates the actuator 40 to pivot the level winder 32 . A first end of the position actuator 54 is pivotally connected to the pivot arm 55 . A second end of the position actuator 54 is pivotally connected to the proximity switch 56 . When the feeding mechanism 44 pivots beyond a certain predetermined position, the position actuator 54 signals the proximity switch 56 . The proximity switch 56 activates movement of the level winder 32 along the arc shaped path by signaling the actuator 40 . Any known type of proximity switch or position detector may be used.
In operation, the cable 28 starts in a fully wound position on the drum 26 . The cable 28 is fed from the drum 26 through the level winder 32 , through the rotatable support 34 , through the guide system within the boom 18 , and out one end of the boom 18 . The cable 28 is secured to a predetermined anchor point located on the terrain and the vehicle 10 moves away from the anchor point via the drive mechanism 16 . In order for the vehicle 10 to move away from the anchor point, the cable 28 must be lengthened or “played out” from the drum 26 . The driver 30 rotates the drum 26 such that the cable 28 unwinds from the drum 26 , thereby allowing the cable 28 to lengthen.
As the cable unwinds from the drum 26 , it releases from the drum at a release point 57 . The release point 57 moves parallel to the longitudinal axis of the drum 26 as the drum 26 rotates. The level winder 32 pivots in an arc such that the feeding mechanism 44 is substantially aligned with the release point 57 . This ensures that the cable 28 is generally perpendicular to the drum 26 at the release point 57 so that the cable does not twist or kink.
After the cable 28 releases from the drum 26 , the cable 28 passes in between the pair of tensioning rollers 49 . As the location of the release point 57 changes, the cable 28 exerts a greater pressure against one of the tensioning rollers 49 . When the resulting pressure on the pressure controller 48 exceeds a predetermined value, the pivot arm 55 pivots just enough to keep the cable 28 perpendicular to the drum 26 . When the pivot arm 55 reaches a maximum pivot point, the position actuator 54 activates the proximity switch 56 . The proximity switch 56 then signals the actuator 40 . The actuator 40 rotates the level winder 32 along an arc shaped path in the direction that the cable 28 is extending toward the drum 26 . As the level winder 32 rotates, the pivot arm 55 is drawn by the cable 28 to rotate independently to ensure the cable 28 remains perpendicular to the drum 26 . These adjustments by the feeding mechanism 44 are constantly repeated while the winch assembly 24 is in operation.
After the cable 28 passes through the tensioning rollers 49 , the cable 28 passes in between the guiding rollers 46 . The guiding rollers 46 ensure that the cable 28 is properly lined up to pass in between the pair of pulleys 38 , regardless of the amount of tension in the cable 28 . Once the cable 28 passes the pair of pulleys 38 , it travels through the cable support frame 36 and onto the rotatable pulley 60 . The rotatable pulley 60 feeds the cable 28 though the rotatable support 34 to the pulleys 20 and rollers 22 located in the guide system in the boom 18 .
To drive the vehicle 10 in a reverse direction towards the anchor point, the rotation of the drum 26 must be reversed by the driver 30 so that any slack in the cable 28 can be tightened. In other words, the cable 28 must be rewound onto the drum 26 . Further, the vehicle 10 may need the power of the winch assembly 24 help pull the vehicle 10 back towards the anchor point. The level winder 32 operates in the same manner as was described above, only the cable 28 moves in the opposite direction and the pulleys 20 , 60 , 38 and rollers 22 , 46 , 49 rotate in the opposite direction.
Due to the relatively compact design of the level winder 32 , the operator of the vehicle 10 can watch the winding process to ensure that the cable 28 is being properly unwound and wound, because the level winder 32 does not obstruct the view of the drum 26 .
It will be understood that the invention encompasses various modifications and alterations to the precise operating systems. For example, although the system is described for use in a heavy duty cable winding assembly, other windable materials may be used in the device, and the device may be adapted for use in smaller manufacturing environments. | A level winder is provided for winding cable in a winch system. The winch is suitable for use on a tracked vehicle, such as a snow grooming vehicle, to assist the vehicle in maneuvering on steep inclines. The level winder uses a pivoting pulley assembly to feed cable onto and off of a drum. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International application PCT/DK00/00677 filed Dec. 7, 2000, the entire content of which is expressly incorporated herein by reference thereto.
BACKGROUND ART
[0002] The invention relates to a closure for temporarily closing an opening in wall in e.g. a building under construction or renovation.
[0003] During the construction or renovation of many buildings, there will normally be wall openings that temporarily are bare and that only later will be mounted with e.g. windows or doors.
[0004] Traditionally, such bare wall openings are temporarily closed by means of wood laths that are joined together to form frames that each have an opening which is closed by an attached plastic sheeting.
[0005] Such a frame of wood laths with attached plastic sheeting is not especially tight in itself, and usually it furthermore fits the respective wall opening badly so that a larger or smaller gap is left between the sides of this wall opening and the frame of wood laths.
[0006] These gaps can be made tight with pointing which however is a labor-consuming and expensive operation which therefore often is skipped.
[0007] The result is that the above traditional solution for, by means of wood laths temporarily, closing bare wall openings is not to a satisfactory extent able to meet the demands that are today made on the environment in a building under construction or renovation.
[0008] The leaks can thus result in water damage to the building and the need for subsequent drying of damp-damaged sections in the building. There are furthermore, especially during the winter term, an expensive loss of heat and draught nuisances that can be health hazardous and cause increased sickness or work absences among the workers.
[0009] Obviously, it is possible to close bare wall openings by means of conventional doors or windows and relating frames. In practice, however, it is not possible to make a rough wall opening with very close tolerances. Instead, the wall opening is made with an overmeasure that allows a conventional frame being inserted and mounted in the opening. Thus, a larger or smaller gap is formed between the frame and the wall opening, and this gap must necessarily be pointed with an appropriate filler if the wall opening is to be closed with the desired tightness.
[0010] It is therefore an expensive and labor-consuming process to close a rough wall opening temporarily in the above conventional way. In the construction phase and at removal of the temporary closing, the applied doors or windows and relating frames will furthermore be very open to being damaged with consequent loss of materials.
SUMMARY OF THE INVENTION
[0011] The invention provides a closure temporarily can close a bare wall opening in a building under construction or renovation in a less expensive, easier and tighter manner than hitherto known.
[0012] This closure comprises a closure frame for detachable mounting in a wall opening, a first plate-shaped part made on the closure frame and extending, in the mounted state of this closure frame, in along the inside face of the wall opening at a distance from this wall opening, a second plate-shaped part made on the closure frame and, in the mounted state of this closure frame, extending outward along one side of the wall, at least one cover for mounting on the closure frame, and means for fastening the closure frame in the opening.
[0013] When on the first part of the closure frame, at least one flap that is elastically bendable in a crosswise direction is located so that it extends along the exterior of the part and having, in unloaded state, a height greater than the gap between the exterior and inside faces of the wall opening, the closure according to the invention can be mounted in the wall opening quickly and easily. During this installation, the flap provides the necessary proofing of the gap between the frame and the rough wall opening without an extra contribution of labor and costs. At the same time, the flap advantageously centers the frame in the wall opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will be explained in greater detail below, describing only exemplary embodiments with reference to the drawing, in which
[0015] [0015]FIG. 1 is a front fractional view of a wall with an opening temporarily tightly closed by a closure according to the invention;
[0016] [0016]FIG. 2 is a sectional view taken along the line II-II of FIG. 1;
[0017] [0017]FIG. 3 is on a larger scale a fractional sectional view of a first embodiment of a closure according to the invention in free position;
[0018] [0018]FIG. 4 is the same in mounted position on the wall in FIGS. 1 and 2;
[0019] [0019]FIG. 5 is on a larger scale a fractional sectional view of a second embodiment of a closure according to the invention in free position;
[0020] [0020]FIG. 6 is the same in mounted position on the wall in FIGS. 1 and 2;
[0021] [0021]FIG. 7 is on a larger scale a fractional sectional view of a third embodiment of a closure according to the invention in free position;
[0022] [0022]FIG. 8 is the same in mounted position of the wall in FIGS. 1 and 2;
[0023] [0023]FIG. 9 is on a larger scale a fractional sectional view of a fourth embodiment of a closure according to the invention in free position;
[0024] [0024]FIG. 10 is the same in mounted position on the wall in FIGS. 1 and 2;
[0025] [0025]FIG. 11 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with a fifth embodiment of a closure according to the invention in mounted position;
[0026] [0026]FIG. 12 is the same seen from the inside face of the wall;
[0027] [0027]FIG. 13 is on a larger scale a fractional sectional view of a sixth embodiment of a closure according to the invention in free position;
[0028] [0028]FIG. 14 is the same in mounted position on the wall in FIGS. 1 and 2;
[0029] [0029]FIG. 15 is a perspective view of the wall in FIGS. 1 and 2;
[0030] [0030]FIG. 16 is a view of the wall in FIG. 15 but mounted with the closure in FIGS. 1 and 2;
[0031] [0031]FIG. 17 is a view of the wall in FIG. 15 but with a face wall under construction on the exterior of the wall;
[0032] [0032]FIG. 18 is a view of the wall in FIG. 17 but with the complete face wall ready for mounting of proper closure;
[0033] [0033]FIG. 19 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with a seventh embodiment of a closure according to the invention in mounted position;
[0034] [0034]FIG. 20 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with an eight embodiment of a closure according to the invention in mounted position;
[0035] [0035]FIG. 21 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with a ninth embodiment of a closure according to the invention in mounted position;
[0036] [0036]FIG. 22 shows the closure according to the invention in a first mounting stage;
[0037] [0037]FIG. 23 shows the closure according to the invention in a second mounting stage;
[0038] [0038]FIG. 24 shows the closure according to the invention in a third mounting stage;
[0039] [0039]FIG. 25 shows the closure according to the invention in a fourth mounting stage;
[0040] [0040]FIG. 26 shows the closure according to the invention in a fifth mounting stage;
[0041] [0041]FIG. 27 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with a tenth embodiment of a closure according to the invention in mounted position; and
[0042] [0042]FIG. 28 is on a larger scale a fractional sectional view of the wall in FIGS. 1 and 2 with an eleventh embodiment according to the invention in mounted position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] In order to easily be able to insert the closure frame in the wall opening, the elastically bendable flap on the first part of the closure frame can be arranged to incline crosswise in the direction of the second part. Thereby, the inside face of the wall opening will automatically bend the flap down during the insertion operation whereby the flap generates a spring power which forces its free edge area into close contact with the inside face of the opening.
[0044] The free edge area of the flap can furthermore be designed with a bend to ensure that the flap will not resist when the frame is pulled out of the wall opening at removal of the closure.
[0045] The closure can for example be fastened in the wall opening by means of screws or similar fastening means.
[0046] In an especially advantageous embodiment, the closure is however fastened by means of longitudinal barbs made on the inside face of the first part and in the mounted position of the window, forced in towards the inside face of the wall opening with the points facing obliquely out towards the side of the wall on which the closure is mounted. At mounting the closure is then quite simply pushed in place in the wall opening after which the barbs ensure the closure against unintentionally being pushed out of the opening due to e.g. the action of the wind.
[0047] Alternatively, the first part can have a longitudinal catch which in the mounted position of the closure, is extending behind the back of the wall and thereby effectively secures the closure in the wall opening.
[0048] In a second embodiment, the closure can be fastened in the wall opening by means of mounted straps/clips which are provided with barbs and drawn through openings in cross members resting against the other side of the wall.
[0049] In a variant of this embodiment, the cross members can jointly consist of a support frame with mounted straps each having a fork with barbs that, in the mounted position of the closure, lockingly engage with a corresponding barb on the closure frame of the closure.
[0050] The above mounting forms of the closure all have the advantage that the closure can be mounted in the wall opening quickly, easily and conveniently without during this having to use tools or other kinds of aids.
[0051] The cover that fills the opening in the closure frame of the closure can advantageously be a flexible cloth which advantageously can consist of one or several layers of transparent plastic sheeting of e.g. polyethylene.
[0052] Such a sheeting allows daylight to penetrate into the building so that the need for artificial lighting is eliminated or at least reduced for a large part of the year.
[0053] The sheeting can furthermore be reinforced with filaments for giving the sheeting the necessary strength to be able to resist the often considerable wind and mechanical actions to which it is subjected in practice.
[0054] The flexible cloth can be mounted on the closure frame quickly, securely and easily when the closure comprises a clamping frame consisting of a number of loose or joined rods and serving for fixing the cloth on the closure frame.
[0055] In an advantageous embodiment the clamping frame—from a cross-sectional view—can be designed as a U while longitudinal grooves can be made in the closure frame for receiving the ends of the legs of the U which thus can squeeze the peripheral area of the flexible cloth together between the legs of the U and the grooves. This fixing can e.g. take place by means of screws.
[0056] In a second advantageous embodiment the clamping frame can have a contact face and the closure frame a second contact face shaped complementarily for fastening a flexible cloth.
[0057] In this embodiment the clamping frame can, as an example, be arranged to hold two flexible cloths at a mutual distance and fix both cloths between the two contact faces.
[0058] For this purpose the closure can have a number of clamps arranged to be fastened on the closure frame and clamp the clamping frame in against the contact face of the closure frame.
[0059] Each clamp can advantageously be designed as a chair with legs for being pressed in grooves shaped complementarily in the first part of the closure frame, a back for bearing against the clamping frame, and a seat for absorbing a pressure for pressing the legs of the chair in the grooves shaped complementarily in the first part of the closure frame.
[0060] In the summer and under warmer skies a cover with only one cloth will be adequate. When it is cold, two cloths can advantageously be used for the cover, thereby saving considerable expenses for heating the respective building.
[0061] In order to obtain great insulating power and a corresponding great cost saving the clamping frame must be arranged to keep the two flexible cloths at a good distance from each other. For this purpose the clamping frame can advantageously be made of a pipe which, with an economically small material consumption, can have a large diameter.
[0062] The pipe can e.g. be round or rectangular. In the latter case, the contact face of the closure frame can include the inside face of a groove made in the closure frame, and the contact face of the pipe can consist of the outer side on a projection shaped complementarily of the rectangular pipe. By means of this solution, a considerable advantage is obtained in that the clamping frame and the closure frame reinforce each other, and that they therefore both can be made with a modest consumption of materials.
[0063] With a view to prevent wind, rain and snow from penetrating in behind the closure, a gap with a sealing ring can be arranged between the second part of the closure and the side of the wall.
[0064] On the first part of the closure can furthermore be made a handle for manually drawing the closure frame into the wall opening from the inside face of the wall. Then, the closure frame can be screwed into the wall opening.
[0065] The above-mentioned flaps on the first plate-shaped part of the closure frame can in a simple embodiment be replaced by one or several lists of an elastically deformable material such as rubber.
[0066] In a second embodiment the flaps can be individual elements consisting of e.g. plastic and mounted on the first plate-shaped part.
[0067] [0067]FIGS. 1 and 2 are fractional views of a wall 1 with a quadrangular wall opening 2 . In the example shown it is assumed that the wall opening 2 is intended for a window in a building under construction, and that the construction has not yet come so far that the associated window has been mounted in the hollowed wall opening.
[0068] In order to avoid heat loss until then, protect the incomplete building against the weather and provide an indoor climate suitable for drying the building, the wall opening 2 is tightly closed with a window 3 according the invention.
[0069] This window mainly consists of a window frame 4 and a cover of a plastic sheeting 5 fastened on the window frame and spanning the opening 6 defined by the window frame.
[0070] The window frame 4 is just as the wall opening 2 quadrangular and the opening 6 is congruent with the opening 2 of the wall.
[0071] In this case the plastic sheeting is transparent so that the sheeting in the same way as the glass in a window allows daylight to penetrate into the building and thereby reduce or render superfluous artificial lighting for a large part of the year.
[0072] The plastic sheeting is furthermore of the type that is flexible and that is reinforced with filaments 7 to give the sheeting the necessary strength to resist wind loads and mechanical actions to which the sheeting might be subjected during construction.
[0073] The reinforcing filaments can e.g. be extending parallel to the sides of the opening or diagonally in relation to these sides. In the last case, the filaments will contribute considerably to increase the stability of the window frame.
[0074] The sheeting can in itself be made of any kind of suitable plastic but is especially made of polyethylene.
[0075] In this case the window frame consists of four V-shaped bars 8 abutting on each other and welded together in the corners 9 of the window frame. The bars can be made of any kind of suitable material, for example aluminium or steel, but consists especially of extruded plastic bars that advantageously can be made with a cross section suited for solving the proposed task by being able to close the bare wall opening in a satisfactorily tight way.
[0076] The plastic that is used for making the bars can advantageously be polyethylene which, by means of relatively simple tools, can be melted together in the areas where the bars of the window frame are abutting on each other and are to be joined.
[0077] The window 3 is located on the front 10 of the wall while the back 11 of the wall is free in this case. The window frame has a first part 12 extending in along the inside face 13 of the wall opening 2 , and a second part 14 extending along the front 10 of the wall 1 . By means of screws 15 or similar fastening means, the first part 12 of the window frame and thereby the window 3 is fastened on the inside face 13 of the wall opening.
[0078] [0078]FIGS. 3 and 4 are on a larger scale fractional views in detail of how the window in FIGS. 1 and 2 is arranged and functions.
[0079] As can be seen, the first part 12 of the window frame 4 is provided with two longitudinal sealing lips 16 and a longitudinal, rigid rib 17 on the inside of the V that the two parts 12 and 14 form with each other. The sealing lips 16 are a little higher than the rib 17 .
[0080] On the inside face of the second part 14 is made a longitudinal, oblique sealing lip 18 and the second part furthermore has a longitudinal cog 19 along the periphery.
[0081] At mounting the window is guided in the direction indicated by the arrow from the free position in FIG. 3 to the mounted position in FIG. 4.
[0082] During this the sealing lips 16 of the first part are bent elastically and will thereby effectively create a sealing with the inside face 13 of the wall opening 2 .
[0083] The window is fastened by means of e.g. screws 15 put through the rigid rib 17 of the first part. When the screws are tightened, the rib 17 will hit the inside face 13 of the wall opening. Thereby, the sealing lips are secured against being bent so much that they are inflicted with permanent deformations and no longer effectively would be able to create a sealing with the inside face of the wall opening.
[0084] The oblique sealing lip 18 on the second part 14 is creating a corresponding sealing with the face 10 of the wall while the cog 19 determines the distance to the face and is creating a jointless conclusion against the wall.
[0085] [0085]FIGS. 5 and 6 show a second embodiment of a window frame for a window according to the invention. The window frame has a first part 20 and a second part 21 . At a distance from the outer side of the second part 21 , a longitudinal rib 22 is made on the first part 20 , said rib faces inwards in the opening 6 of the window frame.
[0086] In this case, the glass pane of the window consists of a first plastic sheeting 23 fastened on the second part 21 and a second plastic sheeting 24 fastened on the rib 22 . The two plastic sheetings 23 and 24 together form an effective double pane unit that makes the window suitable for use during cold periods, for example during the winter term.
[0087] On the first part 20 are made four longitudinal sealing lips 25 and on the second part 21 a longitudinal, oblique sealing lip 26 and a longitudinal cog 27 .
[0088] At mounting the window is guided in the direction indicated by the arrow from the free position in FIG. 5 to the mounted position in FIG. 6 in which the window is moreover functioning in the same way as described with reference to FIGS. 3 and 4.
[0089] [0089]FIGS. 7 and 8 show a third embodiment of a window frame for a window according to the invention. The window frame has a first part 28 and a second part 29 .
[0090] Three longitudinal barbs 30 are made on the first part 28 and on the second part 29 a longitudinal, oblique sealing lip 31 and a longitudinal cog 32 .
[0091] When the window is guided in the direction of the arrow from the free position in FIG. 7 to the mounted position in FIG. 8, the barbs 30 are bent while overcoming the spring power in the barbs and are thereby forced in towards the inside face 13 of the wall opening with the points facing in the opposite direction of the direction of insertion so that the barbs will keep the window frame and thereby the window fixed in the wall opening. At the same time, the barbs function as sealing lips.
[0092] In mounted position, the window is moreover functioning in the same way as described with reference to FIGS. 3 and 4.
[0093] The third embodiment of the window can be mounted quickly and easily by merely pushing the window into the respective wall opening. It is therefore suited for closing especially smaller openings and in the cases where the window is kept clear of larger loads.
[0094] [0094]FIGS. 9 and 10 show a fourth embodiment of a window according to the invention. This window corresponds mainly to the window in FIGS. 5 and 6, and like components are thus similarly referenced.
[0095] In this case the first part 20 of the window frame however has an extension 33 ending in a longitudinal catch 34 facing in the same direction as the second part 21 , that is outwards in the window frame.
[0096] When the window is guided in the direction of the arrow from the free position in FIG. 9 to the mounted position in FIG. 10, the first part 20 is bent inwards in the wall opening while the longitudinal catch 34 is sliding along the inside face 13 of the wall opening until it has reached through the opening and elastically snaps in behind the back 11 of the wall where it is securely detaining the window against being pulled free of the opening again under the action of external forces, such as wind loads.
[0097] In mounted position the window is moreover functioning in the same way as described with reference to FIGS. 5 and 6, it must however be noted that in this case screws are not needed to fasten the window in the wall opening.
[0098] [0098]FIGS. 11 and 12 show a fifth embodiment of a window which in the main corresponds to the window in FIGS. 5 and 6. Like components are thus similarly referenced.
[0099] In mounted position the window is moreover functioning in the same way as described with reference to FIGS. 5 and 6, it must however be noted that neither in this case are screws needed to fasten the window in the wall opening.
[0100] Instead the window frame is effectively fastened by means of a number of straps 35 mounted on the window frame of the window and a number of associated cross members 36 on the back of the wall.
[0101] In FIG. 11 is seen such a strap which, in the case shown, is shaped as a tension string 35 extending upwards from the window frame and provided with a number of barbs 37 having points pointing in the direction from the first side of the wall to the second.
[0102] The tension string 35 is, by means of a thread joint 38 , screwed into a nut 39 welded onto the upper corner between two window frame bars.
[0103] [0103]FIG. 12 shows the back of the wall and as can be seen, the cross member 36 is placed across a corner between two of the adjacent sides 13 of the wall opening. In the cross member is a through hole 40 matching the tension string 35 . The hole is conic and tapers in the same direction as the barbs of the tension string.
[0104] At mounting of the window the tension strings 35 are first screwed into the nuts 39 on the first part 20 of the window frame. Then, the window and the cross members 36 are guided in towards each other in the direction indicated by the arrow so that the tension strings are pushed through the conic holes 40 of the cross members until the cross members 36 are bearing against the back of the wall and the second part 21 of the window frame is bearing against the front of the wall.
[0105] The window is now securely fastened in the wall opening, because the barbs 37 of each tension string will hit the peripheral area around the conic hole 40 on the back of the associated cross member 36 if the window and the cross members are subjected to stresses in the opposite direction of the arrows. Thereby, the window and the cross members are effectively kept in locking engagement with each other.
[0106] [0106]FIGS. 13 and 14 show a sixth embodiment of a window that mainly corresponds to the window in FIGS. 5 and 6. Like components are thus similarly referenced.
[0107] In mounted position the window is functioning in the same way as described with reference to FIGS. 5 and 6, it must however be noted that screws are not needed to fasten the window which instead is fastened in the wall opening by means of a separate support frame 41 resting against the back 11 of the wall.
[0108] The support frame 41 has a first part 42 extending into the wall opening 2 , and a second part 43 extending along the back 11 of the wall 1 . On the first part is placed a number of forks 44 with two opposite rows of barbs 45 . Alternatively, the entire outermost end portion of the part can be forked.
[0109] The first part 20 of the window frame has an extension 46 ending in a longitudinal barb 47 pointing in the direction from the front of the wall to the back.
[0110] At mounting the window frame of the window and the support frame are guided in towards each other in the direction indicated by the arrow whereby the barb 47 on the first part 20 on the window frame of the window is pushed into the fork 44 of the support frame 41 until the second part 43 on the support frame is bearing against the back 11 of the wall and the second part 21 on the window frame of the window is bearing against front 10 of the wall in the ready-mounted position of the window.
[0111] In this position the support frame and the window frame of the window are effectively keeping each other locked in the wall opening 2 by means of the engagement between the barb 47 on the first part 20 on the window frame of the window and the barbs 45 in the forks 44 on the first part 42 of the support frame.
[0112] It is to be noted that the above mounting arrangement alternatively can be arranged in such a way that the forks, on the contrary, are placed on the first part of the window frame of the window and the first part of the support frame has an extension ending in a longitudinal barb.
[0113] The embodiments shown in FIGS. 1 - 14 of the window according to the invention can easily be mounted from within the building, the respective window then being put mainly diagonally out through the wall opening, righted and pulled in towards the exterior of the wall after which the window is fastened in the ways described above and shown in the drawing. Thereby the need for having to use outside scaffolding or lifts is advantageously eliminated when the windows are to be mounted in the wall openings.
[0114] The thus mounted window can be removed quickly and easily when the proper windows are to be mounted. In some case it would be expedient to leave the window in the wall opening as illustrated in FIGS. 15 - 18 .
[0115] [0115]FIG. 15 shows the wall 1 in FIGS. 1 and 2. In this wall is made a wall opening 2 for later mounting of a window.
[0116] In FIG. 16 the building window 3 in FIGS. 1 and 2 is mounted in the wall opening. In the main, the window consists of a window frame 4 and a transparent plastic sheeting 5 functioning as cover in the opening 6 of the window frame. The plastic sheeting is reinforced by filaments 7 .
[0117] In FIG. 17 a face wall 48 is being built with an intermediate insulation 49 up around the wall opening 2 so that the window frame of the window is covered.
[0118] In FIG. 18 the face wall is completed and it is now only necessary to cut away the plastic sheeting in order to be able to mount the proper window.
[0119] In this case, the window was conveniently left in the wall opening in which it was mounted. In other cases it pays to remove the window and use it again at another place in the same or another building.
[0120] In FIG. 19 is shown a seventh embodiment of a window according to the invention. The window has a window frame 50 with a first part 51 extending in along the inside face 13 of the wall opening at a distance from this face, and a second part 52 extending along the face 10 of the wall at a distance from this face. The window frame can consist of a number of loose or joined bars.
[0121] Between the second part and the exterior of the wall is placed a sealing 53 for preventing wind, rain and snow from penetrating in behind the window. The sealing can be made of e.g. rubber, solid foam, or asphalt.
[0122] On the outer side of the first part 51 of the window frame 50 is placed a longitudinal, elastic flap 54 which can be in one piece with the first part or be an individual flap mounted on the first part. The flap is inclining in the direction of the second part 52 and will therefore automatically bend when the window frame is guided into the wall opening 2 . Thereby, the flap is, with a free peripheral area, forced to bear tightly against the inside face 13 of the wall opening by means of the spring power generated in the flap at bending. At the same time the window frame is centred in the wall opening.
[0123] A sealing 55 mounted on a projection 56 facing backwards on the first part 51 of the window frame serves to further ensure the sealing between the window and the inside face of the wall opening and especially in towards the room behind the window.
[0124] As can be seen, the window frame 50 is screwed into the wall opening 2 by means of a number of assembly screws 57 .
[0125] A flexible cloth 58 is fastened on the window frame by means of a clamping frame 59 which can consist of a number of loose of joined bars.
[0126] In this case, the clamping frame 59 is shaped as a U with two legs 60 and a bottom 61 . In the window fame 50 are made a longitudinal grooves 62 for receiving the ends of the legs 60 .
[0127] The cloth 58 is mounted on the window frame 50 by being squeezed into the grooves 62 by the ends on the legs 60 of the U, the clamping frame being fastened on the window frame by means of screws 63 .
[0128] [0128]FIG. 20 shows an eight embodiment of a window according to the invention. The window has a window frame 64 with a first part 65 extending in along the inside face 13 of the wall opening 2 at a distance from this face, and a second part 66 extending along the face 10 of the wall at a distance from this face. The window frame can consist of a number of loose or joined bars.
[0129] Just as in the seventh embodiment, a sealing 67 is placed between the second part and the face of the wall for preventing wind, rain, and snow from penetrating in behind the window.
[0130] On the outer side of the first part 65 of the window frame 64 are made two longitudinal, elastic flaps 66 corresponding to the flap 54 of the seventh embodiment and functioning in the same way.
[0131] Two flexible cloths 69 are fastened on the window frame 64 by means of a rectangular, piped clamping frame 70 which can consist of a number of loose or joined bars.
[0132] On the clamping frame 70 is made a projection 71 and on the window frame 64 a second projection 72 having a groove 73 for receiving the projection 71 of the clamping frame. When the latter projection is engaging the groove 37 in the projection 72 of the window frame, the two frames 64 and 70 advantageously reinforce each other.
[0133] The two cloths 69 are fastened, as shown, on the window frame by means of the clamping frame 70 .
[0134] As shown, a peripheral area on each of the two cloths 69 is squeezed together between the inside face of the groove 73 in the projection 72 of the window frame 64 and the projection 71 on the clamping frame 64 .
[0135] The clamping frame is in itself fastened on the window frame by means of an adequate number of clamps 74 which in this case, each are shaped as a chair with two legs 75 , a back 76 and a seat 77 .
[0136] In the first part 65 of the window frame are furthermore made two grooves 78 for, at mounting, receiving the free ends of the legs 75 of the chair. This mounting takes place by pushing on the seat 77 of the chair whereby the legs 75 are squeezed into the grooves 78 and the back 76 is made to rest against the clamping frame with an intermediate part of the inner cloth.
[0137] To keep the legs 75 in the grooves 78 , their free ends are hook-shaped while the grooves 78 have a shape complementary to these ends.
[0138] The clamps are made of an elastic material and are arranged to, in mounted position, affect the number of clamps with a spring power that is mainly effective in the direction towards the projection on the window frame.
[0139] [0139]FIG. 21 shows a ninth embodiment 79 of a window according to the invention. This window mainly corresponds to the window 64 mentioned above and shown in FIG. 20. Like components are thus similarly referenced.
[0140] In this case, the clamping frame however consists of a round pipe 80 while on the window frame 79 is made a corresponding, complementarily arc-shaped projection 81 .
[0141] In this case, the free peripheral area 83 of the flaps 82 on the first part 65 of the window frame is, as shown, shaped with a bend allowing the window 79 to unobstructedly be drawn out of the wall opening 2 after use.
[0142] On the first part 65 of the window frame is a handle 84 for use at mounting to manually draw the window frame into the wall opening from the inside of the wall. A corresponding handle 84 for the same purpose is on the in FIGS. 19 and 21 shown seventh and eight embodiment, respectively, of the window according to the invention.
[0143] In the case of the window 79 in FIG. 21, mounting takes place as shown in FIGS. 22 - 26 .
[0144] The window frame 79 consists of bars extruded of an appropriate material, for example aluminium, and preferably joined to an assembled frame in advance.
[0145] [0145]FIG. 22 is a cross-sectional view of the window frame 79 with mounted sealing 67 .
[0146] In FIG. 23, the window frame is drawn into the wall opening 2 by a pull in the handle 84 . During this, the sealing 67 is pressed tightly in against the face 10 of the wall and the flaps 82 have been bent and are now bearing closely against the inside of the wall opening with an edge area under the effect of the spring power in the bent flaps.
[0147] In FIG. 24, the window frame is screwed into the wall opening 2 in this position by means of screws 57 .
[0148] In FIG. 25, the clamping frame 80 is made to bear against the arc-shaped projection 81 on the window frame 79 with an intermediate peripheral area of the cloths 69 .
[0149] In FIG. 26, the legs 75 of the chair 74 are pressed into the longitudinal grooves 78 in the first part 65 of the window frame by means of a pressing on the seat 77 . The back 76 of the chair is now fixing the clamp frame 80 towards the arc-shaped projection 81 of the window frame so that the cloths 69 are fastened in the window.
[0150] In this way, the window opening has temporarily been windowed quickly, easily and tightly by means of an inexpensive window that easily can be removed after used merely by loosening the screws 57 .
[0151] [0151]FIG. 27 shows a tenth embodiment of a window according to the invention.
[0152] In this case, an elastic sealing lip 88 is mounted on the first part 86 of the window frame 85 , said lip is made of an elastic material such as plastic. The second part of the window frame is designated with the reference number 87 .
[0153] The window furthermore comprises a clamping frame 89 consisting of a number of loose or joined pipes serving for fastening two flexible cloths 90 on the window frame by means of a number of clamps 91 which themselves are fastened in a groove 92 in the window frame.
[0154] [0154]FIG. 28 shows an eleventh embodiment 93 of a window according to the invention. This embodiment corresponds to the one shown in FIG. 26 with the difference that a list 94 of an elastically compressible material, such as rubber, is used instead of an elastic sealing lip.
[0155] The windows are sometimes reused. As wall openings in buildings often are not designed in standard sizes, it will, in many cases, however not pay to store, catalogue, and distribute the used windows.
[0156] When the different components of the window are made of plastic, they can be disposed of as burnable refuse or be recycled for new productions.
[0157] A window frame of aluminium can bring in a relatively high price as aluminium waste.
[0158] The embodiments of the window according to the invention described above and shown in the drawing are only to be taken as examples, many other embodiments being possible within the scope of the invention.
[0159] Thus, the above embodiments can advantageously be combined in different ways, the first part of the window frames for example being provided with both sealing lips and barbs at the same time.
[0160] The number of sealing lips and barbs need not be the number shown and described either but can be any appropriate number.
[0161] Correspondingly, the panes used in the windows need not be a flexible plastic sheeting either, they can be of any other kind of impermeable material in form of e.g. plastic, aluminium, or iron plates.
[0162] The window according to the invention is not just well suited for temporarily closing a window opening in a building under construction, the window can just as well be used for temporarily closing any kind of opening, such as openings for doors, and openings in buildings that are to be renovated or that have been damaged by e.g. storm.
[0163] Furthermore, the wall openings and windows need not be quadrangular either but can have any other kind of geometric shape. | A building closure for temporarily closing a bare opening in a wall in a building under construction or renovation. The building closure includes a closure frame made up of a number of bars and defining an opening mainly congruent with the wall opening, a plastic sheeting fastened on the closure frame and spanning its opening, and fastening members for fastening the closure frame to one side of the wall in an area around the wall opening. Each of the bars of the closure frame is V-shaped, has a first part mainly at right angles to the plane of the window and defining the closure frame opening, and a second part mainly at right angles to the first part and defining the periphery of the closure frame. The closure according to the invention can cover a bare wall opening in a building under construction or renovation in a less expensive, easier and tighter manner than known so far, with the two parts of the closure frame closing tightly maintained around the edge of the wall opening. | 4 |
FIELD OF THE INVENTION
The invention relates to a workpiece receiving device for a sewing machine, in particular for a computer-controlled automatic sewing device, for receiving a workpiece having at least one tip and to be provided with a seam at its marginal area, said workpiece being in particular a shirt collar, and said workpiece receiving device having receiving elements for clampingly receiving said workpiece on one side of the seam to be generated.
BACKGROUND OF THE INVENTION
In such a workpiece receiving device known from U.S. Pat. No. 4,312,283 one of the receiving elements is stationarily arranged while the other receiving element is linearly adjustable for the adaptation to different shirt collar sizes. Each of the receiving elements consists of a supporting plate and an associated clamp plate. In particular at very acute-angled collar shirts or comparable workpieces the clamping plates must be very carefully machined and profiled at the tip area so as to achieve a uniform clamp action over the total marginal area of the workpiece. Even at keeping these requirements it cannot be prevented that the collar tip will be distorted after the generation of a seam due to a distorsion of the workpiece due to the seam generation.
From U.S. Pat. No. 3,172,379 a workpiece receiving device is known wherein two plates arranged on one another receive clampingly the workpiece and are profiled with congruent slots, in which the seam extends. Thus, the workpiece is clampingly kept on both sides of the same to be generated. Due to the lability of the plates the workpiece can only be weakly clamped in the marginal area outside of the seam to be produced. As the receiving elements are necessarily of large areas, it is difficult to provide a loading device for the automatic loading and removal.
SUMMARY OF THE INVENTION
The object of the invention is to create a workpiece receiving device which is capable to safely clamp the tip areas of the workpiece.
according to the invention the workpiece receiving device is provided with at least one auxiliary workpiece clamp tiltable from an inoperative position into an operative position so as to clamp the workpiece tip. It is thus achieved that the tip areas of the workpiece are safely clamped, so that corner stitches can be precisely positioned. As the auxiliary workpiece clamps can be tilted after the sewing procedure from an operative position into an inoperative position, an unobstructed loading respectively removal of the workpiece by means of a loading device installed in front of the workpiece receiving device is rendered possible without any problems.
A modification of the auxiliary workpiece clamp with two operable tongs parts grasping the workpiece tips, a swinging-in of the auxiliary workpiece clamp is rendered possible without the risk to touch the workpiece tips at this and, possibly, to deform or bend down the tips.
An especially simple construction of the drives of the auxiliary workpiece clamp is achieved be providing a pneumatic cylinder for the drive of the tongs parts.
Furthermore, it is very advantageous to arrange the tongs parts symmetrically with respect to a central plane of symmetry which is in alignment with respect to the central plane of the clamped workpiece.
Other objects, advantages and features of the present invention will appear from the detailed description of the preferred embodiment, which will now be explained in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective total view of an automatic sewing device;
FIG. 2 is a partial front plan view or the automatic sewing device in the direction of arrow II in FIG. 1;
FIG. 3 is a partial side view of the automatic sewing device in the direction of arrow III in FIG. 2;
FIG. 4 is a partial top plan view of the sewing device in the direction of arrow IV in FIG. 3, without sewing head, however;
FIG. 5 is a top plan view of the workpiece receiving device in the direction of the arrow V in FIG. 3, on an enlarged scale;
FIG. 6 is an enlarged representation of an auxiliary workpiece clamp shown in FIG. 5;
FIG. 7 is a front plan view of the auxiliary workpiece clamp in the direction of the arrow VII in FIG. 6, and
FIG. 8 is a representation according to FIG. 7 showing the auxiliary workpiece clamp in operative position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, in FIG. 1 an automatic sewing device is illustrated for producing shirt collars of different sizes, which is controlled by a computer 1 having a tape reader 2. The functions of the computer 1 are manually released by means of a panel 3. Prior to a sewing cycle, the tape reader 2 is loaded with a control tape 4, having coded information which is read into the computer 1 as soon as the command is inserted into the panel 3. Besides coded information for a workpiece receiving device 5 (FIG. 5) receiving a workpiece 6, the tape 4 carries information about significant points defining a sewing contour to be controlled. For the seam to be produced, these significant points are fed into the computer 1 as X-Y-coordinates which represent parameters for the algorithm of computation, in order to calculate the remaining points of the contour by applying linear or square interpolation. Moreover, information of special points of the contour are read into the computer 1, as for example, the corners of collar tips, so that, after reaching such significant points, the computer logic is capable to branch the program for considering the complicated control operation adjacent to these points. Furthermore, the tape 4 delivers information to the computer 1, for which, at sections of the contour, additionally offered parameters have to be considered. Among other things, such parameters define the continuous sizing for adaptation to the different manufacturing sizes. These parameters are considered by the computer 1 in the contour sections as provided by the tape 4.
The automatic sewing device illustrated in FIG. 1 is provided with a workpiece receiving device 5 as illustrated in FIG. 5 for the purpose of manufacturing shirt collars of different sizes. Shirt collars of different sizes differ from one another, as the middle part beside otherwise equal dimensions is extended such that the desired collar size is achieved.
According to FIGS. 2 and 3 a sewing head 7 as a part of a sewing machine 8 is provided with a needle 9. The workpiece receiving device 5 is secured to a stationary bracket 10. As shown in FIGS. 2, 3 and 4, the sewing head 8 is movably arranged on two guide bars 11 (X-direction) and 12 (Y-direction) which are horizontal and perpendicular to each other, and installed so as to allow the sewing machine 8 to move in a horizontal plate. The sewing head 8 is drivingly connected by timing belts 15, 16 to servo motors 13, 14.
The servo motors 13, 14 are equipped with encoders 17, 18 (FIGS. 2 and 4), which indicate the position of the needle 9 relative to the stationary workpiece receiving device 5 in X- and Y-direction. Prior to operation, the encoders 17, 18 are calibrated in conjunction with the switches 19, 20. The computer 1 controls the servo motors 13, 14 in such a manner that the position of the sewing machine 8 corresponds to a given position of the computer 1 when the needle 9 enters the workpiece 6.
In order to inform the computer 1 about the vertical position of the needle 9, the sewing machine 8 is provided with an encoder 22 associated to the sewing head drive 21 (FIG. 3), which puts out a zero pulse per one needle stroke and informs the computer 1 at any time about the position of the needle 9. The sewing head drive 21 as well as the servo motors 13, 14 are controlled by the computer 1, so that, when sewing difficult contours (e.g. collar tips), the needle 9 only pierces points of the desired sewing contour and not such points at such critical points of the contour which may be produced by the overriding sewing machine 8 moved in X- and Y-direction. As so far described the construction of the automatic sewing device is known from U.S. Pat. No. 4,312,283.
As illustrated in FIG. 5 the workpiece receiving device 5 consists of two parts, a stationary workpiece receiving element 23 secured to the stationary bracket 10, and an adjustable workpiece receiving element 24 connected via an intermediate plate 25 to a slide plate 26. The stationary bracket 10 is provided with a lower plate 27 and an upper plate 28, which are connected parallelly to each other and spaced from one another by means of screws 29 and spacers 30. The slide plate 26 is provided with a longhole-profiled guide 31 and displaceably arranged on the lower plate 27 and clamped thereto by a clamping lever 32 passing through the guide 31 so that the slide plate 26 is stationarily but releasably blocked with respect to the stationary bracket 10.
The stationary workpiece receiving element 23 as well as the adjustable workpiece receiving element 24 each are provided with supporting plates 33, 34 and clamping plates 35, 36, the outer edges of which are coincidently profiled according to the contour of a seam 37 to be produced. The function of the workpiece receiving elements 23, 24 is to hold the workpiece 6, at which the space between the workpiece receiving elements 23, 24 may be overbridged by a thin sheet secured to the supporting plate 33 of the stationary workpiece receiving element 23. The sheet is not illustrated in the drawings. Thus, the workpiece 6 is only clamped by the workpiece receiving element 23 resp. 24 at one side of the seam 37 to be produced.
As obvious from FIGS. 3 and 5, the clamping plates 35, 36 are fastened to levers 38, 39. The lever 38 is swingably supported to the lower plate 27 of the stationary bracket 10 and the lever 39 is swingably supported to the intermediate plate 25, which is displaceable together with the slide plate 26. Both clamping plates 35, 36 are displaceable by pneumatic cylinders 40, 41, which on one hand are hinged to the levers 38, 39 and on the other hand to the lower plate 27 resp. the intermediate plate 25.
Upon adjustment of the slide plate 26 the adjustable workpiece receiving element 24 together with the lever 39 and the associated pneumatic cylinder 41 is displaced. For displacement of the slide plate 26 a freely accessible handle 42 is provided in front of the upper plate 28. In order to facilitate displacement of the slide plate 26 and the parts fastened thereto a recess 43 is arranged in the front surface of the lower plate 27 turned to the clamping plates 35, 36 for displaceably receiving the intermediate plate 25. A further recess 44 of the lower plate 27 is arranged at the side of the lever 38 turned away from the adjustable workpiece receiving element 24.
In the area outside of the clamping plates 35, 36 at the lower plate 27 resp. the slide plate 26, two angle levers 45, 46 are arranged symmetrically to each other which are swingable about vertical axes 47, 48. The free ends of the short levers 49, 50 of the angle levers 45, 46 are hinged to the free ends of piston rods 51, 52 of double acting pneumatic cylinders 53, 54. The pneumatic cylinders 53, 54 are hinged to the lower plate 27 resp. the slide plate 26. To each of the other long levers 55, 56 is fastened an auxiliary workpiece clamp 57, 58 by means of screws 59. The auxiliary workpiece clamps 57, 58 are tiltable by means of the angle levers 45, 46 in such a manner that their symmetrical central plane 60 is identical with the plane extending parallelly through the middle of the workpiece 6.
The construction of the auxiliary workpiece clamps 57, 58 is obvious from FIGS. 6-8. As the auxiliary workpiece clamps 57, 58 are mirror-symmetrically constracted, only the auxiliary workpiece clamp 57 is hereinafter described. The auxiliary workpiece clamp 57 is provided with a C-shaped carrier 61, the web 62 of which is formed with a bearing eye 63 through which passes a screw 59 in order to be screwed into the end of the long lever 55. A shank 64 of the carrier 61 is formed with a bore 65 into which is screwed the fastening part 66 of a single acting pneumatic cylinder 67. The pneumatic cylinder 67 has a cylindrical housing 68, in which is displaceably arranged a piston 69 with a piston rod 70. The latter is guided outwards through the fastening part 66. About the piston rod 70 a compression spring 71 is arranged tending to move the piston 69 together with the piston rod 70 into their retracted position in the housing 68. To the free end of the piston rod 70 guided through the fastening part 66 is screwed a U-shaped toggle lever 72, which is secured by a nut 73. The shanks of the toggle lever 72 are provided with flushing bores, into which is pressed a pin 74 for swingable supporting two adjoining butt straps 75, 76. To the free ends of the butt straps 75, 76 the ends 77, 78 of two double-armed levers 79, 80 are hinged by means of rivets 83. In their longitudinal center the two double-armed levers 79, 80 are provided with a common swivel bearing 82 wherein is received a rivet 83 defined as a swivel axis for swingably securing the double-armed levers 79, 80 to the other shank 84 of the carrier 61. With their surfaces turned to each other, tongs parts 85, 86 of the double-armed levers 79, 80 turned away from the butt straps 75, 76 are provided with clamping surfaces 87, 88. In the closed position of the auxiliary workpiece clamp 57, as illustrated in FIG. 8, the clamping surfaces 87, 88 extend parallelly to each other with a distance therebetween having approximately the thickness of the workpiece 6. the tongs parts 85, 86 each narrow to a blunt tip 89.
The pneumatic cylinder 67 is supplied by compressed air via a hose 90. In the long lever 56 of the angle lever 46 an offset 91 is formed so that the auxiliary workpiece clamp 58 moves in the same plane as the auxiliary workpiece clamp 57 as already described above.
By corresponding air pressurization of the pneumatic cylinders 53, 54 the auxiliary workpiece clamps 57, 58 are displaced between two end positions, i.e. an inoperative position A (see auxiliary workpiece clamp 57 in FIG. 5) and an operative position B (see auxiliary workpiece clamp 58 in FIG. 5). When the auxiliary workpiece clamps 57, 58 are in their inoperative position A, an unobstructed loading of the workpiece receiving device 5 with a workpiece 6 respectively the removal of the workpiece 6 out of the workpiece receiving device 5 is possible. In the operative position B clamping of a workpiece tip 92 resp. 93 is possible by means of the two auxiliary workpiece clamps 57 resp. 58. Displacement of the two auxiliary workpiece clamps 57, 58 is performed simultaneously, i.e. both clamps 57, 58 are positioned either in the inoperative position A or in the operative position B. As obvious from FIG. 5, the automatic sewing device is provided with a loading device 94 having a displaceable plate 95, which is movable to and fro between two end positions, i.e. a loading position C and a not illustrated transferring position. In the loading device 94 is positioned a not sewn workpiece 96 which is held on the plate 95 by means of the positioning/clamping elements 97, 98. In FIG. 5 the plate 95 is illustrated in an intermediate position D. In the not-illustrated transferring position the not sewn workpiece 96 and the already sewn workpiece 6 are positioned coincidently one above the other. Thus, the plate 95 is so arranged with respect to the sewing plane as to be positioned in the transferring position above the already sewn workpiece 6. The suspension of the plate 95 additionally renders possible a slight lowering upon the workpiece 6 when the workpiece receiving elements 23, 24 receive a not sewn workpiece 96. With respect to the workpiece the lower surface of the plate 95 has a higher coefficient of friction that the upper surface so that when the plate 95 is moved back from the transferring position into the loading position C the sewn workpiece 6 is drawn out of the workpiece receiving device 5 and subsequently stored in a not illustrated magazine arranged below the loading device 94. The positioning/clamping element 98 associated to the adjustable workpiece receiving element 24, is adjustably secured in an oblong hole 99 of the plate 95. Both elements 97, 98 are formed so as to prevent a collision with the clamping plates 35, 36 while the plate 95 is moved.
The pneumatic cylinders 40, 41, 53, 54 and 67 are connected via compressed air hoses, e.g. the hose 90, to compressed air valves, e.g. solenoid valves, the electrical actuation of which is controlled by the computer 1 according to the sequence of operations.
In the hereinafter described operation it is assumed that the sewing machine 8 together with its needle 9 is positioned in a right end position R (FIG. 5), that the clamping plates 35, 36 are located in a dot-dashed position according to FIG. 3, that there is no workpiece 6 in the workpiece receiving element 23, that the auxiliary workpiece clamps 57, 58 are positioned in their inoperative positions A and that the plate 95 is positioned in the loading position C.
After the operator has positioned a not sewn workpiece 96 on the plate 95, the workpiece 96 is clamped by means of the positioning/clamping elements 97, 98. Subsequently, the plate 95 with the workpiece 96 clamped thereon is inserted into the opened workpiece receiving elements 23, 24. As soon as the plate 95 has reached the transferring position, the computer 1 causes the lowering of the clamping plates 35, 36 by correspondingly pressurizing the pneumatic cylinders 40, 41. Simultaneously, the positioning/clamping elements 97, 98 are opened so that the not sewn workpiece 96 is released. Then the plate 95 is moved back into the loading position C. As the clamping plates 35, 36 rest upon the workpiece 96, the latter remains in the workpiece receiving elements 23, 24, wherein it is clamped between the clamping plates 35, 36 and the associated supporting plates 33, 34. Subsequently, the computer 1 causes the sewing machine 8 at inoperative sewing head drive 21 to be moved by means of the servo motors 13, 14 in the X- and Y-direction in such a manner, that the needle 9 is positioned above the seam starting point E. From this starting point E sewing of the seam 37 is started, at which the sewing machine 8 is completely controlled by the computer 1. In order to perform this sewing operation the computer 1 is informed about the actual position of the needle 9 in X- and Y-direction by the encoders 17, 18 and the encoder 22. As soon as the sewing machine 8 has carried out some stitches from the seam starting point E, the computer 1 gives order to displace the auxiliary workpiece clamps 57, 58 out of their inoperative positions A into their operative positions B. As soon as the operative positions B are reached, the computer 1 causes the pneumatic cylinders 67 to be pressurized so that the tongs parts 85, 86 of each auxiliary workpiece clamp 57, 58 are closed. At this, the tongs parts 85, 86 seize the corresponding workpiece tip 92 as obvious from FIG. 8. This kind of clamping the workpiece tips 92 prevents the workpiece from being distorted when the corner points Z are produced. Consequently, the strain in the workpiece, especially at the workpiece tips 92, 93 occuring during the stitch formation is absorbed by the auxiliary workpiece clamps 57, 58. Of course, the tongs parts 85, 86 seize the workpiece tips 92, 93 with a sufficient distance with respect to the seam 37 to be produced and especially with an adequate distance from the corner point Z to be produced. As illustrated in FIG. 8, the tubular stud 101 arranged at the lower arm 100 of the sewing machine 8, and the presser foot 102 surrounding the needle 9, pass the tips 89 of the tongs parts 85, 86 without any trouble.
Finally, the continuing sewing operation produces a further corner point Z in the area of a further workpiece tip 92 and a further seam 37 terminating at a seam end point F. Here a thread cutting cycle is accomplished, which is controlled by the computer 1. Subsequently, the computer 1 moves the sewing machine 8 without sewing into an end position L--shown in FIG. 5 on the left side--wherein the position of the sewing machine 8 is illustrated by dot-dashed lines. After reaching the end position L the computer 1 causes the releasing of the workpiece tips 92, 93 by depressurizing the pneumatic cylinders 67 of the auxiliary workpiece clamps 57, 58, the returning of the auxiliary workpiece clamps 57, 58 from their operative positions B into their inoperative positions A and finally the lifting of the clamping plates 35, 36 by pressurizing the pneumatic cylinders 40, 41 in reversed order.
At this, a not sewn workpiece 96 positioned by the operator on the plate 95 during the sewing operation may be inserted into the opened workpiece receiving elements 23, 24 in the already described manner, and the sewn workpiece 6 may be removed and stored in the magazine. Removal of the sewn workpiece 6 is in such a manner that it is taken along due to the already mentioned high coefficient of friction with respect to the lower surface of the plate 95. This kind of loading and removal is known from U.S. Pat. No. 3,869,998.
Usually the manufacture of shirt collars is such that the workpiece tips 92, 93 form the collar tips. These workpiece tips must not be tips in the mathematical sense, they also may have slight roundings up to a radius of approximately 6 mm. Also in this case the auxiliary workpiece clamps 57, 58 according to this invention may be advantageously applied.
For the production of shirt collars of different sizes the adjustable workpiece receiving element 24 together with the associated auxiliary workpiece clamp 58 may be displaced by means of the handle 42 after releasing of the clamping lever 32. Such a displacement requires a re-adjustment of the positioning/clamping element 98 of the loading device 94. After the new size adjustment the adjustable workpiece receiving element 24 is again locked by means of the clamping lever 32. This kind of size adjustment is known from U.S. Pat. No. 4,312,283.
As the workpiece tips 92, 93 are held by the auxiliary workpiece clamps 57, 58 the associated tips of the supporting plates 33 res. 34 and the clamping plates 35 resp. 36 may be rounded as a sufficient fixing of the workpiece 96 resp. 6 is ensured in the area of the workpiece tips 92, 93. | A workpiece receiving device for a sewing machine, in particular for an automatic sewing device, is provided with workpiece receiving elements for clampingly receiving a workpiece at one side of a seam to be produced in the marginal area of the workpiece, the workpiece, namely a shirt collar, being provided at least with one tip. In order to also safely clamp the tip area of the workpiece for producing exact corner stitches without distortion of the workpiece, the workpiece receiving device is provided with an auxiliary workpiece clamp for clamping the workpiece tip, the auxiliary workpiece clamp being movable from an inoperative position into an operative position. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to fiber-reinforced pressure containers or vessels and is more particularly concerned with the design of such containers to avoid excess strains due to the effect of internal pressure.
It is known that the strain in the middle, cylindrical part of pressure vessel with domed ends is greater than on the ends in the sense that the cylindrical part would deformed into the form of a barrel if it were not strong enough. In order to take this into account, pressure vessels of fiber-reinforced material have been designed so that the cylindrical middle part is provided with a casing to increase the resistance to pressure of this part of the structure between the domed ends. Such a casing is generally in the form of wound-on tape or thread material that is impregnated with synthetic resin.
A further relevant design consideration is that the transitions between the middle part and the domed ends of such a pressure vessel are particularly likely to be damaged by excess strain. It is however so far not proved feasible to reinforce the transitions by winding on backup material as used on the middle part, since if the winding were to be extended beyond the cylindrical middle part onto the domed ends, the wound material would tend to slip off because of the rounded shape of the domes. For this reason it has so far not been possible to reduce the pressure-induced strain load at the transitions between the domed ends and the middle part of a pressure vessel of the sort in question without the use of such complex methods and apparatus which would mean that the production of such pressure containers would no longer be an economic proposition.
SUMMARY OF THE PRESENT INVENTION
For this reason, one object of the present invention is to design a pressure container of fiber-reinforced resin, with a cylindrical middle part and domed ends and with a reinforcing layer for the middle part such that it effectively strengthens the transitions between the middle part and the domed ends and protects them against pressure-induced strains.
A still further aim of the present invention is to create a simple and easily performed method for the production of such pressure vessels.
In order to achieve these or other objects, a pressure container of the type in question is so made that the reinforcing layer is located on the inner side of the cylindrical middle part and lines the transitions between the middle part and the domed ends of the vessel.
In accordance with one form of the method of the invention, carbon fiber material impregnated with a thermosetting resin is wound in one layer or in superposed layers on a cylindrical mandril, thermosetting of the resin is caused by heating and the mandril is removed from the carbon-fiber-reinforced resin cylinder. Bowl-like mold members of a frangible material are pressed against the ends of the resin-carbon fiber cylinder, the outer curved faces of the mold members corresponding to the inner face of the domed ends to be produced. The mold members furthermore have edges with an annular cross section whose inner parts are able to be fitted against the end faces of the cylinder and furthermore outer parts, exceeding the outer diameter of the cylinder and having a chamfer. Elastomeric material is introduced into the space around the outer face of the cylinder and between the chamfered out parts of the annular edges of the molding and such elastomeric material is vulcanized. The wall of the pressure container is formed by helically winding a thread impregnated with thermosetting resin so that coils of the thread are adjacent to each other and at least two superposed layers of wound thread are formed. The resin is then cured and the bowl-like mold members are broken and removed from the interior of the container through openings in the wall thereof.
A more detailed account of the invention will now follow using the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of a pressure container in accordance with the invention in a longitudinal section to indicate a preferred form of the structure of the reinforcing layer.
FIGS. 2-4 are views of different stages in the method of the invention for the production of such a pressure vessel.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a longitudinal section through a pressure container 1 in accordance with the invention, omitting the inlet and outlet connection pieces normally provided in the apices of the domed ends 3 and 4. The container as such is formed by the cylindrical body or middle part 2 and the domed ends 3 and 4. There are transitions 5 between the body 2 and the domed ends 3 and 4, but it is to be stressed that in the container produced in accordance with the present invention there are no joints between abutting components of the structure; and in fact the entire pressure container 1, that is to say the middle part and the domed ends, takes the form of a single coherent structure, as will furthermore be seen from the later account herein of the method steps for manufacturing the container.
On the inner face of the cylindrical body 2 of the container 1 there is a reinforcing layer 6, which, as will be seen from FIG. 1, lines the transitions 5. This constitutes an effective safeguard for the transitions against pressure loading.
Preferably the reinforcing layer is in the form of a layer 6a of carbon fibers bonded with thermosetting resin adjacent to the interior space of the container, and a layer 6b, placed between the wall 2 and the layer 6a, of elastomeric material. The thickness of the different layers of the wall members and the reinforcing layers of the container are exaggerated in the figure to make it more readily intelligible.
It is preferred for the carbon fibers of the layer 6a to be coiled helically and placed side by side and wound in one or more layers, this endowing the layer with a particularly high degree of strength and resistance to pressure.
An account will now be given of the preferred method of producing a pressure container in accordance with the invention, referring to FIGS. 2 through 4.
The first step is that of winding a carbon fiber thread impregnated with thermosetting resin on a cylindrical mandril in such a way that the separate coils or loops of thread so produced are closely adjacent to each other. The length of the coil will be aproximately equal to the length of the body of the pressure container. The winding may be in one or more layers, dependent on the desired thickness of the layer 6a to be produced.
The man in the art will know of a large range of thermosetting resins that may be used, the guiding principal being the intended use of the pressure container and more specifically what chemicals will come into contact with the layer 6a. As a general proposition however, it is possible for any thermosetting resin to be used with a slight preference being given to resins that cure under 150° and more particularly between 80° and 100° C.
The next step is the curing of the resin at the appropriate temperature. Thereafter the mandril is withdrawn from the wound package so that the product is a cured resin-carbon fiber hollow cylinder or package, which represents the layer 6a of the pressure container to be manufactured. This is made somewhat clearer by FIG. 2, in which the right of a hollow, cylindrical mandril 12 will be seen of a longitudinally sectioned arrangement, on which the cylinder 6a made of resin and carbon fibers is seated. After removal of the mandril this cylinder 6a will be ready as the first component of the pressure container.
The ensuing step is for bowl-like mold members 7 (FIG. 2) of frangible material to be produced. These mold members have--in a way similar to foundry operations--merely the function of endowing the structure to be produced with the desired form and after they have fulfilled this function they are broken or disintegrated. For performing the method of the invention a material will be used for the mold members that is preferably plaster of paris or another readily available material, which after being mixed in the form of a powder with water may be cast to form a fragile structure.
The bowl-like mold members 7 are so shaped that their outer curved faces correspond to the inner wall face of each domed end of the pressure container to be fashioned. Furthermore their annular edges 13 have inner parts 13a that are adapted to be fitted on the ends of the resin-carbon fiber cylinder 6a, and outer parts 13b, that project beyond the ends of the cylinder 6a and are chamfered (FIG. 2) frusto-conically.
The mold members 7 are pressed to the right and the left, respectively, against the ends of the cylinder 6a, the one on the right-hand end being indicated in FIG. 2. The pressing operation may take place using any suitable holding device. Since however it is necessary to have openings in the container for the supply and discharge of fluid under pressure therefrom, the bowl-like mold members 7 have openings at their apices 14 matching the eventual ports of the container and through which a support mandril 8 is inserted that has positioning rings 10 thereon. By clamping the positioning rings 10, using screws 11 in positions pressing the bowl-like mold members 7 against the end walls of the cylinder 6a and the mold members 7 are held together.
Before mounting the positioning rings 10 on the mandril 8 it is preferred to position connection pieces 9, that are preferably made of a metal such as aluminum, on the mandril. At their ends adjacent to the mold members 7 the connection pieces 9 each have a conical head 9a positioned in a conical wider part in the openings 14 of the mold members 7 and functioning as an anchor for holding the respective connection piece in the wall 3 and 4 of the domed ends of the container that are yet to be fabricated.
Elastomeric material is now introduced into the space around the outer wall of the resin-carbon fiber cylinder 6a and between the chamfered outer parts 13b of the present on mold members 7. The elastomeric material is then vulcanized. The vulcanized material then forms the elastomeric intermediate layer 6b of the container 1 to be produced.
Those in the art will also know of a large number of products that may be used as the elastomeric material, as for example natural rubber, different forms of synthetic rubber such as chloroprene, and in principle any type of elastomeric material may be used which is compatible with the fluid under pressure for which the container is to be used.
The structure resulting in this stage of the process is to be seen from the side in FIG. 3 and is delimited by the surfaces of the elastomeric layer 6b of the bowl-like mold members 7, the outer wall layer 2, 3 and 4 not having been so far produced. This wall layer is produced by winding thread impregnated with thermosetting resin helically and in a number of superimposed layers and curing the resin. As in bulding up the layer 6a, the thread material may be carbon fiber, but other forms of filaments or fibers such as glass fiber may be used. As regards the choice of the thermosetting resin, the same observations apply as were made in connection with the production of the layer 6a, the possible range being in fact even larger because the resin does not come into contact with the fluid for which the container is intended.
The threads are wound in coils with the closest possible packing, one layer being produced on top of the other until the desired thickness of the outer container wall 2, 3 and 4 has been produced. In this respect the term winding is intended to denote guiding the thread as shown in FIGS. 3 and 4. For example the one end of the impregnated thread is made fast to the foot of the left connection piece 9 at the bottom and then trained in the direction of the arrow over the surfaces of the mold member 7 and the layer 6b as far as the foot of the right connection piece 9 at the top, while the entire structure is turned about the longitudinal axis of the supporting mandril 8 in a clockwise direction at such a speed that the coils of the thread formed are placed side by side. The position of the threads may be seen from FIG. 4, that is a right end-on view of the structure as seen in FIG. 3. The course of the first thread coil on the two sides of the foot of the connection piece 9 is here marked by one arrow head, the second one by two arrow heads and the third one by three arrow heads. The spacing of the thread coils from each other is somewhat exaggerated in the figure to make it more straightforward. It will be seen that the threads run close together at the foot of the connection piece 9 so that the part 9a of the connection piece 9 is firmly anchored in the container wall 2, 3 and 4 in the process of being built up.
After the completion and curing of the container wall 2, 3 and 4, the positioning rings 10 are detached, the supporting mandril 8 is removed and the bowl-like mold members 7 of plaster of paris or some similar material are disintegrated. After clearing the fragments of the members from the interior via the openings of the connection pieces 9 the container in accordance with the invention is finished.
In the container of the invention it is not only a question of covering the transitions, which otherwise tend to form zones of weakness, when the container is subjected to pressure forces as explained hereinbefore, between the cylindrical body and the domed ends 3 and 4, but this reinforcing effect due to this guard layer is even further enhanced because the container wall 2, 3 and 4 of the pressure container of the invention forms an integral and coherent body and does not consist of a middle part with domed ends welded thereto. Lastly the coherence of the pressure container of the invention is even further increased by the shrinkage of the threads of the helical winding to a degree not so far experienced. | The pressure container of fiber-reinforced resin having a cylindrical body and domed ends differs from designs proposed so far inasmuch as the reinforcing layer is not on the outside but on the inside of the wall in the form of lining, and is so placed as to overlap transitions between the domed ends and the cylindrical body of the container. This safeguards the transitions against damage by pressure-induced strains. For the production of such a pressure container the reinforcing layer is first produced and the rest of the container wall is formed on top of it. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an improved thermally conductive and electrically insulative laminate for use as a mounting pad and electrical chassis barrier in combination with solid-state electronic devices, particularly for mounting such devices with an electrically insulative layer being interposed between the thermally conductive base of the solid-state device and the chassis or other ultimate heat sink and wherein the pad is provided with tubular projections for insulatively protecting the shanks of the mounting screws or bolts from contact with the substrate including any electrical conductors disposed thereon. The properties required are that the laminates be both thermally conductive, electrically insulative, and conformable to the devices being received or mounted thereon, a combination of properties not readily found in nature.
Mounting pads for solid-state devices have been known in the past, with examples of such devices being disclosed and claimed in copending application Ser. No. 584,897, filed Feb. 29, 1984, and entitled "MOUNTING PAD FOR SOLID-STATE DEVICES". The present invention, while utilizing certain features of the device disclosed in copending application Ser. No. 584,897, is provided with the additional feature of self-locking tubular projections which extend along an axis normal to the plane of the mounting pad.
In the assembly of electronic systems, it is frequently desirable, as one operation, to initially set the mounting pad in place on a circuit board or other mounting substrate. In certain applications the mounting pad may be set in place, with the next operation including the actual positioning of the solid-state device on the pad. However, in certain assembly operations and systems, it may become desirable to move, rotate, invert, or otherwise shift the positioning of the substrate in such a way that it becomes desirable for the mounting pad to be at least temporarily held or affixed to the substrate. In accordance with the present invention, a system is provided which includes providing tubular projections for the mounting pad which are designed to extend through the thickness of the substrate, and which are provided with retention burrs for holding the mounting pad in place prior to receiving the solid-state device thereon.
It is desirable that the mounting pad be thermally conductive and electrically insulative.
Materials, including elements, compounds, and compositions of matter rarely possess the combined properties of being both thermally conductive and electrically insulative. Since the number of materials possessing such a combination of properties is relatively limited, one must seek compromises in other physical and electrical properties in order to find a useful material. Also, one technique for decreasing the thermal impedance in an electrically insulative material is to provide a material with an extremely thin cross-sectional thickness. However, as the cross-sectional thickness decreases, the risk of rupture, cracking, or fracture of the material increases, thereby increasing the risk for electrical failures. Also, in the present arrangement, a flexible tubular projection is employed, along with flexible retention burrs, so as to provide for suitable electrical insulation and mechanical durability to achieve appropriate mounting of the solid-state device on the mounting pad.
Further desirable properties or characteristics include toughness, and mechanical durability, these properties rendering the barrier member resistent to cutting, ripping, cracking, or puncturing during subsequent assembly operations. In addition, it is desirable that the barrier member per se be reasonably pliable so as to increase the area of surface contact in order to maximize the heat transfer, with the tubular projections and retention burrs being, of course, reasonably resilient, pliable, and mechanically tough. The mechanical properties are desirable in order to provide an electrical chassis barrier member which is sufficiently tough and durable to withstand the forces of over-torqued mounting screws or bolts, and furthermore reduce the occurrences of burr cut-through or cracking, which are frequent occurrences in production operations.
With respect to other physical-thermal properties which are desirable for use in combination with high power type solid-state devices, and in addition to being thermally conductive, it is desirable that the material possess an appropriate high temperature capability.
In co-pending application Ser. No. 584,897, filed Feb. 29, 1984, it is suggested that a laminate utilizing polyimide (amide) film be employed for use in combination with power type semiconductor devices. Such devices have, of course, been found to be highly useful for device mounting applications. The devices of the present invention may also employ a laminate structure for the mounting pad portion of the device, with the tubular projections and retention burrs being fabricated from silicone rubber or other desired moldable substrate material.
SUMMARY OF THE INVENTION
In accordance with the present invention, a thermally conductive electrically insulative solid-state device mounting pad member is provided, with the device including tubular projections with retention burrs for assisting in holding the mounting pad in place while assembly operations are in progress. The mounting pad member of the present invention comprises a relatively thin molded pad, which may be a layer of silicone rubber or alternatively be in the form of a laminate which is both tough and durable, with good electrical and mechanical properties, and having high temperature capabilities including resistance to high temperature problems including high pressure creep. The tubular projections are preferably fabricated from silicone rubber, which is moldable through the use of conventional molding operations. When the pad portion of the device is a laminate, it preferably includes at least three layers with a pair of outer layers disposed on opposite sides of a center film layer. The center layer may comprise a polyimide (amide) film filled with a quantity of a particulate solid selected from the group consisting of aluminum oxide and boron nitride, and with the outer layers consisting essentially of silicone rubber preferably containing a quantity of a particulate solid, preferably aluminum oxide or boron nitride. The combination of features available from the mounting pad are indicated above, and have been found to provide a highly versatile and operationally advantageous mounting pad or chassis barrier for use in the assembly of electronic systems, including the mounting of solid-state electronic devices onto heat dissipating chassis or other heat sink assemblies without requiring intermediate mounting or temporary retaining operations for the pad.
Therefore,it is a primary object of the present invention to provide an improved thermally conductive electrically insulative member which is designed to be held upon a mounting pad without need for adhesive films or the like, and with the member having good thermal properties which permit its use in a variety of applications.
It is a further object of the present invention to provide an improved thermally conductive electrically insulative member for use as a chassis barrier in combination with solid-state electronic devices, wherein the member comprises a mounting pad with tubular projections extending therefrom to insulatively isolate a mounting screw or bolt from the substrate, and with the tubular projections including retention burrs for retaining the pad in place on a mounting substrate.
Other and further objects of the present invention will become apparent to those skilled in the art upon a study of the following specification, appended claims, and accompanying drawing.
IN THE DRAWING
FIG. 1 is an elevational view, partially in section, illustrating a typical application of the thermally conductive electrically insulative mounting pad prepared in accordance with the present invention, and illustrating the manner in which the tubular projections extend therefrom, and further illustrating the manner in which such a device is typically interposed between a solid-state electronic device such as a transistor and a base chassis or substrate, with FIG. 1 being taken, at least partially, along the line and in the direction of the arrows 1--1 of FIG. 2;
FIG. 2 is a perspective view partially broken away of a typical thermally conductive electrically insulative member fabricated in accordance with the present invention;
FIG. 3 is a vertical sectional view of a device fabricated in accordance with the present invention;
FIG. 4 is a bottom plan view of a device fabricated in accordance with the present invention, and illustrating the manner in which the retention burrs extend radially outwardly from the tubular projections;
FIG. 5 is a view similar to FIG. 1, and illustrating a somewhat modified form of the thermally conductive electrically insulative mounting pad of the present invention; and
FIG. 6 is a partial perspective view of a thermally conductive electrically insulative member in accordance with the embodiment illustrated in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the preferred embodiment of the present invention, the thermally conductive electrically insulative member generally designated 10 is utilized as a chassis mounting barrier pad in combination with a solid-state electrical device such as transistor assembly 11, with the member 10 being interposed between the undersurface of the metal base substrate of transistor 11 and metallic chassis or rigid circuit board 12. The thermally conductive electrically insulative member 10 is preferably in the form of a laminate, but may, alternatively, be in the form of a molded silicone rubber device. As an alternative to silicone rubber, other film or layer forming materials with high temperature capability may be employed.
In those instances where a laminate is employed, films of polyimide (amide) may be used and are available commercially. Polymeric poly(imide-amides), or polyimides as they are sometimes referred to herein, as a general class of materials have been known for many years. Reference is made to U.S. Pat. Nos. 2,149,286; 2,407,896; 2,421,024; and 2,502,576. Polyimides having exceptional capabilities at high temperatures are disclosed in U.S. Pat. No. 2,710,853, these high temperature polyimides being prepared from an aromatic dianhydride such as pyromellitic dianhydride together with an aromatic diamine, and particularly 4,4' diamino diphenylether or para-phenylenediamine. Polyimides of the type disclosed in these various patents are available commercially in several forms, cured films, partially reacted resins, and the like. Such films are available commercially under the registered trademark KAPTON from E. I. DuPont de Nemours Corp. of Wilmington, Del. Moreover, such films are available commercially when filled with a particulate solid selected from the group consisting of aluminum oxide (alumina) and boron nitride. More specifically, the particulate solids preferably have a particle size with a major dimension ranging from between about 2 microns and 30 microns, and are included in the polymer matrix in an amount ranging from between about 10% and 50% by volume.
With continuing attention being directed to the drawings, a pair of tubular projections 14 and 15 extend from the plane of the pad, with projections 14 and 15 having radially extending retention burrs 16--16 extending therefrom. The retention burrs are preferably fabricated from silicone rubber so as to be flexible, as well as durable, and provide a means for temporarily retaining or supporting the mounting pad in place on the substrate and/or circuit board. While retention burrs are set forth in the embodiments illustrated herein, other related forms of radially extending members may be employed with either greater or lesser degrees of circumferential integrity.
As indicated hereinabove, the aluminum oxide or boron nitride particles may be utilized as fillers for the polyimide (amide) film in an amount ranging from between about 10% and 50% by volume. For most electrical applications, however, it has been found that a loading of about 30% to 35% by volume is preferred for aluminum oxide, and about 35% by volume for boron nitride. Also, boron nitride, being anisotropic thermally, is the desired filler. Exposure to strong electrical fields may be employed in the formation of films as they are being filled and cured with boron nitride, for example, in order to enhance the anisotropic thermal characteristics.
When aluminum oxide is employed as the particulate solid, it is generally preferred that an amount of about 30% to 35% of aluminum oxide particles be utilized. Also, for most purposes, particle sizes of aluminum oxide and boron nitride in the range of about 2 to 10 microns are preferred.
It has been found that silicone rubber coated polyimide (amide) films containing aluminum oxide or boron nitride particulate solids possess a desirable balance of physical and electrical properties including a toughness which enhances the ability of the members to withstand forces frequently occasioned due to over-torqued screws or bolts and also possess a resistance to tearing, so as to reduce or eliminate the occurences of electrical shorts caused by burr cut-throughs or cracking and a substantial reduction of thermal aging. The high temperature properties of the polyimide (amide) films, together with the silicone rubber coatings, are such that exposure to wave-solder processes is possible, a feature which is desirable for use in electronic assembly operations. In addition, the properties of silicone rubber coated polyimide (amide) films are such that resistance to deterioration due to exposure to chemicals or solvents is reduced.
Preferably, the durometer of the silicone rubber layer, when cured, is in the range of about 75. Such silicone rubber polymers are available commercially, and are available from the General Electric Co. of Schenectady, N.Y. The polymers are preferably loaded with a quantity of particulate solids selected from the group consisting of aluminum oxide and boron nitride. It has been ascertained that the electrical properties of silicone rubber do not deteriorate when loaded with aluminum oxide or boron nitride particulate solids in the range contemplated herein, and for certain applications the electrical properties of the device are improved. The quantity of loading of aluminum oxide or boron nitride particles is preferbly in the range of between about 30% and 40% by volume based upon silicone rubber solids. The particle size is preferably in the range of from about 2 microns to 10 microns. Also, while it has been indicated that aluminum oxide or boron nitride solids may be employed, mixtures or blends of these materials may be employed as well.
In a typical surface mounting application for a solid-stage electronic device such as transistor 11, and with attention being directed to FIG. 1 of the drawing, transistor 11 is mounted upon chassis 12 by means of bolts 18--18, with attachment being rendered secure by nuts 19--19. Electrical insulation is achieved by virtue of the tubular or cylindrical projections 14, 15, together with the insulating washers 20. Also, lead pin 21 extends outwardly from conductive base member 22 of transistor assembly 11, through an insulator 23. Pin 21 is appropriately coupled to the circuitry in a conventional manner.
The thermal, electrical, and other properties of a typical product prepared in accordance with the present invention are set forth in Table I hereinbelow:
TABLE I______________________________________PROPERTY TYPICAL VALUE TEST METHOD______________________________________Thickness .006 +/- .002 inchContinuous -60 to +200° C.Use Temp.Volume Resistivity 10.sup.13 minimum ASTM D 257Dielectric Strength 6000 Volts min. ASTM D 149Tenacity, 18.6 KPSI ASTM D 412Minimum FilmThermal 1.2 × 10.sup.-3Conductivity CAL/°C. CM SEC.Thermal .40° C/WResistance______________________________________
In Table I, the thermal conductivity is given as that observed for an alumina filled material (18% by volume fill in the polyimide (amide) center film and 35% by volume fill in the silicone rubber layers). When boron nitride is employed, this value is increased to 1.5×10 -3 CAL/°C. CM SEC., it being understood that the thermal conductivity for boron nitride filled materials may be improved by certain processing techniques by virtue of its higher thermal conductivity and the anisotropic thermal behavior of the product.
In addition to alumina and boron nitride, other materials with good electrical properties and high temperature capability may be used including, for example, silica, beryllium oxide, aluminum nitride, silicon carbide and silicon nitride.
Attention is directed to FIGS. 5 and 6 of the drawings wherein a modifed form of the invention is illustrated. In particular, and in FIG. 5, the semiconductor device 11 is mounted on substrate 12 upon the pad 30. Pad 30 is fabricated in substantilly the same fashion as pad member 10, with the exception being, however, that sleeve projection 34 extends in two directions from the planar portion of pad member 30. The lower end of tubular projection 34 is terminated in the same fashion as that in the modification shown in FIGS. 1-4 hereinabove; however, the upper portion of tubular projection 34 is provided with an upwardly extending segment 31 which terminates in an annular flange 32. Washer 33 is utilized to assist in assembly such as with bolt 18.
It will be appreciated that the various modifications may be employed in connection with the fabrication of thermally conductive electrically insulative members without departing from the scope of the present invention. | A thermally conductive electrically insulative laminate for use as a mounting pad and electrical chassis barrier for use with solid-state electronic devices. The pad includes a number of bores with tubular projections extending outwardly therefrom for insulatively protecting the shanks of the mounting screws, bolts or other conductive materials from contact with the substrate. Additionally, the tubular projections are provided with radially extending retention burrs for mechanically holding the mounting pad in place on a substrate pending actual mounting of a semiconductor device thereon. | 7 |
This is a division of application Ser. No. 572,098, filed Apr. 28, 1975, now U.S. Pat. No. 4,034,201, issued July 5, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to devices for treating hair with vapor and heat. More particularly, this invention relates to devices for treating hair with vapor and heat by curling the hair around a treating mandrel.
2. Technical Considerations and Prior Art
A widely practiced method of treating hair involves winding the hair around a mandrel or curler and then treating the hair with heat and vapor to plasticize and thereby set the hair. This method is successfully practiced by the device of U.S. Pat. No. 3,835,292. However, the device disclosed by this patent uses a curler or treating mandrel of only one diameter and configuration.
In setting the hair, it is often advantageous to have mandrels or curlers of different diameters and different geometrical configurations to effect different hair styles and to accommodate different types of hair. The prior art does not disclose a hair treating device having mandrels of different diameters and configurations which may be utilized with the type of device disclosed in U.S. Pat. No. 3,835,292. In order to effectively utilize the concept of U.S. Pat. No. 3,835,292 with mandrels of different sizes and configurations, it is necessary that each of the mandrels has a structure that will cooperate with a similar supporting member from which vapor and heat are generated.
Exemplary of the prior art are U.S. Pat. Nos. 3,215,148; 3,224,454; and 3,291,141. Each of these patents teaches using a plurality of mandrels or curlers of different diameters. However, none of these patents discloses adequate structure for conveying a vapor such as steam to the surface of the mandrels.
In addition to providing mandrels or curlers of different diameters, it is also advantageous to have mandrels for waving or straightening hair which are readily interchangeable with curling mandrels. The prior art does not provide for this interchangeability.
Any electrical appliance which utilizes interchangeable components needs a safety switch to render the appliance inoperative while the components are being changed, in order that the user will not be shocked, burned or otherwise injured while the components are being changed or while no component is on the device. This is a special problem with devices such as hand-held steam curling irons which operate from house current and eject steam. The prior art does not concern itself with this problem.
From an operability standpoint, it is necessary to provide each mandrel with a clamp to initially clamp the hair to the mandrel before the hair is rolled up. In order to firmly clamp the hair in place without kinking the hair along the clamping area, it is necessary that the surface of the clamp complements the surface of the mandrel with which it is associated. In the prior art, this is accomplished by telescoping a plurality of rollers together with their treating surfaces in generally tangential relationship at an area near the clamp. This may not be a satisfactory relationship for a hair treating device which utilizes both heat and vapor because the larger diameter mandrels are not coaxial with the tubular barrel around which they are mounted. This eccentricity can conceivably result in an uneven distribution of heat and vapor to the hair wound around the mandrel.
In view of the afore-mentioned limitations and other limitations of the prior art, it is necessary to provide a new and improved device to enable the device of U.S. Pat. No. 3,835,292 to operate effectively with hair treating mandrels of different sizes and configurations.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the instant invention to provide a new and improved device for treating hair with heat and vapor.
Another object of the instant invention is to provide a new and improved device for treating hair with heat and vapor, wherein hair treating mandrels of different sizes and configurations can be utilized.
It is a further object of the instant invention to provide a new and improved device for treating hair with heat and vapor, wherein a single appliance is provided with interchangeable hair treating mandrels.
It is still another object of the instant invention to provide a new and improved device for treating hair with heat and vapor, wherein the device has increased flexibility and utility.
It is an additional object of the instant invention to provide a new and improved device for treating hair with heat and vapor, wherein cylindrical mandrels are provided of different diameters and wherein hair wound around relatively large diameter mandrels is uniformly treated.
It is a still further object of the instant invention to provide a new and improved device for treating hair with heat and vapor, wherein mandrels of different sizes and configurations are provided and wherein clamps are provided to effectively clamp the hair to each mandrel without damaging the hair.
It is yet an additional object of the instant invention to provide a new and improved device for treating hair with heat and vapor, wherein mandrels of different sizes and configurations may be used with the concept of the device disclosed in U.S. Pat. No. 3,835,292.
In view of these and other objects, the instant invention contemplates a hair treating or curling device which includes a means for generating heat and vapor with which to treat hair, a tubular barrel means for containing or defining the heat and vapor generating means, and a plurality of generally tubular mandrels of different sizes and configurations which are selectively slidable over the tubular barrel means. In addition, means are provided for conveying vapor and conducting heat to the mandrels and a handle is provided at one end of the tubular barrel means so that the device may be manually manipulated.
A mandrel for straightening strands of hair is adapted to be removably associated with the heat and vapor generating means and includes a hair treating surface, a sinusoidal-configured clamp and a bottom portion cooperating with the hair treating surface. The surface has a sinusoidal configuration and apertures therethrough for conveying vapor to strands of hair engaged therewith. Contact points formed on the hair treating surface are also provided for conducting heat from the heat and vapor generating means to the surface and hair engaged therewith. The clamp is for urging the strands of hair into engagement with the treating surface and has a configuration which complements the sinusoidal configuration of the treating surface. The bottom portion forms with the treating surface a means for slideably receiving the heat and vapor generating means. A heat insulating shield is positioned around the bottom portion to prevent the bottom portion from burning the hand of a person using the mandrel. The mandrel may be used for straightening strands of hair when moved relative to the strands and for waving the strands of hair when held stationary relative to the strands.
Other objects and advantages of the instant invention will become apparent from the following description of the preferred embodiments, taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top planar view of a hair curling device according to the instant invention illustrating a basic configuration of such a device.
FIG. 2 is a longitudinal section of the steam curling device of FIG. 1 taken along lines 2--2 of FIG. 1.
FIG. 3 is an enlarged section of the hair curling device of FIG. 2 taken along lines 3--3 of FIG. 1.
FIG. 4 is an enlarged section of a hair treating mandrel taken along lines 4--4 of FIG. 1.
FIG. 5 is an enlarged section of an end cap of a hair treating mandrel taken along lines 5--5 of FIG. 1.
FIG. 6 is an enlarged section of a hair treating mandrel of a relatively small diameter taken along lines 6--6 of FIG. 1.
FIG. 7, FIG. 8 and FIG. 9 are enlarged sectional details showing how the end cap of FIG. 5 is attached to the hair treating mandrel of FIG. 6.
FIG. 10 is an enlarged portion of a sectional view showing an operating switch with a safety device.
FIG. 11 is a top view of the switch of FIG. 10 taken along lines 11--11 of FIG. 10.
FIG. 12 is a section taken along lines 12--12 of FIG. 11.
FIG. 13 is a side sectional view of a suggested commercial embodiment of the instant invention showing suggested locations of various associated components.
FIG. 14 is a top sectional view of the handle of the embodiment of FIG. 13.
FIG. 15 is a partial top view of another embodiment of the instant invention showing a hair waving and straightening mandrel combined with an optional comb.
FIG. 16 is a sectional view taken along lines 16--16 of FIG. 15.
FIG. 17 is a side view in section of a hair waving and straightening mandrel similar to that of FIGS. 15 and 16; however, it is shown not including tines for forming a comb.
FIG. 18 is a sectional view through lines 18--18 of FIG. 17 showing the mandrel and associated clip with sinusoidal treating surfaces and showing, in addition, an optional heat shield
FIG. 19 is a portion of the sectional view of FIG. 17 showing an alternative method of securing a shield to the mandrel.
FIGS. 20 and 21 are sectional views showing fins made from generally W-shaped spring members.
FIGS. 22 and 23 are sectional views showing fins made from generally U-shaped spring members.
FIG. 24 is a planar view showing how a plate of spring material is cut and creased for subsequent formation into a plurality of fins.
FIG. 25 is a sectional view showing the plate of FIG. 24 folded to form a plurality of fins.
FIGS. 26 and 27 are sectional views showing how the plate of FIG. 24 is folded to form the fins of FIG. 25.
FIG. 28 is a sectional view of an embodiment using a pair of spring members to form heat conducting fins.
FIGS. 29 and 30 are sectional views of an embodiment using a single spring member to form a heat conducting fin.
FIG. 31 is a top planar view of a metallic plate which has been cut to form a mandrel with integral fins projecting therefrom.
FIG. 32 is a sectional view showing the plate of FIG. 30 rolled to form the mandrel with the fins projecting toward a tubular barrel upon which the mandrel is mounted.
FIGS. 33 and 34 are sectional views of the plate of FIG. 31 showing how the fins are bent to project out of the plane of the plate.
FIG. 35 is a side sectional view showing a preferred approach for a heater barrel structure.
FIG. 36 is a side sectional view showing a preferred fin and end cap configuration.
FIG. 37 is a side sectional view showing an embodiment in which the fins are generally rectangular in configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
General Illustration of the Invention
Referring now to FIG. 1, there is shown a hair curling device, designated generally by the numeral 20, having a handle 21 and a detachable hair treating mandrel, designated generally by the numeral 22. The hair treating device 20 is preferably a steam curling iron which includes some features of the steam curling iron of U.S. Pat. No. 3,835,292, which is incorporated herein by reference. In use, the hair treating device 20 is gripped by the handle 21 and strands of hair to be treated are inserted between a clamp 23 and the mandrel 22. The device is then rotated manually to curl the hair around the mandrel 22. By structure hereinafter described, a button 24 is then depressed to eject steam from the device 20 through the mandrel 22 onto the hair wrapped therearound while, at the same, the hair is being treated by heat which is conducted to the mandrel 22. In accordance with the principles of the instant invention, the mandrel 22 is removable from the device 20 and replaceable by a mandrel of a different diameter or configuration. A finger grip 26 having grippable ribs 27 is supplied for this purpose and is integral with the mandrel 22.
Referring now to FIG. 2, a plurality of mandrels of different diameters 22, 22a and 22b are shown. The mandrels 22a and 22b are shown in dotted lines because only one mandrel is mounted on the device 20 at one time. If it is desired to mount a different size mandrel 22, then the mandrel already on the device 20 must first be removed.
In operation, the heat and vapor or steam are generated in accordance with the principles of U.S. Pat. No. 3,835,292. Accordingly, a metallic tubular barrel 28 is provided to house a heater 29 and a vapor generator, designated generally by the numeral 30. The heater 29 both heats the mounted mandrel 22 and energizes the vapor generator 30.
The vapor generator 30 includes a heat transfer anvil 31 which is in engagement with the heater 29 and a wick 32 which extends into a reservoir 33. The reservoir 33 is filled with water which migrates into the wick 32. The button 24 forms the end of the reservoir 33 and, when pressed, moves the reservoir 33 against the bias of a coil spring 35, thereby engaging the wick 32 with the heat transfer anvil 31. The water in the wick 32 vaporizes and escapes from the tubular barrel through openings or apertures 37 formed therein.
Referring now to FIG. 4 and FIG. 6, where cross-sections of mandrels 22 and 22a of different sizes are shown, the vapor escapes through the apertures 37 into ducts 38 and is conveyed via apertures 39 to the surface 41 or 41a of the mandrel mounted on tubular barrel 28. The ducts 38 are formed by fins 42 which extend from the inner surface 43 of the mandrel to define an area at their opposite ends approximating the external dimensions of the tubular barrel 28. In addition to defining the ducts 38, the fins 42 conduct heat from the tubular barrel 28 to the mandrels 22. In order to provide a relatively rigid structure which is also light in weight, the fins 42 of adjacent ducts are joined by arcuate struts 45. The fins 42 are secured to the mandrels 22 by welding or other bonding techniques which insure good heat transfer. In FIG. 4, this is accomplished by welding tabs 46 to the inner surface 43 of the mandrels 22.
The fins 42 are formed preferably of aluminum or an aluminum alloy and have enough resiliency to firmly grip the tubular barrel 28 when slid thereover. Consequently, the fins 42 have sufficient contact with the tubular barrel 28 to conduct heat from the barrel to the mandrel 22 mounted thereon. In addition, the resiliency of the fins 42 provides the means for holding the mandrels 22 on the tubular barrel 28.
As set forth in U.S. Pat. No. 3,835,292, it is important that the vapor or steam emerging from the mandrels 22 not impinge directly on the scalp of the user. Accordingly, the apertures 39 are disposed to direct the vapor obliquely with respect to the radii of the mandrels 22. This is accomplished by having grooves 51 extending in the mandrels 22 which have a long and short wall, wherein the long wall is more oblique with respect to the radii than the short wall. The apertures 39 are then formed in the short wall. In addition, the grooves 51 permit distribution of the vapors when hair is tightly wound around the mandrels 22. It should be kept in mind that the fins 42 extend longitudinally within the mandrels 22 beneath the grooves 51 and that a plurality of apertures 39 register with each duct 38.
Each mandrel 22 is equipped with first and second plastic caps 55 and 56. The plastic cap 56 is attached to the second end 57 of the mandrel 22 by any of the devices shown in FIGS. 7, 8 and 9. In FIG. 7, it is secured by a screw or rivet 58; in FIG. 8, it is secured to a rib-in-slot arrangement 59; and in FIG. 9, it is secured by an overlapped rib arrangement 61. The same arrangement may be used for the first cap 55 on the first end 63 of the mandrel 22.
The plastic caps 55 and 56 have sleeve portions 64 and 65 extending therefrom which have an inner diameter providing slight clearance around the outer diameter of the tubular barrel 28. Consequently, the mandrels 22 may be slid over the tubular barrel 28 while end caps 55 and 56 are not in contact with the outer surface of the tubular barrel 28. This permits the flexibility of fins 42 to center the mandrel assembly on the tubular barrel 28 and, thus, equalize the pressure between the fins and tubular barrel. As mentioned before, end cap 56 has raised ribs 27 thereon to provide a finger grip portion so that the mandrels 22 may be readily pulled from the tubular barrel 28.
According to the instant invention, the first end cap 55 of each mandrel 22 has a clip, designated generally by the numeral 71, pivoted thereon. The clip 71 includes the metallic clamp 23 which extends therefrom and, as explained previously, initially grips strands of hair between itself and the mandrel 22 prior to rolling the strands of hair around the mandrel. For each mandrel 22, a different clamp 23 is provided which has an arc complementing the cylindrical surface of the associated mandrel.
In order to mount the clip 71, each end cap 55 has a pair of spaced flanges 72 projecting therefrom, as perhaps best seen in FIG. 3. These flanges support an axle 73 which, in turn, is registered with a slot 74 in a finger tab portion 75. As seen in FIG. 2, the slot 74 is slightly elongated and extends at an angle oblique to the axis of the device 20. A spring 77 is provided to bias the clip 71 so as to rotate about the axle 73 in a counterclockwise direction with respect to FIG. 2 so that the clamp 23 is urged toward and against the mandrel 22. In order to accommodate the finger tabs 75, the handle 21 has a slot 78 formed therein into which the end of the finger tab 75 projects. The slot 78 is deep enough so that clamp 23 may be lifted sufficiently far above the mandrel 22 to conveniently insert strands of hair therebetween.
After the hair is wound around the mandrel 22 and is set, it is necessary to remove the mandrel from the curl by withdrawing the device 20. Before it can be removed, however, the clamp 23 must be disengaged. This is accomplished by pushing on the rear surface 81 of the finger portion 75 to slide the entire clip 71 to the left with respect to FIG. 2. As the clip slides, it lifts the clamp 23 clear of the mandrel 22 and removes the clamping force from the hair. This is accomplished because the slot 74 rises with respect to the axle 73 as the clip is pushed. The device 20 is then pulled to the right to disengage the curl of hair from around the mandrel 22. As mentioned before, each mandrel 22, 22a and 22b has its own separate clip 71.
Referring now to FIGS. 10, 11 and 12, a safety switch is shown for allowing current to flow to the heater 29 (FIG. 2). The safety switch is mounted in the handle 21 and includes a pair of contacts 91 and 92 which, as shown in dotted lines in FIG. 11, are normally biased apart by leaf springs 93 and 94, respectively. When the contacts 91 and 92 are engaged, as shown in FIG. 10, a circuit is completed to energize the heater 29. This is accomplished by conventional means, as is disclosed in U.S. Pat. No. 3,835,292. When the contacts 91 and 92 are apart, as shown in dotted lines in FIG. 11, the circuit is open and the heater 29 is off.
In order to provide the device 20 with a safety feature so that it will not operate unless a mandrel is in place, a push rod 96 is provided which is engaged by leaf spring 93 and biased to the left, as shown in dotted lines in FIG. 11. In order to move the contact 91 to a position where it may be engaged by the contact 92, the push rod 96 must be moved to the right. This is accomplished by sliding a mandrel 22 onto the tubular barrel 28 so that the sleeve 64 projecting from the end cap 55 will engage the end 97 of push rod 96, and thereby slide the push rod to the right. In the illustrated embodiment, the push rod 96 is journalled to slide in a tube 98 supported by flanges 99, and is prevented from dropping out of the handle 21 by a ring 101 secured to the push rod. The spring 93 can urge the push rod 96 to the left only until the ring 101 engages the flange 99.
In order to selectively operate the device 20, a cam 102 is mounted in the handle 21 and is operated by a rotating button 103 projecting to the exterior of the handle 21. The cam engages a follower 104 which projects from spring 94. Upon turning the cam in the counterclockwise direction, as shown in FIG. 11, contact 92 is urged against contact 91 if a mandrel is in place on the tubular barrel 28, thereby energizing the heater 29.
FIGS. 13 and 14--Suggested Commercial Embodiment
In practice, a commercial embodiment of the invention as set forth by the disclosure of FIGS. 1 through 12 might assume the configuration of FIGS. 13 and 14, in which the basic components are shown fully assembled. In FIGS. 13 and 14, the same numerals are used as are used in FIGS. 1-12 to identify similar components.
Power is supplied to the heater 29 and heat transfer anvil 31 by a power cord 111 which is configured to plug into general household electric circuits. Cord 111 is attached to the handle 21 by an electrical connector 112 which is preferably of the type disclosed and covered by U.S. Pat. No. 3,950,052 issued Aug. 7, 1975.
The circuit between the heater 29 and connector 112 includes the cam-operated switch shown in FIGS. 10, 11 and 12, an indicator light 114 and a thermostat 115 which is positioned within the barrel 28 proximate the heater 29. The indicator light 114 is preferably lit to show that the appliance is in operating condition only after a mandrel 22 is slid into place over the barrel 28 to engage contacts 91 and 92 (see FIG. 10) and the nob 113 is turned to an "on" position, i.e., rotated counterclockwise as shown in FIGS. 11 and 14. The thermostat 115 is of a conventional bi-metal design and directly senses the temperature of the heater 29. When the heater 29 exceeds the desired temperature level, the thermostat 115 cuts off power to the heater until the heater drops below the desired temperature level. Cycling of the thermostat 115 keeps the heater 29 within the desired temperature range for constant operation.
FIGS. 15 through 19--Hair Waving and Straightening Embodiments
In these embodiments in which a mandrel 22c cooperates with the clamp 23c to form a hair waving or straightening device, the tubular barrel 28 is the same as the tubular barrel of FIG. 2 and operates in the same fashion. However, in these embodiments, the mandrel 22c is resilient, having an internal cross-sectional area slightly less than the external diameter of the tubular barrel 28. As seen in FIG. 16, when slid over the tubular barrel 28, the mandrel frictionally engages the barrel directly at points 116 to both secure the mandrel on the barrel and to provide for heat conduction from the barrel to the mandrel. The apertures 39c in mandrel 22c are not connected to the apertures 37 of the barrel 28 with ducts, but rather the vapor or steam enters space 117 and, from space 117, flows through apertures 39c.
As seen in FIG. 16, the mandrel 22c now has a treating surface 118 which undulates and resembles a "W". The surface of clamp 23c complements the treating surface 118 so as to hold hair tightly in engagement therewith. In addition, the clamp 23c may have tines 119 extending from opposite sides thereof to form a pair of combs which serve to align strands of hair as the strands are waved between the clamp 23c and treating surface 118.
As seen in FIGS. 15 and 17, a finger tab 120 may project from the clamp 23c in order to control the force with which the clamp holds the hair against the mandrel 22c. In operation, the device 20 may be held in both hands, with one hand gripping handle 21 and operating finger portion 75, and the other hand gripping end cap 56c and manipulating tab 120.
Referring now to FIGS. 18 and 19, there is shown a modification of this embodiment in which tines 119 are not utilized in order that hair close to the scalp may be treated with heat and vapor. The tines 119, of course, prevent the appliance from getting close to the scalp. In this modification, a mandrel 22c' is shown with a relatively smooth, sinusoidal treating surface which is complemented by the opposing surface of clamp 23c'. As seen in FIG. 18, the mandrel 22c' has a bottom surface 121 which is covered by a shield 122 made of an appropriate type of insulating material. The shield 122 prevents the hot bottom surface 121 from engaging the scalp and burning the user. The shield 122 may be secured in place by lips 123 along opposite edges which fit into grooves 124 in the mandrel 22c'. In the alternative, as shown in FIG. 19, the shield 122 may be provided with expanding fasteners 125 which snap into apertures 126 in the mandrel 22c'.
Generally, in operation, the device or appliance shown in FIGS. 15-19 operates as a hair waving device when hair is clamped between the mandrel 22c or 22c' and the clamp 23c or 23c' while the appliance is held stationary. The appliance functions as a hair straightening device when the hair is clamped between the mandrel and clamp, and the appliance is moved to continuously draw down strands of hair while the hair is steamed. By using tension, heat and stream in combination with the undulating path provided by the surfaces of the mandrel and clamp, hair straightening is readily accomplished because the undulating surfaces prevent the hair from rolling as it is straightened. By preventing the hair from rolling while it is treated with heat, steam and tension, the tendency for the hair to curl is eliminated.
FIGS. 20 through 34--Fin Configurations
Fins 42 which are used to support mandrels 22 on the barrel 28 may assume many different forms, as seen in FIGS. 20-34. It is only necessary that the fins 42 have sufficient resiliency or spring action to hold the associated mandrel 22 on the barrel 28 and that the fins contact both the barrel 28 and the mandrel 22 with sufficient force to ensure conduction of heat from the barrel to the mandrel.
In the group of modifications illustrated by FIGS. 20-30, the fins 42 are configured as separate elements which deflect toward the inner surface 43 of the mandrels 22 upon sliding the mandrels 22 over the barrel 28. More specifically, in FIGS. 20 and 21, the fins 42 form legs of "W"-shaped elements. In FIG. 20, the legs of the W-shaped elements forming the fins 42 are straight and spread so that the ducts 38 formed by adjacent legs converge from the barrel 28 to the mandrel 22. In FIG. 21, the legs of the W formed by the fins 42 are bent so that the ducts 38 first converge and then diverge from the barrel 28 to the mandrel 22.
In the modification of FIGS. 22 and 23, the fins 42 are formed by legs of "U"-shaped members with the ducts 38 formed between the legs of adjacent U-shaped members. In FIG. 22, the U-shaped members have their open ends facing inwardly toward the barrel 28, whereas in the embodiment of FIG. 23, the U-shaped members have their open ends facing outwardly toward the inner surface 43 of the mandrel 22.
Referring now to FIGS. 24-27, another modification is shown in which the fins are formed by a single sheet 130. As seen in FIG. 24, the sheet 130 is cut to form the fins 42 as separate tabs. The sheet 130 is then creased alongs lines 131 and bent as shown in FIG. 26 so as to eventually collapse into the configuration shown in FIG. 27. The portions 132 intermediate the creases 131 then form a spring element which also supports the tabs which form fins 42. When arranged in a circular fashion, as shown in FIG. 25, the fins 42 extend between the barrel 28 and mandrel 22 to form heat conduction paths and to form ducts 38 between adjacent fins. Preferably in this arrangement, the spring member will fill the entire circular cross-section between the barrel 28 and mandrel 22.
A further modification of the concept of using separate spring members to define the fins 42 is shown in FIGS. 28, 29 and 30, wherein the fins 42 are configured as bowed leaf springs. In FIG. 28, a pair of springs are utilized in which one spring is longer than the other. The springs have apertures or other openings 150 extending therethrough which allow vapor to migrate from openings 37 to openings 39. In the case of FIG. 29, just a single spring 152 is utilized, and in this case, the spring 152 will cooperate with end caps such as end caps 55 and 56 (see FIGS. 1 and 2) to frictionally hold the mandrel 22 on the barrel 28. As seen in FIG. 30, the spring 152 forming the fins 42 may have its end 153 bent over in order to facilitate attachment to the mandrel 22. The arrangement of FIG. 29 is especially suitable for mandrels of relatively small diameter because mandrels having a relatively small diameter do not need as much heat transferred thereto from the barrel 28 as mandrels of larger diameters. In the embodiment of FIG. 29, there are, in effect, only two fins 42 (an upper fin and a lower fin). Two fins will conduct less heat than the eight fins, as shown, for example, in FIGS. 20-23. The optimum number of fins and desired fin configuration are determined by the amount of heat generated in the barrel 28, the amount of vapor generated and the diameter and material of the mandrel 22.
Referring now to FIGS. 31-34, there is shown another embodiment in which a mandrel 22e is formed from a flat sheet 160. The flat sheet 160 has the fins 42 formed by U-shaped cuts in the sheet which are bent up from the surface of the sheet, as shown in FIG. 33. As shown in FIG. 34, the fins 42 may then have their free end 162 bent to form a surface for engaging the surface of barrel 28. Upon bending the sheet 160 into a circular configuration, as shown in FIG. 32, a mandrel 22e is formed with fins 42 that are integral with the mandrel. The spaces left by bending the fins inwardly form the apertures 39 through which vapor is passed to hair wound around the mandrel 22e.
FIGS. 35 through 37--Structure for Avoiding Heat Transfer Damage
Referring now to FIG. 35, the tube or barrel 28 is made of stainless steel and is assembled with the reservoir 33 by using an intermediate retaining sleeve 182 which preferably is made of a heat resistance plastic. The sleeve 182 has recesses 183 into which tangs 184 depending from the tube 28 project. Cooperation between the recesses 183 and tangs 184 prevents the sleeve 182 from separating from the tube 28.
The sleeve 182 has threads 186 therein which engage with corresponding threads on the button 24. When the button 24 is pressed so as to move to the right, the sleeve 182 is also carried to the right. The button 24 and sleeve 182 slide relative to the tube 28 because the slot 183 is elongated.
Since the sleeve 56 is spaced from the stainless steel tube 28, there is no direct heat transfer therebetween which protects the sleeve 56 from damage due to heat transfer. In addition, the amount of heat transferred to the finger projections 27 is reduced so that the appliance may be comfortably held in one's hand.
Further to this point, the damp 23 may have a relatively rigid plastic finger tab 120c projecting therefrom which may be used as explained in the embodiments of FIGS. 15 through 19. By making the finger tab 120c of rigid heat resistant plastic, the clamp 23 may be manipulated by applying and controlling pressure at both ends thereof.
In order to prevent excessive heat transfer to the end cap 55, the end cap 55 is spaced from the stainless steel tube 28, as shown by the space 188. In addition, the ceramic heater does not extend beneath the sleeve portion 64. By the afore-mentioned arrangements, heat transfer to the end caps is controlled to prevent damage to the end caps and injury to the user.
Referring now to FIGS. 36 and 37, an arrangement is shown in FIG. 36 for configuring the fins 42 so as to conform to the shape of the end caps 55d and 56d while, at the same time, limiting or controlling heat transfer to the end caps. The fins of the preferred embodiment shown in FIG. 36 are tapered so that the edges 190 and 191 thereof converge inwardly and fins engage the barrel 28 only on edges 193. The edges 193 are preferably over the area coupled by heater 29. In the embodiment of FIG. 36, the sleeves 64d and 65d project outwardly from converging flanges 194 and are spaced by gaps 195 from the barrel 28. The gaps 195 terminate with circular shoulders 196 which closely approximate the diameter of the tube 28 and thereby keep vapor generated from escaping out of either end. By the afore-described arrangement, heat is discouraged from being conducted by the fins to areas of the appliance not adjacent the heater 29 while, at the same time, the surface of the mandrel 22 receives heat along its entire length. In cross-section, the fins 42 may assume any appropriate configuration such as the configuration exemplified in FIGS. 4, 6 and 20-34. The embodiment of FIG. 37 provides no structure for limiting heat transfer by the fins 42 to areas which either do not need heat or which might be damaged by heat.
The foregoing examples and embodiments are merely illustrative of the invention, which should be limited only by the following appended claims. | An appliance or device for treating hair includes a tubular barrel containing a generator for heat and vapor and a plurality of hair winding mandrels which are slidably mounted over the tubular barrel. The mandrels have different external sizes and configurations, but have interior structures which, though they may differ, allow each mandrel to be used with the same tubular barrel. A mandrel for straightening strands of hair when moved relative to the strands and for waving strands of hair when held stationary relative to the strands is provided. The mandrel is adapted to be removably associated with the tubular barrel. In the preferred embodiment, the mandrel is comprised of a heat-treating surface having a sinusoidal configuration. Apertures through the surface convey vapor from the vapor generator in the tubular barrel to the strands of hair engaged therewith. Contact points formed on the hair treating surface engage the surface of the tubular barrel to conduct heat from the heated vapor generating means to the hair treating surface and hair engaged therewith. A sinusoidal-configured clamp for urging the strands of hair into engagement with the treating surface is also employed. The mandrel further includes a bottom portion which cooperates with the hair treating surface to form a continuous, unobstructed vapor chamber substantially coextensive with the hair treating surface slideably receiving the tubular barrel. A heat insulating shield is positioned around the bottom portion to prevent the bottom portion from burning the hand of a person using the mandrel. Tines tangential to the tubular barrel extend laterally from opposite sides of the clamp to form combs which serve to align the hair. | 0 |
This is a continuation of application Ser. No. 07/493,030 filed Mar. 12, 1990, now abandoned, which is a division of Ser. No. 07/036,726, filed Apr. 10, 1987, now U.S. Pat. No. 5,005,118.
BACKGROUND
The present invention relates to the execution of macro instructions by a central processing unit utilizing sequences of microcode instructions.
In a typical modern computer, a program is executed by fetching an instruction from memory and placing it in an instruction register. The instruction is then decoded to point to a starting address or series of addresses in a microcode memory. The microcode memory provides the operations which make up the instruction. The various operations from the microcode memory are sequentially placed into a micro instruction register where they are decoded to produce control signals for executing the operations. These control signals may enable an access of memory, the placement of operands into an arithmetic logic unit, the combination of operands in an arithmetic logic unit, etc. After all the microcode operations for a particular macro-instruction have been executed, a new macro-instruction is fetched from memory and the process is repeated.
Once the macro-instruction has been decoded, there is typically no interaction between the micro coded operations and the macro-instruction except for instances in which the macro-instruction includes a data operand or a register specifier for a data operand.
In efforts to speed computer operation, attempts have been made to shorten the number of clock cycles required for the macro instructions. One method of doing this involves performing redundant microcode operations and storing the results of these operations in separate registers where necessary. The next macro-instruction can then be decoded to determine whether it requires these operations. If it does, the precomputed results can be used. If not, the result of the redundant operation is thrown out. Unfortunately, this method requires a significant amount of additional hardware and often results in wasted operations. This type of scheme is employed in the TXP and VLX processors manufactured by Tandem Computers, Inc.
Another method involves processing multiple microcode instructions at one time to do some operations not requiring the ALU in parallel with ALU operations. The advantages of increased speed and simplified control logic are balanced by the disadvantage of requiring more hardware and making microcode branches slower.
Another method involves simply handwriting certain macro-instruction operations so that microcode does not have to be accessed at all for such operations. The obvious disadvantage of this method is that the hardwired circuit becomes dedicated to that function and can't be used for other purposes.
U.S. Pat. No. 4,312,034 describes yet another method for reducing the amount of time required to execute a macro-instruction. Referring to FIG. 15 of that patent, a macro-instruction register (IRD) and a ROM output register (microcode) are factored into a ROM address whose outputs control an ALU and condition codes. Thus, the macro-instruction itself is used to control the ALU and condition codes instead of relying on the microcode instructions entirely. Thus, for example, to do an add or subtract operation the microcode would simply do the same fetch operation with the controller looking directly to the macro-instruction to determine whether to add or subtract.
SUMMARY OF THE INVENTION
The present invention provides a method and mechanism for shortening the execution time of certain macro-instructions by looking at both a present macro-instruction and a next macro-instruction. The invention includes two, interrelated aspects for accomplishing this. First, a first operation of a next macro-instruction is performed concurrently with a last operation of a current macro-instruction. Second, the next macro-instruction is decoded to determine the minimum number of clock cycles it requires. If this minimum number is below a specified number, the micro operations of the present instruction are modified to perform appropriate set-up operations for the next macro-instruction to enable it to be completed in the computed minimum number of clock cycles.
In the preferred embodiment, the processor is provided with two computational units which allow the execution of two operations concurrently. These operations can be classified into two groups. The first group is referred to as macro-sequencing operations and include operations that are performed for all macro-instructions or are performed for all macro-instructions of a certain type (i.e., all arithmetic instructions requiring an operand). For example, these instructions include incrementing the program counter, fetching a next instruction from memory, calculating the address of an operand for the next instruction and fetching the operand for the next instruction. The second type of instruction which is executed in parallel covers micro operations which are dependent upon the particular macro-instruction. For example, this type of operation includes addition, subtraction and other arithmetic operations or specific movement of operands between registers. In a typical instruction, four operations of the first group are required, thus requiring four clock cycles. However, often only three operations of the second group are required, or in some instances, only two. Accordingly, by performing the first operation of the first group for a next instruction concurrently with the last operation of the first group for a current instruction, if the next instruction requires only three operations of the second group, the next operation can then be performed in three clock cycles. If the next instruction in fact requires four operations of the second group, the performance of its first operation of its first group by the previous instruction cycle is simply redundant. This procedure is followed because it is simpler to redo the operation when needed rather than store the result for the next clock cycle. The invention differs from the redundancy found in the prior art because the redundancy depends upon the number of operations specified by the next macro-instruction.
In the second aspect of the invention, the next instruction in the next instruction register is decoded to determine the number of clock cycles required. If the number is less than a specified number of clock cycles, the operations of the current instruction are modified accordingly. For a specific example, if the next instruction does not require an operand, no operand address calculation and no operand fetch is required. Accordingly, these operations, which are performed by the present instruction for the next instruction, are modified so that they become another operation, such as incrementing the program counter. This can be done by changing the coding value of the operation at the output of the microcode register. Thus, when the next instruction is itself executed, it need not perform the steps required for incrementing the program counter and can instead perform the macro-sequencing steps of calculating and fetching the operand for the next instruction, thus enabling the instruction to be executed in two clock cycles.
By using a combination of the redundancy aspect of the invention and the modifying of a micro operation, the average number of clock cycles required for the macro-instruction is reduced. This is accomplished with a minimal amount of hardware.
For a fuller understanding of the nature and advantages of the invention, reference should be made to the ensuing detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a typical prior art controller;
FIG. 2 is a block diagram of a controller according to the invention; and
FIG. 3 is a diagram of the controller of FIG. 2 with a specific function unit arrangement for the logic functions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram of a typical prior art processor. An instruction register 10 receives an instruction from memory which is decoded by microcode address generation logic 12 to produce addresses to a microcode memory 14. The instructions stored in microcode memory 14 are supplied to a micro-instruction register 16, which may itself affect the address of the next instruction in microcode memory 14. The instruction in micro-instruction register 16 is decoded by microcode decode logic 18. The decoded logic generates control signals which are supplied to function units 20 and 22. The function units perform the memory fetches, arithmetic operations, and other manipulations specified by the micro-instruction.
Because the processor of FIG. 1 has two function units, during any one clock cycle two operations may be performed concurrently. A typical macro-instruction sequence may require a number of macro-sequencing operations as well as micro operations which may be performed concurrently. The macro-sequencing operations would be operations which are done for all macro-instructions or for certain types of macro-instructions (i.e., arithmetic operations requiring the fetching of an operand), while other micro-instructions are dependent upon a particular macro-instruction (i.e., particular arithmetic operations). Thus, for example, function unit 20 of FIG. 1 could be performing a macro-sequencing operation (such as incrementing a program counter) while function unit 22 could be performing another operation, such as adding two operands. This parallel operation is shown in the following table for macro-instructions 0 and 1 where A, B, C and D represent macro-sequencing microinstructions and w, x, y and z represent instruction-dependent micro operations.
TABLE 1______________________________________Macro Instr. Clock Cyc. Operation______________________________________0 0 A(0) w(0)0 1 B(0) x(0)0 2 C(0) y(0)0 3 D(0) z(0)1 0 A(1) x(1)1 1 B(1) y(1)1 2 C(1) z(1)1 3 D(1)______________________________________
As can be seen from the above table, by doing operations in parallel, only four clock instructions are required for each macro-instruction. In the example shown, for macro-instruction 1, four macro-level operations are required while only three instruction-dependent micro-operations are required. The present invention takes advantage of this feature of certain macro-instructions by adding a third function unit so that three operations can be performed in parallel.
The present invention has two aspects. The first aspect is the parallel performance of macro-sequencing operations. For most instruction-dependent micro-operations (w, x, y, z) the operations must be performed sequentially, and thus a time savings by parallel operation is not possible. However, oftentimes more than one macro-sequencing operation can be performed simultaneously. Accordingly, the present invention uses a third function unit to perform a first macro-sequencing operation of a next instruction concurrently with the last macro-sequencing operation of a first instruction. As can be seen in Table 2 below, this results in macro-instruction 1 of Table 1 requiring only three clock cycles to execute.
TABLE 2______________________________________Macro Instr. Clock Cyc. Operation______________________________________0 0 A(0) w(0)0 1 B(0) x(0)0 2 C(0) y(0)0 3 D(0) A(1) z(0)1 0 B(1) x(1)1 1 C(1) y(1)1 2 D(1) A(2) z(1)2 0 A(2) w(2)2 1 B(2) x(2)2 2 C(2) y(2)2 3 D(2) A(3) z(2)______________________________________
As can be seen from Table 2, if a macro-instruction 2 requires four instruction-dependent micro operations (w, x, y, z), then step A(2) performed during macro-instruction 1 simply becomes redundant and is repeated. Alternately, step A(2) could simply be omitted from macro-instruction 2 with no macro-sequencing operation being performed during the first clock cycle, L-3.
The second aspect of the present invention involves looking at a next instruction and modifying the operations of the current instruction if the next instruction is less than a predetermined number. Referring to FIG. 2, both an instruction register 24 and a next instruction register 26 are provided to give a macro-instruction pipeline. These registers are coupled to microcode address generation logic 28, microcode memory 30 and micro-instruction register 32 in similar manner to the circuit of FIG. 1. However, rather than using simply microcode decode logic which only decodes micro-instruction register 32, a decode logic block 34 is used which takes inputs from the macro-instruction register as well as the micro-instruction register. Decode logic 34 looks at the contents of the next instruction register (NIR) 26 and, if it requires less than a certain number of clock cycles, modifies the code from micro-instruction register 32 to alter the control signals provided to function units 36 and 38-40 (F1, F2 through FN). Decode logic 34 looks at the next instruction in next instruction register 26 and determines how many clock cycles it could be done in. For instance, if a next instruction requires only instruction-dependent operations y and z, then it can be done in two clock cycles if macro-sequencing instruction A and B are performed during the current instruction. This can be done by doing A and B in parallel with C and D of the current instruction or, if C and D are not needed because of the nature of the next instruction, operations C and D can be modified to become operations A and B.
An example is where A and B relate to incrementing the program counter and C and D relate to calculating an operand address and fetching the operand for the next instruction. Where the next instruction has only two instruction-dependent operations (y, z), and does not require an operand, steps C and D being performed by the current instruction are unnecessary. Accordingly, steps C and D can be modified to become steps A and B for the next instruction. When the next instruction is executed, it can thus do its steps C and D concurrently with steps y and z.
Table 3 below shows the resulting sequence of operations where a current instruction 0 in instruction register 24 requires four clock cycles while a next instruction in NIR register 26 requires only two clock cycles. Decode logic 34 of FIG. 2 looks at the contents of NIR 26 and determines that only two clock cycles are required. Accordingly, it modifies operations C(0) and D(0) to become operations A(1) and B(1), respectively. Thus, when macro-instruction 1 is itself executed, since steps A and B have already been performed, it can perform steps C(1) and D(1) concurrently with instruction-dependent steps y(1) and z(1), thus enabling the instruction to be completed in only two clock cycles.
TABLE 3______________________________________Macro Instr. Clock Cyc. Operation______________________________________0 0 A(0) w(0)0 1 B(0) x(0)0 2 [C(0)] A(1) y(0)0 3 [D(0)] B(1) z(0)1 0 C(1) y(1)1 1 D(1) z(1)2 0 A(2) w(2)2 1 B(2) x(2)2 2 C(2) y(2)2 3 D(2) z(2)______________________________________
FIG. 3 shows a specific embodiment of the circuit of FIG. 2. In FIG. 3, the contents of next instruction register 26 are provided via a bus 42 to microcode address generation logic 28. A data bus 59 couples IR 24 to the function units to provide data to be operated on when appropriate. The decode logic 34 consists of a NIR decode circuit 44, microcode decode logic 46 and combination logic 48. NIR decode logic 44 determines whether a two cycle instruction is present in NIR 26 and, if so, presents a signal on a line 50 to decode logic 48. Decode logic 48 passes control signals 52 from microcode decode logic 46 if no signal is present on line 50. Otherwise, the signal on line 50 modifies the digital content of the control signals.
Three function units 54, 56 and 58 are utilized. Function units 54 and 56 contain arithmetic logic units 60 and 62, respectively. In addition, each contains a register file 64 or 66, respectively. Register file 66 includes the program counter. Function unit 58 is used to access memory 68.
The sequencing of instructions through the three function units is shown in Table 4 below.
TABLE 4______________________________________Clock Cyc. F1 F2 F3______________________________________0 w(0) A(0) --1 x(0) -- B(0)2 y(0) C(0) or A(1) --3 z(0) A(1) D(0) or B(1)______________________________________
Table 4 shows a four clock cycle sequence which combines the redundancy of Table 2 and the macro-sequencing instruction modification of Table 3. In clock cycles L-1 and L, if the next instruction is a two cycle instruction, steps C(0) and D(0) are modified to become A(1) and B(1). During clock cycle L, while either step D(0) or B(1) is being performed in function unit F3, step A(1) is being performed in function unit F2. As can be seen, the operation in function unit F2 during clock cycle L will be redundant when the next instruction is a two clock instruction, and will be used only if the next instruction is a three-clock instruction. In addition, it can be seen that function unit F2 is not used during clock cycle L-2 and function unit F3 is not used during clock cycles L-3 and L-1. Accordingly, this gives added flexibility to the programming to enable instruction-dependent operations w, x and y to use two function units concurrently if necessary.
The actual operations A, B, C and D performed in the preferred embodiment and the modifications performed for a two tick (clock) cycle are set forth below.
A(0):
Calculate the address of the macro program counter (P) plus 1. This is equal to the address of the present instruction plus 2.
B(0):
Fetch the instruction from memory whose address was calculated in A. Store the address calculated in A to P.
C(0):
If not two tick (NIR) then: Calculate the address (base +displacement) of the operand for the next instruction.
(Else A(1): calculate the address of the macro program counter (P) plus 1. This is equal to the address of the present instruction plus 3.)
Load the current instruction register (IR) with the instruction in the next instruction register (NIR) and the instruction fetched in B into NIR.
D(0):
If not two tick (NIR) then: Fetch the operand for the next instruction, now in IR.
(Else B(1): Fetch the instruction from memory whose address was calculated in C. Store the address calculated in C to P.)
A(1): Calculate the address of the macro program counter (P) plus 1. This is equal to the address of the instruction 3 after the present one.
A(1) is the redundant operation which is done in parallel with D(0) for the sake of a three micro cycle macro instruction which might follow the present instruction. "Two tick (NIR)" is a decode of the next instruction register that indicates that the next instruction will be executed in two micro cycles. "Two tick (IR)" of D(0) reflects the movement of the next instruction into the instruction register during C(0). Because of this shift, NIR decode logic 44 includes a register for storing the portion of the next instruction needed for D(0). The above description does not include the instruction-dependent operations (x(0), y(0), etc.) that occur in parallel with the macro sequencing operations.
In a preferred embodiment, the macro-instructions have lengths of either two, three or four or more clock cycles. This results in six possible micro-instruction flows: four or more clock instructions, three clock instructions and two clock instructions which are followed by either two or more clock instructions or a two clock instruction. This instruction flow is as set forth in the following table.
TABLE 5______________________________________ Inst. 1 is < Inst. 1 is = 2 Clocks 2 Clocks______________________________________≧4 Clock ClockInstruction Cyc. Operation Operation______________________________________ 0,L-3 A(0), .sup. w(0) A(0), .sup. w(0) 0,L-2 B(0), .sup. x(0) B(0), .sup. x(0) 0,L-1 C(0), .sup. y(0) A(1), .sup. y(0) 0,L D(0),A(1),z(0) B(1),A(1),z(0)______________________________________ClockInstruction -1,L D(-1,A(0),z(-1) D(-1,A(0),z(-1)______________________________________ 0,0 B(0), .sup. x(0) B(0), .sup. x(0) 0,1 C(0), .sup. y(0) A(1), .sup. y(0) 0,2 D(0),A(1),z(0) B(1),A(1),z(0)______________________________________Clock -1,L-1 A(0), .sup. y(-1) A(0), .sup. y(-1)Instruction -1,L B(0),A(0) z(-1) B(0),A(0),z(-1)______________________________________ 0,0 C(0), .sup. y(0) A(1), .sup. y(0) 0,1 D(0),A(1),z(0) B(1),A(1), z(0)______________________________________
As will be understood by those familiar with the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, a next instruction which would require modification of the macro-sequencing operations of a current instruction could be other than a two clock cycle instruction. Alternately, instead of modifying the operations, other operations could be performed in parallel. Accordingly, the disclosure of the preferred embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention which is set forth in the following claims. | A method and mechanism for shortening the execution time of certain macro-instructions by looking at both a present macro-instruction and a next macro-instruction. The invention includes two, interrelated aspects for accomplishing this. First, a first operation of a next macro-instruction is performed concurrently with a last operation of a current macro-instruction. Second, the next macro-instruction is decoded to determine the minimum number of clock cycles it requires. If this minimum number is below a specified number, the micro operations of the present instruction are modified to perform appropriate set-up operations for the next macro-instruction to enable it to be completed in the computed minimum number of clock cycles. | 6 |
This is a divisional of application Ser. No. 08/192,144, filed Feb. 4, 1994 now U.S. Pat. No. 5,427,652.
BACKGROUND OF THE INVENTION
The present invention relates to an improved resin system for imparting wet strength to paper which yields a sheet which is readily repulpable.
Paper which is manufactured with chemical additives to improve the physical properties when in contact with a water-containing medium is known as wet strength paper. The wet strength resins which provide these properties are classified as being either "permanent" or "temporary," based on the permanence of the wet strength they provide. A number of chemical treatments have been used to impart permanent wet strength to paper, but the most common, by far, is the use of aminoplast and polyamide-epichlorohydrin (PAE) resins.
As a result of the heightened awareness and increased demand for paper products containing recovered cellulose fiber, efforts have been undertaken to develop paper products which are more readily recyclable. Commercially available wet strength paperboard products are difficult to repulp because they utilize permanent wet strength resins. The addition of permanent wet strength resins interferes with and detracts from the repulpability of paper. Wet strength paper generally cannot be defibered and repulped in neutral water without extraordinary means. Permanent resins are resistant to hydrolysis and retain their properties during repulping. The mechanism by which they provide wet strength is through bonding to or encapsulation of the cellulose fibers to provide a water-resistant, hydrolytically-stable, polymer-reinforced cellulose fiber network. Paperboard treated with aminoplast resin requires high temperatures and/or low pH during repulping to be recycled. On the other hand, high pH and elevated temperatures are required to repulp PAE-treated papers. Polyamide and polyamine-epichlorohydrin (PAE) resins form ether linkages with the hydroxyl groups in the cellulose through an epoxide linkage. These bonds are difficult to break.
Temporary wet strength resins are generally distinguished from permanent wet strength resins in that wet strength achieved using temporary wet strength resins is essentially lost after 10 to 30 minutes soaking in water at neutral pH and room temperature. Temporary wet strength resins are well known and have been used in the art to make disposable products, such as toweling and tissues. Temporary wet strength agents are generally hydrolytically unstable or shear sensitive. These properties enable the resin to break down readily when the product is commercially repulped. While temporary wet strength agents are more compatible with repulping than permanent wet strength agents, they do not develop satisfactory wet strength for most paperboard applications.
SUMMARY OF THE INVENTION
In accordance with the present invention a paperboard is provided which provides adequate wet strength, e.g., it retains at least 50% of its dry tear strength when saturated with water, and yet it is readily repulpable. The paperboard is made by treating paper fibers with a cationic temporary wet strength agent in combination with either a permanent wet strength agent or an internal size. In accordance with a preferred embodiment of the invention, a cationic promoter is added to the paper fiber before adding the wet strength agents to neutralize anionic agents present in or added to the pulp.
Wet strength board must retain its physical properties when in contact with an aqueous medium. It is commonly used for beverage carriers that may be partially or completely wetted by the customer. It should retain its strength in relatively static water at room temperature (20°-30° C.) and a neutral pH. To be readily repulpable, however, it should disintegrate easily in a repulper at a temperature of 38°-60° C. and a pH of 6-8. Thus, it will be appreciated that the service conditions for paperboard are not greatly different from those encountered in repulping. The critical differences are the higher temperature and the energy and shear that result from the agitation of repulping.
In accordance with the invention, to take advantage of the higher temperature, a resin that hydrolyses more quickly than the PAE resin commonly used in paperboard is incorporated into the board. Such resins are so-called temporary wet strength resins, such as a glyoxalated polyacrylamide like Parez 631NC. This resin will weaken quickly at the temperature in the pulper.
Temporary wet strength agents alone do not provide adequate wet strength and must be combined with another material to provide useful wet strength for most paperboard applications. In accordance with one embodiment of the invention, the temporary wet strength agent is combined with a permanent wet strength agent such as PAE. While not desiring to be bound, it is believed that the two resins, which are both cellulose reactive, achieve part of their wet strength performance by bonding to the cellulose fibers. The two resins may also react with each other and form an interpolymer network that provides wet strength by encapsulating the cellulose fibers. This long-chain interpolymer network is shear sensitive so that under the high shear conditions in the repulper, the polymer chains are broken, the wet strength is lost and the board repulps easily.
In another embodiment, the temporary wet strength agent is combined with a reactive size such as an alkyl ketene dimer (AKD). An AKD size has been found to enhance the wet strength of board containing a temporary agent like Parez and still produce a repulpable board. The mechanism for the ease of repulping this product is believed to arise from the shear sensitivity of AKD. Under high shear, such as that in a repulper, the polymer chain length is broken and the interpolymer network of the AKD and temporary wet strength agent holding the cellulose fibers together is believed to be broken down. Without this "glue" the board disintegrates under the action within the repulper.
DETAILED DESCRIPTION OF THE INVENTION
The term "paperboard" is used herein as it is used in the Pulp and Paper Dictionary, 1986, to mean any thick, heavyweight, rigid, single or multi-ply paper used in wrappings, packaging, boxes, containers, advertising, merchandising displays, building construction, etc. and includes any cellulosic fiber-containing mat or web having a thickness of about 12 mil (0.012 inch) or greater which is prepared from any aqueous suspension of cellulose fiber and which may contain other fibrous matter such as organic, inorganic, or synthetic fibers. Examples include paperboard, linerboard medium and container board or boxboard, any of which may be coated or uncoated.
It has been found the wet strength system of the invention is effective on cellulosic fibers from any fiber source including, but not limited to, any bleached or unbleached hardwood or softwood chemical, mechanical or chemimechanical pulp. The treatment has been found to be particularly useful with unbleached pulps and, still more particularly with sulfite, Kraft and semi-chemical pulps and other pulps used in the manufacture of paperboard. The wet strength system is also useful in making paperboard which contains recycled fiber from sources such as old corrugated container board or OCC.
The cationic temporary wet strength agent used in the invention can be selected from among those cationic temporary wet strength agents known in the art such as dialdehyde starch, polyethylene imine, mannogalactan gum, glyoxal, and dialdehyde mannogalactan. A particularly useful class of temporary wet strength agent is cationic glyoxylated vinylamide wet strength resins.
Glyoxylated vinylamide wet strength resins useful herein are described in U.S. Pat. No. 3,556,932 to Coscia. These resins are typically reaction products of glyoxal and preformed water soluble vinylamide polymers. Suitable polyvinylamides include those produced by copolymerizing a vinylamide and a cationic monomer such as 2-vinylpyridine, 2-vinyl-N-methylpyridinium chloride, diallyldimethyl ammonium chloride, etc. Reaction products of acrylamide diallyldimethyl ammonium chloride in a molar ratio of 99:1 to 75:25 glyoxal, and polymers of methacrylamide and 2-methyl-5-vinylpyridine in a molar ratio of 99:1 to 50:50, and reaction products of glyoxal and polymers of vinyl acetate, acrylamide and diallyldimethyl ammonium chloride in a molar ratio of 8:40:2 are more specific examples provided by Coscia. These vinylamide polymers may have a molecular weight up to 1,000,000, but polymers having molecular weights less than 25,000 are preferred. The vinylamide polymers are reacted with sufficient glyoxal to provide a water soluble thermoset resin. In most cases the molar ratio of glyoxal derived substituents to amide substitutes in the resin is at least 0.06:1 and most typically 0.1:1 to 0.2:1. A commercially available resin useful herein is Parez 631NC sold by Cytec Industries.
The cationic temporary wet strength agent is generally added to the paper in an amount up to about 8 pounds per ton or 0.4 wt %. Generally, the cationic temporary wet strength agent is provided by the manufacturer as an aqueous solution and is added to the pulp in an amount of about 0.05 to 0.4 wt % and more typically in an amount of about 0.1 to 0.2 wt %. Unless otherwise indicated all weights and weight percentages are indicated herein on a dry basis. Depending on the nature of the resin, the pH of the pulp is adjusted prior to adding the resin. The manufacturer of the resin will usually recommend a pH range for use with the resin. The Parez 631NC resin can be used at a pH of about 4 to 8.
The permanent wet strength agents used in practicing the invention can be selected from among those aminoplast resins (e.g., urea-formaldehyde and melamine-formaldehyde) resins and those polyamine-epichlorohydrin, polyamide epichlorohydrin or polyamide-amine epichlorohydrin resins (collectively "PAE resins") conventionally used in the papermaking art. Representative examples of these resins are described throughout the literature. See, for example, Wet Strength in Paper and Paperboard, TAPPI Monograph Series No. 29, Tappi Press (1952) John P. Weidner, Editor, Chapters 1, 2 and 3 and U.S. Pat. Nos. 2,345,543 (1944) 2,926,116 (1965), and 2,926,154 (1960). Typical examples of some commercially available resins include the PAE resins sold by Hercules under the name Kymene, e.g., Kymene 557H and by Georgia Pacific under the name Amres, e.g., Amres 8855.
The permanent wet strength agent is added to the paper fiber in an amount up to about 8 pounds per ton or 0.4 wt % and typically about 0.01 to 0.2 wt % and still more typically about 1 to 2 pounds per ton or 0.05 to 0.1 wt %. The exact amount will depend on the nature of the fibers and the amount of wet strength required in the product. As in the case of the temporary wet strength agent, these resins are generally recommended for use within a predetermined pH range which will vary depending upon the nature of the resin. For example, the Amres resins are typically used at a pH of about 4.5 to 9.
It has been found that repulpable papers having satisfactory wet strength can also be prepared using a reactive internal size instead of or in addition to the aforesaid permanent wet strength agent. By "reactive" is meant that the size chemically bonds to the cellulose fiber. Examples of reactive internal sizes useful in the invention are alkyl ketene dimers (AKD) as described in U.S. Pat. Nos. 4,627,477; 2,785,067; 2,762,270, 3,483,077 and alkenyl succinic anhydride (ASA) as described in U.S. Pat. No. 3,821,069. These sizes are commercially available and their usage is well established in the papermaking art. A representative example of a commercially available AKD size is Hercon 70 from Hercules Chemical Co. A representative example of an ASA size is Accosize AT manufactured by Cytec Industries. Other materials which may have application as internal sizes are fatty acid chlorides, fatty acid enol esters, fatty acid alkyl isocyanates and rosin acid anhydride.
The reactive internal size is used in an amount of about 0.01 to 0.3% and typically in an amount of about 0.05 to 0.1%.
The presence of anionic additive or agents in the pulp has a deleterious effect on the efficiency of the temporary wet strength agent, which is cationic. This adverse impact can be eliminated by treating the stock with cationic resins known in the industry as cationic promoters. These cationic promoters enable more of the wet strength resins to bond to the cellulose because less anionic material is present to consume the resin. These resins are generally selected for their low cost. Some examples of cationic resins useful for this application are polyethyleneimine with a cationic charge of about 0.75 to 3.5 milliequivalents/gram, quaternized polyamines, such as polydiallyldimethylammonium chloride, or cationic starch. Particularly useful cationic resins are polyquaternary amines and are available from Cytec Industries under the trade names CYPRO 514, 515, 516.
Cationic promoters are added to the stock well in advance of the wet strength resins to ensure adequate mixing and adequate contact with the fibers. When used, the cationic resins are generally used in an amount of about 1 to 10 pounds per ton or 0.05 to 0.5%. The cationic promoter can be used at 0 to 0.5 wt %, typically the resins are used in an amount of about 0.02 to 0.3 wt % and preferably 0.1 to 0.2 wt %. The manufacturer of the promoter will typically recommend a pH for its use. The Cypro resins are effective over a pH of about 4 to 9.
Wet strength papers prepared in accordance with the invention may also incorporate other additives conventionally used in the paper industry such as sizes and fillers. In particular, it is desirable to incorporate sizes such as rosin and alum into the stock. Rosin is generally added to the stock as a neutral or acid size in an amount of about 4 to 8 lb/ton of fiber. Alum is used in an amount of about 20 to 40 lb/ton of fiber.
To prepare the wet strength paper, a paper stock, typically having a consistency of about 0.3 to 1.0% is prepared. The point of addition of the wet strength system can vary depending on the design of the paper machine and the nature of the paper product as long as the wet strength chemicals have an adequate opportunity to react with the fiber before the sheet is formed. The wet strength agents can be added at any point before the head box, such as in the stock chest, refiners, or fan pump. In one preferred treatment, the alum and rosin are added to the stock and mixed followed by the addition of the cationic promoter. After the cationic promoter has had an adequate opportunity to react with the fiber (e.g., about 20 sec. to 5 minutes at 3-8 pH), a solution of the temporary wet strength agent is added with the permanent wet strength agent and/or the reactive size.
The amount and ratio of the wet strength agents and size are adjusted to provide a wet strength comparable to that achieved with PAE resins yet provide a repulpable product. The amounts can be varied to provide the necessary balance between wet strength and repulpability. In terms of comparability to PAE, in making paperboard a wet to dry tear ratio of at least 70% is desired. To be considered easily recyclable, a product should yield more than 30% and preferably at least 60% and most preferably at least 75% usable fiber after repulping 15 to 60 minutes at 100° F., 4% consistency at a pH 9 or less. The amount of reusable fiber is the amount of fiber collected through a "six cut" vibrating screen with 0.006 inch slots. The fiber is dried and weighed after equilibrating at 50% RH at 23° C.
The invention is illustrated in more detail by the following non-limiting examples:
EXAMPLE 1
A 70 lb/1000 ft 2 board sheet was made from virgin, unbleached, kraft pine pulp with a Canadian standard freeness of 650 ml. The sheet was made on an M-K sheet former manufactured by M-K Systems. This device makes a sheet that is 12-in.×12-in.
To make the sheet, pulp containing 31.8 grams of fiber on a dry basis was diluted to 0.6 wt. % with distilled water, poured into the sheet former, and the temperature adjusted to 70° to 80° F. Then 48 gms. of a 1% solution of papermakers alum was mixed with the pulp. Next 0.128 gms. of a liquid rosin size (50% solids), Plasmene N-750-P made by Georgia-Pacific, was stirred into the pulp. The pH of the pulp slurry was then adjusted to 4.8 with 5% sulfuric acid. Then 0.05% (0.032 gms. of a 50% aqueous solution) of a polyquaternary amine cationic promoter, Cypro 515 made by Cytec Industries was mixed well with the pulp. Next 0.05% (0.13 gms. of a 12.5% aqueous solution) of a polyamide-polyamine-epichlorohydrin resin, Amres 8855 made by Georgia-Pacific, was mixed into the pulp. Lastly, 0.05% (0.27 gms. of a 6% aqueous solution) of a glyoxalated polyacrylamide resin solution, Parez 631NC made by Cytec Industries, was mixed into the pulp.
The sheet was then deposited on the wire of the former. After couching the sheet from the wire, it was pressed between blotter paper at 90 psi. The sheet was dried, under constraint, for 15 min. at 105° C. and then placed in a room at 50% relative humidity and 23° C. for 24 hrs. before testing.
The dry tensile index of the board was determined by TAPPI method T 456-om-88. The wet tensile index was determined by the same method after the board has been soaked in distilled water for one hour at 23° C. The ratio of these two values was 0.77.
The repulpability of the board was determined by adding 110 grams of it to 2895 grams of deionized water at 120° F. with a pH of 6-7 and repulping in a Maelstrom laboratory pulper manufactured by Adirondac Machine Co. The board was allowed to soak for 15 min. before turning on the pulper motor. After 15 minutes of agitation, a sample of pulp containing 11 grams of dry fiber was taken from the pulper and screened through a vibrating plate, Somerville screen with 0.006 in. slots manufactured by Messmer-Buchel. The fiber retained on the screen and that passing through the screen were collected separately and dried and weighed after equillibrating at 50% relative humidity and 23° C. The percent of the fiber fed to the screen that passed through it was the repulping yield. For this board the yield was 82%.
EXAMPLE 2
Board was made as described in Example 1 with alum and rosin size, but without the use of any cationic promoter (Cypro). A quantity of 0.05% (0.13 gms. of a 12.5% aqueous solution) of a polyamide-polyamine-epichlorohydrin resin, Amres 8855 made by Georgia-Pacific, was added along with 0.15% (0.80 gms. of a 6% aqueous solution) of a glyoxalated polyacrylamide resin solution, Parez 631NC made by Cytec Industries.
The ratio of the wet to dry tear of this board was 0.71. The fiber yield after 15 min. of repulping was 66%.
EXAMPLE 3
A board was prepared by the method of Example 1 which contained, in addition to the rosin and alum, 0.2% (0.52 gms. of a 12.5% aqueous solution) of Amres 8855, but no glyoxalated polyacrylamide resin or cationic promoter.
The wet to dry tear ratio was 0.82 and the fiber yield on repulping was 32%.
EXAMPLE 4
A board was prepared by the method of Example 1 which contained, in addition to the rosin and alum, 0.10% (0.26 gms. of a 12.5% aqueous solution) of Amres 8855, 0.10% (0.53 gms. of a 6% aqueous solution) of Parez 631NC. Before depositing the sheet 0.1% (0.26 gms. of a 12.5% aqueous solution) of alkyl ketene dimer, Hercon 70 manufactured by Hercules, Inc. was mixed with the pulp.
The wet to dry tear ratio was 0.77 and the fiber yield on repulping was 50%.
EXAMPLE 5
A board was prepared by the method of Example 1 which contained, in addition to the rosin and alum, 0.25% (1.36 gms. of a 6% aqueous solution) of Parez 631NC. Before depositing the sheet 0.1% (0.26 gms. of a 12.5% aqueous solution) of alkyl ketene dimer, Hercon 70 manufactured by Hercules, Inc., was mixed with the pulp.
The wet to dry tear ratio was 0.72 and the fiber yield on repulping was 87%.
EXAMPLE 6
A board was prepared by the method of Example 1 which contained, in addition to the rosin and alum, 0.05% (0.032 gms. of a 50% aqueous solution) of a polyquaternary amine promoter, Cypro 515 made by Cytec Industries that was mixed well with the pulp. Then 0.20% (1.1 gms. of a 6% aqueous solution) of Parez 631NC was stirred with the pulp. Before depositing the sheet 0.1% (0.26 gms. of a 12.5% aqueous solution) of alkyl ketene dimer, Hercon 70 manufactured by Hercules, Inc., was mixed with the pulp.
The wet to dry tear ratio of this board was 1.07 and the fiber yield on repulping was 37%. The wet to dry tear ratio of this product is much higher than necessary. By reducing the amount of the resins and AKD, a board having lower but adequate wet to dry tear and higher repulped fiber yield should be available.
COMPARATIVE EXAMPLE 7
A board was prepared by the method of Example 1 which contained, rosin and alum, but no other resins.
The wet to dry tear ratio was 0.41 and the fiber yield on repulping was 99%.
EXAMPLE 8
A board was prepared by the method of Example 1 which contained, in addition to the rosin and alum, 0.05% (0.032 gms. of a 50% aqueous solution) of the cationic promoter Cypro 515), 0.05% (0.13 gms. of a 12.5% aqueous solution) of Amres 8855, and 0.1% (0.53 gms. of a 6% aqueous solution) of Parez 631NC, and 0.1% (0.26 grams of a 12.5% aqueous solution) of Hercon 70.
The wet to dry tear ratio was 1.16 and the fiber yield on repulping was 20%. The wet to dry tear ratio of this product is much higher than necessary. By reducing the amount of the resins and AKD, a board having lower but adequate wet to dry tear and higher repulped fiber yield should be available.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. | A repulpable wet strength paperboard formed from an aqueous dispersion of cellulosic fibers treated with a temporary cationic wet strength agent and a permanent wet strength agent or a reactive internal size wherein said temporary wet strength agent and said permanent wet strength agent or size are used in combined amounts sufficient to impart wet strength to said paper yet render said paper readily repulpable. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotary compressor which compresses a refrigerant by a rotary compression element to discharge it, a method for manufacturing the same, and a defroster for a refrigerant circuit using the same.
2. Description of the Related Art
Conventionally, in a multi-stage compression type rotary compressor, a refrigerant gas-is sucked through a suction port of a first rotary compression element into a low-pressure chamber side of a cylinder, compressed by the operations of a roller-and a vane to have a medium pressure, and discharged into a, sealed vessel through a discharge port of the side of a high pressure chamber of the cylinder. Then, the refrigerant gas having the medium pressure in the sealed vessel is sucked through a suction port of a second rotary compression element into the low-pressure chamber side of the cylinder, undergoes second-stage compression through the operations of the roller and the vane to have a high temperature and a high pressure, and is discharged from the discharge port of the high-pressure chamber side. The refrigerant thus discharged from this compressor flows into a radiator to radiate its heat, is squeezed by an expansion valve to absorb heat at an evaporator, and sucked into the first rotary compression element, which cycle is repeated.
In such a multi-stage compression type rotary compressor, especially when, for example, carbon dioxide (CO 2 ) having a large difference between the high and low pressures is used as the refrigerant, as shown in FIG. 5 , a pressure of the discharged refrigerant reaches 12 MPaG in the second rotary compression element where the refrigerant has the high pressure (HP) and becomes 8 MPaG (medium pressure: MP) in the first rotary compression element which is the lower-stage side (where a suction pressure LP of the first rotary compression element is 4 MPaG). As a result, a differential pressure at the second stage (difference between the suction pressure MP of the second rotary compression element and the discharge pressure HP of the second rotary compression element) becomes a large value of 4 MPaG. Especially when an outside air temperature is low, the discharge pressure MP of the first rotary compression element becomes lower and, therefore, the second-stage differential pressure (difference between the suction pressure MP of the second rotary compression element and the discharge pressure HP of the second rotary compression element) increases further, so that a compression load of the second rotary compression element increases to bring about a problem that durability and reliability deteriorate.
Therefore, conventionally, by altering a dimension of thickness (or height) of the cylinder of the first rotary compression element so that a displacement volume of the second rotary compression element may be smaller than that of the first rotary compression element, a displacement volume ratio has been set so as to reduce a differential pressure at a second stage.
By such a setting method, however, the thickness (or height) of the first cylinder becomes large, so that correspondingly all of a cylinder material and the roller of the first rotary compression element, an eccentric portion, etc. have had to be replaced. Furthermore, as the thickness (or height) of the cylinder increases, the thickness (or height) of a rotary compression mechanism also increases, so that overall size of the relevant multi-stage compression type rotary compressor becomes larger, thus bringing about a problem of a difficulty in miniaturization of the compressor.
It is to be noted that the vane attached to such a multi-stage compression type rotary compressor is inserted movably in a groove formed in a radial direction of the cylinder. Such a vane is pressed against the roller to divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side in such a configuration that on a rear side of the vane a spring is provided to urge this vane on a roller side and also in the groove a back pressure chamber is provided which communicates with the high-pressure chamber of the cylinder to urge this vane on the roller side.
It is to be noted that in an internal medium-pressure type rotary compressor a pressure is higher in the cylinder of the second rotary compression element than in the sealed vessel, so that a pressure on a refrigerant discharge side of the second rotary compression element is applied to the back pressure chamber which urges the vane of this second rotary compression element.
If, for example, carbon dioxide (CO 2 ) having a large difference between high and low pressures is used as the refrigerant, however, as shown in FIG. 5 , a discharged refrigerant pressure reaches 12 MPaG in the second rotary compression element where it has the high pressure (HP). Accordingly, when a pressure on the refrigerant discharge side of the second rotary compression element is applied to the back pressure chamber, a pressure to press the vane against the roller becomes higher than necessary to thereby apply a large load on a portion where a tip of the vane slides along an outer periphery of the roller, thus bringing about a problem that the vane and the roller may be worn heavily or, in the worst case, be damaged.
Furthermore, a discharge-noise silencer chamber of each of the first and second rotary compression elements is provided with a discharge valve to prevent back-flow of the refrigerant when it is discharged into the discharge-noise silencer chamber, using which discharge valve the discharge port can be opened and closed when necessary.
It is to be noted that if, for example, carbon dioxide (CO 2 ) having a large difference between high and low pressures is used as the refrigerant, as shown in FIG. 5 , the discharged refrigerant pressure reaches 12 MPaG at the second rotary compression element where it has the high pressure (HP) and, on the other hand, becomes 8 MPaG (medium pressure: MP) at the first rotary compression element which is a lower-stage side at an outside air temperature of 15° C. (where the suction pressure LP of the first rotary compression element is 4 MPaG). As a result, a differential pressure at the first stage (difference between the suction pressure LP of the first rotary compression element and the discharge pressure MP of the first rotary compression element) becomes a large value of 4 MPaG. Moreover, with an increasing temperature of an outside air, the discharge pressure MP of the first rotary compression element increases rapidly, so that the first-stage differential pressure (difference between the suction pressure LP of the first rotary compression element and the discharge pressure MP of the first rotary compression element) increases further.
When the first-stage differential pressure increases in such a manner, a pressure difference between an inside and an outside of the discharge valve which opens and closes the discharge port of the first rotary compression element becomes excess, thus bringing about a problem of deterioration in durability and reliability such as damages of the discharge valve.
If the outside air temperature drops to reduce an evaporation temperature of the refrigerant, the discharge pressure MP of the first rotary compression element decreases, so that the second-stage differential pressure (difference between the suction pressure MP of the second rotary compression element and the discharge pressure HP of the second rotary compression element) increases further.
When the second-stage differential pressure increases in such a manner, a pressure difference between an inside and an outside of the discharge valve of the second rotary compression element becomes excess, thus bringing about a problem that the discharge valve etc. of the second rotary compression element may be damaged by this pressure difference.
Furthermore, the vane used in the rotary compressor is inserted movably in a guide groove provided in a radial direction of the cylinder. This vane, however, needs to be pressed toward the roller side always, so that conventionally, in configuration, the vane has been urged on the roller side not only by a spring but also by a back pressure applied to a back pressure chamber formed in the cylinder beforehand, thus complicating a construction.
Especially at the second rotary compression element of such an internal medium-pressure, multi-stage compression type rotary compressor, a pressure in the cylinder is higher than the medium pressure in the sealed vessel, thus bringing about a problem that a communication path needs to be formed through which a high back pressure is applied to the back pressure chamber.
Furthermore, in a refrigerant circuit using such a multi-stage compression type rotary compressor, an evaporator is liable to be frosted and so needs to be defrosted; however, if, to defrost this evaporator, a high-temperature refrigerant discharged from the second rotary compression element is supplied to the evaporator without being decompressed at a decompression device (in both cases of being directly supplied to the evaporator and being supplied thereto only by being passed through the decompression device but not being decompressed therethrough), the suction pressure of the first rotary compression element rises to thereby increase the discharge pressure (medium pressure) of the first rotary compression element. Thus, when this refrigerant is discharged through the second rotary compression element, it is not decompressed, so that the discharge pressure of the second rotary compression element becomes almost the same as the suction pressure of the first rotary compression element, thus bringing about a problem that a pressure level relationship may be reversed when the refrigerant is discharged from or sucked into the second rotary compression element.
This reversion in pressure level relationship during discharge and suction at the second rotary compression element can be avoided by providing such a refrigerator circuit as to supply the evaporator with a refrigerant discharged from the first rotary compression element without decompressing it so that the evaporator can be defrosted by supplying, using this refrigerant circuit, it with also the refrigerant discharged from the rotary compression element.
In this case, however, a discharge side of the first rotary compression element and that of the second rotary compression element communicate to each other in construction, so that a same pressure appears on the suction side and the discharge side of the second rotary compression element, thus bringing about a problem of unstable operation of the second rotary compression element such as breakaway of the vane from the second rotary compression element.
SUMMARY OF THE INVENTION
To solve those problems of the conventional technologies, the present invention has been developed, and it is an object of the present invention to provide a method for manufacturing a multi-stage compression type rotary compressor which can avoid the replacement of parts to be used as much as possible to reduce costs and also which enables easily setting an appropriate displacement volume ratio while preventing the compressor from being increased in size.
That is, a multi-stage compression type rotary compressor manufacturing method according to the present invention is directed to, a method for manufacturing a multistage compression type rotary compressor which comprises an electrical-power element and first and second rotary compression elements driven by the electrical-power element in a sealed vessel and in which these first and second rotary compression elements are constituted of first and second cylinders and first and second rollers which are fitted to first and second eccentric portions formed on a rotary shaft of the electrical-power element so as to eccentrically revolves in these cylinders; and a refrigerant gas compressed in the first rotary compression element and discharged therefrom is sucked into the second rotary compression element, compressed and then discharged therefrom; wherein an inner diameter of the first cylinder is altered without altering its thickness (or height); and a displacement volume ratio between the first and second rotary compression elements is set in accordance with the alteration.
By the present invention, therefore, costs can be reduced without replacing all of the cylinder material and the roller of the first rotary compression element, the eccentric portion of the rotary shaft, etc. as much as possible, for example, by replacing only the roller or only the roller and the eccentric portion. Furthermore, it is possible to prevent an increase in overall size of the compressor, thus reducing dimensions thereof.
Furthermore, to satisfy the above-mentioned object, the multi-stage compression type rotary compressor manufacturing method according to the present invention sets a displacement volume of the second rotary compression element to not less than 40% and not more than 75% of that of the first rotary compression element.
By thus setting the displacement volume of the second rotary compression element at a value between 40% and 75%, both inclusive, of that of the first rotary compression element, a displacement volume ratio between the first and second rotary compression elements can be set optimally.
It is another object of the present invention to improve durability of a vane and a roller in an internal medium-pressure, multi-stage compression type rotary compressor, thus avoiding damages of the vane and the roller beforehand.
That is, in a multi-stage compression type rotary compressor according to the present invention comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant gas compressed at the first rotary compression element is discharged into the sealed vessel and this discharged medium pressure refrigerant gas is compressed at the second rotary compression element, wherein there are provided a cylinder constituting the second rotary compression element, a roller which is fitted to an eccentric portion formed on a rotary shaft of the electrical-power element to eccentrically revolve in the cylinder, a vane which butts against this roller to divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, a back pressure chamber for urging this vane on a roller side always, a communication path which communicates a refrigerant discharge side of the second rotary compression element and the back pressure chamber to each other, and a pressure adjustment valve for adjusting a pressure applied to the back pressure chamber through this communication path, so that by using this pressure adjustment valve, force for pressing the vane against the roller can be held appropriately. Furthermore, by holding a pressure of the back pressure chamber at a predetermined value which is lower than a pressure on a refrigerant discharge side of the second rotary compression element and higher than a pressure in the sealed vessel, it is possible to prevent a back pressure higher than necessary from being applied to the vane while preventing a so-called vane breakaway, thus optimizing force for urging the vane toward the roller.
Accordingly, it is possible to reduce a load applied to a portion where a tip of the vane slides along an outer periphery of the roller to thereby avoid damages of the vane and the roller beforehand, thus improving durability thereof.
Furthermore, by the present invention, in addition to this configuration, there are provided a support member which blocks an opening face of the cylinder and also which has a bearing for the rotary shaft of the electrical-power element and a discharge-noise silencer chamber arranged in this support member in such a configuration that the communication path is formed in the support member to communicate the discharge-noise silencer chamber and the back pressure chamber to each other and also the pressure adjustment valve is provided in the support member, so that it is possible to adjust a pressure in the back pressure chamber of the vane without complicating a construction while effectively utilizing an internal limited space of the sealed vessel. Furthermore, since the communication path and the pressure adjustment valve can be provided in the support member beforehand, a work efficiency in assembly can be improved.
It is a further object of the present invention to provide a multi-stage compression type rotary compressor which can avoid beforehand such deterioration in durability and reliability as to be caused by an excessive first-stage differential pressure.
That is, in a multi-stage compression type rotary compressor according to the present invention comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant gas compressed in the first rotary compression element and discharged therefrom is sucked into the second rotary compression element to be compressed and discharged therefrom, there are provided a communication path which communicates a refrigerant suction side and a refrigerant discharge side of the first rotary compression element to each other and a valve device which opens and closes this communication path in such a manner as to open it if a pressure difference between the refrigerant suction side and the refrigerant discharge side of the first rotary compression element exceeds a predetermined upper limit value, so that it is possible to suppress the pressure difference between the refrigerant suction side and the refrigerant discharge side of the first rotary compression element, which is the first-stage differential pressure, down to the predetermined upper limit value or less. Accordingly, it is possible to avoid a trouble such as damaging of the discharge valve provided on the first rotary compression element caused by an excessive value of the first-stage differential pressure, thus improving durability and reliability of the rotary compressor.
Furthermore, by the present invention, there are also provided a cylinder constituting the first rotary compression element, a support member which blocks an opening face of this cylinder and which has a bearing for the rotary shaft of the electrical-power element, and a suction path and a discharge-noise silencer chamber which are arranged in this support member in such a configuration that the communication path is formed in the support member to communicate the suction path and the discharge-noise silencer chamber to each other and also the valve device is provided in the support member, so that the communication path and the valve device can be integrated into the cylinder of the first rotary compression element to realize miniaturization and also the valve device can be set into the cylinder beforehand, thus improving a work efficiency in assembly.
It is a still further object of the present invention to provide a multi-stage compression type rotary compressor which can avoid beforehand a damage and a trouble of the discharge valve etc. of the second rotary compression element caused by a second-stage differential pressure.
That is, a multi-stage compression type rotary compressor according to the present invention comprises an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel so as to suck a medium pressure refrigerant gas compressed in the first rotary compression element into the second rotary compression element and then compress and discharge it therefrom, wherein there are provided a communication path which communicates a passage through which the medium pressure refrigerant gas passes as compressed at the first rotary compression element and a refrigerant discharge side of the second rotary compression element to each other and a valve device which opens and closes this communication path in such a manner as to open it if a pressure difference between the medium pressure refrigerant gas and the refrigerant gas on a refrigerant discharge side of the second rotary compression element exceeds a predetermined upper limit value, so that it is possible to suppress a pressure difference between a discharge pressure and a suction pressure of the second rotary compression element, that is, a second-sage differential pressure, down to the predetermined upper limit value or less.
Accordingly, it is possible to avoid an occurrence of a trouble such as damaging of the discharge valve of the second rotary compression element.
Furthermore, by the present invention, in addition to this configuration, there are provided a cylinder which constitutes the second rotary compression element and a discharge-noise silencer chamber which discharges a refrigerant gas compressed in this cylinder in such a configuration that a medium pressure refrigerant gas compressed at the first rotary compression element is discharged into the sealed vessel and then sucked into the second rotary compression element, the communication path is formed in a wall defining the discharge-noise silencer chamber to communicate an inside of the sealed vessel and the discharge-noise silencer chamber, and the valve device is provided in the wall, so that it is possible to integrate the communication path which communicates the passage for the medium pressure refrigerant compressed at the first rotary compression element and the refrigerant discharge side of the second rotary compression element to each other and the valve device which opens and closes the communication path into a wall of the second rotary compression element.
Accordingly, it is possible to simplify a construction and reduce overall size.
It is an additional object of the present invention to provide a rotary compressor which simplifies a construction related to a vane for dividing an inside of a cylinder into a low-pressure chamber and a high-pressure chamber.
That is, in a rotary compressor according to the present embodiment of the present invention comprising an electrical-power element and a rotary compression element driven by this electrical-power element in a sealed vessel to compress a CO 2 refrigerant, there are provided a cylinder constituting the rotary compression element, a swing piston having a roller portion which is engaged to an eccentric portion formed on a rotary shaft of the electrical-power element to eccentrically move in the cylinder, a vane portion which is formed on this swing piston in such a manner as to project from the roller portion in a radial direction to thereby divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, and a holding portion which is provided on the cylinder to hold the vane portion of the swing piston in such a manner that the vane portion can slide and swing, so that as the eccentric portion of the rotary shaft revolves eccentrically, the swing piston correspondingly swings and slides round the holding portion as a center, and therefore the vane portion thereof always divides the inside of the cylinder into the low-pressure chamber side and the high-pressure chamber side.
Accordingly, it is possible to eliminate a necessity of conventionally providing a spring for urging the vane on a roller side, a back pressure chamber, or a structure for applying a back pressure to the back pressure chamber, thus simplifying a construction of the rotary compressor and reducing costs in manufacture.
Furthermore, in a rotary compressor according to the present invention comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a CO 2 gas compressed at the first rotary compression element is discharged into the sealed vessel and this discharged medium pressure gas is compressed at the second rotary compression element, there are provided a cylinder constituting the second rotary compression element, a swing piston having a roller portion which is engaged to an eccentric portion formed on a rotary shaft of the electrical-power element to eccentrically move in the cylinder, a vane portion which is formed on this swing piston in such a manner as to project from the roller portion in a radial direction in order to divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, and a holding portion which is provided on the cylinder to hold the vane portion of the swing piston in such a manner that the vane can slide and swing, so that similarly, as the eccentric portion of the rotary shaft revolves eccentrically, the swing piston correspondingly swings and slides round the holding portion as a center, and therefore the vane portion thereof always divides the inside of the cylinder of the second rotary compression element into the low-pressure chamber side and the high-pressure chamber side.
Accordingly, it is possible to eliminate a necessity of conventionally providing a spring for urging the vane on the roller side, a back pressure chamber, or a structure for applying a back pressure to the back pressure chamber. Although as by the present invention the structure for applying a back pressure is complicated especially in a so-called multi-stage compression type rotary compressor which provides a medium pressure in a sealed vessel, by thus using a swing piston, it is possible to remarkably simplify a construction and reduce costs in manufacture.
Besides the above-mentioned configuration of the present invention, the holding portion is constituted of a guide groove which is formed in the cylinder and which the vane portion of the swing piston can enter movably and a bush which is provided rotatably at this guide groove to slidingly support the vane portion, so that it is possible to smooth swinging and sliding operations of the swing piston. Accordingly, it is possible to greatly improve performance and reliability of the rotary compressor.
It is another additional object of the present invention to provide a defroster which can prevent unstable operation from occurring during defrosting of an evaporator, in a refrigerant circuit using a multi-stage compression type rotary compressor.
In a refrigerant circuit comprising a multi-stage compression type rotary compressor including an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant compressed at the first rotary compression element is then compressed at the second rotary compression element, a gas cooler into which the refrigerant discharged from the second rotary compression element of this multi-stage compression type rotary compressor flows, a first decompression device connected to an outlet side of this gas cooler, and an evaporator connected to an outlet side of this first decompression device in such a configuration that the refrigerant discharged from this evaporator is compressed at the first rotary compression element., a defroster according to the present invention comprises a defrosting circuit for supplying the evaporator with the refrigerant, without decompressing it, discharged from the first and second rotary compression elements, a first flow-path control device which controls flow of the refrigerant through this defrosting circuit, a second decompression device provided along a refrigerant path for supplying the second rotary compression element with the refrigerant discharged from the first rotary compression element, and a second flow-path control device which controls whether the refrigerant is allowed to flow through this second decompression device or the refrigerant is allowed to bypass it, wherein this second flow-path control device allows the refrigerant to flow through the second decompression device, when the first flow-path control device allows the refrigerant to flow through the defrosting circuit, so that during defrosting operation of the evaporator, the refrigerant discharged from the first and second rotary compression elements is supplied to the evaporator without being decompressed, thus avoiding reversion in pressure level relationship at the second rotary compression element.
In particular, by the present invention, during such defrosting operation, a refrigerant is controlled to be supplied to the second rotary compression element through the decompression device provided along the refrigerant path, so that a predetermined pressure difference is established between suction and discharge sides of the second rotary compression element.
Accordingly, the second rotary compression element becomes stable in operation, thus improving reliability. Remarkable effects are obtained especially in the case of a refrigerant circuit using a CO 2 gas as a refrigerant.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view for showing a multi-stage compression type rotary compressor according to an embodiment of the present invention;
FIG. 2 is a front view for showing the rotary compressor of FIG. 1 ;
FIG. 3 is a side view for showing the rotary compressor of FIG. 1 ;
FIG. 4 is a diagram for showing a refrigerant circuit of a hot-water supply apparatus to which the rotary compressor of FIG. 1 is applied;
FIG. 5 is a graph for showing a relationship between an outside air temperature and various pressures in the case of a multi-stage compression type rotary compressor;
FIG. 6 is a vertical cross-sectional view for showing a multi-stage compression type rotary compressor according to another embodiment of the present invention;
FIG. 7 is an expanded cross-sectional view for showing a pressure adjustment valve of a second rotary compression element of the multi-stage compression type rotary compressor of FIG. 6 ;
FIG. 8 is a vertical cross-sectional view for showing a multi-stage compression type rotary compressor according to a further embodiment of the present invention;
FIG. 9 is an expanded cross-sectional view for showing a communication path portion of a first rotary compression element of the multi-stage compression type rotary compressor of FIG. 8 ;
FIG. 10 is a bottom view for showing a lower-part support member of the multi-stage compression type rotary compressor of FIG. 8 ;
FIG. 11 is a top view for showing an upper-part support member of the multi-stage compression type rotary compressor of FIG. 8 ;
FIG. 12 is a bottom view for showing a lower cylinder of the multi-stage compression type rotary compressor of FIG. 8 ;
FIG. 13 is a top view for showing an upper cylinder of the multi-stage compression type rotary compressor of FIG. 8 ;
FIG. 14 is a vertical cross-sectional view for showing a multi-stage compression type rotary compressor according to a still further embodiment of the present invention;
FIG. 15 is an expanded cross-sectional view for showing a communication path of a second rotary compression element of the multi-stage compression type rotary compressor of FIG. 14 ;
FIG. 16 is an expanded cross-sectional view for showing the communication path of the second rotary compression element of another multi-stage compression type rotary compressor which corresponds to FIG. 15 ;
FIG. 17 is a bottom view for showing a lower-part support member of the multi-stage compression type rotary compressor of FIG. 14 ;
FIG. 18 is a vertical cross-sectional view for showing a rotary compressor according to an additional embodiment of the present invention;.
FIG. 19 is an expanded cross-sectional view for showing a swing piston portion of a second rotary compression element of the rotary compressor of FIG. 18 ;
FIG. 20 is a vertical cross-sectional view for showing a multi-stage compression type rotary compressor according to an additional embodiment of the present invention applied to a defroster for a refrigerant circuit; and
FIG. 21 is a diagram for showing a refrigerant circuit of a hot-water supply apparatus to which the rotary compressor of FIG. 20 is applied.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following will detail embodiments of the present invention with reference to drawings. In figures, a reference numeral 10 indicates an internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide as a refrigerant which comprises a cylindrical sealed vessel 12 made of a steel plate and a rotary compression mechanism portion 18 which includes an electrical-power element 14 arranged and housed in an upper part of an internal space of the sealed vessel and a first rotary compression element 32 (first stage) and a second rotary compression element 34 (second stage) which are arranged below the electrical-power element 14 to be driven by a rotary shaft 16 of the electrical-power element 14 . The sealed vessel 12 has its bottom used as an oil reservoir and is composed of a vessel body 12 A which houses the rotary compression mechanism portion 18 and the electrical-power element 14 and a roughly cup-shaped end cap (lid) 12 B which blocks an upper part opening of the vessel body 12 A in such a configuration that the end cap 12 B has a circular attachment hole 12 D formed therein at a center of its top face, in which attachment hole 12 D a terminal 20 (wiring of which is omitted) is attached which supplies power to the electrical-power element 14 .
The electrical-power element 14 is composed of a stator 22 mounted annularly along an inner peripheral face of an upper-part space of the sealed vessel 12 and a rotor 24 disposed and inserted in the stator 22 with some gap set therebetween. This rotor 24 is fixed to the rotary shaft 16 which vertically extends centrally.
The stator 22 has a stack 26 formed by stacking donut-shaped electromagnetic steel plates and a stator coil. 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, similar to the stator 22 , the rotor 24 is also made of a stack 30 of electromagnetic steel plates and a permanent magnet MG inserted into the stack 30 .
An intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . That is, a combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , an upper cylinder 38 and a lower cylinder 40 arranged above and below the intermediate partition plate 36 respectively, an upper roller 46 and a lower roller 48 which eccentrically revolve within the upper and lower cylinders 38 and 40 respectively at upper and lower eccentric portions 42 and 44 provided on the rotary shaft 16 with a phase difference of 180 degrees therebetween, vanes 50 and 52 which butt against the upper and lower rollers 46 and 48 to divide an inside of the respective upper and lower cylinders 38 and 40 into a low-pressure chamber side and a high-pressure chamber side, and an upper-part support member 54 and a lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
The upper and lower cylinders 38 and 40 constituting the second and first rotary compression elements 34 and 32 respectively are made up of a material having the same thickness in the present embodiment. Furthermore, assuming an inner diameter of the cylinders 38 and 40 obtained by cutting them to be D 2 and D 1 respectively, when altering a displacement volume ratio between the first and second rotary compression elements 32 and 34 , this ratio is set by altering the inner diameter D 1 of the lower cylinder 40 of the first rotary compression element 32 .
It is to be noted that when the displacement volume ratio is set by altering thickness (or height) of the lower cylinder 40 , for example, it is necessary to alter all of a material of the lower cylinder 40 and thickness (or height) of the lower eccentric portion 44 and the lower roller; 48 . That is, in this case, it is necessary at least to alter the lower cylinder 40 and the lower roller 48 starting from their materials and also alter how to cut the rotary shaft 16 for the lower eccentric portion 44 . By the present invention, on the other hand, at least the lower cylinder 40 need not be altered in material but only needs to be altered in inner diameter when being cut. Furthermore, although the lower roller 48 needs to be altered at least in outer diameter, the lower eccentric portion 44 need not be altered if the inner diameter is the same. Thus, by the present invention, the displacement volume ratio can be altered without altering at least the material of the lower cylinder 40 but by altering only a cutting process of the lower cylinder 40 and an outer diameter of the lower roller 48 or outer and inner diameters of the lower roller 48 as well as the lower eccentric portion 44 . It is thus possible to set an optimal displacement volume ratio between the first and second rotary compression elements 32 and 34 while minimizing replacement of parts at the same time. It is to be noted that in the present embodiment a displacement volume of the second rotary compression element 34 is set in a range of not less than 40% through not more than 75% of that of the first rotary compression element 32 .
A combination of the upper-part support member 54 and the lower-part support member 56 , on the other hand, is provided therein with a suction path 60 (and an upper-side suction path not shown) which communicate with insides of the upper and lower cylinders 38 and 40 through suction ports not shown and discharge-noise silencer chambers 62 and 64 which are formed by concaving a surface partially and then blocking resultant concavities by an upper cover 66 and a lower cover 68 respectively.
It is to be noted that the discharge-noise silencer chamber 64 communicates with an inside of the sealed vessel 12 through a communication path which penetrates the upper and lower cylinders 38 and 40 and the intermediate partition plate 36 in such a configuration that at an upper end of the communication path, an intermediate discharge pipe 121 is provided as erected, through which a medium pressure refrigerant compressed at the first rotary compression element 32 is discharged into the sealed vessel 12 .
Furthermore, the upper cover 66 which blocks an upper-face opening of the discharge-noise silencer chamber 62 communicating with an inside of the upper cylinder 38 of the second rotary compression element 34 partitions the inside of the sealed vessel 12 into a side of the discharge-noise silencer chamber 62 and a side of the electrical-power element 14 .
In this configuration, by the present embodiment, as a refrigerant, carbon dioxide (CO 2 ) which is a natural refrigerant friendly to environments of the earth is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, ester oil, or poly-alkyl glycol (PAG).
Onto a side face of the vessel body 12 A of the sealed vessel 12 , sleeves 141 , 142 , 143 , and 144 are fixed by welding at positions that correspond to the suction path 60 (and an upper-side suction path not shown) of the respective upper-part support member 54 and the lower-part support member 56 , the discharge-noise silencer chamber 62 , and an upper side of the upper cover 66 (a lower end of the electrical-power element 14 roughly) respectively. The sleeves 141 and 142 are adjacent to each other vertically, while the sleeve 143 is roughly in a diagonal direction of the sleeve 141 . Furthermore, the sleeve 144 is positioned as shifted by about 90 degrees with respect to the sleeve 141 .
In the sleeve 141 is there inserted and connected one end of a refrigerant introduction pipe 92 for introducing a refrigerant gas to the upper cylinder 38 , which one end communicates with the suction path, not shown, of the upper cylinder 38 . This refrigerant introduction pipe 92 passes through an upper part of the sealed vessel 12 up to the sleeve 144 , while the other end is inserted and connected in the sleeve 144 to communicate with the inside of the sealed vessel 12 .
In the sleeve 142 , on the other hand, is there inserted and connected one end of a refrigerant introduction pipe 94 for introducing a refrigerant gas to the lower cylinder 40 , which one end communicates with the suction path 60 of the lower cylinder 40 . The other end of this refrigerant introduction pipe 94 is connected to a lower end of an accumulator 146 . Furthermore, in the sleeve 143 is there inserted and connected a refrigerant discharge pipe 96 , one end of which communicates with the discharge-noise silencer chamber 62 .
The accumulator 146 is a tank for separating an sucked refrigerant into vapor and liquid and attached via a bracket 148 thereof to the bracket 147 of a sealed vessel side welded and fixed to an upper-part side face of the vessel body 12 A of the sealed vessel 12 (FIG. 2 ).
In this configuration, a multi-stage compression type rotary compressor 10 of the present embodiment is used in a refrigerant circuit of a hot-water supply apparatus 153 such as shown in FIG. 4 . That is, the refrigerant discharge pipe 96 of the multi-stage compression type rotary compressor 10 is connected to an inlet of a gas cooler 154 for heating water. This gas cooler 154 is provided to a hot-water storage tank, not shown, of the hot-water supply apparatus 153 . The pipe exits the gas cooler 154 and passes through an expansion valve 156 , which serves as a decompression device, up to an inlet of an evaporator 157 , an outlet of which is connected to the refrigerant introduction pipe 94 . Furthermore, as shown in FIG. 4 , a defrosting pipe 158 constituting the defrosting circuit branches from the refrigerant introduction pipe 92 at somewhere along it and is connected through an electromagnetic valve 159 , which serves as a flow-path control device, to the refrigerant discharge pipe 96 extending to the inlet of the gas cooler 154 . It is to be noted that the accumulator 146 is omitted in FIG. 4 .
The following will describe operations with reference to this configuration. It is to be noted that the electromagnetic valve 159 is supposed to stay closed during heating. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, the upper and lower rollers 46 and 48 are fitted to the upper and lower eccentric portions 42 and 44 provided integrally with the rotary shaft 16 , to eccentrically revolve in the upper and lower cylinders 38 and 40 respectively.
Accordingly, a low-pressure refrigerant sucked into the low-pressure chamber side of the cylinder 40 from the suction port, not shown, through the refrigerant introduction pipe 94 and the suction path 60 formed in the lower-part support member 56 is compressed by operations of the roller 48 and the vane 52 to have a medium pressure, passed through the high-pressure chamber side of the lower cylinder 40 , a discharge port not shown, the discharge-noise silencer chamber 64 formed in the lower-part support member 56 , and the communication path not shown, and discharged into the sealed vessel 12 from the intermediate discharge pipe 121 . Thus, the medium pressure develops in the sealed vessel 12 .
Then, the medium pressure refrigerant gas in the sealed vessel 12 exits it through the sleeve 144 , passes through the refrigerant introduction pipe 92 and the suction path, not shown, formed in the upper-part support member 54 , and is sucked from the suction port, not shown, into the lower-pressure chamber side of the upper cylinder 38 . The medium pressure refrigerant gas thus sucked undergoes second-stage compression through operations of the roller 46 and the vane 50 to provide a high-temperature, high-pressure refrigerant gas, which in turn passes through the high-pressure chamber side, the discharge port not shown, the discharge-noise silencer chamber 62 formed in the upper-part support member 54 , and the refrigerant discharge pipe 96 to then flow into the gas cooler 154 . At this moment, the refrigerant has a raised temperature of about +100° C. and, therefore, such a high temperature, high pressure gas radiates heat to heat water in the hot-water storage tank, thus generating hot water having a temperature of about +90° C.
The refrigerant itself, on the other hand, is cooled at the gas cooler 154 and exits it. Then, the refrigerant is decompressed at the expansion valve 156 , flows into the evaporator 157 to evaporate there, passes through the accumulator 146 (not shown in FIG. 4 ), and is sucked into the first rotary compression element 32 through the refrigerant introduction pipe 94 , which cycle is repeated.
Thus, by altering the inner diameter D 1 of the lower cylinder 40 without altering its thickness (or height) to thus set the displacement volume of the second rotary compression element 34 at not less than 40% and not more than 75% of that of the first rotary compression element 32 , a displacement volume ratio between the first and second rotary compression elements 32 and 34 is set, so that it is possible to reduce a compression load of the second rotary compression element 34 while minimizing alterations of the cylinder material and parts such as the eccentric portions and rollers as much as possible, to thereby provide an optimal displacement volume ratio with a differential pressure suppressed as much as possible. Furthermore, the rotary compression mechanism portion 18 also stays as unexpanded in vertical size, thus enabling minimizing the multi-stage compression type rotary compressor 10 .
Although in the present embodiment the upper and lower cylinders 38 and 40 are supposed to have the same thickness (or height), the present invention is not limited thereto; for example, the displacement volume ratio may be set by altering the inner diameter of the cylinder of the first rotary compression element in a condition where the upper and lower cylinders 38 and 40 are different in thickness (or height) originally.
Furthermore, although the present embodiment has been described in all cases with reference to a multi-stage compression type rotary compressor in which the rotary shaft 16 is mounted vertically, of course the present invention can be applied also to a multi-stage compression type rotary compressor in which the rotary shaft is mounted horizontally. Furthermore, the multi-stage compression type rotary compressor has been described as a two-stage compression type rotary compressor equipped with first and second rotary compression elements, the present invention is not limited thereto; for example, the multi-stage compression type rotary compressor may be equipped with three, four, or even more stages of rotary compression elements.
Furthermore, although the present embodiment has used the multi-stage compression type rotary compressor 10 in a refrigerant circuit of the hot-water supply apparatus 153 , the present invention is not limited thereto; for example, the present invention may well be applied for warming of a room.
As detailed above, according to the present embodiment of the present invention, when manufacturing a multi-stage compression type rotary compressor which comprises an electrical-power element and first and second rotary compression elements driven by the electrical-power element in a sealed vessel in such a configuration that the first and second rotary compression elements are constituted of first and second cylinders and first and second rollers which are fitted to first and second eccentric portion formed on a rotary shaft of the electrical-power element so as to eccentrically revolve in the cylinders respectively and also that a refrigerant gas compressed in the first rotary compression element and discharged therefrom is sucked into the second rotary compression element to be compressed and discharged therefrom, an inner diameter of the first cylinder is altered without altering its thickness (or height) to thereby set a displacement volume ratio between the first and second rotary compression elements, so that costs can be reduced without replacing all of a cylinder material and the roller of the first rotary compression element, the eccentric portion of the rotary shaft, etc. as much as possible, for example, by replacing only the roller or only the roller and the eccentric portion. Furthermore, it is possible to prevent an increase in overall size of the compressor, thus reducing dimensions thereof. Also, for example, by setting the displacement volume of the second rotary compression element at not less than 40% and not more than 75% of that of the first rotary compression element, a displacement volume ratio between the first and second rotary compression elements can be optimized.
The following will describe a multi-stage compression type rotary compressor according to another embodiment of the present invention with reference to FIGS. 6 and 7 . FIG. 6 is a vertical cross-sectional view of the multi-stage compression type rotary compressor according to the present embodiment of the present invention and FIG. 7 , an expanded cross-sectional view of a pressure adjustment valve 107 of the rotary compressor 10 . It is to be noted that the same reference numerals in FIGS. 6 and 7 as those in FIGS. 1-5 indicate the same or similar functions.
In the figures, a reference numeral 10 indicates the internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide (CO 2 ) as a refrigerant which comprises the cylindrical sealed vessel 12 made of a steel plate and the rotary compression mechanism portion 18 which includes the electrical-power element 14 arranged and housed in an upper part of an internal space of the sealed vessel 12 and the first rotary compression element 32 (first stage) and the second rotary compression element 34 (second stage) which are arranged below the electrical-power element 14 to be driven by the rotary shaft 16 of the electrical-power element 14 .
The sealed vessel 12 has its bottom used as an oil reservoir and is composed of the vessel body 12 A which houses the rotary compression mechanism portion 18 and the electrical-power element 14 and the roughly cup-shaped end cap (lid) 12 B which blocks an upper part opening of the vessel body 12 A in such a configuration that the end cap 12 B has the circular attachment hole 12 D formed therein at a center of its top face, in which attachment hole 12 D the terminal 20 (wiring of which is omitted) is attached which supplies power to the electrical-power element 14 .
The electrical-power element 14 is composed of the stator 22 mounted annularly along an inner peripheral face of an upper-part space of the sealed vessel 12 and the rotor 24 disposed and inserted in the stator 22 with some gap set therebetween. This rotor 24 is fixed to the rotary shaft 16 which vertically extends centrally.
The stator 22 has the stack 26 formed by stacking donut-shaped electromagnetic steel plates and the stator coil 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, similar to the stator 22 , the rotor 24 is also made of the stack 30 of electromagnetic steel plates and the permanent magnet MG inserted into the stack 30 .
The intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . That is, a combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , the upper cylinder 38 and the lower cylinder 40 arranged above and below the intermediate partition plate 36 respectively, the upper roller 46 and the lower roller 48 which are fitted to the upper and lower eccentric portions 42 and 44 provided on the rotary shaft 16 with a phase difference of 180 degrees set therebetween so as to eccentrically revolve within the upper and lower cylinders 38 and 40 respectively, the upper and lower vanes 50 and 52 which butt against the upper and lower rollers 46 and 48 to divide respective upper and lower cylinders 38 and 40 into a low-pressure chamber side and a high-pressure chamber side, and the upper-part support member 54 and the lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
It is to be noted that a displacement volume ratio between the first rotary compression element 32 and the second rotary compression element 34 is supposed to be (displacement volume of the second rotary compression element 34 )/(displacement volume of the first rotary compression element 32 )×100=30−75%.
As shown in FIG. 7 , within the upper cylinder 38 constituting the second rotary compression element 34 , a guide groove 70 for housing the vane 50 is formed; and outside the guide groove 70 , that is, on a rear face side of the vane 50 , there is formed a housing portion 70 A for housing a spring 74 serving as a spring member. The spring 74 butts against a rear face side end of the vane 50 to thereby always urge the vane 50 on the roller 46 . The housing portion 70 A has an opening on a side of the guide groove 70 and a side of the sealed vessel 12 (vessel body 12 A) and is provided with a metal-made plug 137 on a side of the sealed vessel 12 with respect to the spring 74 housed in the housing portion 70 A for preventing fall-out of the spring 74 . Furthermore, on a peripheral face of the plug is there attached an O-ring, not shown, for sealing an inner face of this plug 137 and that of the housing portion 70 A off each other.
Furthermore, between the guide groove. 70 and the housing portion 70 A is there provided a back pressure chamber 99 which applies a refrigerant discharge pressure of the second rotary compression element 34 to the vane 50 to work with the spring 74 in order to always urge the vane 50 on the roller 46 . An upper face of this back pressure chamber 99 communicates with a later-described second path 106 .
Furthermore, a combination of the upper-part support member 54 and the lower-part support member 56 is provided therein the suction path 60 (and upper-side suction path not shown) communicating with insides of the upper and lower cylinders 38 and 40 respectively through a suction port not shown and the discharge-noise silencer chambers 62 and 64 formed by concaving a surface partially and blocking resultant concavities by the upper and lower covers 66 and 68 respectively.
It is to be noted that the discharge-noise silencer chamber 64 and an inside of the sealed vessel 12 communicate to each other through an communication path which penetrates the upper and lower cylinder 38 and 40 and the intermediate partition plate 36 in such a configuration that at an upper end of the communication path is there provided the intermediate discharge pipe 121 as erected, from which pipe 121 a medium pressure refrigerant gas-compressed at the first rotary compression element 32 is discharged into the sealed vessel 12 .
In this configuration, the upper cover 66 which blocks the upper-face opening of the discharge-noise silencer chamber 62 communicating with an inside of the upper cylinder 38 of the second rotary compression element 34 partitions an inside of the sealed vessel 12 into the discharge-noise silencer chamber 62 and a side of the electrical-power element 14 .
Furthermore, a communication path 100 is formed in the upper-part support member 54 . This communication path 100 is provided to communicate to each other the back pressure chamber 99 and the discharge-noise silencer chamber 62 which communicates with a discharge port, not shown, of the upper cylinder 38 of the second rotary compression element 34 and is constituted of a valve housing chamber 102 which penetrates the upper-part support member 54 vertically and has its upper side blocked by the upper cover 66 , a first path 101 which communicates an upper end of this valve housing chamber 102 and the discharge-noise silencer chamber 62 to each other, and a second path 106 which is positioned outside the valve housing chamber 102 to communicate this valve housing chamber 102 and the back pressure chamber 99 to each other as shown in FIG. 7 .
The valve housing chamber 102 is a cylindrical hole extending vertically and has its lower end blocked by a sealing agent 103 . On a upper side of the sealing agent 103 is there attached a lower end of a valve disc 104 (coil spring.), at an upper end of which is, in turn attached a valve disc 105 . This valve disc 105 is provided in the valve housing chamber 102 vertically movably and butts against a peripheral wall of this valve housing chamber 102 as sliding to divide the valve housing chamber 102 vertically. These valve disc 105 and spring member 104 constitute a pressure adjustment valve 107 of the present invention.
The second path 106 is formed from a position below a lower end of the valve housing chamber 102 by a predetermined distance down to the back pressure chamber 99 in such a configuration that if the valve disc 105 is above the path 106 , the communication path 100 is closed and, if an upper face of the valve disc 105 is below an upper end of the second path 106 , the communication path 100 is opened. The spring member 104 always urges this valve disc 105 in such a direction as to raise it.
Furthermore, the valve disc 105 receives downward force due to a high pressure refrigerant gas flowing through the first path 101 into the valve housing chamber 102 and upward force due to a pressure in the back pressure chamber 99 through the second path 106 . That is, the valve disc 105 moves downward and upward respectively owing to a pressure of the refrigerant gas compressed in the upper cylinder 38 of the second rotary compression element 34 and discharged into the discharge-noise silencer chamber 62 and a combination of urging force of the spring member 104 and a pressure in the back pressure chamber 99 .
The urging force of this spring member 104 is supposed to be set so that if, for example, a pressure difference between the discharge-noise silencer chamber 62 and the back pressure chamber 99 (pressure of the discharge-noise silencer chamber 62 —pressure of the back pressure chamber 99 ) becomes larger than, for example, 2 MPaG, an upper face of the valve is lowered below the upper end of the second path 106 to thereby open the communication path 100 and, if the pressure difference becomes 2 MPaG or less, the valve disc 105 is raised until its upper face exceeds in height the upper end of the second path 106 to thereby close the communication path 100 .
In this case, as a refrigerant, carbon dioxide (CO 2 ), which is a natural refrigerant friendly to environments of the earth, is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, ester oil, or poly-alkyl glycol (PAG).
On a side face of the vessel body 12 A of the sealed vessel 12 , the sleeves 141 , 142 , 143 , and 144 are fixed by welding at positions that correspond to the suction path 60 (and an upper-side suction path not shown) of the respective upper-part support member 54 and the lower-part support member 56 , the discharge-noise silencer chamber 62 , and an upper side of the upper cover 66 (a lower end of the electrical-power element 14 roughly) respectively. The sleeves 141 and 142 are adjacent to each other vertically, while the sleeve 143 is roughly in a diagonal direction of the sleeve 141 . Furthermore, the sleeve 144 is positioned as shifted by about 90 degrees with respect to the sleeve 141 .
In the sleeve 141 is there inserted and connected one end of the refrigerant introduction pipe 92 for introducing a refrigerant gas to the upper cylinder 38 , which one end communicates with a suction path, not shown, of the upper cylinder 38 . This refrigerant introduction pipe 92 passes through the upper part of the sealed vessel 12 up to the sleeve 144 , while the other end is inserted and connected in the sleeve 144 so as to communicate with an inside of the sealed vessel 12 .
In the sleeve 142 , on the other hand, is there inserted and connected one end of the refrigerant introduction pipe 94 for introducing a refrigerant gas to the lower cylinder 40 , which one end communicates with the suction path 60 of the lower cylinder 40 . The other end of this refrigerant introduction pipe 94 is connected to a lower end of the accumulator 146 . Furthermore, in the sleeve 143 is there inserted and connected the refrigerant discharge pipe 96 , one end of which communicates with the discharge noise silencer chamber 62 .
The accumulator 146 is a tank for separating an sucked refrigerant into vapor and liquid and attached via the bracket 148 thereof to the bracket 147 of a sealed vessel side welded and fixed to an upper-part side face of the vessel body 12 A of the sealed vessel 12 (see FIG. 2 ).
Accordingly, the multi-stage compression type rotary compressor 10 of the present embodiment is used in a refrigerant circuit of a hot-water supply apparatus such as shown in FIG. 4 . That is, the refrigerant discharge pipe 96 of the multi-stage compression type rotary compressor 10 is connected to the inlet of the gas cooler 154 for heating water. This gas cooler 154 is provided to a hot-water storage tank, not shown, of the hot-water supply apparatus 153 . The pipe exits the gas cooler 154 and passes through the expansion valve 156 serving as a decompression device up to an inlet of the evaporator 157 , an outlet of which is connected to the refrigerant introduction pipe 94 . Furthermore, as shown in FIG. 4 , the defrosting pipe 158 constituting the defrosting circuit branches from the refrigerant introduction pipe 92 at somewhere along it and is connected through the electromagnetic valve 159 serving as a flow-path control device to the refrigerant discharge pipe 96 extending to the inlet of the gas cooler 154 .
The following will describe operations with reference to this configuration. It is to be noted that the electromagnetic valve 159 is supposed to stay closed during ordinary heating. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, the upper and lower rollers 46 and 48 are fitted to the upper and lower eccentric portions 42 and 44 provided integrally with the rotary shaft 16 , to eccentrically revolve in the upper and lower cylinders 38 and 40 respectively.
Accordingly, a low-pressure (first-stage suction pressure: 4 MPaG) refrigerant sucked into the low-pressure chamber side of the cylinder 40 from a suction port, not shown, through the refrigerant introduction pipe 94 and the suction path 60 formed in the lower-part support member 56 is compressed by operations of the lower roller 48 and the vane 52 to have a medium pressure (first-stage discharge pressure: 8 MPaG), passed through the high-pressure chamber side of the lower cylinder 40 and a discharge port not shown, and discharged into the discharge-noise silencer chamber 64 formed in the lower-part support member 56 . Then, the medium pressure refrigerant gas discharged into the discharge-noise silencer chamber 64 is discharged through the communication path into the sealed vessel 12 from the intermediate discharge pipe 121 , thus providing the medium pressure (8 MPaG) in the sealed vessel 12 .
Then, the medium pressure refrigerant gas in the sealed vessel 12 exits it through the sleeve 144 , passes through the refrigerant introduction pipe 92 and the suction path, not shown, formed in the upper-part support member 54 , and is sucked from a suction port, not shown, into the lower-pressure chamber side of the upper cylinder 38 . The medium pressure refrigerant gas thus sucked undergoes second-stage compression through operations of the roller 46 and the vane 50 to provide a high-temperature, high-pressure refrigerant gas (second-stage discharge pressure: 12 MPaG), which in turn passes from the high-pressure chamber side and a discharge port not shown to be discharged into the discharge-noise silencer chamber 62 formed in the upper-part support member 54 .
The refrigerant gas thus sucked into the discharge-noise silencer chamber 62 flows into the gas cooler 154 from the refrigerant discharge pipe 96 . At this moment, the refrigerant has a raised temperature of about +100° C. and, therefore, such a high temperature, high pressure gas radiates heat to heat water in the hot-water storage tank to thus generate hot water having a temperature of about +90° C.
The refrigerant itself, on the other hand, is cooled at the gas cooler 154 and exits it. Then, the refrigerant is decompressed at the expansion valve 156 , flows into the evaporator 157 to evaporate there, passes through the accumulator 146 , and is sucked into the first rotary compression element 32 through the refrigerant introduction pipe 94 , which cycle is repeated.
During such heating operation, a pressure in the discharge-noise silencer chamber 62 reaches an extremely high value of 12 MPaG as mentioned above, so that if a pressure of the back pressure chamber 99 is lower than the pressure in the discharge-noise silencer chamber 99 with a difference therebetween being larger than 2 MPaG, as mentioned above, the valve disc 105 of the pressure adjustment valve 107 opens the communication path 100 . Accordingly, the high-pressure refrigerant gas in the discharge-noise silencer chamber 62 flows into the back pressure chamber 99 .
If such introduction of the pressure increases a pressure in the back pressure chamber 99 until the difference between the pressure in the back pressure chamber 99 and the pressure in the discharge-noise silencer chamber 62 decreases to 2 MPaG, as mentioned above, the valve disc 105 of the pressure adjustment valve 107 closes the communication path 100 , thus stopping flow of the refrigerant gas into the back pressure chamber.
In such a manner, when the second-stage discharge pressure is 12 MPaG, a pressure in the back pressure chamber 99 is held at about 10 MPaG higher than the medium pressure 8 MPaG and lower than the second-stage discharge pressure 12 MPaG, so that it is possible to prevent the back pressure higher than necessary from being applied to the vane 50 while preventing a so-called vane breakaway, thus optimizing force for urging the vane 50 on the upper roller 46 . Accordingly, it is possible to reduce a load applied to a portion where a tip of the vane slides along an outer periphery of the roller to thereby improve durability of the vane 50 and the upper roller 46 , thus avoiding damages of the vane and the roller beforehand.
In this case, especially in a low outside-air temperature environment, heating operation causes the evaporator 157 to be frosted. In such a case, the electromagnetic valve 159 is opened and the expansion valve 156 is opened fully to defrost the evaporator 157 . Thus, a medium-pressure refrigerant in the sealed vessel 12 (including a small amount of high pressure refrigerant discharged from the second rotary compression element 34 ) passes through the defrosting pipe 158 to reach the gas cooler 154 . This refrigerant has a temperature of roughly +50° C. through +60° C. and so radiates no heat at the gas cooler 154 but, instead, absorbs heat at the beginning. Then, the refrigerant discharged from the gas cooler 154 passes through the expansion valve 156 to reach the evaporator 157 . That is, the roughly medium-pressure, comparatively high-temperature refrigerant is essentially supplied to the evaporator 157 directly without being decompressed, thus heating the evaporator 157 to defrost it.
Thus, the rotary compressor according to the present embodiment which comprises the electrical-power element 14 and the first and second rotary compression elements 32 and 34 driven by the electrical-power element 14 in the sealed vessel 12 in such a configuration that a refrigerant gas compressed at the first rotary compression element 32 is discharged into the sealed vessel 12 and this medium pressure refrigerant gas thus discharged is then compressed at the second rotary compression element 34 , wherein there are also provided the upper cylinder 38 constituting the second rotary compression element 34 , the upper roller 46 which is fitted to the upper eccentric portion 42 formed on the rotary shaft 16 of the electrical-power element 14 to thereby eccentrically revolves in the upper cylinder 38 , the vane 50 which butts against this upper roller 46 to divide an inside of the upper cylinder 38 into a low-pressure chamber side and a high-pressure chamber side, the back pressure chamber 99 which urges this vane 50 on a side of the upper roller. 46 always, the communication path 100 which communicates a refrigerant discharge side of the second rotary compression element 34 and the back pressure chamber 99 to each other, and the pressure adjustment valve 107 for adjusting a pressure applied to the back pressure chamber 99 through this communication path, so that by using this pressure adjustment valve 107 to set a pressure of the back pressure chamber 99 to a predetermined value lower than a high pressure on the refrigerant discharge side of the second rotary compression element 34 and higher than a medium pressure in the sealed vessel 12 , it is possible to prevent a back pressure higher than necessary from being applied to the vane 50 while preventing the so-called vane breakaway, thus optimizing force for urging the vane 50 on the upper roller 46 .
Accordingly, it is possible to reduce a load applied to a portion where a tip of the vane slides along an outer periphery of the upper roller 46 to thereby improve durability of the vane 50 and the upper roller 46 , thus avoiding damages of the vane and the roller beforehand.
In particular, the communication path 100 is formed in the upper-side support member 54 to communicate the discharge-noise silencer chamber 62 and the back pressure chamber 99 to each other and also the pressure adjustment valve 107 is provided in the upper-part support member 54 , so that it is possible to adjust a pressure in the back pressure chamber 99 of the vane 50 without complicating a construction while effectively utilizing an internal limited space of the sealed vessel 12 . Furthermore, since the communication path 100 and the pressure adjustment valve 107 can be provided in the upper-part support member 54 beforehand, a work efficiency in assembly can be improved.
It is to be noted that pressure values employed on the present embodiment are not restrictive and so may be set appropriately corresponding to a capacity and a function of various compressors. Furthermore, although the present embodiment has been described with reference to a multi-stage compression type rotary compressor 10 in which the rotary shaft 16 is mounted vertically, of course the present invention can be applied also to a multi-stage compression type rotary compressor in which the rotary shaft is mounted horizontally.
Furthermore, the multi-stage compression type rotary compressor has been described as a two-stage compression type rotary compressor equipped with first and second rotary compression elements, the present invention is not limited thereto; for example, the multi-stage compression type rotary compressor may be equipped with three, four, or even more stages of rotary compression elements. Furthermore, although the present embodiment has used the multi-stage compression type rotary compressor 10 in a refrigerant circuit of the hot-water supply apparatus 153 , the present invention is not limited thereto; for example, the present invention may well be applied for warming of a room.
As detailed above, by the present invention, in a multi-stage compression type rotary compressor according to the present embodiment which comprises an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant gas compressed at the first rotary compression element is discharged into the sealed vessel and this medium pressure refrigerant gas thus discharged is compressed at the second rotary compression element, there are also provided a cylinder constituting the second rotary compression element, a roller which is fitted to an eccentric portion formed on a rotary shaft of the electrical-power element to thereby eccentrically revolves in the cylinder, a vane which butts against this roller to divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, a back pressure chamber which always urges this vane on a side of the roller, a communication path which communicates a refrigerant discharge side of the second rotary compression element and the back pressure chamber to each other, and a pressure adjustment valve for adjusting a pressure applied to the back pressure chamber through this communication path, so that by setting a pressure of the back pressure chamber at a predetermined value lower than a pressure on a refrigerant discharge side of the second rotary compression element and higher than a pressure in the sealed vessel 12 , it is possible to prevent a back pressure higher than necessary from being applied to the vane while preventing the so-called vane breakaway, thus optimizing force for urging the vane on the roller.
Accordingly, it is possible to reduce a load applied to a portion where a tip of the vane slides along an outer periphery of the roller to thereby improve durability of the vane and the roller, thus avoiding damages of the vane and the roller beforehand.
Furthermore, there are also provided a support member which blocks an opening face of the cylinder and also which has a bearing for the rotary shaft of the electrical-power element and a discharge-noise silencer chamber arranged in this support member in such a configuration that the communication path is formed in the support member to communicate the discharge-noise silencer chamber and the back pressure chamber to each other and also the pressure adjustment valve is provided in the support member, so that it is possible to adjust a pressure in the back pressure chamber of the vane without complicating a construction while effectively utilizing an internal limited space of the sealed vessel. Furthermore, since the communication path and the pressure adjustment valve can be provided in the support member beforehand, a work efficiency in assembly can be improved.
The following will describe a multi-stage compression type rotary compressor according to a further embodiment of the present invention with reference to FIGS. 8-13 . FIG. 8 is a vertical cross-sectional view of the multi-stage compression type rotary compressor according to the present embodiment. It is to be noted that the same reference numerals in these figures as those in FIGS. 1-5 have the same or similar functions.
In FIG. 8 , a reference numeral 10 indicates an internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide as a refrigerant which comprises the cylindrical sealed vessel 12 made of a steel plate and a rotary compression mechanism portion 18 which includes an electrical-power element 14 arranged and housed in an upper part of an internal space of the sealed vessel 12 and the first rotary compression element 32 (first stage) and the second rotary compression element 34 (second stage) which are arranged below the electrical-power element 14 to be driven by the rotary shaft 16 of the electrical-power element 14 .
The sealed vessel 12 has its bottom used as an oil reservoir and is composed of the vessel body 12 A which houses the rotary compression mechanism portion 18 and the electrical-power element 14 and the roughly cup-shaped end cap (lid) 12 B which blocks an upper part opening of the vessel body 12 A in such a configuration that the end cap 12 B has the circular attachment hole 12 D formed therein at a center of its top face, in which attachment hole 12 D the terminal 20 (wiring of which is omitted) is attached which supplies power to the electrical-power element 14 .
The electrical-power element 14 is composed of the stator 22 mounted annularly along an inner peripheral face of an upper-part space of the sealed vessel 12 and the rotor 24 disposed and inserted in the stator 22 with some gap set therebetween. This rotor 24 is fixed to the rotary shaft 16 which vertically extends centrally.
The stator 22 has the stack 26 formed by stacking donut-shaped electromagnetic steel plates and the stator coil 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, similar to the stator 22 , the rotor 24 is also made of the stack 30 of electromagnetic steel plates and the permanent magnet MG inserted into the stack 30 .
The intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . That is, a combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , the upper and lower cylinders 38 and 40 arranged above and below this intermediate partition plate 36 respectively, the upper and lower rollers 46 and 48 which are fitted to the upper and lower eccentric portions 42 and 44 provided on the rotary shaft 16 with a phase difference of 180 degrees therebetween to thereby eccentrically revolve within these upper and lower cylinders 38 and 40 respectively, the upper and lower vanes 50 and 52 which butt against the upper and lower rollers 46 and 48 to divide an inside of the respective upper and lower cylinders 38 and 40 into a low-pressure chamber side and a high-pressure chamber side, and the upper-part support member 54 and the lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
A combination of the upper-part support member 54 and the lower-part support member 56 is provided therein with the suction paths 58 and 60 which communicate with insides of the upper and lower cylinders 38 and 40 through suction ports 161 and 162 respectively and the concave discharge-noise silencer chambers 62 and 64 in such a configuration that openings of these two discharge-noise silencer chambers 62 and 64 are blocked by respective covers. That is, the discharge-noise silencer chamber 62 is blocked by the upper cover 66 serving as a cover and the discharge-noise silencer chamber 64 , by the lower cover 68 serving as a cover.
In this case, a bearing 54 A is formed as erected at a center of the upper-part support member 54 . At a center of the lower-part support member 56 is there formed a bearing 56 A as going through, so that the rotary shaft 16 is held by the bearing 54 A of the upper-part support member 54 and the bearing 56 A of the lower-part support member 56 .
It is to be noted that a communication path 200 is formed in the lower-part support member 56 between the suction path 60 of the first rotary compression element 32 and the discharge-noise silencer chamber 64 . This communication path 200 communicates, to each other, the suction path 60 which is on a refrigerant suction side of the first rotary compression element 32 and the discharge-noise silencer chamber 64 which is on a refrigerant discharge side where a medium refrigerant compressed at the first rotary compression element 32 is discharged, details of which path 200 are shown in FIG. 9 . That is, one end of a first path 201 opens into the discharge-noise silencer chamber 64 , while the other end thereof opens into a valve-device housing chamber 202 , thus communicating the discharge-noise silencer chamber 64 and the valve-device housing chamber 202 to each other.
This valve-device housing chamber 202 is formed vertically in such a configuration that an upper-part opening thereof toward the suction path 60 and a lower-part opening thereof toward the lower cover 68 are blocked by sealing, agents 204 and 205 respectively.
Above a position where the first path 201 opens into the valve-device housing chamber 202 , one end of a second path 203 opens into it and the other end thereof opens into the suction path 60 , thus communicating the valve device housing chamber 202 and the suction-path 60 to each other. These first and second paths 201 and 203 and valve-device housing chamber 202 are formed in the lower-part support member 56 , thus constituting the communication path 200 . In this valve-device housing chamber 202 is there vertically movably housed a valve device 206 which functions as a release valve. On an upper face of this valve device is there provided a telescoping spring 207 in a condition where one end thereof butts against it and the other end thereof is fixed to the sealing agent 204 , so that the valve device 206 is downward urged by the spring 207 always.
Furthermore, if the valve device 206 is placed between an opening position of the first path 201 and that of the second path 203 as shown in FIG. 9 , a combination of a pressure in the suction path 60 (low pressure LP) and force of the spring 207 downward urges the valve device 206 , whereas the medium pressure upward urges the valve device 206 through the first path 201 . That is, the valve device 206 moves up and down in the valve-device housing chamber 202 owing to a pressure difference between a pressure of a low-pressure refrigerant gas on a refrigerant suction side plus urging force of the spring 207 and that of a medium-pressure refrigerant gas on a refrigerant discharge side.
Furthermore, by the present embodiment, if the pressure difference between a pressure of the low-pressure refrigerant gas and that of the medium-pressure refrigerant gas is 5 MPaG or less, the valve device 206 housed in the valve-device housing chamber 202 is put in a state shown in FIG. 9 in being positioned between the other end of the first path 201 and the second path 203 in the valve-device housing chamber 202 , so that the refrigerant suction side and the refrigerant discharge side are not communicated to each other but blocked from each other by the valve device 206 .
The urging force of the spring 207 is set so that if the medium pressure rises until the pressure difference between a pressure of the low-pressure refrigerant gas and that of the medium-pressure refrigerant gas increases up to 5 MPaG (upper limit value), the valve device 206 is raised above the second path 203 by the mediate-pressure refrigerant gas flowing through the first path 201 to communicate the first path 201 and the second path 203 to each other (open the communication path 200 ) in order to flow the medium-pressure refrigerant gas on the refrigerant discharge side into the suction path 60 on the refrigerant suction side. If the pressure difference between the two becomes less than 5 MPaG, on the other hand, the valve device 206 is lowered to a position between a communication position of the first path 201 below the second path 203 and a communication position of the second path 203 to block the first path 201 and the second path 203 from each other, thus closing the communication path 200 . In such a manner, it is possible to regulate below the upper limit value a first-stage differential pressure, that is, a pressure difference between the refrigerant discharge side and the refrigerant suction side of the first rotary compression element 32 .
The lower cover 68 , on the other hand, is made of a donut-shaped circular steel plate and fixed upward to the lower-part support member 56 by main bolts 129 disposed peripherally, to block a lower-part opening of the discharge-noise silencer chamber 64 communicating with an inside of the lower cylinder 40 of the first rotary compression element 32 through the discharge port 41 . Tips of these main bolts 129 are screwed to the upper-part support member 54 . FIG. 10 shows a bottom of the lower-part support member, in which a reference numeral 128 indicates a discharge valve of the first rotary compression element 32 for opening and closing the discharge port 41 in the discharge-noise silencer chamber 64 .
Further, the discharge-noise silencer chamber 64 and a face of the upper cover 66 on a side of the electrical-power element 14 in the sealed vessel 12 are communicated to each other through a communication path, not shown, which penetrates the upper and lower cylinders 38 and 40 and the intermediate partition plate 36 . In this case, at an upper end of the communication path is there provided the intermediate discharge pipe 121 as erected, through which a medium-pressure refrigerant is discharged into the sealed vessel 12 .
Furthermore, the upper cover 66 blocks an upper-face opening of the discharge-noise silencer chamber 62 communicating with an inside of the upper cylinder 38 of the second rotary compression element 34 through a discharge port 39 , thus partitioning an inside of the sealed vessel 12 into the discharge-noise silencer chamber 62 and a side of the electrical-power element 14 . As shown in FIG. 11 , this upper cover 66 is made of a roughly donut-shaped circular steel plate in which a hole is formed through which the bearing 54 A for the upper-part support member 54 extends through and fixed downward to the upper-part support member 54 by main bolts 78 peripherally. Tips of these main bolts 78 are screwed to the lower-part support member 56 . It is to be noted that a reference numeral 127 in FIG. 11 indicates a discharge valve of the second rotary compression element 34 for opening and closing the discharge port 39 in the discharge-noise silencer chamber 62 .
It is to be noted that discharge valves 127 and 128 are made of an elastic member such as a vertically long metal plate, one sides of which valves 127 and 128 butt against the discharge ports 39 and 41 respectively in close contact therewith and the other sides of which are fixed by screws, not shown, in screw holes, not shown, formed somewhere distant from the discharge ports 39 and 41 by a predetermined spacing. The discharge valves 127 and 128 butt against the discharge ports 39 and 41 with constant urging force to open and close the discharge ports 39 and 41 by elasticity respectively.
In FIG. 8 , a reference numeral 94 indicates a suction pipe of the first rotary compression element 32 , which suction pipe is attached and communicated to the suction path 60 of the lower-part support member 56 . Reference numerals 92 and 96 indicate a suction pipe and a discharge pipe of the second rotary compression element 34 , one end of which suction pipe 92 communicates to an inside of the sealed vessel 12 above the upper cover 66 and the other end of which communicates with the suction path 58 of the second rotary compression element 34 . The discharge pipe 96 is attached and communicated to the discharge-noise silencer chamber 62 of the second rotary compression element 34 .
In this case, as a refrigerant, carbon dioxide (CO 2 ) which is a natural refrigerant friendly to environments of the earth is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, or ester oil.
The following will describe operations with reference to this configuration. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, the upper and lower rollers 46 and 48 are fitted to the upper and lower eccentric portions 42 and 44 provided integrally with the rotary shaft 16 , to eccentrically revolve in the upper and lower cylinders 38 and 40 respectively.
Accordingly, a low-pressure (LP) refrigerant sucked into the low-pressure chamber side of the lower cylinder 40 from the suction port 162 shown in FIG. 12 illustrating a bottom of the lower cylinder 40 through the suction pipe 94 and the suction path 60 formed in the lower-part support member 56 is compressed by operations of the lower roller 48 and the lower vane 52 to have a medium pressure (MP), passed through the high-pressure chamber side of the lower cylinder 40 and the discharge port 41 , and discharged into the discharge-noise silencer chamber 64 formed in the lower-part support member 56 .
At this moment, if a pressure difference of the refrigerant gas between a pressure of a refrigerant gas in the suction path 60 on a refrigerant suction side and that in the discharge-noise silencer chamber 64 on a refrigerant discharge side is less than 5 MPaG, the valve device 206 is positioned between the communication position of the first path 201 and that of the second path 203 in the valve device housing chamber 202 , so that the communication path 200 is blocked. Then, a medium-pressure refrigerant gas discharged into the discharge-noise silencer chamber 64 passes through a communication path not shown and is discharged into the sealed vessel 12 from the intermediate discharge pipe 121 . Accordingly, the sealed vessel 12 has the medium pressure therein.
In this case, for example, if an outside air temperature rises to increase an evaporation temperature of a later-described evaporator and thereby increase the medium pressure until the pressure difference of the refrigerant gas between a pressure of the refrigerant gas in suction path 60 on a low pressure side and that in the discharge-noise silencer chamber 64 on a medium pressure side reaches the upper limit value of 5 MPaG, this increased medium pressure causes the valve device 206 to be pressed upward above the communication position of the second path 203 in the valve device housing chamber 202 , so that the first path 201 and the second path 203 communicate with each other, thus flowing the medium-pressure refrigerant gas into the suction path 60 on the lower pressure side. When the medium-pressure refrigerant is thus discharged to the suction side to thereby reduce the pressure difference between the two below 5 MPaG, the valve device 206 returns downward to a position below the communication position of the second path 203 , so that the communication path 200 (first path 201 , valve device housing chamber 202 , and second path 203 ) is closed by the valve device 206 .
Then, the medium-pressure refrigerant gas in the sealed vessel 12 exits it and passes through the suction pipe 92 , enters the suction path 58 formed in the upper-part support member 54 , and is sucked therethrough into a low-pressure chamber side of the upper cylinder 38 from the suction port 161 shown in FIG. 13 illustrating a top of the upper cylinder 38 . The medium-pressure refrigerant gas thus sucked undergoes second-stage compression through operations of the upper roller 46 and the upper vane 50 to provide a high-temperature, high-pressure refrigerant gas (HP), which passes from a high-pressure chamber side through the discharge port 39 and is sucked from the discharge-noise silencer chamber 62 formed in the upper-part support member 54 and through the discharge pipe 96 into the gas cooler 154 shown in FIG. 4 provided outside the multi-stage compression type rotary compressor 10 . Then, it flows from the gas cooler 154 into the expansion valve 156 and the evaporator 157 sequentially.
Thus, in the multi-stage compression type rotary compressor 10 comprising the electrical-power element 14 and the first and second rotary compression elements 32 and 34 driven by the electrical-power element 14 in the sealed vessel 12 in such a configuration that a refrigerant gas compressed at the first rotary compression element 32 and discharged therefrom is sucked into the second rotary compression element 34 to be compressed and discharged therefrom, there are provided the communication path 200 which communicates a refrigerant suction side and a refrigerant discharge side of the first rotary compression element 32 to each other and the valve device 206 which opens and closes the communication path 200 in such a manner as to open it if a pressure difference between the refrigerant suction side and the refrigerant discharge side of the first rotary compression element 32 exceeds a predetermined upper limit value (5 MPaG), so that it is possible to suppress a first-stage differential pressure down to the upper limit value or less. Accordingly, it is possible to suppress a pressure difference between an inside and an outside of the discharge valve 127 of the first rotary compression type element 32 down to the upper limit value or less, thus avoiding a trouble that the discharge valve 127 may be damaged by the pressure difference.
Furthermore, by the present embodiment, the suction path 60 and the discharge-noise silencer chamber 64 arranged in the lower-part support member 56 which blocks an opening face of the lower cylinder 40 constituting the first rotary compression element 32 and also which has a bearing for the rotary shaft 16 of the electrical-power element 14 are communicated to each other through the communication path 200 formed in the lower-part support member 56 and the valve device 206 is also provided in the lower-part support member 56 , so that the communication path 200 and the valve device 206 can be integrated into the lower-part support member 56 to realize miniaturization. Furthermore, it is possible to form the communication path 200 in the lower-part support member 56 beforehand to attach and set the valve device 206 thereto, thus improving a work efficiency in assembly of the multi-stage compression type rotary compressor 10 .
It is to be noted that although the present embodiment has been described in all cases with reference to the multi-stage compression type rotary compressor 10 in which the rotary shaft 16 is mounted vertically, of course the present invention can be applied also to a multi-stage compression type rotary compressor in which the rotary shaft is mounted horizontally. Furthermore, the upper limit of the first-stage differential pressure given in the present embodiment is not restricted to the above-mentioned value and so may be set appropriately corresponding to a capacity and an employed pressure of the rotary compressor.
Furthermore, the multi-stage compression type rotary compressor has been described as a two-stage compression type rotary compressor equipped with first and second rotary compression elements, the present invention is not limited thereto; for example, the multi-stage compression type rotary compressor may be equipped with three, four, or even more stages of rotary compression elements.
As detailed above, according to the present embodiment of the present invention, in a multi-stage compression type rotary compressor comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant gas compressed in the first rotary compression element and discharged therefrom is sucked into the second rotary compression element to be compressed and discharged therefrom, there are provided a communication path which communicates a refrigerant suction side and a refrigerant discharge side of the first rotary compression element to each other and a valve device which opens and closes this communication path in such a manner as to open it if a pressure difference between the refrigerant suction side and the refrigerant discharge side of the first rotary compression element exceeds a predetermined upper limit value, so that it is possible to suppress the pressure difference between the refrigerant suction side and the refrigerant discharge side of the first rotary compression element which is the first-stage differential pressure down to the predetermined upper limit value or less. Accordingly, it is possible to avoid a trouble such as damaging of the discharge valve provided on the first rotary compression element caused by an excessive value of the first-stage differential pressure, thus improving durability and reliability of the rotary compressor.
Furthermore, by the present invention, there are provided a cylinder constituting the first rotary compression element, a support member which blocks an opening face of this cylinder and also which has a bearing for the rotary shaft of the electrical-power element, and a suction path and a discharge-noise silencer chamber which are arranged in this support member in such a configuration that the communication path is formed in the support member to communicate the suction path and the discharge-noise silencer chamber to each other and also the valve device is provided in the support member, so that the communication path and the valve device can be integrated into the cylinder of the first rotary compression element to realize miniaturization and also the valve device can be set into the cylinder beforehand, thus improving a work efficiency in assembly.
The following will describe a multi-stage compression type rotary compressor according to a still further embodiment of the present invention with reference to FIGS. 14-17 . FIG. 14 shows a vertical cross-sectional view of the multi-stage compression type rotary compressor according to the present embodiment. It is to be noted that the same reference numerals in these figures as those in FIGS. 1-3 have the same or similar functions.
In FIG. 14 , a reference numeral 10 indicates an internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide as a refrigerant which comprises the sealed vessel 12 composed of the cylindrical vessel body 12 A made of a steel plate and the roughly cup-shaped end cap (lid body) 12 B which blocks an upper-part opening of this vessel body 12 A and the rotary compression mechanism portion 18 which includes the electrical-power element 14 arranged and housed in an upper part of an internal space of the vessel body 12 A of the sealed vessel 12 and the first rotary compression element 32 (first stage) and the second rotary compression element 34 (second stage) which are arranged below this electrical-power element 14 to be driven by the rotary shaft 16 of the electrical-power element 14 . It is to be noted that the sealed vessel 12 has its bottom used as an oil reservoir. Furthermore, the end cap 12 B has the circular attachment hole 12 D formed therein at a center of its top face, in which attachment hole 12 D the terminal 20 (wiring of which is omitted) is attached for supplying power to the electrical-power element 14 .
The electrical-power element 14 is composed of the stator 22 mounted annularly along an inner peripheral face of an upper space of the sealed vessel 12 and the rotor 24 disposed and inserted in the stator 22 with some gap set therebetween. To this rotor 24 , the rotary shaft 16 which vertically extends is fixed.
The stator 22 has the stack 26 formed by stacking donut-shaped electromagnetic steel plates and the stator coil 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, similar to the stator 22 , the rotor 24 is also made of the stack 30 of electromagnetic steel plates and the permanent magnet MG inserted into the stack 30 .
The intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . That is, a combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , the cylinders 38 and 40 arranged above and below the intermediate partition plate 36 respectively, the upper and lower rollers 46 and 48 which are fitted to the upper and lower eccentric portions 42 and 44 provided on the rotary shaft 16 with a phase difference of 180 degrees therebetween to thereby eccentrically revolve within the upper and lower cylinders 38 and 40 respectively, the upper and lower vanes 50 and 52 which butt against these upper and lower rollers 46 and 48 to divide an inside of the respective upper and lower cylinders 38 and 40 into a low-pressure chamber side and a high-pressure chamber side, and the upper-part support member 54 and the lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
Furthermore, as shown in FIGS. 11-13 and FIG. 17 , a combination of the upper-part support member 54 and the lower-part support member 56 is provided therein with the suction paths 58 and 60 which communicate with insides of the upper and lower cylinders 38 and 40 through the suction ports 161 and 162 respectively and the discharge muffler chambers 62 and 64 formed by blocking concavities in the upper-part support member 54 and the lower-part support member 56 by covers serving as a wall respectively. That is, the discharge muffler chamber 62 is blocked by the upper cover 66 serving as a wall defining the discharge muffler chamber 62 and the discharge muffler chamber 64 , by the lower cover 68 serving as a wall defining the discharge muffler chamber 64 .
In this case, the bearing 54 A is formed as erected at a center of the upper-part support member 54 . At a center of the lower-part support member 56 is there formed the bearing 56 A as going through, so that the rotary shaft 16 is held by the bearing 54 A of the upper-part support member 54 and the bearing 56 A of the lower-part support member 56 .
Furthermore, the lower cover 68 is made of a donut-shaped circular steel plate to define the discharge-noise silencer chamber 64 communicating with an inside of the lower cylinder 40 of the first rotary compression element 32 , and it is fixed upward to the lower-part support member 56 by the main bolts 129 disposed peripherally, tips of which are screwed to the upper-part support member 54 . FIG. 17 shows a bottom of the lower-part support member 56 , in which a reference numeral 128 indicates the discharge valve of the first rotary compression element 32 for opening and closing the discharge port 41 in the discharge-noise silencer chamber 64 .
Further, the discharge-noise silencer chamber 64 of the first rotary compression element 32 and the inside of the sealed vessel 12 communicate with each other through an communication path, which is a hole, not shown, penetrating the upper cover 66 , the upper and lower cylinders 38 and 40 , and the intermediate partition plate 36 . In this case, at an upper end of the communication path is there provided the intermediate discharge pipe 121 as erected, through which a medium-pressure refrigerant is discharged into the sealed vessel 12 .
Furthermore, the upper cover 66 defines the discharge-noise silencer chamber 62 communicating through the discharge port 39 with an inside of the upper cylinder 38 of the second rotary compression element 34 , above which upper cover 66 is there provided the electrical-power element 14 with a predetermined spacing present therebetween. Similarly, as described with reference to FIG. 11 , this upper cover 66 is made of a roughly donut-shaped circular steel plate in which a hole is formed through which the bearing 54 A for the upper-part support member 54 extends through and fixed by the main bolts 78 peripherally. Therefore, tips of these main bolts 78 are screwed to the lower-part support member 56 .
It is to be noted that the discharge valves 127 and 128 are constituted of an elastic member made of a vertically long rectangular metal plate, one sides of which valves 127 and 128 butt against the discharge ports 39 and 41 respectively to seal them and the other sides of which are fixed by screws, not shown, provided somewhere distant from the discharge ports 39 and 41 by a predetermined spacing therebetween. The discharge valves 127 and 128 butt against the discharge ports 39 and 41 with constant urging force to open and close the discharge ports 39 and 41 by elasticity respectively.
Furthermore, in the upper cover 66 of the second rotary compression element 34 is there provided a communication path 300 according to the present embodiment of the present invention. This communication path 300 communicates, to each other, the inside of the sealed vessel 12 which provides a path through which a medium-pressure refrigerant gas compressed at the first rotary compression element 32 and the discharge-noise silencer chamber 62 on a refrigerant discharge side of the second rotary compression element, in such a configuration that, as shown in FIG. 15 , one end of a horizontally extending first path 301 communicates with the inside of the sealed vessel 12 and the other end of the first path 301 communicates with a valve device housing chamber 302 . This valve device housing chamber 302 is a hole penetrating the upper cover 66 vertically in such a configuration that an upper face thereof opens into the sealed vessel 12 and a lower face thereof opens into the discharge-noise silencer chamber 62 . Furthermore, upper and lower openings of this valve device housing chamber 302 are blocked by sealing agents 303 and 304 respectively.
In the sealing agent 304 provided at a bottom of the valve device housing chamber 302 is there formed a second path 305 which communicates the valve device housing chamber 302 and the discharge-noise silencer chamber 62 to each other. These first path 301 , valve device housing chamber 302 , and second path 305 are combined to constitute the communication path 300 . Furthermore, in the valve device housing chamber 302 of this communication path 300 is there housed a spherical valve device 307 , a top face of which is abutted by one end of a telescoping spring 306 (urging member). The other end of this spring 306 is fixed at the upper side sealing agent 303 , so that the valve device 307 is always downward urged by this spring 306 to thereby block the second path 305 always.
Furthermore, in construction, a medium pressure refrigerant in the sealed vessel 12 flows through the first path 301 into the valve device housing chamber 302 to downward urge the valve device 307 , while a high pressure refrigerant in the discharge-noise silencer chamber 62 flows through the second path 305 formed in the lower side sealing agent 304 into the valve device housing chamber 302 to upward urge the valve device 307 at its bottom.
Thus, the valve device 307 is downward urged by the medium pressure refrigerant gas and the spring 306 from a side where the spring 306 butts against, that is, from the above and, from an opposite side, upward urged by the high pressure refrigerant gas. Therefore, the bottom of the valve device 307 always butts against the second path 305 to be sealed, so that the communication path 300 is blocked by the valve device 307 always.
It is to be noted that the urging force of the spring 306 is supposed to be set so that when a pressure difference between a pressure of a medium pressure refrigerant gas in the sealed vessel 12 and that of a high pressure refrigerant gas in the discharge-noise silencer chamber 62 has reached an upper limit value of, for example, 8 MPaG, the valve device 307 abutted against the first path 305 to close it may be pressed upward by the high pressure refrigerant gas flowing in through the second path 305 . Therefore, if this pressure difference exceeds 8 MPaG (upper limit value), the first path 301 and the second path 305 communicate with each other through the valve device housing chamber 302 , so that the high pressure refrigerant gas in the discharge-noise silencer chamber 62 flows into the sealed vessel 12 . If this pressure difference is reduced below 8 MPaG, on the other hand, the spring 306 abuts the valve device 307 against the second path 305 to close it, so that the valve device 307 blocks the first path 301 and the second path 305 from each other. Thus, a second-stage differential pressure can be prevented beforehand from becoming excess.
As described above, as a refrigerant, carbon dioxide (CO 2 ) which is a natural refrigerant friendly to environments of the earth is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, or ester oil.
The following will describe operations with reference to this configuration. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, the upper and lower rollers 46 and 48 are fitted to the upper and lower eccentric portions 42 and 44 provided integrally with the rotary shaft 16 , to eccentrically revolve in the upper and lower cylinders 38 and 40 respectively.
Accordingly, a low-pressure refrigerant sucked into the low-pressure chamber side of the lower cylinder 40 from the suction port 162 through the suction path 60 formed in the lower-part support member 56 as shown in FIG. 11 is compressed by operations of the lower roller 48 and the lower vane 52 to have a medium pressure, passed through the high-pressure chamber side of the lower cylinder, and the discharge port 41 , the discharge-noise silencer chamber 64 formed in the lower-part support member 56 , and a communication path not shown, and is discharged into the sealed vessel 12 from the intermediate discharge pipe 121 .
Then, the medium-pressure refrigerant gas in the sealed vessel 12 passes through a refrigerant path not shown and the suction path 58 formed in the upper-part support member 54 , and is sucked into the low-pressure chamber side of the upper cylinder 38 from the suction port 161 shown in FIG. 13 . The medium-pressure refrigerant gas thus sucked undergoes second-stage compression through operations of the upper roller 46 and the upper vane 50 to provide a high-temperature, high-pressure refrigerant gas, which passes from the high-pressure chamber side through the discharge port 39 and is sucked into the discharge-noise silencer chamber 62 formed in the upper-part support member 54 .
If, a this moment, a pressure difference between a pressure of the medium pressure refrigerant gas in the sealed vessel 12 and that of the high pressure refrigerant gas in the discharge-noise silencer chamber 62 is less than 8 MPaG, as mentioned above, the valve device 307 is abutted against the second path 305 to close it in the valve-device housing chamber 302 , so that the communication path 300 is not opened and, therefore, the high pressure refrigerant gas discharged into the discharge-noise silencer chamber 62 all flows through a refrigerant path not shown into the gas cooler 154 ( FIG. 4 ) provided outside the multi-stage compression type rotary compressor 10 .
After flowing into the gas cooler 154 , the refrigerant radiates heat to exert a heating action. After exiting the gas cooler 154 , the refrigerant is decompressed at the expansion valve 156 and enters the evaporator 157 to evaporate there. Finally, the refrigerant is sucked to the suction path 60 of the first rotary compression element 32 , which cycle is repeated.
It is to be noted that if an outside air temperature drops to reduce an evaporation temperature of the refrigerant in the evaporator, as described above, it is difficult also for a pressure (medium pressure) of a refrigerant discharged from the first rotary compression element 32 into the sealed vessel 12 to rise. Thus, when a pressure difference between a pressure of a medium pressure refrigerant gas in the sealed vessel 12 and that of a high pressure refrigerant gas in the discharge-noise silencer chamber 62 has reached 8 MPaG, the valve device 307 abutted against the second path 305 by a pressure in the discharge-noise silencer chamber 62 is pressed upward against the spring 306 to be released from the second path 305 , so that the first path 301 and the second path 305 communicate with each other to flow the high pressure refrigerant gas into the sealed vessel 12 on a medium pressure side. If the pressure difference between the two drops below 8 MPaG, on the other hand, the valve device 307 butts against the second path 305 to close it, thus blocking the second path 305 .
As described above, in the present embodiment comprising the electrical-power element 14 and the first and second rotary compression elements 32 and 34 driven by this electrical-power element 14 in the sealed vessel 12 in such a configuration that a medium pressure refrigerant gas compressed at the first rotary compression element 32 is sucked into the second rotary compression element 34 to be compressed and discharged therefrom, there are provided the communication path 300 which communicates a passage for the medium pressure refrigerant compressed at the first rotary compression element 32 and a refrigerant discharge side of the second rotary compression element 34 to each other and the valve device which opens and closes this communication path 300 , wherein a pressure difference between a pressure of the medium pressure refrigerant gas and that of a refrigerant gas on a refrigerant discharge side of the second rotary compression element 34 exceeds a predetermined upper limit value of 8 MPaG, the valve device 307 opens the communication path 307 , so that it is possible to suppress a second-stage differential pressure below the upper limit value, thus avoiding damaging of the discharge valve 128 of the second rotary compression element 34 beforehand.
Furthermore, there are also provided the upper cylinder 38 constituting the second rotary compression element 34 , the discharge-noise silencer chamber 62 into which a refrigerant gas compressed in this upper cylinder 38 is discharged, and the upper cover 66 serving as a wall defining this discharge-noise silencer chamber 62 in such a configuration that the communication path 300 is formed in the upper cover 66 to communicate an inside of the sealed vessel 12 and the discharge-noise silencer chamber 62 to each other and also the valve device 307 is provided in the upper cover 66 , so that it is possible to suppress the second-stage differential pressure without complicating a construction of the communication path 300 .
Although the present embodiment has been described in all cases with reference to the multi-stage compression type rotary compressor 10 in which the rotary shaft 16 is mounted vertically, of course the present invention can be applied also to a multi-stage compression type rotary compressor in which the rotary shaft is mounted horizontally.
Furthermore, the multi-stage compression type rotary compressor has been described as a two-stage compression type rotary compressor equipped with first and second rotary compression elements, the present invention is not limited thereto; for example, the multi-stage compression type rotary compressor may be equipped with three, four, or even more stages of rotary compression elements.
It is to be noted that although the present embodiment has employed a spherical valve device 307 , the present invention is not limited thereto; for example, a cylindrical valve device 317 such as shown in FIG. 16 may be employed. In this case, the valve device 317 is arranged to butts against a wall face of the valve-device housing chamber 302 to seal it in such a configuration that it is ordinarily placed in the valve-device housing chamber 302 between the first path 301 and the second path 305 to thereby block the communication path 300 . In this configuration, if the pressure difference exceeds 8 MPaG, the valve device 317 is pressed upward above the first path 301 to thereby communicate the first path 301 and the second path 305 to each other, thus flowing a high pressure refrigerant gas into the sealed vessel 12 having a medium pressure. If the pressure difference between the two drops below 8 MPaG, the valve device 317 returns back below the first path 301 , thus blocking the first path 301 and the second path 305 from each other.
As detailed above, according to the present embodiment of the present invention, in a multi-stage compression type rotary compressor comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a medium pressure refrigerant gas compressed at the first rotary compression element is sucked into the second rotary compression element to be compressed and discharged therefrom, there are provided a communication path which communicates a passage for the medium pressure refrigerant compressed at the first rotary compression element and a refrigerant discharge side of the second rotary compression element to each other and a valve device which opens and closes this communication path in such a manner as to open it if a pressure difference between a pressure of the medium pressure refrigerant gas and that of a refrigerant gas on the refrigerant discharge side of the second rotary compression element exceeds a predetermined upper limit value, so that it is possible to suppress a pressure difference between a discharge pressure and a suction pressure of the second rotary compression element, that is, a second-stage differential pressure, below the predetermined upper limit value.
Accordingly, it is possible to avoid an occurrence of a trouble such as damaging of the discharge valve of the second rotary compression element.
Furthermore, there are provided also a cylinder which constitutes the second rotary compression element and a discharge-noise silencer chamber which discharges a refrigerant gas compressed in this cylinder in such a configuration that a medium pressure refrigerant gas compressed at the first rotary compression element is discharged into the sealed vessel and then sucked into the second rotary compression element, the communication path is formed in a wall defining the discharge-noise silencer chamber to communicate an inside of the sealed vessel and the discharge-noise silencer chamber to each other, and the valve device is provided in the wall, so that it is possible to integrate the communication path which communicates the passage for the medium pressure refrigerant compressed at the first rotary compression element and the refrigerant discharge side of the second rotary compression element to each other and the valve device which opens and closes the communication path into a wall of the second rotary compression element.
Accordingly, it is possible to simplify a construction and reduce overall size.
The following will describe a multi-stage compression type rotary compressor according to an additional embodiment of the present invention with reference to FIGS. 18 and 19 . FIG. 18 shows a vertical cross-sectional of a multi-stage compression type rotary compressor according to the present embodiment. It is to be noted that the same reference numerals in these figures as those in FIGS. 1-17 have the same or similar functions.
In FIG. 18 , a reference numeral 10 indicates an internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide (CO 2 ) as a refrigerant which comprises the cylindrical sealed vessel 12 made of a steel plate and the rotary compression mechanism portion 18 which includes the electrical-power element 14 arranged and housed in an upper part of an internal space of the sealed vessel 12 and the first rotary compression element 32 (first stage) and the second rotary compression element 34 (second stage) which are arranged below this electrical-power element 14 to be driven by the rotary shaft 16 of the electrical-power element 14 .
It is to be noted that in the rotary compressor 10 of the present embodiment, a displacement volume of the second rotary compression element 34 is set smaller than that of the first rotary compression element 32 .
The sealed vessel 12 has its bottom used as an oil reservoir and is composed of the vessel body 12 A which houses the electrical-power element 14 and the rotary compression mechanism portion 18 and the roughly cup-shaped end cap (lid) 12 B which blocks an upper part opening of this vessel body 12 A in such a configuration that at a top face of the end cap 12 B is there attached the terminal 20 (wiring of which is omitted) which supplies power to the electrical-power element 14 .
The electrical-power element 14 is composed of the stator 22 mounted annularly along an inner peripheral face of an upper-part space of the sealed vessel 12 and the rotor 24 disposed and inserted in the stator 22 with some gap set therebetween. This rotor 24 is fixed to the rotary shaft 16 which vertically extends centrally.
The stator 22 has the stack 26 formed by stacking donut-shaped electromagnetic steel plates and the stator coil 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, similar to the stator 22 , the rotor 24 is also made of the stack 30 of electromagnetic steel plates and the permanent magnet MG inserted into the stack 30 .
The intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . A combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , the upper and lower cylinders 38 and 40 arranged above and below the intermediate partition plate 36 respectively, the upper and lower eccentric portions 42 and 44 which are positioned in the upper and lower cylinders 38 and 40 respectively and provided on the rotary shaft 16 with a phase difference of 180 degrees therebetween, and the upper-part support member 54 and the lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
The first rotary compression element 32 is provided with the lower roller 48 which eccentrically revolves as engaged to the lower eccentric portion 44 and the vane 52 which butts against this lower roller 48 to thereby divide an inside of the lower cylinder 40 into a low-pressure chamber side and a high-pressure chamber side. The cylinder 40 is provided with a guide groove for housing the vane 52 in such a manner that the vane 52 can slide therein and a spring 76 arranged outside this guide groove, so that this spring 76 butts against an outer end portion of the vane 52 to always urge the vane 52 on the roller 48 . Furthermore, on a side of the sealed vessel 12 in a housing of this spring 76 is there provided a metallic plug 437 which serves to prevent fall-out of the spring 76 .
The guide groove in the cylinder 40 communicates with an inside of the sealed vessel 12 on a side of the outer end of the vane 52 , so that a later-described medium pressure in the sealed vessel 12 is applied as a back pressure for the vane 52 in configuration.
Furthermore, the upper cylinder 38 of the second rotary compression element 34 is provided therein with a swing piston 410 , which is constituted of a roller portion 412 and a vane portion 414 (FIG. 19 ). The roller portion 412 is engaged to the upper eccentric portion 42 of the rotary shaft 16 , so that as the upper eccentric portion 42 revolves in this roller portion 412 eccentrically, correspondingly the roller portion 412 itself moves eccentrically as butting against an inner face of the upper cylinder 38 .
The vane portion 414 , which projects from this roller portion 412 in a radial direction, enters a holding groove 416 A in a later-described bush 416 and is held therein to thereby divide an inside of the upper cylinder 38 into a low-pressure chamber-side and high-pressure chamber side in configuration (FIG. 19 ).
Furthermore, in the upper cylinder 38 is there formed the guide groove 70 extending from an inner circumference in a radial direction, at an inner end of which guide groove 70 is there formed as expanded a roughly cylindrical holding hole 88 vertically. Into this holding hole 88 the bush 416 described above is inserted-to be held therein as rotating round a vertical axis as a center.
The holding groove 416 A described above is formed through in this bush 416 along its center in a direction of a diameter of this bush 416 (radial direction of the upper cylinder 38 ), in such a configuration that the vane portion 414 of the swing piston 410 enters the guide groove 70 and passes through this holding groove 416 A to be held in this holding groove 416 A in such a manner that it can slide. In this condition, the vane portion 414 can move in the guide groove 70 and also, when the bush 416 itself rotates, the swing piston 410 itself is held in such a manner that it can slide and swing.
That is, the swing piston 410 has the roller portion 412 which eccentrically moves in the upper cylinder 38 in a condition where it is engaged to the upper eccentric portion 42 formed on the rotary shaft 16 of the electrical-power element 14 and is provided with the vane portion 414 which projects from this roller portion 412 in a radial direction to divide an inside of the upper cylinder 38 into a low-pressure chamber side and a high-pressure chamber side. In this configuration, as the upper eccentric portion 42 revolves eccentrically, the swing piston 410 swings in the upper cylinder 38 . In the present embodiment, the guide groove 70 and the bush 416 constitute the holding portion of the present invention.
In this case, a spacing between the holding hole 88 and the bush 416 and that between the holding groove 416 A and the vane portion 414 are dimensioned so that they may be sealed off from each other with oil therebetween respectively, to prevent a discharge pressure of the second rotary compression element 34 from being released. Such a construction eliminates a necessity of a spring on the second rotary compression element 34 for urging the vane 52 provided on the first rotary compression element 32 on the roller 48 . If the second rotary compression element 34 is configured like the first rotary compression element 32 , on the other hand, a back pressure is to be applied to the vane to urge it on the roller; a necessity of applying the back pressure to the vane, however, is rendered unnecessary because the second rotary compression element 34 is provided with the swing piston 410 . This swing piston 410 is held by the bush 416 in such a manner that it can swing and slide, so that it is possible to smooth operations of the vane portion 414 owing to the swing piston 410 , thus greatly improving performance of the rotary compressor 10 .
The upper-part support member 54 and the lower-part support member 56 , on the other hand, have the concave discharge-noise silencer chambers 62 and 64 formed therein, openings of which are blocked by respective covers. That is, the discharge-noise silencer chamber 62 is blocked by the upper cover 66 serving as a cover, while the discharge-noise silencer chamber 64 is blocked by the lower cover 68 serving as a cover.
It is to be noted that a portion of the upper cover 66 on a side of the electrical-power element 14 in the discharge-noise silencer chamber 64 and the sealed vessel 12 penetrates the upper and lower cylinders 38 and 40 and the intermediate partition 36 to communicate with an inside of the sealed vessel 12 through a communication path, not shown, which opens into the sealed vessel 12 .
In this case also, as a refrigerant, carbon dioxide (CO 2 ) which is a natural refrigerant friendly to environments of the earth is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, or ester oil.
On a side face of the vessel body 12 A of the sealed vessel 12 , the sleeves 141 , 142 , 143 , and 144 are fixed by welding at positions that correspond to the upper-side support member 54 , the lower-part support member 56 , the discharge-noise silencer chamber 62 , and an upper side of the upper cover 66 (a lower end of the electrical-power element 14 roughly) respectively. The sleeves 141 and 142 are adjacent to each other vertically, while the sleeve 143 is roughly in a diagonal direction of the sleeve 141 . Furthermore, the sleeve 144 is positioned as shifted by about 90 degrees with respect to the sleeve 141 .
In the sleeve 141 is there inserted and connected one end of the refrigerant introduction pipe 92 for introducing a refrigerant gas to the upper cylinder 38 , which one end communicates with a suction path of the upper cylinder 38 . This refrigerant introduction pipe 92 passes through an upper part of the sealed vessel 12 up to the sleeve 144 , while the other end is inserted and connected in the sleeve 144 so as to communicate with an inside of the sealed vessel 12 .
In the sleeve 142 , on the other hand, is there inserted and connected one end of the refrigerant introduction pipe 94 for introducing a refrigerant gas to the lower cylinder 40 , which one end communicates with a suction path of the lower cylinder 40 . The other end of this refrigerant introduction pipe 94 is connected to a lower end of an accumulator. Furthermore, in the sleeve 143 is there inserted and connected the refrigerant discharge pipe 96 , one end of which communicates with the discharge-noise silencer chamber 62 . It is to be noted that a reference numeral 147 indicates the bracket for holding the accumulator.
The following will describe operations with reference to this configuration. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, a roller portion 112 of the swing piston 410 engaged to the upper eccentric portion 42 integrally provided with the rotary shaft 16 revolves in the upper cylinder 38 as described above, so that the roller 48 engaged to the lower eccentric portion 44 revolves eccentrically in the lower cylinder.
Accordingly, a low-pressure (first-stage suction pressure LP: 4 MPaG) refrigerant gas sucked into the low-pressure chamber side of the cylinder 40 from a suction port, not shown, through the refrigerant introduction pipe 94 and a suction path formed in the lower-part support member 56 is compressed by operations of the lower roller 48 and the vane 52 to have a medium pressure (MP 1 : 8 MPaG), passed through the high-pressure chamber side of the lower cylinder 40 , a discharge port not shown, and the discharge-noise silencer chamber 64 formed in the lower-part support member 56 , and is discharged into the sealed vessel 12 from the communication path described above. Thus, the sealed vessel 12 has the medium pressure (MP 1 ) therein.
Then, the medium pressure refrigerant gas in the sealed vessel 12 exits it through the sleeve 144 , passes through the refrigerant introduction pipe 92 and a suction path formed in the upper-part support member 54 , and is sucked from a suction port, not shown, into the lower-pressure chamber side of the upper cylinder 38 . The medium pressure refrigerant gas thus sucked undergoes second-stage compression through swinging of the swing piston 410 (the vane portion 414 and the roller portion 412 ) held slidingly in the holding groove 416 A provided in the bush 416 held rotatably in the holding groove 88 in the upper cylinder 38 to thereby provide a high-temperature, high-pressure refrigerant gas (second-stage discharge pressure HP: 12 MPaG), which in turn passes from the high-pressure chamber side through a discharge port not shown, the discharge-noise silencer chamber 62 formed in the upper-part support member 54 , and the refrigerant discharge pipe 96 , and is discharged to an outside. This discharged refrigerant flows into the gas cooler 154 . At this moment, the refrigerant has a raised temperature of about +100° C. and, therefore, such a high temperature, high pressure gas radiates heat to heat water in, for example, the hot-water storage tank to thus generate hot water having a temperature of about +90° C.
The refrigerant itself, on the other hand, is cooled at the gas cooler 154 and exits it. Then, the refrigerant is decompressed at the expansion valve 156 , flows into the evaporator 157 to evaporate there, passes through the accumulator described above, and is sucked into the first rotary compression element 32 through the refrigerant introduction pipe 94 , which cycle is repeated.
Thus, the present embodiment according to the present embodiment comprises the upper cylinder 38 which constitutes the second rotary compression element 34 and the swing piston 410 which has the roller portion 412 which is engaged to the upper eccentric portion 42 formed on the rotary shaft 16 of the electrical-power element 14 to thereby move in the upper cylinder 38 eccentrically, in which on the swing piston 410 is there formed the vane portion 414 which projects from the roller portion 412 in a radial direction to divide an inside of the upper cylinder 38 into a low-pressure chamber side and a high-pressure chamber side in such a configuration that the vane portion 414 of the swing piston 410 is held at the upper cylinder 38 in such a manner that the vane portion 414 can slide and swing, so that a conventional construction to apply a back pressure to the vane and a spring to urge the vane on the roller are rendered unnecessary. Especially in an internal medium-pressure, multi-stage compression type rotary compressor according to the present embodiment, it is unnecessary to provide a construction to apply a discharge pressure of the second rotary compression element 34 to the vane as a back pressure, thus simplifying a construction of the rotary compressor 10 and greatly reducing productions costs.
Although the present embodiment has provided the swing piston 410 on the second rotary compression element 34 , the present invention is not limited thereto; for example, the swing piston 410 may be provided on the first rotary compression element 32 instead. By providing the swing piston 410 only to the second rotary compression element 34 as in the case of the present embodiment, costs of parts can be reduced. Furthermore, although the present embodiment has applied the present invention to an internal medium-pressure, multi-stage compression type rotary compressor, the present invention is not limited thereto; for example, the present invention may be applied to an ordinary single-cylinder type roller.
As detailed above, by the present invention, in a rotary compressor for compressing a CO 2 refrigerant according to the present embodiment which comprises an electrical-power element and a rotary compression element driven by this electrical-power element in a sealed vessel, there are provided a cylinder constituting the rotary compression element, a swing piston having a roller portion which is engaged to an eccentric portion formed on a rotary shaft of the electrical-power element to eccentrically moves in the cylinder, a vane portion formed on this swing piston in such a manner as to project from the roller portion in a radial direction to thereby divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, and a holding portion provided on the cylinder to hold the vane portion of the swing piston in such a manner that the vane portion can slide and swing, so that as the eccentric portion of the rotary shaft revolves eccentrically, the swing piston correspondingly swings and slides round the holding portion as a center and, therefore, the vane portion thereof always divides the inside of the cylinder into the low-pressure chamber side and the high-pressure chamber side.
Accordingly, it is possible to eliminate a necessity of conventionally providing a spring for urging the vane on a roller side, a back pressure chamber, or a structure for applying a back pressure to the back pressure chamber, thus simplifying a construction of the rotary compressor and reducing costs in production.
Furthermore, in a rotary compressor comprising an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a CO 2 refrigerant gas compressed at the first rotary compression element is discharged into the sealed vessel and this discharged medium pressure gas is compressed at the second rotary compression element, there are provided a cylinder constituting the second rotary compression element, a swing piston having a roller portion which is engaged to an eccentric portion formed on a rotary shaft of the electrical-power element to eccentrically move in the cylinder, a vane portion which is formed on this swing piston in such a manner as to project from the roller portion in a radial direction to thereby divide an inside of the cylinder into a low-pressure chamber side and a high-pressure chamber side, and a holding portion which is provided on the cylinder to hold the vane portion of the swing piston in such a manner that the vane can slide and swing, so that similarly, as the eccentric portion of the rotary shaft revolves eccentrically, the swing piston correspondingly swings and slides round the holding portion as a center and, therefore, the vane portion thereof always divides the inside of the cylinder of the second rotary compression element into the low-pressure chamber side and the high-pressure chamber side.
Accordingly, it is possible to eliminate a necessity of conventionally providing a spring for urging the vane on the roller side, a back pressure chamber, or a structure for applying a back pressure to the back pressure chamber. Especially in a so-called multi-stage compression type rotary compressor in which a medium pressure develops in a sealed vessel as in the case of the present invention, a structure for applying a back pressure is complicated; by using a swing piston, however, it is possible to simplify the structure remarkably and reduce production costs.
Furthermore, the holding portion is constituted of a guide groove which is formed in the cylinder and which the vane portion of the swing piston can enter movably and a bush which is provided rotatably at this guide groove to slidingly support the vane portion, so that it is possible to smooth swinging and sliding operations of the swing piston. Accordingly, it is possible to greatly improve performance and reliability of the rotary compressor.
The following will describe a defroster for a refrigerant circuit according to another additional embodiment of the present invention with reference to FIGS. 21 and 21 . FIG. 20 shows a vertical cross-sectional of a multi-stage compression type rotary compressor used in this case. It is to be noted that the same reference numerals in these figures as those in FIGS. 1-19 indicate the same or similar functions.
In FIG. 20 , a reference numeral 10 indicates an internal medium-pressure, multi-stage compression type rotary compressor using carbon dioxide (CO 2 ) as a refrigerant which comprises the cylindrical sealed vessel 12 made of a steel plate and the rotary compression mechanism portion 18 which includes the electrical-power element 14 arranged and housed in an upper part of an internal space of the sealed vessel 12 and the first rotary compression element 32 (first stage) and the second rotary compression element 34 (second stage) which are arranged below the electrical-power element 14 to be driven by the rotary shaft 16 of the electrical-power element 14 .
The sealed vessel 12 has its bottom used as an oil reservoir and is composed of the vessel body 12 A which houses the electrical-power element 14 and the rotary compression mechanism portion 18 and the roughly cup-shaped end cap (lid) 12 B which blocks an upper part opening of the vessel body 12 A. Furthermore, the end cap 12 B has the circular attachment hole 12 D formed therein at a center of its top face, in which attachment hole 12 D the terminal 20 (wiring of which is omitted) is fixed by welding which supplies power to the electrical-power element 14 .
The electrical-power element 14 is composed of the stator 22 mounted annularly along an inner peripheral face of an upper-part space of the sealed vessel 12 and the rotor 24 disposed and inserted in the stator 22 with some gap therebetween in such a configuration that to this rotor 24 is there fixed the rotary shaft 16 which vertically extends centrally.
The stator 22 has the stack 26 formed by stacking donut-shaped electromagnetic steel plates and the stator coil 28 wound round teeth of the stack 26 by direct winding (concentrated winding). Furthermore, the rotor 24 is constituted of the stack 30 of electromagnetic steel plates and the permanent magnet MG inserted into the stack 30 .
The intermediate partition plate 36 is sandwiched between the first rotary compression element 32 and the second rotary compression element 34 . That is, a combination of the first rotary compression element 32 and the second rotary compression element 34 is composed of the intermediate partition plate 36 , the upper and lower cylinders 38 and 40 arranged above and below the intermediate partition plate 36 respectively, the upper and lower rollers 46 and 48 which are fitted to the upper and lower eccentric portions 42 and 44 provided on the rotary shaft 16 with a phase difference of 180 degrees therebetween so as to eccentrically revolve within the upper and lower cylinders 38 and 40 respectively, upper and lower vanes 50 and 52 , not shown, which butt against the upper and lower rollers to divide an inside of the respective upper and lower cylinders 38 and 40 into a low-pressure chamber side and a high-pressure chamber side, and the upper-part support member 54 and the lower-part support member 56 given as a support member for blocking an upper-side opening face of the upper cylinder 38 and a lower-side opening face of the lower cylinder 40 respectively to serve also as a bearing for the rotary shaft 16 .
Furthermore, a combination of the upper-part support member 54 and the lower-part support member 56 is provided therein with the suction paths 58 and 60 communicating with insides of the upper and lower cylinders 38 and 40 through the suction ports 161 and 162 respectively and the discharge-noise silencer chambers 62 and 64 which are formed by concaving a surface partially and then blocking resultant concavities by the upper cover 66 and the lower cover 68 respectively.
It is to be noted that the discharge-noise silencer chamber 64 communicates with an inside of the sealed vessel 12 through a communication path, not shown, which penetrates the upper and lower cylinders 38 and 40 and the intermediate partition plate 36 in such a configuration that at an upper end of the communication path, an intermediate discharge pipe 121 is provided as erected, through which a medium pressure refrigerant compressed at the first rotary compression element 32 is discharged into the sealed vessel 12 .
Furthermore, the upper cover 66 defines the discharge-noise silencer chamber 62 communicating with an inside of the upper cylinder 38 of the second rotary compression element 34 , above which upper cover 66 is there provided the electrical-power element 14 with a predetermined spacing therebetween.
In this case also, as a refrigerant, carbon dioxide (CO 2 ) which is a natural refrigerant friendly to environments of the earth is used taking into account inflammability, toxicity, etc., while as a lubricant, such existing oil is used as mineral oil, alkyl-benzene oil, ether oil, ester oil, or poly-alkyl glycol (PAG).
Onto a side face of the vessel body 12 A of the sealed vessel 12 , sleeves 141 , 142 , 143 , and 144 are fixed by welding at positions that correspond to the suction paths 58 and 60 of the respective upper-part support member 54 and the lower-part support member 56 , the discharge-noise silencer chamber 62 , and an upper side of the upper cover 66 (a lower part of the electrical-power element 14 roughly) respectively. The sleeves 141 and 142 are adjacent to each other vertically, while the sleeve 143 is roughly in a diagonal direction of the sleeve 141 . Furthermore, the sleeve 144 is positioned as shifted by about 90 degrees with respect to the sleeve 141 .
In the sleeve 141 is there inserted and connected one end of a refrigerant introduction pipe 92 serving as a refrigerant path for introducing a refrigerant gas to the upper cylinder 38 , which one end communicates with the suction path 58 of the upper cylinder 38 . This refrigerant introduction pipe 92 passes through an upper part of the sealed vessel 12 up to the sleeve 144 , while the other end is inserted and connected in the sleeve 144 to communicate with the inside of the sealed vessel 12 .
In the sleeve 142 , on the other hand, is there inserted and connected one end of a refrigerant introduction pipe 94 for introducing a refrigerant gas to the lower cylinder 40 , which one end communicates with the suction path 60 of the lower cylinder 40 . The other end of this refrigerant introduction pipe 94 is connected to a lower end of an accumulator not shown. Furthermore, in the sleeve 143 is there inserted and connected the refrigerant discharge pipe 96 , one end of which communicates with the discharge-noise silencer chamber 62 .
This accumulator is a tank for separating an sucked refrigerant into vapor and liquid and attached via a bracket thereof, not shown, to the bracket 147 of a sealed vessel side welded and fixed to an upper-part side face of the vessel body 12 A of the sealed vessel 12 .
Next, FIG. 21 shows a refrigerant circuit of a hot-water supply apparatus 553 to which the present embodiment of the present invention is applied, in which the multi-stage compression type rotary compressor 10 constitutes part of a refrigerant circuit of the hot-water supply apparatus 553 shown in FIG. 21 . That is, the refrigerant discharge pipe 96 of the multi-stage compression type rotary compressor 10 is connected to an inlet of a gas cooler 154 , which is provided to a hot-water storage tank, not shown, of the hot-water supply apparatus 553 in order to heat water and generate hot water. The pipe exits the gas cooler 554 and passes through an expansion valve 556 serving as a decompression device up to an inlet of an evaporator 557 , an outlet of which is connected via the accumulator described above (not shown) to the refrigerant introduction pipe 94 .
Furthermore, a defrosting pipe 558 constituting a defrosting circuit branches from somewhere along the refrigerant introduction pipe (refrigerant path) 92 for introducing a refrigerant in the sealed vessel 12 into the second rotary compression element 34 and is connected through an electromagnetic valve 559 constituting a first flow-path control device to the refrigerant discharge pipe 96 extending to the inlet of the gas cooler 554 .
Another defrosting pipe 568 is provided to communicate, to each other the refrigerant discharge pipe 96 and a pipe interconnecting the expansion valve 556 and the evaporator 557 , to which defrosting pipe 568 is there equipped another electromagnetic valve 569 constituting the first flow-path control device. Furthermore, to the refrigerant introduction pipe 92 on a downstream side of a branching point 570 of the defrosting pipe 558 are there provided a capillary tube 560 serving as a second decompression device and an electromagnetic valve 563 connected in parallel with this capillary tube 560 to serve as a second flow-path control device.
In this configuration, the electromagnetic valves 559 , 569 , and 563 are controlled in opening and closing by the control device 564 . The electromagnetic valve 563 is opened by the control device 563 in ordinary defrosting operation. Accordingly, during defrosting operation, a refrigerant gas supplied to the second rotary compression element 34 is decompressed through the capillary tube 560 (decompression device) provided to the refrigerant introduction pipe 92 (refrigerant path) and then supplied to the second rotary compression element 34 . In such a way, as described later, a pressure difference develops between an suction side and a discharge side of the second rotary compression element 34 to thereby prevent breakaway of the vane, thus avoiding unstable operation during defrosting for improvements in reliability.
The following will describe operations with reference to this configuration. It is to be noted that the control device 564 closes the electromagnetic valves 559 and 569 and opens the electromagnetic valve 563 in heating operation as described above. When the stator coil 28 of the electrical-power element 14 is electrified through the terminal 20 and a wiring line not shown, the electrical-power element 14 is actuated, thus causing the rotor 24 to revolve. By this revolution, the rollers 46 and 48 fitted to the upper and lower eccentric portions 42 and 44 provided integrally with the rotary shaft 16 revolve eccentrically in the upper and lower cylinders 38 and 40 respectively.
Accordingly, a low-pressure (first-stage suction pressure LP: 4 MPaG) refrigerant sucked into the low-pressure chamber side of the cylinder 40 from a suction port 562 through the refrigerant introduction pipe 94 and the suction path 60 formed in the lower-part support member 56 is compressed by operations of the lower roller 48 and the vane to have a medium pressure (MP 1 : 8 MPaG), passed through the high-pressure chamber side of the lower cylinder 40 , a discharge port not shown, and the discharge-noise silencer chamber 64 formed in the lower-part support member 56 and is discharged into the sealed vessel 12 from a communication path not shown. Thus, the sealed vessel 12 has the medium pressure (MP 1 ) therein.
Then, the medium pressure refrigerant gas in the sealed vessel 12 exits it through the refrigerant introduction pipe 92 of the sleeve 144 (where an intermediate discharge pressure is MP 1 described above), passes through the electromagnetic valve 563 connected in parallel with the capillary tube 560 of this refrigerant introduction pipe 92 and the suction path 58 formed in the upper-part support member 54 , and is sucked into the low-pressure chamber side of the upper cylinder 38 from the suction port 161 (second-stage suction). The medium pressure refrigerant gas thus sucked undergoes second-stage compression through operations of the roller 46 and a vane not shown to thereby provide a high-temperature, high-pressure refrigerant gas (second-stage discharge pressure HP: 12 MPaG), which in turn passes from the high-pressure chamber side through a discharge port not shown, the discharge-noise silencer chamber 62 formed in the upper-part support member 54 , and the refrigerant discharge pipe 96 , and flows into the gas cooler 554 . At this moment, the refrigerant has a raised temperature of about +100° C. and, therefore, such a high temperature, high pressure gas radiates heat through the gas cooler 554 to heat water in the hot-water storage tank to thus generate hot water having a temperature of about +90° C.
The refrigerant itself, on the other hand, is cooled at the gas cooler 554 and exits it. Then., the refrigerant is decompressed at the expansion valve 556 , flows into the evaporator 557 to evaporate there (while absorbing heat from surroundings), passes through the accumulator, and is sucked into the first rotary compression element 32 through the refrigerant introduction pipe 94 , which cycle is repeated.
Especially in a low outside-air temperature environment, such heating operation causes the evaporator 557 to be frosted. Therefore, periodically or according to an arbitrary instruction for operation, the control device 564 opens the electromagnetic valves 559 and 569 and closes the electromagnetic valve 563 and, furthermore, opens the expansion valve 556 fully to thereby defrost the evaporator 557 . When the electromagnetic valves 559 and 569 are opened, a refrigerant gas discharged from the first rotary compression element 32 into the sealed vessel 12 flows either through the refrigerant introduction pipe 92 , the defrosting pipe 558 , the refrigerant discharge pipe 96 , and the defrosting pipe 568 toward a downstream side of the expansion valve 556 or through the gas cooler 554 and the expansion valve 556 (opened fully), in both cases of which the refrigerant directly flows into the evaporator 557 without being decompressed.
Furthermore, a refrigerant gas discharged from-the second rotary compression element 34 passes through the refrigerant discharge pipe 96 and the defrosting pipe 568 to flow toward the downstream side of the expansion valve 556 into the evaporator 557 directly without being decompressed. When such a high-temperature, high-pressure refrigerant gas flows into the evaporator 557 , it is heated and defrosted as melting.
In this case, when the electromagnetic valves 559 and 569 are opened, a discharge side and a suction side of the second rotary compression element 34 communicate with each other through the refrigerant discharge pipe 96 , the defrosting pipe 558 , and the refrigerant introduction pipe 92 and so have the same pressure naturally; by the present invention, however, the electromagnetic valve 563 is closed in defrosting operation, so that the capillary tube 560 is interposed between the suction side (side of the refrigerant introduction pipe 92 ) and the discharge side (side of the refrigerant discharge pipe 96 ) of the second rotary compression element 34 in configuration.
Accordingly, a refrigerant gas to be compressed at the first rotary compression element 32 , discharge into the sealed vessel 12 , and supplied to the second rotary compression element 34 through the refrigerant introduction pipe 92 is actually supplied through this capillary tube 560 to the second rotary compression element 34 . That is, since the refrigerant gas is decompressed at the capillary tube 560 , a pressure difference occurs between a suction side and a discharge side of the second rotary compression element 34 to thereby prevent breakaway of the vane in order to avoid unstable defrosting operation, thus improving reliability.
Such defrosting operation ends, for example, when the evaporator 557 reaches a predetermined defrosting temperature or time. When defrosting ends, the control device 564 closes the electromagnetic valves 559 and 569 and opens the electromagnetic valve 563 to return to ordinary heating operation.
Although the present embodiment has used the multi-stage compression type rotary compressor 10 in a refrigerant circuit of the hot-water supply apparatus 553 , the present invention is not limited thereto; for example, it may well be applied for warming of a room. Furthermore, although the present embodiment has employed an internal medium-pressure multi-stage compression type rotary compressor, the present invention is not limited thereto; for example, it is applicable also to such a configuration that a refrigerant discharged from the first rotary compression element 32 is supplied through the refrigerant introduction pipe 92 to the second rotary compression element 34 without passing it through the sealed vessel 12 .
As detailed above, according to the present embodiment of the present invention, in a refrigerant circuit comprising a multi-stage compression type rotary compressor including an electrical-power element and first and second rotary compression elements driven by this electrical-power element in a sealed vessel in such a configuration that a refrigerant compressed at the first rotary compression element is then compressed at the second rotary compression element, a gas cooler into which the refrigerant discharged from the second rotary compression element of this multi-stage compression type rotary compressor flows, a first decompression device connected to an outlet side of this gas cooler, and an evaporator connected to an outlet side of this first decompression device in such a configuration that the refrigerant discharged from this evaporator is compressed at the first rotary compression element, there are provided a defrosting circuit for supplying the refrigerant discharged from the first and second rotary compression elements to the evaporator without decompressing it, a first flow-path control device which controls flow of the refrigerant through this defrosting circuit, a second decompression device provided along a refrigerant path for supplying the second rotary compression element with the refrigerant discharged from the first rotary compression element, and a second flow-path control device which controls whether the refrigerant is allowed to flow through this second decompression device or the refrigerant is allowed to bypass it, wherein when the refrigerant is controlled by the first flow-path control device to flow to the defrosting circuit, this second flow-path control device controls the refrigerant to flow to the second decompression device, so that during defrosting operation of the evaporator, the refrigerant discharged from the first and second rotary compression elements is supplied to the evaporator without being decompressed, thus avoiding reversion in pressure level relationship at the second rotary compression element.
In particular, by the present invention, during such defrosting operation, a refrigerant is controlled to be supplied to the second rotary compression element through the decompression device provided along the refrigerant path, so that a predetermined pressure difference is established between suction and discharge sides of the second rotary compression element.
Accordingly, the second rotary compression element becomes stable in operation, thus improving reliability. In particular, remarkable effects are obtained in the case of a refrigerant circuit using a CO 2 gas as a refrigerant. | A method for manufacturing a multi-stage compression type rotary compressor which avoids the replacement of parts to be used as much as possible to reduce costs and also which enables easily setting an appropriate displacement volume ratio between first and second rotary compression elements without increasing the size of the compressor outer housing. This is done by altering the inner diameter of the cylinder of one of the rotary compression elements without altering the thickness (or height) of this cylinder to set a displacement volume ratio between the first and second rotary compression elements to an optimum value in accordance with the alteration. | 5 |
FIELD OF USE
This invention is in the field of methods and devices for accessing the renal arteries for the treatment of high blood pressure.
BACKGROUND OF THE INVENTION
There are now several catheters being developed by several different companies whose goal is to perform renal nerve denervation to reduce the blood pressure for hypertensive patients. Therefore, it will become increasingly important over the next several years to create improved means for renal denervation catheters to access the renal arteries.
The current practice for accessing the renal arteries is to first use an arterial access needle puncture at the groin, and then a guide wire is placed through that needle into the femoral artery. The needle is then removed while the guide wire remains in place in the femoral artery at the groin. An introducer sheath with dilator would then be advanced over the guide wire and into the lumen of the femoral artery. The dilator and the guide wire would then be removed and a guiding catheter would be advanced through the introducer sheath until its distal end would be placed into a renal artery. A catheter for renal denervation could then be advanced through the guiding catheter and it would be used to kill a section of the renal nerves that surround the renal artery thus permanently lowering the blood pressure of a patient that is hypertensive.
The renal denervation catheters require a fairly large diameter guiding catheter; typically 6, 7 or 8 French size. Since the outer diameter of the sheath through which the guiding catheter is inserted is typically 2 to 3 French sizes larger than the outer diameter of the guiding catheter, a fairly large diameter hole must be made through the wall of the femoral artery. These larger size holes can lead to excessive bleeding at the groin after the guiding catheter and the sheath are removed.
At this time, all guiding catheters designed for accessing the renal arteries terminate at their proximal end with a Luer fitting. To perforin an intra-arterial procedure with any existing guiding catheter, it is necessary to attach a Tuohy-Borst “Y” adaptor onto the Luer fitting at the guiding catheter's proximal end. The introducer sheath and Tuohy-Borst “Y” adaptor are each components that require additional time for the interventional cardiologist to properly place, and they add to the cost of performing intra-arterial procedures. Also, the introducer sheath through which the guiding catheter is inserted typically must have a three-way stopcock attached to a Luer fitting on a side arm tube that is located near the proximal end of the introducer sheath. The additions of a Tuohy-Borst “Y” adaptor to the guiding catheter and adding a three-way stopcock to the side tube of the introducer sheath adds additional cost and time to any procedure for accessing the renal artery. If a means for accessing the renal artery could be accomplished without requiring an introducer sheath and without requiring the additional parts of a Tuohy-Borst “Y” adaptor and a three-way stopcock, the procedure could be done in less time and at a lower cost.
In U.S. Pat. No. 5,389,090, Fischell et al describe an improved guiding catheter that is particularly useful for accessing the coronary arteries. However, there are no specific features of that invention that are specifically devoted for improved access for the renal arteries. Specifically, the invention described in the '090 patent does not teach markings on the shaft of the guiding catheter to assist in the placement of that guiding catheter into the renal arteries. The '090 patent also fails to teach the importance of a side arm tube that lies in the same plane as does the curve at the distal section of the guiding catheter, which feature enables the operator to have the correct azimuth angle for placement of the distal end of the guiding catheter into and through the ostium of the renal artery. Still further, the '090 patent fails to teach a three-way stopcock formed integral with the side arm tube at the guiding catheter's proximal end that precludes the need for the operator to open a separate package to attach that device to the guiding catheter. A guiding catheter design that would not require the use of an introducer sheath and would have a Tuohy-Borst fitting and a three-way stopcock each formed integral with the guiding catheter at its proximal end would result in savings of both time and cost for the procedure to access the renal arteries.
SUMMARY OF THE INVENTION
The present invention is an improved guiding catheter designed explicitly to access the renal artery. This renal artery guiding catheter eliminates the need for: 1) an introducer sheath; 2) a separate Tuohy-Borst “Y” adaptor; and 3) a separate three-way stopcock. By this means, the present invention provides a means and method for reducing the time and expense for performing renal artery procedures. Furthermore, the guiding catheter with straightening dilator as described herein allows the hole in the wall of the femoral artery to be approximately 2 to 3 French sizes smaller in diameter as compared to the hole that would be created if an introducer sheath is also used, thus decreasing the possibility of bleeding at the groin. Still further by making the curve at the distal section of the shaft of the guiding catheter to be coplanar with the guiding catheter's side arm tube, the interventional cardiologist can more easily place the distal end of the guiding catheter into and through the ostium of the renal artery. Additionally, explicit markings along the tube of the guiding catheter allow the interventional cardiologist to more accurately place the distal end of the guiding catheter into the aorta prior to removing the dilator and guide wire from the guiding catheter. Still further, the shape of the distal section of this special guiding catheter allows entry of a straight section at the distal end of the guiding catheter to be advantageously placed into the renal artery irrespective of the angle that the renal artery makes with the aorta.
The advantages of the present invention are accomplished by utilizing a dilator that has a curved distal section placed 180 degrees opposite from the curve at the guiding catheter's distal section, which opposing curve of the dilator is used to initially straighten the curved distal section of the renal artery guiding catheter as it is advanced through the patient's arterial system. In this way, the dilator straightens the guiding catheter so that it can be used like an introducer sheath to enter the femoral artery by being advanced over a previously placed guide wire. Once the distal ends of the guide wire, dilator and guiding catheter are placed just beyond the ostium of a renal artery, the dilator and guide wire are withdrawn which allows a distal section of the guiding catheter to assume its normally bent shape. By pulling the guiding catheter back down the aorta, the cardiologist can then place the guiding catheter's distal end into and through the ostium of either the right or the left renal artery. Any one of several well-known procedures can then be performed including denervation of the renal nerves, angiography, balloon angioplasty, and atherectomy or stent placement. The unique design of the distal section of the guiding catheter allows a short straight section at that curves distal end to be placed into the renal artery irrespective of the angle that the renal artery makes with the aorta. This design feature precludes the need for making a variety of shapes for different guiding catheters that would otherwise be required to access renal arteries that make different entry angles relative to the aorta. Another means for expressing this advantage is that only one product code is required to be manufactured by the company that makes this product, which product will include a guiding catheter having a distal straight section that is able to readily enter a renal artery irrespective of the angle that that renal artery makes with the aorta. A marketing advantage for the present invention is that the manager of a cath lab will prefer to have a reduced inventory of guiding catheters to access the femoral artery. Therefore, having only a single product code would provide that desired goal of a reduced inventory for this renal artery guiding catheter product.
The guiding catheter of the present invention utilizes a Tuohy-Borst fitting that is formed integral with the guiding catheter and a side arm tube all placed at the guiding catheter's proximal end. This capability obviates the need for attaching a separate Tuohy-Borst “Y” adaptor at the guiding catheter's proximal end to accomplish arterial access with minimum bleeding. The guiding catheter's Tuohy-Borst fitting could be tightened around guide wires or the shaft of catheters that are advanced through the guiding catheter.
The side arm tube, also located at the proximal end of the guiding catheter. could terminate in a female Luer fitting as described in the '090 patent, or more advantageously it could have a three-way stopcock formed integral with the side arm tube at the tube's proximal end. That three-way stopcock could be attached to a manifold for the introduction of saline solution, contrast medium, medications or a solution such as alcohol, which liquids can be used in the procedure for renal denervation. Thus, the Tuohy-Borst fitting with side arm at the guiding catheter's proximal end eliminates the need for a separate Tuohy-Borst “Y” adaptor and the three-way stopcock formed integral at the proximal end of the side arm tube eliminates the need to have that device separately attached to a Luer fitting at the proximal end of the side arm tube. Still further, the direction of the side arm tube relative to the guiding catheter tube being the same as the direction of the curved distal section of the guiding catheter allows the interventional cardiologist to easily find the correct azimuth angle around the circumference of the aorta for the easy placement of the distal end of the guiding catheter through the ostium of the renal artery.
Another novel feature of the present invention are markings on the outer cylindrical surface of the elongated hollow tube that constitutes most of the length of the guiding catheter. These markings are set at the distance to advance the guiding catheter through the patient's arterial system so that the distal end of the guiding catheter will be situated approximately 10±5 cm beyond the ostia of the renal arteries depending on the height of that patient. This can be accomplished because the distance from the skin at the groin entry site for the guiding catheter to the point at a 10±5 cm distance beyond the ostium of either renal artery is highly dependent upon how tall a particular patient would be.
Thus, it is an objective of the present invention to allow placement of a renal artery guiding catheter to have its distal end placed into the renal artery without requiring insertion of the guiding catheter through an introducer sheath thus allowing a smaller hole to be made in the wall of the femoral artery.
Another objective of this invention is to eliminate the need for a separate Tuohy-Borst “Y” adaptor by having a Tuohy-Borst fitting formed integral with the guiding catheter at the guiding catheter's proximal end.
Still another objective of the present invention is to have a side arm tube that has a three-way stopcock formed integral at the proximal end of that side arm tube thus eliminating the need for a separately attached three-way stopcock.
Still another objective of the present invention is to have a side arm tube that extends outward from the shaft of the guiding catheter so as to be co-planar with plane of the guiding catheter's curved distal section and also to be extending in the same direction as that curved distal section of the guiding catheter thus assisting the interventional cardiologist in placing the distal end of the guiding catheter into and through the ostium of a renal artery.
Still another objective of the invention is to use a guide wire and a dilator within a guiding catheter for placement of the guiding catheter without requiring an introducer sheath.
Still another objective of the invention is to utilize a dilator having a curved distal section that when placed inside a guiding catheter that has a curved dilator section in the opposite direction causes the dilator-guiding catheter assembly to be essentially straight for easy insertion through the arterial system.
Still another objective of the invention is to reduce the cost and time required for performing arterial interventional procedures for accessing the renal arteries by eliminating the need for an introducer sheath and by having a Tuohy-Borst fitting and a three-way stopcock each formed integral with the guiding catheter at its proximal end.
Still another objective of the invention is to reduce the probability of bleeding at the skin where the guiding catheter enters the femoral artery by eliminating the need for an introducer sheath to have the guiding catheter gain access to the patient's arterial system.
These and other objects and advantages of this invention will become obvious to a person of ordinary skill in this art upon reading of the detailed description of this invention including the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a guiding catheter system including a guide wire, straightening dilator and a guiding catheter with Tuohy-Borst fitting and a three-way stopcock mounted onto the side arm tube of the guiding catheter.
FIG. 2 is a side view of the guiding catheter showing its curved distal section that occurs when the oppositely curved dilator is withdrawn.
FIG. 3 is a side view of a straightening dilator illustrating its curved distal section that curves opposite in its direction compared to the curved distal section of the guiding catheter into which the dilator is inserted so that the combination of both curves, as seen in FIG. 1 , provides a comparatively straight distal section of the combined guiding catheter and straightening dilator for improved insertion through the patient's arterial system.
FIG. 4 is an enlarged partial longitudinal cross section of the proximal end of the guiding catheter at section 4 - 4 of FIG. 2 .
FIG. 5 is an enlarged transverse cross section of the Tuohy-Borst fitting at section 5 - 5 of FIG. 1 .
FIG. 6A is a cross section of a Tuohy-Borst gland with a half “O” ring with the gland in a fully open position.
FIG. 6B is a cross section of a Tuohy-Borst gland with a half “O” ring with the gland in a fully closed position.
FIG. 7 illustrates the initial position of the distal ends of the guide wire, dilator and guiding catheter as they are initially inserted into the aorta just beyond the ostia of the left and right renal arteries.
FIG. 8 shows the initial position of the distal section of the guiding catheter within the aorta immediately after the guide wire and dilator have been withdrawn.
FIG. 9 shows the distal end of the guiding catheter placed into the renal artery after it has been pulled back from the position shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 , 2 and 3 illustrate the guiding catheter system 10 having a guiding catheter 12 with an elongated tube 11 with a distal section 11 A having a distal end 19 E, a Tuohy-Borst fitting 20 , a side arm tube 14 with a three-way stopcock 30 at its proximal end, and a guide wire 15 and a straightening dilator 16 each situated within the tube 11 . It should be noted that the configuration of FIG. 1 is how this guiding catheter system 10 would be placed through the patient's skin at the groin, then into the femoral artery and then advanced through the aorta and beyond the renal arteries as shown in FIG. 7 .
As best seen in FIG. 2 , the guiding catheter 12 has an elongated cylindrical tube 11 with a curved distal section 11 A ending at point 19 D where a short straight section 19 S begins. The straight section 19 S extends to its distal end 19 E. It should be noted that the angle “a” that the centerline of the straight section 19 S makes with the centerline of the straight section of the tube 11 should optimally be about 30 degrees. This angle “a” makes it possible for the straight section 19 S to have a straight entry into a renal artery even if that renal artery makes a downward angle of as little as 30 degrees relative to the aorta. This is shown in greater detail with the assistance of FIG. 9 .
The tube 11 also has markings 11 B, 11 C, 11 D, 11 E, 11 F and 11 G that indicate points on the tube 11 corresponding to how far the interventional cardiologist should advance the system 10 into the patient's arterial system depending on the height of the patient. The single line mark 11 C indicates the extent to which the tube 11 should be advanced if the patient is approximately 5 feet tall. The number “5” (which is element 11 B) reminds the cardiologist that the mark 11 C corresponds to the point on the patient's skin at the groin to which the tube 11 should be advanced if the patient is approximately five feet tall. If the patient is 6 feet tall, as indicated by the “6” of element 11 E, then the three lines of element 11 F indicate the point to which the tube 11 should be advanced to place the mark 11 F at the skin of the patient at his/her groin if that patient is six feet tall. The marks 11 D and 11 G correspond respectively to patient heights of five feet, six inches and six feet, six inches. For patient heights corresponding to a position between these markers, the cardiologist can set the depth to which the tube 11 is inserted through the patient's skin to be between the appropriate markers. For example, for a woman whose height is five feet, three inches, the tube 11 would be advanced through the patient's skin at her groin with the tube 11 placed at her skin halfway between the one line of mark 11 C and the two lines of mark 11 D. The approximate distance between each adjacent pair of the marks 11 C, 11 D, 11 F and 11 G would be 5±2 cm.
FIG. 2 also shows a proximal section of the guiding catheter 12 that has a threaded base 21 , a threaded nut 22 and a side arm tube 14 that has a three-way stopcock 30 at its proximal end. When the marker 27 on the threaded base 21 is aligned with the marker 28 on the threaded nut 22 , then the curved distal sections of the tube 11 and the dilator 16 will be 180 degrees in opposite directions and the distal curved sections 11 A and 16 A will act together to create a generally straight guiding catheter system 10 as shown in FIG. 1 . This function will be described in greater detail with the assistance of FIGS. 3 , 4 and 5 below.
As shown in FIG. 3 , the dilator 16 has a distal curved section 16 A that is connected to the straight section 16 S at the point 16 D, and the straight section 16 S terminates at a tapered distal end 16 E. The dilator tube 16 is designed to fit snugly around the guide wire 15 . The dilator tube 16 is designed to be advanced over the guide wire 15 and within the lumen 13 of the guiding catheter tube 11 so that the assembly of the guiding catheter system 10 (as shown in FIG. 1 ) can be in a straightened condition so that it can be readily advanced through the patient's arterial system. All the sections of the dilator tube 16 are designed to fit slideably within the interior lumen 13 of the guiding catheter tube 11 . It should be understood that there could be only one bend, or two or more bends at this distal section of the dilator tube 16 and the curved section 11 A of the tube 11 . The dilator also has at its proximal end a handle 17 with a cone 17 A having a key 17 B for mating with the keyway 26 of the threaded nut 22 of the Tuohy-Borst fitting 20 as seen in FIGS. 4 and 5 .
As seen in FIGS. 1 , 2 and 4 , the guiding catheter 12 has a Tuohy-Borst fitting 20 that is integrally attached as a one-piece construction at the proximal end of the catheter tube 11 . As best seen in FIG. 4 , the Tuohy-Borst fitting 20 has a threaded base 21 , a side arm 14 having a three-way stopcock 30 at its proximal end, a threaded nut 22 with conical entry lumen 23 , a soft elastomer gland 24 and a comparatively hard washer 25 . As seen in FIG. 4 , when the nut 22 is not tightened down, the gland 24 is not compressed and the lumen 23 is in fluid communication with the lumen 13 of the elongated tube 11 and the lumen 18 of the side arm tube 14 . When the nut 22 is screwed into the threaded base 21 , the washer 25 compresses the soft elastomer gland 24 which can then fit snugly around a guide wire 15 or a dilator 16 or the shaft of a renal artery denervation catheter or a stent delivery catheter. Furthermore, when the nut 22 is fully screwed onto the threaded base 21 , the central lumen of the gland 24 can be totally closed so that no blood will leak out of the guiding catheter's proximal end even if there is no guide wire 15 or catheter tube 11 placed through that gland 24 .
As shown in FIGS. 1 and 2 , the threaded base 21 has an indicator mark 27 which, when aligned with an indicator mark 28 on the nut 22 , informs the operator that the tube 11 and the dilator 16 are positioned so that together they form a straight distal end section as shown in FIG. 1 . It is also conceived that a straight dilator with a comparatively stiff distal section 16 A could be used to straighten out the curved end section 11 A of the guiding catheter 12 as is shown in FIG. 1 . The stiffer the distal section of such a dilator 16 , the straighter would be the distal section of the assembly of the dilator 16 with the guiding catheter 12 . Of course, when such a straight (or curved) dilator would be pulled out, the distal section 11 A of the guiding catheter 12 would assume its proper shape as generally illustrated in FIG. 2 .
FIG. 4 shows the three-way stopcock 30 fixedly attached to the side arm tube 14 by means of the connecting tube 31 . Specifically, FIG. 4 shows the stopcock 30 with an operating lever 34 in an intermediary position. For an external fluid source to connect to the lumen 18 by means of the Luer fitting 33 , the lever 34 would be placed over the Luer fitting 32 . For a fluid source to deliver fluid into the lumen 18 via the Luer fitting 32 , the lever 34 would be placed over the Luer fitting 33 . To close the side arm tube 14 from any access through either Luer fitting 32 or 33 , the lever 34 would be placed over the connecting tube 31 . It should be understood that a two-way or a four-way stopcock could be used instead of the three-way stopcock 30 shown in FIGS. 1 and 4 . In general, a multi-way stopcock could be advantageously formed integral at the proximal end of the side arm tube 14 .
FIGS. 4 and 5 also show a keyway 26 in the nut 22 which is adapted to mate with the key 17 B of the dilator handle 17 . When the marks 27 and 28 are aligned as shown in FIGS. 1 and 2 , the alignment formed by keyway 26 and the key 17 B guarantees that the bends in the distal sections of the guiding catheter tube 11 and the dilator 16 oppose each other so as to straighten the guiding catheter system 10 as shown in FIGS. 1 and 7 . In this position, the guiding catheter 12 with dilator 16 in place can be readily advanced over the guide wire 15 until the distal end 19 E of the guiding catheter tube 11 is located just beyond the ostium of the renal artery to which access is desired as is shown in FIG. 7 . The dilator 16 and guide wire 15 can then be withdrawn and the guiding catheter 12 will assume its desired distal section shapes as shown in FIGS. 8 and 9 . The cardiologist can then place the guiding catheter's distal end 19 E through the ostium of a renal artery as shown in FIG. 9 .
It is important to note that the guiding catheter system 10 should not be stored or packaged in the configuration as shown in FIG. 1 . If that were to be done, then in time, and particularly if there is any exposure to an elevated temperature, the final distal section curve of the catheter tube 11 could be reduced and that would not be the optimum curve which is most suitable for accessing the renal arteries. If the package containing the system 10 was sold as shown in FIG. 1 , then the final curvature at the distal section of the tube 11 could be considerably reduced as compared to the curve shown in FIG. 2 . Therefore, the present invention conceives of the fact that the elements of the guiding catheter system 10 should be separated into a kit that at least allows the guiding catheter tube 11 and the dilator tube 16 to remain apart until the guiding catheter system 10 is assembled prior to insertion of the guiding catheter system 10 into the patient's arterial system.
FIGS. 6A and 6B illustrate an alternative design for the soft elastomer gland of a Tuohy-Borst fitting 20 . Specifically, FIG. 6A shows a gland 70 in its open (not compressed) state. The gland 70 has a generally cylindrical interior surface 71 A on which is placed a half “O” ring 72 A. When the nut 22 of FIG. 4 is tightened, the gland 70 can be deformed to the shape shown in FIG. 6B wherein a highly curved interior surface 71 B is formed with the half “O” ring 72 B being distorted to a closed or nearly closed position as shown in FIG. 6B .
FIGS. 7 , 8 and 9 illustrate how the present invention would be used to effectively access either one or both of the renal arteries 82 and 83 . FIG. 7 is a posterior view of certain body parts showing the aorta 80 , the left kidney 81 , the left renal artery 82 , the right renal artery 83 , the right kidney 84 and also the guiding catheter tube 11 in its straightened condition due to the insertion of the dilator 16 which was previously advanced with the guiding catheter 12 over the guide wire 15 . It should be noted that the right renal artery 83 is typically longer than the left renal artery 82 due to the placement of the inferior vena cava between the aorta 80 and the right kidney 83 . The distal end 85 of the guiding catheter tube 11 is shown in a position that is a length “D” beyond the centerline 85 of the ostia of the left and right renal arteries. An optimum distance for this distance D would be 10±5 cm. Thus, even if a patient of a particular height had his or her renal artery centerline further away from the entry of the guiding catheter system 10 at the patient's groin than that which is indicated by the marks 11 B to 11 H on the tube 11 (as shown in FIGS. 1 and 2 ) the distal end 19 E of the tube 11 would still lie distinctly above the renal artery centerlines. It should be noted that the total length of the renal artery catheter 12 could optimally be approximately 60 cm. The distance from the catheter's distal end 19 E to the first mark 11 C (of FIGS. 1 and 2 ) being about 35±5 cm and the length from the distal end 19 E to the mark 11 G being approximately 50±5 cm. It should be noted that the mark 11 C corresponds to a patient height of five feet and the mark 11 G corresponds to a patient height of six feet, six inches. These lengths have been chosen so that at least a length of approximately 10 cm will typically be situated outside of the patient's skin at the groin irrespective of the patient's height. This 10 cm length provides the interventional cardiologist with additional margin for an extremely rare case when the renal arteries are even further away from the femoral artery entry point of the guiding catheter system 10 at the skin near the patient's groin.
After the guide wire 15 and the dilator 16 are withdrawn from the guiding catheter tube 11 , the curved distal section 11 A of the tube 11 would be situated as shown in FIG. 8 . In this position, the distal end 19 E of the curved distal section 11 A of the catheter tube 11 would move against the wall of the aorta 80 opposite the wall where the tube 11 is situated. When that condition has been obtained, the cardiologist would typically inject contrast medium (not shown) through the three-way stopcock 30 to visualize the geometry of the ostium of the right renal artery 83 . After that is accomplished, the cardiologist would pull back the proximal end of the guiding catheter 12 until the straight section 19 S at the distal end of the curved distal section 11 A enters into and through the ostium of the right renal artery 84 as shown in FIG. 9 . It should be understood that the distal section 11 A of the tube 11 would be made radiopaque so that it can be readily visualized by the interventional cardiologist using conventional image intensified fluoroscopy.
A unique feature of the present invention is that the interventional cardiologist could always get the straight section 19 S to be aimed directly into the lumen of the renal artery irrespective of the angle that the renal artery typically makes with the aorta 80 . This is certainly true for all angles “a” of the axis of a renal artery relative to the axis of the aorta (as shown in FIGS. 8 and 9 ) as normally found in human subjects. Particularly, any angle “a” between 90 degrees and 30 degrees downward could be readily accessed because of the shapes of the curved distal section 11 A and the straight distal section 11 S of the guiding catheter tube 11 . The reason why this is the case is because, as the cardiologist pulls the guiding catheter tube 11 in a downward direction, the distal end 19 E of the tube 11 will snap into and through the ostium of the renal artery into which it is aimed by means of the orientation of the side arm tube 14 at the proximal end of the guiding catheter 12 . This is true because the straight section 19 S will engage the point “p” (which is the apex of the angle “a”) as the guiding catheter tube 11 is pulled downward through the aorta 80 . The cardiologist can then adjust the position of the proximal end of the guiding catheter 12 so that the straight section 19 S is aimed essentially straight into the right renal artery 83 as shown in FIG. 9 . It is obvious that this technique can also be used to access either the right or the left renal artery.
The orientation of the side arm tube 14 that remains outside the patient's body will indicate to the cardiologist the correct angular orientation (i.e., the azimuth) of the curved distal section 11 A and the straight section 19 S at the distal portion of the guiding catheter tube 11 . This is achievable because when the side arm tube 14 lies horizontally relative to the table on which the patient has been placed on his or her back, then the straight distal section 19 S of the tube 11 will have the correct azimuth angle around the interior lumen of the aorta 80 in order to enter the correct renal artery. Thus when the side arm tube 14 would lie in a direction to the right and parallel to the operating table, then the distal end 19 E of the tube 11 would enter the left renal artery 82 . Likewise, if the side arm tube 14 is lying to the left and is parallel to the operating table, then the azimuth angle of the distal end 19 E of the guiding catheter tube 11 will be correct for entering the right renal artery 83 as shown in FIG. 9 .
This invention envisions that the Tuohy-Borst gland (such as glands 24 or 70 ) could be fabricated from a soft elastomer such as a low durometer silicone rubber. Furthermore, powdered Teflon or powdered graphite could be incorporated into the soft elastomer to improve its lubricity.
Thus the objectives of using a guiding catheter without passing it through an introducer sheath and the elimination of the need for a separate Tuohy-Borst “Y” adaptor and a separately attached three-way stopcock have been shown. Furthermore, the objective of inserting a guiding catheter and dilator over a guide wire without the free release of blood through the guiding catheter's proximal end can be accomplished by compressing the gland 24 around the guiding catheter tube 11 as the guiding catheter system 10 is advanced through the arterial system.
Although the discussion herein has been principally concerned with renal guiding catheter systems, the present invention is well suited for the placement of guiding catheters into the ostium of other arteries such as the carotid and coronary arteries as well as coronary artery bypass grafts.
Various other modifications, adaptations, and alternative designs are, of course, possible in light of the above teachings. Therefore, it should be understood at this time that within the scope of the appended claims, the invention may be practiced otherwise then as specifically described herein. | An elongated hollow tube guiding catheter forming a portion of a guiding catheter includes a proximal end, distal end, and distal section. The distal section includes a curved section and a straight section. The curved and straight sections are shaped for facilitating introduction and retention of the catheter into the ostium of a renal artery. The system includes a dilator inserted into the catheter hollow tube with a curved distal section of the dilator opposingly extending opposite the curved distal section of the guiding catheter hollow tube. The guiding catheter includes a side arm positioned near the guiding catheter's proximal end with a multi-way stop cock fixedly attached onto a proximal end of the side arm tube. | 0 |
TECHNICAL FIELD
This invention relates generally to smoking articles such as cigarettes, cigars and the like and the wrapper for the tobacco column thereof, and more particularly to an improved wrapper for such smoking articles for use either by itself or as an inner wrapper in combination with a conventional outer wrapper.
BACKGROUND OF THE PRIOR ART
A problem associated with smoking articles such as cigarettes or cigars is the amount of sidestream smoke that is given off during static burning, for example when the smoking article is idling and not being drawn upon by the smoker or is simply resting in an ashtray while burning. Visible sidestream smoke that is given off by a smoking article such as a cigarette during static burning is irritating and objectionable to nonsmokers in the vicinity of the idling cigarette.
A problem with heretofor developed wrappers that produced low sidestream smoke is that they give a flaky and/or off color ash due to poor ashing characteristics of the wrappers. Various mechanisms have been incorporated into smoking articles to reduce visible sidestream smoke and to improve the ashing characteristics of wrappers, but none to date has been commercially successful in overcoming both of these problems.
Probably the most effective means of reducing visible sidestream smoke, to date is disclosed and claimed in U.S. Pat. No. 3,231,377, Cline et al owned by applicant's assignee. Olin Corporation.
In this patent there is disclosed a wrapper for smoking articles such as cigarettes, cigars and the like containing at least 15% by weight magnesium oxide or its hydrate and at least 0.5% by weight of specific chemical adjuvant such as the alkali metal acetates, carbonates, citrates, nitrates or tartrates. The combination of magnesium oxide or its hydrate with any of the chemical adjuvants significantly reduces visible sidestream smoke that emanates during static burning from smoking articles employing the wrapper. The wrapper may comprise conventional cigarette paper with magnesium oxide and the adjuvant incorporated therein as the filler in the paper furnish or either or both of the additives may be applied to the paper as a coating. Wrappers containing the additives can be used in place of conventional wrappers for smoking articles or used as an inner wrapper for the tobacco column in combination with a conventional outer wrapping of cigarette paper or cigar wrap.
Following the teaching of this patent substantial and very desirable reduction in visible sidestream smoke can be achieved by using cigarette paper containing magnesium oxide as a filler in combination with certain chemical adjuvants. These papers have consistently given a flaky ash and have been determined to be unacceptable for use by the cigarette manufacturers due to the poor ashing characteristics. Extensive testing has not identified any chemical adjuvant or burning chemical or combination thereof which overcomes this problem.
The more reactive grades of magnesium oxide which are very effective as sidestream reducing fillers are at least partially converted to magnesium hydroxide during the papermaking process. MagChem 40, manufactured by the Martin Marietta Company, is an example of this type of product which gives a very flaky cigarette paper ash. In contrast, a hard-burned, unreactive magnesium oxide such as MagChem 10, produced by the same company, gives a white, solid ash which shrinks and holds on well. This unreactive oxide hydrates to give magnesium hydroxide only very slowly at ambient temperatures and remains essentially unchanged in the finished paper when used as a filler. Papers filled with unreactive magnesium oxide give no sidestream smoke reduction beyond that which can be achieved with calcium carbonate at equivalent high levels of basis weight, and burn rate accelerators.
These facts lead to the conclusion that magnesium hydroxide is a necessary ingredient if optimum sidestream reduction is to be achieved. It was speculated that if the effect of magnesium hydroxide on cigarette combustion was due to its endothermic dehydration at approximately 350° C., then the yield of sidestream tar should be inversely related to the amount of magnesium hydroxide in the paper. This has been determined not to be entirely true. Thus, MagChem 40, completely hydrated by slurrying in water overnight, is no more effective than when used without pretreatment to make handsheets. Approximately 50% of the unpretreated filler was converted to magnesium hydroxide during the process of making the handsheets. Also, powdered magnesium hydroxide used as the only filler component gave no greater sidestream reduction than the partially hydrated oxide and gave a darker, very flaky ash.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved cellulosic wrapper for smoking articles which has reduced sidestream smoke and a solid non-flaking ash.
A further object is to provide an improved cellulosic wrapper and smoking articles wrapped therein which avoids the expense and possible hazards of adding inorganic fibers to the wrapper to provide non-flaking ash.
These objects and advantages are provided by my discovery that probably intimate contact between magnesium hydroxide and cellulose fibers is required for effective sidestream smoke reduction. Thus then as the amount of filler added to the paper increases a point is reached where additional quantities of magnesium hydroxide no longer contact fiber surfaces but deposit on filler already laid down, forming larger aggregates. Further then magnesium hydroxide with a small particle size should be effective in covering the fiber surfaces at a lower overall content in the sheet.
In general the average particle size should be not greater than 10 micrometers and preferably not greater than 2 micrometers.
Since poor ash has been found to be related to magnesium hydroxide concentration in the sheet, it should be possible to achieve both improved ash and a low sidestream smoke yield by using an inert filler such as MagChem 10 (a non-reactive magnesium oxide) with a minor proportion of fine particle size magnesium hydroxide. Experiments have shown that this can be done.
The invention then consists of an improved cigarette paper product which gives greatly reduced yields of sidestream tar and visible sidestream smoke while giving a light colored solid ash which tends to hold on rather than to flake off the smoking article. The filler in the paper consists of a mixture of a major amount of unreactive magnesium oxide or other inert fillers with a minor amount of finely divided magnesium hydroxide. The paper should also contain a burn rate accelerating chemical adjuvant as described in U.S. Pat. No. 4,231,377.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a chart illustrating sidestream tar yields plotted against porosity for the tests set forth in Example III.
DETAILED DESCRIPTION OF THE INVENTION
Cellulosic wrappers made according to this invention may be made by incorporating the magnesium hydroxide and unreactive magnesium oxide fillers in the wrapper pulp furnish. Additionally, other inert fillers may be used in combination with Mg(OH) 2 and MgO such as calcium carbonate. The Mg(OH) 2 and MgO fillers may be applied to the improved wrapper as a coating, but this is not as desirable because it does not provide as much contact between the fillers and the fiber of the paper. In the case of cigarette papers, the fillers and magnesium hydroxide are added to an ordinary paper furnish such as pulped wood or flax fibers. The furnish of fiber pulp, magnesium hydroxide and fillers are then used to make a paper sheet on conventional papermaking machines.
The magnesium hydroxide and fillers may be added to fiber pulps customarily used to make cellulsoic paper wrappers for cigarettes or the tobacco materials used to make cigar wrap. Thus, in addition to wood and flax fibers, the furnish may be pulped tobacco stalks or stems to which is added a small percentage of fine particle magnesium hydroxide and unreactive magnesium oxide.
Smoking article wrappers containing the small percentage of magnesium hydroxide and the unreactive magnesium oxide with or without the other fillers according to this invention may be used as an inner wrapper under a normal outer wrapper for the tobacco column of the cigarette or cigar. Conventional cigarette paper, and preferably very porous or perforated cigarette paper, or cigar wrap may be used as the outer wrapping for the smoking article. Such a combination can reduce the tobacco weight necessary to make a satisfactory product, increases the tobacco rod firmness, and does not alter the appearance of the cigarette or cigar. Wrappers containing the additives according to this invention also may be used as the single wrap for smoking articles. With cigarettes, it is especially desirable to use high basis weight papers if only a single wrap is employed.
As heretofor set forth, some reduction in sidestream smoke and improvement in the ash appearance results when these fillers are used at the typical cigarette paper levels of 30% and basis weights in the range of 25 g/M 2 . Optimum benefits will be achieved at basis weights of 40 g/M 2 to 100 g/M 2 and total filler levels of 40% to 60%. The concentration of magnesium hydroxide in the filler will depend on its particle size among other things but will range between 5% to 50% or 2.5% to 25% of total sheet weight for paper with 50% total filler. For best results the wrappers should also contain at least 0.5% and preferably 2% or more of at least one of the class of burn rate accelerating chemical adjuvants disclosed in U.S. Pat. No. 3,231,377.
All of the handsheets in the following examples, which illustrate the invention, were made to contain 50% total filler as 100 g/M 2 basis weight. All were treated on the size press with 3.0% sodium acetate. Test cigarettes were rerolled using matched weights of Kentucky Referee 1R3 tobacco. Except where noted flax from the same beater run was used for all handsheets within each example.
EXAMPLE I
HydroMagma, magnesium hydroxide paste manufactured by Merck and Company, has an everage particle size much below 1 micrometer. This example compares mixtures of HydroMagma and MagChem 10 (an unreactive magnesium oxide) to similar mixtures of MagChem 10 and a sample of dry powdered magnesium hydroxide (supplied by Basic, Incorporated) with a particle size in the 10 micrometer range. The results are tabulated below:
______________________________________ Greiner Sidestream Average Porosity Tar Burning (seconds/ (mg/ TimeFiller Composition 50cc) cigarette) (minutes)______________________________________75% MagChem 10/ 61.0 9.6 13.825% HydroMagma50% MagChem 10/ 112.0 9.8 14.650% HydroMagma75% MagChem 10/ 22.9 13.0 10.425% Magnesium HydroxidePowder50% MagChem 10/ 19.2 12.3 9.950% Magnesium HydroxidePowder100% MagChem 40* 16.3 10.3 9.4(Control)______________________________________ *(MagChem 40 manufactured by Martin Marietta Company, is a reactive form of magnesium oxide which is partially converted to magnesium hydroxide during the papermaking process)
The comparison of the two forms of magnesium hydroxide is slightly flawed by the fact that different flax stock was used in the two cases. It is evident, however, that the magnesium hydroxide with the smaller particle size is more effective in reducing sidestream tar. The ash from all papers with the mixed fillers was much more solid and lighter in color than that from the control.
EXAMPLE II
In this series of test handsheets MagChem 10 was again used as the unreactive portion of the filler along with various levels of magnesium hydroxide derived from a slurry supplied by Merck and Company and designated as R1458. The average particle size of this magnesium hydroxide was larger than that of the HydroMagma of the previous example but still less than 1 micrometer. The results are tabulated below:
______________________________________Percent AverageMagnesium Greiner BurningHydroxide Porosity Sidestream Tar TimeIn Filler (seconds/50cc) (mg/cigarette) (minutes)______________________________________25 25.0 11.3 10.420 22.8 11.5 9.715 22.0 11.6 9.810 20.6 12.0 9.6 5 20.9 14.5 9.5MagChem 40 10.5 9.6 9.9Control______________________________________
As in Example I all of the papers with mixed filler gave lighter colored, less flaky ash than the MagChem 40 control.
EXAMPLE III
In this example, 75:25 mixtures of MagChem 10 with four different types of magnesium hydroxide were each used to make handsheets from three different flax stocks refined to different levels of weight length and freeness. The magnesium hydroxides used in this study were the HydroMagma paste; R1458 slurry; the Basic, Incorporated dry powder; and another dry powder of similar particle size manufactured by Merck and Company called Marinco H. The results are presented graphically in the drawing where sidestream tar yields are plotted against porosity which is related to the degree of refining. While there may be some minor differences due to other factors, clearly particle size of the magnesium hydroxide is the most important variable affecting sidestream yield. Thus, the curves for the HydroMagma paste and R1458 slurry with their much smaller particle size lie close together and much below those for the two dry powders which have larger particles.
EXAMPLE IV
Two aqueous dispersions of magnesium hydroxide supplied by Dow Chemical Company were used in this example. One of these, a commercial product called MHT-60, has a mean particle size in the 5 to 10 micrometers range. The other micronized (wet ground) version of MHT-60 had an average particle size less than 1.0 micrometer. The other component of the filler was either MagChem 10 magnesium oxide or Mississippi Lime Company bagged calcium carbonate. The results of tests on cigarettes rerolled in these papers are tabulated below:
______________________________________ Greiner Sidestream Average Porosity Tar Burning (seconds/ (mg/ TimeFiller Composition 50cc) cigarette) (minutes)______________________________________75% MagChem 10/ 17.0 11.5 9.325% MHT-60(Micronized)75% MagChem 10/ 10.0 13.6 10.325% MHT-6075% Calcium Carbonate 17.5 13.0 9.925% MHT-60(Micronized)75% Calcium Carbonate 12.5 13.3 10.025% MHT-60100% MagChem 10 9.3 18.7 10.3Control______________________________________
When used in combination with MagChem 10 the micronized MHT-60 with its smaller particle size was more effective in reducing sidestream tar yield. This effect was not apparent in the mixtures with calcium carbonate. These fillers did give substantially more sidestream reduction than the MagChem 10 control. All of the handsheets of this example gave lighter colored ash than paper made with magnesium hydroxide or one of the reactive grades of magnesium oxide as the only filler.
STATEMENT OF INDUSTRIAL APPLICATION
Cellulosic wrappers for smoking articles are made with fillers of fine grain magnesium hydroxide and unreactive magnesium oxide. Additionally, other inert fillers such as calcium carbonate may be used in a wrapper pulp furnish. The magnesium hydroxide and unreactive magnesium oxide may be applied to the improved wrapper as a coating although this is less effective. In the case of cigarette papers, the materials are added to an ordinary paper furnish such as pulped wood or flax fibers. The furnish of fiber pulp, magnesium hydroxide and magnesium oxide fillers are then used to make a paper sheet on conventional papermaking machines. | There is disclosed a wrapper for smoking articles such as cigarettes, cigars and the like comprising a cellulosic sheet containing a filler of fine grain magnesium hydroxide having an average particle size less than 10 micrometers and unreactive magnesium oxide.
This is also disclosed a method for reducing the visible sidestream smoke emanating from a smoking article and solidifying the ash by wrapping the tobacco charge in the smoking article in a combustible cellulosic sheet containing a filler of fine grain magnesium hydroxide having an average particle size less than 10 micrometers and unreactive magnesium oxide. | 3 |
This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/937,115 filed Feb. 7, 2014 and U.S. Provisional Patent Application Ser. No. 61/970,604 filed Mar. 26, 2014. The entire disclosure of each of the applications listed in this paragraph are incorporated herein by specific reference thereto.
FIELD OF INVENTION
This invention relates to beverage container accessories, and in particular to attachable and detachable shot glass and pocket type accessories having a clip formed on one side for allowing the shot glass type accessories to securely clip onto exterior edges of a larger beverage glass while keeping liquid contents in the shot glass level with liquid contents in the larger beverage glass.
BACKGROUND AND PRIOR ART
Shot glasses have generally been known to be small generally conical shaped flat bottomed glasses that can hold a shot of a beverage such as a shot of alcohol. Attempts have been made over the years to try to hang small shot glasses from a larger beverage glasses with a hook portion. However, these hanging shot glasses have problems making their usefulness not desirable.
For example, the hook hanging shot glass generally have inwardly tapering round exterior surfaces, which tend to cause the narrower diameter bottom of the shot glass to swing to an non-level and loose position against the tapering wall of a beverage glass, which can cause the contents of the shot glass to easily tilt and spill out. Additionally, the hook portions form a loose attachment point where the shot glass itself can easily fall off from the beverage glass.
Furthermore, the loose fitting hook and shape of the hook hanging shot glass does not allow for the larger beverage glass to be safely moved with the hook hanging shot glass hanging from one side. The loose attachment and shape of the hook hanging shot glass can easily result in the contents of the shot glass falling out and/or the shot glass easily falling from the larger beverage glass that it is being hung from. Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the invention is to provide attachable and detachable shot glass and pocket type accessories having a clip formed on one side for allowing the shot glass type accessories to securely clip onto exterior edges of a larger beverage glass while keeping liquid contents in the shot glass and pocket level with liquid contents in the larger beverage glass.
A secondary objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, which can increase sales of liquids being sold within the shot glasses and/or beverage glasses.
A third objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, and the shot glass and pocket being branded for advertisements.
A fourth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, with the clip and shot glass and pocket being able to match the radius of the lip of any tapered beverage container.
A fifth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, where the shot glass and pocket can stand alone as a 2 ounce drinking container.
A sixth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, where the shot glasses and pockets are nestable with identical shot glasses and pockets for both easy packaging and reduced storage space needs.
A seventh objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a larger beverage glass, having a softened rounded edge on the clip radius of the drinking side of the shot glass and pocket.
An eighth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of coffee and tea cups.
An ninth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of paper and cardboard cups and plastic cups.
A tenth objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a food cup, such as a yogurt cup, parfait cup, and the like.
An eleventh objective of the invention is to provide attachable and detachable shot glass and pocket having a clip formed on one side for allowing the shot glass and pocket to securely clip onto exterior edges of a container that holds painting supplies where the glasses and pockets can hold different colors of paint therein.
An attachable and detachable shot glass, can include a container having a front wall and a rear wall, the rear wall tapering outward from an upper edge to a base, the rear wall having an elongated clip formed thereon for allowing the shot glass to securely clip onto exterior edges of a larger beverage container while keeping liquid contents in the shot glass level with liquid contents in the larger beverage container.
The elongated clip can have a generally convex curved outer side for matching to a concave curved lip of the larger beverage container. The elongated clip can have both a generally convex curved inner lip, and convex curved upper wall.
The rear wall can have a generally convex curved exterior surface and the front wall with a generally convex curved exterior surface.
The container can further include tapered sides for allowing the shot glass to be stacked with another shot glass.
The shot glass can have a height of approximately 1.801 inches, a depth of approximate 1.069 inches, and a rear wall having a length of approximately 2.461 inches.
The container can have a front convex shaped wall and a concave rear wall.
The larger beverage container can hold at least approximately 8 ounces of fluid. The larger beverage container can hold at least approximately 12 ounces of fluid. The larger beverage container can be a paper cup, coffee cup, and the like.
The shot glass can be formed from molded plastic. The shot glass can be formed from translucent material. The shot glass can be formed from paper. The shot glass can be formed from cardboard.
The shot glass can have an interior volume for holding approximately 2 ounces. The front wall can taper inward from the upper edge to the base. The rear wall can have a generally convex curved exterior surface and the front wall with a generally convex curved exterior surface. The elongated clip can have a generally convex curved outer side for matching to a concave curved lip of the larger beverage container. The elongated clip can have both a generally convex curved inner lip, and convex curved upper wall.
The shot glasses can be clipped about other containers, such as bowls, buckets, and the like, holding food products, such as yogurt, parfaits, ice cream, and the like, with the shot glasses holding toppings.
The shot glasses can be clipped about other containers holding painting supplies, such as paint brushes with the shot glasses holding different paint colors.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a front upper right perspective view of the attachable and detachable shot glass with clip formed on a rear side.
FIG. 1B is a rear lower right perspective view of the shot glass of FIG. 1A .
FIG. 2A is a left side view of the shot glass of FIG. 1A .
FIG. 2B is a right side view of the shot glass of FIG. 1A .
FIG. 2C is a front view of the shot glass of FIG. 1A .
FIG. 2D is a rear view of the shot glass of FIG. 1A .
FIG. 2E is top view of the shot glass of FIG. 1A .
FIG. 2F is a bottom view of the shot glass of FIG. 1A .
FIG. 3A is an upper perspective view of the shot glass of the preceding figures clipped to an upper edge of a large beverage glass.
FIG. 3B is a side view of the beverage glass with clipped on shot glass of FIG. 3A .
FIG. 3C is a top view of the beverage glass with clipped on shot glass of FIG. 3A .
FIG. 4A is an upper perspective view of the shot glass of the preceding figures clipped to an upper edge of a coffee cup.
FIG. 4B is a side view of the coffee cup with clipped on shot glass of FIG. 4A .
FIG. 5A is an upper perspective view of the shot glass of the preceding figures clipped to an upper edge of an insulation sleeve around a coffee cup.
FIG. 5B is a side view of the coffee cup and sleeve with clipped on shot glass of FIG. 5A .
FIG. 6 is an upper perspective view of another embodiment with the shot glasses of the preceding figures attached about the rim of a yogurt/parfait cup.
FIG. 7 is an upper perspective view of another embodiment with the shot glasses of the preceding figures attached about the rim of bowl holding painting supplies.
FIG. 8 is an upper front perspective view of the shot glass of the preceding figures with a removable lid.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
In the Summary above and in the Detailed Description of Preferred Embodiments and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
In this section, some embodiments of the invention will be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.
The components of the figures will now be described.
1 shot glass 10 front convex curved wall tapers down to base 12 right convex curved wall 14 left convex curved wall 16 rim 20 base 26 edges 30 rear wall 32 side edges 34 bottom edge 36 upper edge 42 rear clip 44 upper curved edge of clip 100 beverage glass embodiment 110 inward tapering side walls of beverage glass 112 upper edge(rim) of beverage glass 200 coffee cup embodiment 210 inwardly tapering side walls of coffee cup 220 insulation sleeve on coffee cup 222 upper edge of insulation sleeve 300 parfait/yogurt container 310 sidewalls 312 upper edge(rim) 400 paint supplies container 410 sidewalls 412 rim 500 removable lid/cover embodiment 510 removable lid
FIG. 1A is an upper front right perspective view of the attachable and detachable shot glass 1 with clip 42 formed on a rear side 30 . FIG. 1B is a rear lower right perspective view of the shot glass 1 of FIG. 1A . FIG. 2A is a left side view of the shot glass 1 of FIG. 1A . FIG. 2B is a right side view of the shot glass 1 of FIG. 1A . FIG. 2C is a front view of the shot glass 1 of FIG. 1A . FIG. 2D is a rear view of the shot glass 1 of FIG. 1A . FIG. 2E is top view of the shot glass 1 of FIG. 1A . FIG. 2F is a bottom view of the shot glass 1 of FIG. 1A .
Referring to FIGS. 1A-2F , the shot glass 1 can include a front convex curved wall 10 with upper rim 16 which tapers down to base 20 ( FIG. 2A ) at an angle of approximately 76.44 degrees, and a right convex curved wall 12 which also tapers from upper rim 16 down to base 20 , and left convex curved wall 14 with upper rim 16 which tapers down to base 20 . The upper rim 16 can be slightly larger in thickness (approximately 0.042 inches) than the thickness (approximately 0.032 inches) of the front wall 10 and side walls 12 , 14 . The base 20 can have a substantially flat upper and lower surface with rounded curved edges 26 . The rear wall 30 can be a concave curved wall with tapers outward from the upper edge 36 to lower edge 34 at an angle of approximately 76.44 degrees. The rear wall 30 can include a rear bottom edge 34 and the rear upper edge 36 can both have rounded edges and have a generally concave configuration. Extending rearwardly from the shot glass 1 can be a downwardly protruding clip 42 having an upper convex curved portion which attaches to a mid portion of the rear upper edge 36 . The clip 42 can have a generally concave curved configuration being parallel to the concave curved rear wall 30 .
The novel shot glass can have a height of approximately 1.801 inches, a thickness between rear convex curved wall 30 and exterior convex curved front wall 10 of approximately 1.069 inches, along the top of the shot glass 1 . The width between the left side 14 and right side 12 of the upper portion of the shot glass 1 can be approximately 2.461 inches, which tapes down to a width between the left side 14 and the right side 12 on the bottom of the shot glass 1 of approximately 1.832 inches. The thickness of the walls of the shot glass can have a thickness of approximately 0.032 inches and the width of the rim 16 can have a thickness of approximately 0.042 inches. The term approximately can include +/−10% of the values listed. In addition the dimensions can be increased and decreased depending on the size of the shot glass application used.
The molded on upper edge 44 of the clip 42 can have a width of approximately 1.538 inches where the clip 42 is attached to the upper rear wall 36 of the shot glass 1 , with the clip 42 having a rounded upper edge 44 and exterior facing tab portion having a length of approximately 1.366 inches, with the clip 42 having a generally convex curved shape parallel to the inner concave curved wall of the shot glass itself. The radius R 1 of the upper rear edge 36 is approximately 1.514 inches and the radius R 2 of the lower rear edge 34 is approximately 1.681 inches.
Referring to FIGS. 1A-2F , the novel shot glass 1 can be molded from clear translucent plastic, and have an interior volume that can hold approximately 2 ounces of liquid therein. The novel attachable/detachable shot glass 1 can be used as an easy to slide-on 2 ounce plastic shot glass, with a 1.75 ounce fill line, that introduces a simple up-sell opportunity for eating and drinking establishments which provide the ability to increase the sales of distilled beverage purchases. The novel attachable/detachable shot glass can create a conversation between the server and the patron about its appearance on the glass.
The novel attachable/detachable shot glass 1 has a unique ability to raise the visibility of any premium distilled beverage because it can be branded with any company's logo. The novel attachable/detachable shot glass 1 can be germane to any ancillary product that can go on a glass; it can be filled with distilled beverages, such as alcohol, as well as other beverages such as non-alcoholic beverages, including soda, juice, and the like, as well as specialty beverages, such as but not limited to energy drinks, and the like.
FIG. 3A is an upper perspective view of the shot glass 1 of the preceding figures clipped to an upper edge(rim) 112 of a large beverage glass 100 . FIG. 3B is a side view of the beverage glass 100 with clipped on shot glass 1 of FIG. 3A . FIG. 3C is a top view of the beverage glass 100 with clipped on shot glass 1 of FIG. 3A .
Referring to FIGS. 1A-3C , the shot glass 1 can be clipped on so that the upper portion 44 closely fits onto the rim 112 of the beverage glass 100 and the clip 42 fits into the upper edge of the side walls 110 of the beverage glass 110 . The rear side 30 of the shot glass 1 which tapers outward from top to bottom rests against the inwardly tapering sidewalls 110 of the beverage glass 100 . The novel configuration of the shot glass 1 allows for the rim 16 of the shot glass 1 to remain level with the rim 112 of the beverage glass 100 when the shot glass 1 is clipped onto the rim 112 of the beverage glass 100 . This level arrangement is able to keep the contents in the shot glass 1 from spilling out, especially when the beverage glass 100 is transported with the shot glass 1 while both the beverage glass 100 and shot glass 1 are filled with liquids., such as when carried or on a serving tray and the like.
The larger beverage glass can be larger than an 8 ounce glass, 12 ounce glass, 16 ounce glass, 20 ounce glass, and the like, and be formed from glass material. Alternatively, the beverage glass can be formed from plastic, and the like, or cardboard, and the like, or some other variation of a paper product, and the like.
The novel attachable/detachable shot glass 1 can also be disposable and recyclable or the end-user can take it home as a souvenir/novelty.
The novel shot glasses are nestable with one another to allow for plural shot glasses to take up less storage space when not being used. The shot glasses can be stacked on top of one another with the base of one shot glass fitting into the upper opening of the shot glass below. The bottom edge of the clip of one shot glass can rest on the rim edge of a lower shot glass.
A novel step-by-step example of using the novel attachable/detachable shot glass will now be described.
1. The customer orders a beverage. 2. The bartender pours a beverage in a glass and slides on an empty attachable/detachable shot glass then serves it to the customer. 3. The customer asks about the empty attachable/detachable shot glass on the side of the glass thus giving the bartender the opportunity to up-sell with a premium shot of a distilled beverage. 4. The customer requests said premium shot to be added to the order. 5. The bartender pours the shot into the attachable/detachable shot glass while it is still on the side of the glass. 6. The customer removes the attachable/detachable shot glass from the side of the glass and drinks from the attachable/detachable shot glass.
The novel attachable/detachable shot glass has many unique features that include allowing for the shot glass to fit on any tapered beverage container. The novel attachable/detachable shot glass has a slide-on clip is designed with 1 degree of draft so the shot glass sits securely on the edge of a beverage container. The novel attachable/detachable shot glass can be made from FDA (Food and Drug Administration) approved plastic. The novel attachable/detachable shot glass can be designed to match the radius of the lip of any tapered beverage container. The novel attachable/detachable shot glass has can stand alone as a 2 ounce drinking container. The novel attachable/detachable shot glass has the ability to nest with itself for easy packaging.
The novel attachable/detachable shot glass can be branded by any company to promote their product. The novel attachable/detachable shot glass has as a softened edge on the radius of the drinking side.
FIG. 4A is an upper perspective view of the shot glass 1 of the preceding figures clipped to an upper edge of a coffee cup 200 . FIG. 4B is a side view of the coffee cup 200 with clipped on shot glass 1 of FIG. 4A .
Referring to FIGS. 4A-4B , the plastic shot glass 1 of the preceding figures can be clipped on the upper edge(rim) 212 of a coffee cup 200 , which has inwardly tapering side walls 210 . The outwardly tapering rear wall 30 of the shot glass 1 can rest against the inwardly tapering side wall 210 of the coffee cup 200 allowing for both the rim 16 of the shot glass 1 to be level with the rim 212 of the coffee cup 200 .
In this embodiment, the novel shot glass 1 can be used to hold cream, milk, other liquids and the like. Additionally, the shot glass 1 can hold condiments such as loose sugar or low calorie sweeteners, as well as packaged condiments and the like, as well as a stir. The cup 200 can be used for other beverages, such as but not limited to holding hot chocolate, tea, and the like As such, the shot glass 1 can hold other liquids such as lemon juice, tea bags, and the like.
In addition, the novel shot glass 1 can be used as a receptacle for light trash, such as used bags of sweeteners, a stir, new or used tea bag(s), napkins, and the like. While the cup is referred to a coffee cup, the cup can be a tea cup or any type of beverage cup, and the like.
FIG. 5A is an upper perspective view of the shot glass 1 of the preceding figures clipped to an upper edge 222 of an insulation sleeve 220 around a coffee cup 200 . FIG. 5 B is a side view of the coffee cup 200 and sleeve 220 with clipped on shot glass 1 of FIG. 5A . When desired, the shot glass 1 can be clipped on the upper edge 222 of the insulation sleeve 220 , and be used to hold liquids, and/or condiments, and/or utensils, such as a plastic or wood stir, spoon, and the like, as well as be a receptacle for loose trash.
FIG. 6 is an upper perspective view of another embodiment with the shot glasses 1 of the preceding figures attached about the rim 312 of a yogurt/parfait container 300 , which can include a cup, bowl, and the like. The clips 42 overhang the side walls 310 of the cup 300 . The cup 300 can be used to hold yogurt or parfait or ice cream or other deserts, foods, and the like. Each of the shot glasses 1 can hold different add-on toppings, and the like, such as but not limited to granola, chocolate, cherries, candy, and the like. Users can dispense the contents of the container 300 and selectively take different add-ons from each of the shot glasses 1 .
FIG. 7 is an upper perspective view of another embodiment with the shot glasses 1 of the preceding figures attached about the rim 412 of a container 400 such as a bucket, large bowl and the like, for holding painting supplies in the individual shot glasses 1 . The inside of container 400 can hold supplies such as paint brushes, small squeezable paint holders, while the shot glasses 1 can each store different colors of paint, so that this embodiment can be used for different groups such as children, students and the like, as well as for a single artist.
FIG. 8 is an upper front perspective view of a covered shot glass embodiment 500 the shot glass 1 of the preceding figures with a removable lid 510 that can be removed by being peeled off and the like. The lid 510 can be formed from a water proof type paper used with small creamers, or be of other materials, such as but not limited to aluminum foil, and the like. The lid 510 can also be a snap on plastic lid, and the like. The covered shot glass 1 with lid 510 can store liquids, or solids inside, such as but not limited to food items, beverage items, condiments, and the like, as well as any other storable item, and the like.
Although the preferred embodiments describe the shot glass as being molded from plastic, the shot glass can be formed from glass material as well. The novel shot glasses can also be formed from paper material with or without a water sealing layer, as well as made out of cardboard material and the like.
While the rigid formed shot glasses formed from glass material, plastic, paper, cardboard, and the like, can be nestable with one another. The pliable materials such as paper, cardboard, and the like, can allow for the shot glasses to be flattened when not being used.
Although preferred sizes of the shot glasses are described above, the shot glass can be made smaller to hold as low as approximately an ounce of fluid or solid materials, as well as larger to hold a few ounces of liquid or materials as needed.
While the clip is described as being molded on the shot glass, the clip can be applied by fasteners, such as adhesives, and the like.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Attachable and detachable shot glass and pocket type accessories having a clip on one side for allowing the shot glass type accessories to securely clip onto exterior edges of larger beverage containers, such as glasses, plastic container, paper and cardboard cups, while keeping top of the shot glass and the liquid contents in the shot glass level with the top of and the liquid contents in the larger beverage container, such as beverage glasses, coffee and tea and beverage cups, on insulation sleeves on cups, and the like. The shot glass can hold extra liquids, such as alcohol and non-alcohol therein, as well as hold sweeteners, creams, and the like. The shot glass is attachable to containers of other edible substances, such as desserts to hold toppings in the shot glasses. Shot glasses can be used to hold paints clipped on a container holding painting supplies, such as brushes. | 1 |
BACKGROUND
1. Field of the Invention
The present invention relates to a buoyant recreational flotation apparatus. More particularly, this invention pertains to a board-like device adapted to accommodate the body of a recreational user.
2. Description of the Prior Art
Numerous water sports, requiring skill and offering pleasurable recreation, require equipment suitable for the joint purposes of (1) buoyantly supporting the recreational user and (2) appropriately traveling through or transversing the aquatic medium.
With the exception of boating apparatus falling generally within the above parameters, the most thrilling and skillful aquatic diversions require equipment of sufficiently simple design and compact size to permit the user to act in concert with his equipment as a unitary, maneuverable body. Representative water sports include, but are not limited to, jet skiing, surfing, water skiing and board sailing.
"Body boarding" an offshoot, or "poor cousin", of classic surfing, has experienced a significant amount of popularity. This sport requires a board-like flotation device to support a prone user as he "rides" a wave as it cascades and then breaks at a beach. The sport thus constitutes a hybrid of the classic or erect surfing and the prone and boardless body surfing experience.
While body boarding offers a pleasurable experience for the recreational user, present-day equipment principally provides flotation, lacks maneuverability and adds little to the enjoyment of boardless body surfing.
SUMMARY AND OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide flotation apparatus suitable for aquatic sports that offers the recreational user substantial additional maneuverability.
It is yet another object of the present invention to provide such apparatus which is further suitable for both wave-powered and towed recreations.
It is yet still another object of the present invention to provide apparatus as described above that permits various recreational postures.
The preceding and other objects are addressed and attained by the present invention which provides a flotation apparatus for aquatic recreation. Such apparatus includes a buoyant body. Such body includes a region at the upper surface thereof adapted to receive a user. A handle is engaged to the body. Such handle is arranged for grasping by the user while supported by the body.
The preceding and other features and advantages of the invention will become further apparent from the detailed description that follows. Such description is accompanied by a set of drawing figures. Numerals of the drawing figures, corresponding to those of the written text, point to the features of the invention. Like numerals refer to like features throughout both the written text and the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the flotation apparatus of the invention supporting a recreational user in operation (squat-like posture);
FIG. 2 is a detailed perspective view of the flotation apparatus of the invention;
FIG. 3 is a cross-sectional view of the body of the flotation apparatus of the invention taken at section line 3--3 of FIG. 2; and
FIG. 4 is a perspective view of an alternative embodiment of the invention arranged to receive a recreational user in a substantially-prone posture.
DETAILED DESCRIPTION
Turning now to the drawings, FIG. 1 is a perspective view of the flotation apparatus 10 of the invention in operation. As shown, the apparatus 10 is employed in FIG. 1 by a user 12 while assuming a substantially squat-like posture to navigate through a non-placid aquatic medium 14, such as the ocean, to "ride" (i.e., usurp the power of) a wave 16. While illustrated in FIG. 1 with regard to a wave-propelled use, the present invention is also suitable for towed usage as provided, for example, by a motor boat. An eyelet 18, preferably of metallic fabrication, is anchored to the deck of the apparatus 10 for attachment to a tow line (not shown).
FIG. 2 is a detailed perspective view of the flotation apparatus 10 of the invention. Referring to FIGS. 1 and 2 in combination, one can see that the apparatus 10 comprises a body 20, preferably of buoyant pressed polyurethane, that has been molded into a shape appropriate for accommodating the recreational user 12 in a selected recreational posture. A depression 22 is formed within the deck of the body 20 for receiving the knees and shins of the user 12 in accordance with the posture illustrated in FIG. 1. In an alternative embodiment, described below, the depression is adapted to receive the upper body of the user 12, permitting the recreational user to assume a more-or-less prone posture.
The body 20 is generally apportioned between an upper deck 24 and a hull 26. Symmetrical, opposed arcuate sides 28 and 30 of the body define a pointed bow 32 and a substantially straight keel 34. Ports 36 may be optionally provided for drainage purposes.
As show in FIG. 1, a handle 38 is provided for grasping by the user during use. The handle 38 provides a distinct advantage. The handle 38 provides both a means for grasping and stabilizing one's position and attitude while "at the mercy" of a wave 16 or of a towing boat's wake. Additionally, the handle 38 provides the less-than-advanced user 12 with a means for maneuvering the apparatus 12 without employing or requiring the skilled balancing techniques of classic erect surfing.
FIG. 3 is a cross-sectional view of the body 20 taken at section line 3--3 of FIG. 2. As can be seen, the hull 26 includes a central, gently arcuate or convex portion 40 that is bordered at its edges by inclined side sections 42 and 44. The inclined side edges 42 and 44 provide a shape that is suitable for "edging" motion into a wave 16 as shown in FIG. 1. Further, by inclining the edges 42 and 44, the apparatus 10 is made readily steerable under the influence of torsion applied to the handle 38 by a recreational user. The hull is coated with a layer of high density polyurethane 46 that acts as a sealant of the buoyant pressed polyurethane 48 of the remainder of the body 20.
Seen in cross-section, the handle 38 comprises a tubular piece 50 that is anchored within an elevated region of the upper deck of the body 20 by means of an appropriate adhesive 52. The tubular piece 50 is terminated at either end by hand holds 54 and 56 for grasping in the manner illustrated in FIG. 1.
FIG. 4 is perspective view of an alternative embodiment of the invention. As discussed above, the embodiment of FIG. 4 differs from that of the prior figure in that the depression 58 of the upper deck of the body is arranged for receiving the upper body, as opposed to the knees and shins, of a user. Unlike the configuration shown in FIGS. 1 and 2, the embodiment of FIG. 4 is adapted to support a recreational user while lying substantially prone and grasping the hand holds 54 and 56.
While this invention has been described with reference to its presently preferred embodiment, it is not limited thereto. Rather, this invention is limited only insofar as it is defined by the following set of patent claims and includes within its scope all equivalents thereof. | Apparatus for recreational use in an aquatic medium. A buoyant body includes a depressed region adapted to receive the body of a user in a preferred recreational posture. Handles are provided, anchored in the deck of the apparatus, for grasping by the user, allowing the less-than-expert to obtain maneuverability and enjoy surfing-type sports. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a mechanism that enables an occupant of a vehicle seat to manually adjust the vertical and the fore and aft positions of the seat.
2. Description of the Related Art
Traditionally, vertical seat adjustment capability in automobiles was reserved for expensive luxury vehicles. Recently, however, in response to increased consumer demands, many automobile manufacturers have begun providing, in smaller economy cars, vehicle seats that are adjustable in the vertical as well as the fore and aft direction. One problem encountered in providing such a feature is that the increased weight, complexity, and expense of conventional powered seat adjustment systems have made such devices impractical for use in smaller, less-expensive cars. Thus, automobile manufacturers have turned to compact, manually operated, and mechanically simple seat adjustment mechanisms for economy cars.
The manual, six-way seat adjuster, providing fore and aft horizontal adjustment capabilities, and independent height adjustment capabilities for the forward and rearward portions of the seat cushion, is well known in the art. Typically, one or more adjusting levers are provided for the occupant of the seat to manipulate to allow manual adjustment of the seat to a desired position. While six-way seat adjusters are well known, there nevertheless remains the constant need and challenge to improve the reliability of the manual six-way seat adjuster while at the same time reducing the number of parts required and simplifying the construction and operation of such devices.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a six-way manual seat adjustment mechanism that meets the aforementioned needs and challenges. Specifically, a manually adjustable vehicle seat assembly is provided which includes a seat, including a seat cushion assembly having forward and rearward portions constructed and arranged to support an occupant sitting thereon and a seat back assembly constructed and arranged to support the back of an occupant sitting on the seat cushion assembly. Furthermore, there is provided a pair of track assemblies disposed in a spaced parallel arrangement, each track assembly includes a stationary track fixed to a vehicle floor and a translating track slidably interconnected with the stationary track. A horizontal adjustment mechanism is provided that is constructed and arranged with respect to the track assemblies to provide an occupant of the seat with the ability to position the translating tracks in a selected one of a multiplicity of different horizontal positions with respect to the stationary tracks.
Forward and rearward seat support arm assemblies, constructed and arranged to support the forward and rearward portions, respectively, of the seat cushion assembly in a selected one of a multiplicity of vertical positions, are provided. In addition there is provided, a mounting structure constructed and arranged to support the forward and rearward seat support arm assemblies and the seat supported thereon on the translating tracks to allow the horizontal positioning of the translating tracks to horizontally position the seat. The rearward seat support assembly includes a biasing system operatively coupled therewith and constructed and arranged to urge the rearward seat support arm assembly and the rearward portion of the seat cushion assembly into an upward position.
Finally, there is provided a vertical adjusting mechanism, constructed and arranged to allow either of said seat support arm assemblies to be moved into a selected vertical position and to be retained thereat. The vertical adjusting mechanism includes forward and rearward sector gears having a plurality of locking projections operatively coupled with the forward and rearward seat support arm assemblies respectively and moveable with the forward and rearward seat support arm assemblies as the forward or rearward portion of the seat cushion assembly is positioned in the selected one of a multiplicity of vertical positions.
Forward and rearward locking members are provided, each having locking teeth, an engaging surface, and a disengaging surface. Each locking member is mounted with respect to the mounting structure for movement between: (1) an engaged position wherein the locking teeth of the locking member are engaged with the locking projections of the corresponding sector gear, thereby preventing movement of the sector gear, the corresponding seat support arm assembly, and the corresponding forward or rearward portion of the seat cushion assembly, and (2) a disengaged position wherein the locking teeth of the locking member are disengaged from the locking projections of the corresponding sector gear, thereby releasing the sector gear, the corresponding seat support arm assembly, and the corresponding forward or rearward portion of the seat cushion assembly for movement of the portion of the seat cushion assembly into the selected one of a multiplicity of vertical positions.
Next are provided forward and rearward camming members each having a locking surface and a camming surface. Each forward and rearward camming member is mounted with respect to the mounting structure for movement between: (1) a locked position wherein the locking surface of the camming member is engaged with the engaging surface of the corresponding forward or rearward locking member so as to urge the locking member into its engaged position, and (2) a released position wherein the camming surface of the camming member is engaged with the disengaging surface of the corresponding forward or rearward locking member so as to urge the locking member into its disengaged position.
A resilient coupling is provided between the forward and rearward camming members which is constructed and arranged to urge the forward and rearward camming members into their engaged positions.
A lever actuated control member is provided which is mounted with respect to the mounting structure for movement between a centered position and either (1) a fully forward position or (2) a fully rearward position. Furthermore, an actuating lever is provided which is constructed and arranged to enable an occupant of the seat to move the lever actuated control member from the centered position into a selected one of the fully forward position and the fully rearward position. Finally, the vertical adjusting mechanism includes a fore and aft motion transmitting member coupled at an intermediate portion thereof with the lever actuated control member and at opposite ends thereof with the forward and rearward camming members by pin and slot connections.
When the lever actuated control member is moved from the centered position to its fully forward position the pin and slot connection with the rearward camming member causes the same to move against the urging of the resilient coupling from the locked position thereof into the released position thereof while the pin and slot connection with the forward camming member allows the same to remain in the locked position thereof. When the lever actuated control member is moved from the centered position to its fully rearward position the pin and slot connection with the forward camming member causes the same to move against the urging of the resilient coupling from the locked position thereof into the released position thereof while the pin and slot connection with the rearward camming member allows the same to remain in the locked position thereof.
It is another object of the invention to provide a vertical adjustment mechanism requiring a minimum number of parts and having simple construction. The vertical adjustment mechanism of the present invention satisfies this object by providing a construction that is symmetric about a vertical plane that is transverse to the fore and aft direction. The components employed and the assembly required in the foreword portion of the vertical adjustment mechanism of the present invention are identical to the components employed and the assembly required in the rearward portion of the device.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view with partial cutout of a manual six way seat adjustment assembly illustrating a preferred embodiment of the present invention.
FIG. 2 is a perspective view of a preferred embodiment of a vertical adjustment mechanism according to the present invention.
FIG. 3 is an elevational view of a vertical adjustment mechanism according to the present invention with the actuating lever in a locking position.
FIG. 4 is an elevational view of a vertical adjustment mechanism according to the present invention with the actuating lever in a fully rearward position.
FIG. 5 is an elevational view of a vertical adjustment mechanism according to the present invention with the actuating lever in a fully forward position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the six-way manually adjustable vehicle seat assembly 10 provided in accordance with the present invention is shown in FIG. 1. The adjustable seat assembly 10 includes a vehicle seat shown in phantom in FIG. 3 which includes a seat cushion and a back rest.
The adjustable seat assembly 10 further includes left and right track assemblies 102, 104. The track assemblies include elongated stationary tracks 106, 108 that are fixedly mounted on a vehicle floor (not shown), and elongated translating tracks 110, 112 that are slidably interconnected with the stationary tracks 106, 108. A horizontal adjustment mechanism 100 is provided to allow an occupant of the seat to selectively position the translating tracks 110, 112 in one of a multiplicity of horizontal positions relative to the stationary tracks 106, 108. The horizontal adjustment mechanism includes an apparatus, such as an adjusting bail 114, which is pivotally mounted on pins 116 (right side only shown) to the translating tracks 110, 112 and with which an occupant can selectively disengage locking mechanisms 118 (right side only shown) by lifting the adjusting bail 114. With the locking mechanisms 118 disengaged, the translating tracks 110, 112 are slidable relative to the stationary tracks 106, 108, and the occupant of the seat may manually position the seat, which is fixed to the translating tracks in a manner to be described below, in a selected one of a multiplicity of different horizontal positions in a fore and aft direction. Upon release of the adjusting bail 114, biasing members 119 (right side only shown) within the locking mechanisms 118 will urge the locking mechanisms back into a locked position. A mechanism such as that disclosed in U.S. Pat. No. 4,733,845 exemplifies a suitable horizontal adjustment mechanism for use with the present invention.
Next are provided forward and rearward seat support arm assemblies 203,205, each including a forward torsion rod 202 and a rearward torsion rod 206, respectively. As shown in FIG. 1, mounted on opposite ends of the forward torsion rod 202 are left and right forward seat support arms 222, 226. The forward seat support arms 222, 226 are fixedly mounted to the forward torsion rod 202 so as to be rotatable along with the forward rod 202, the left forward seat support arm 222 being a slave of the right forward seat support arm 226, and vice versa. Forward seat support arm 222 is held on torsion rod 202 by nut 240.
Mounted on opposite ends of the rearward torsion rod 206 are left and right rearward seat support arms 230, 234. The rearward seat support arms 230, 234 are fixedly mounted to the rearward torsion rod 206 so as to be rotatable with the rearward rod 206, the left rearward seat support arm 230 being a slave of the right rearward seat support arm 234, and vice versa. Rearward seat support art 230 is held on torsion rod 206 by nut 242. In addition, as shown in FIG. 1, the rearward torsion rod is operatively coupled with a biasing system 238 which urges the rearward torsion rod 206 to rotate in such a manner as to rotate the rearward seat support arms 230, 234 into an upward position.
Left and right seat cushion mounting members 244, 250 are provided for securing the vehicle seat to the six-way seat adjustment assembly 10. The end portions 224, 228 of the left and right forward seat support arms 222, 226 are pivotally coupled with the forward portions 246, 252 of the left and right seat cushion mounting members 244,250 respectfully. The forward seat support arms 222, 226 are coupled with the seat cushion mounting members 244, 250 by means of pins 256, 258 extending from the forward pivoting seat support arms 222, 226 and into longitudinal slots 260, 262 (see FIG. 1) in the forward portions 246, 252 of the seat cushion mounting members 244, 250, thus effecting a lost motion coupling. Also, the end portions 232 (see FIG. 2), 236 of the left and right rearward seat support arms 230, 234 are pivotally attached to the rearward portions 248, 254 of the left and right seat cushion mounting member 244, 250 respectively. The seat, including the seat cushion and the seat back, is mounted to the seat cushion mounting members 244, 250 by any suitable means such as bolts or rivets.
A mounting structure is provided, which includes a left and right rod mounting members 210, 212 and a component mounting structure 214. The torsion rods 202, 206 are journally supported in a parallel arrangement by the left and right rod mounting members 210, 212. Furthermore, the left and right rod mounting members support the forward and rearward seat support arm assemblies 203,205 and the seat supported thereon on the translating tracks 110, 112 to allow the seat and the translating tracks to be positioned horizontally relative to the stationary tracks, 106, 108. The seat support arm assemblies are fixed to the translating tracks by any suitable means such as bolts, rivets, welds, or the like. In this manner, the vehicle seat is also secured to the vehicle floor.
As also shown in FIG. 1, a vertical adjustment mechanism 200 is also provided. The vertical adjustment mechanism 200 allows the occupant of the seat to independently position either the forward or rearward seat support assemblies 203,205 into a selected one of a multiplicity of vertical positions and then retain the seat support assembly thereat.
The vertical adjustment mechanism 200 includes the component mounting structure 214 that is arranged adjacent to and parallel with one of the track assemblies. The component mounting structure 214 is shown in FIG. 1 positioned adjacent to and parallel with the left track assembly 102, however, it will be clear to one skilled in the art that the component mounting structure may be fixed alongside the right track assembly 104 as well. As best seen in FIG. 2, the component mounting structure 214 is constructed of an inner component mounting structure plate 216 and an outer component mounting structure plate 218, disposed in a substantially parallel arrangement and defining a space 220 therebetween.
The remaining details of the vertical adjustment mechanism are best shown in FIGS. 2-5 depicting the component mounting structure 214 of the vertical seat adjustment mechanism 200 separate from the remainder of the six-way seat adjustment assembly 10.
A forward sector gear 264 having locking projections 266 along a curved portion thereof is mounted on the forward torsion rod 202 in the space 220 between the inner and outer component mounting structure plates 216, 218. The forward sector gear 264 is fixedly mounted to the forward torsion rod 202 so as to be rotatable with the rod and is oriented in such a manner that the locking projections 266 generally face rearwardly. The range of rotational motion of the forward sector gear 264, and thus of the forward torsion rod 202, is preferably restricted by means of a restraining pin 268 extending from the forward sector gear 264 and into a forward arcuate slot 270 located in the component mounting structure 214.
In a mirror construction of the forward sector gear 264, a rearward sector gear 274 having locking projections 276 along a curved portion thereof is mounted on the rearward torsion rod 206 in the space 220 between the inner and outer component mounting structure plates 216, 218. The rearward sector gear 274 is fixedly mounted to the rearward torsion rod 206 so as to be rotatable with the rod and is oriented in such a manner that the locking projections 276 generally face forwardly. The range of rotational motion of the rearward sector gear 274, and thus of the rearward torsion rod 206, is preferably restricted by means of a restraining pin 278 extending from the rearward sector gear 274 and into a rearward arcuate slot 280 located in the component mounting structure 214.
At a position toward the center of the component mounting structure 214 from the forward sector gear 264, a forward locking member 282 (see FIGS. 3-5) having locking teeth 284, an engaging surface 286, and a disengaging surface 288 is pivotally mounted on a pin 290 in the space 220 between the inner and outer component mounting structure plates 216, 218. The forward locking member 282 is pivotable between: (1) an engaged position, shown in FIGS. 3 and 5, wherein the locking teeth 284 are engaged with the locking projections 266 of the forward sector gear 264 thereby preventing rotation of the forward sector gear, the forward seat support arm assembly, and the forward portion of the seat cushion assembly, and (2) a disengaged position, shown in FIG. 4, wherein the locking teeth 284 are disengaged from the locking projections 266 of the forward sector gear 264, thereby releasing the forward sector gear 264, the forward seat support arm assembly 203, and the forward portion of the seat cushion assembly for vertical positioning of the forward portion of the seat cushion assembly.
In a mirror construction of the forward locking member 282, at a position toward the center of the component mounting structure 214 from the rearward sector gear 274, a rearward locking member 292 having locking teeth 294, an engaging surface 296, and a disengaging surface 298 is pivotally mounted on a pin 300 in the space 220 between the inner and outer component mounting structure plates 216, 218. The rearward locking member 292 is pivotable between: (1) an engaged position, shown in FIGS. 3 and 4, wherein the locking teeth 294 are engaged with the locking projections 276 of the rearward sector gear 274 thereby preventing rotation of the rearward sector gear, the rearward seat support arm assembly, and the rearward portion of the seat cushion assembly, and (2) a disengaged position, shown in FIG. 5, wherein the locking teeth 294 are disengaged from the locking projections 276 of the rearward sector gear 274, thereby releasing the rearward sector gear 274, the rearward seat support arm assembly 205, and the rearward portion of the seat cushion assembly for vertical positioning of the rearward portion of the seat cushion assembly.
At a position toward the center of the component mounting structure 214 from the forward locking member 282, a forward camming member 302 having a locking surface 304 and a camming surface 306 is pivotally mounted on a pin 308 in the space 220 between the inner and outer component mounting structure plates 216, 218. The forward camming member 302 is mounted for pivotal movement between: (1) a locked position, shown in FIGS. 3 and 5, wherein the locking surface 304 is engaged with the engaging surface 286 of the forward locking member 282 so as to urge the forward locking member into its engaged position, and (2) a released position, shown in FIG. 4, wherein the camming surface 306 is engaged with the disengaging surface 288 of the forward locking member 282 so as to urge the forward locking member into its disengaged position.
In a mirror construction of the forward camming member 302, at a position toward the center of the component mounting structure 214 from the rearward locking member 292, a rearward camming member 312, having a locking surface 314 and a camming surface 316, is pivotally mounted on a pin 318 in the space 220 between the inner and outer component mounting structure plates 216, 218. The rearward camming member 312 is mounted for pivotal movement between: (1) a locked position, shown in FIGS. 3 and 4, wherein the locking surface 314 is engaged with the engaging surface 296 of the rearward locking member 292 so as to urge the rearward locking member into its engaged position, and (2) a released position, shown in FIG. 5, wherein the camming surface 316 is engaged with the disengaging surface 298 of the rearward locking member 292 so as to urge the rearward locking member into its disengaged position.
The vertical adjustment mechanism 200 is further provided with a resilient coupling 322, such as a tension spring or the like, disposed within a horizontal slot 324 in the component mounting structure 214. Opposite ends of the resilient coupling 322 are attached to lower portions 326, 336 of the forward and rearward camming members 302, 312, so that the resilient coupling urges the forward and rearward camming members into their locked positions.
A lever actuated control member 338 (see FIG. 2) is pivotally mounted at 340 to the component mounting structure 214 generally at its center. The lever actuated control member is moveable between a centered position, see FIG. 1, and either a fully forward position, see FIG. 5, or a fully rearward position, see FIG. 4.
As can be seen in FIG. 3, the lever actuated control member 338 defines a line of symmetry about which the geometry of the components mounted to the forward portion of the component mounting structure mirrors the geometry of the components mounted to the rearward portion of the component mounting structure.
A fore and aft motion transmitting member 342 having a forward longitudinal slot 344 and a rearward longitudinal slot 346 is coupled with the lever actuated control member 338 at an end of the lever actuated control member opposite the end at which it is pivotally mounted to the component mounting structure 214. The fore and aft motion transmitting member 342 is coupled with the lever actuated control member 338 preferably by means of a lost motion coupling formed by a pin 348 extending from the lever actuated control member and into a transversely elongated hole 350 located in the fore and aft motion transmitting member 342 between the forward longitudinal slot 344 and the rearward longitudinal slot 346.
A forward camming member sliding pin 310 extending from the forward camming member 302 and into the forward longitudinal slot 344 couples the fore and aft motion transmitting member 342 with the forward camming member 302. Similarly, a rearward camming member sliding pin 320 extending from the rearward camming member 312 and into the rearward longitudinal slot 346 couples the fore and aft motion transmitting member 342 with the rearward camming member 312.
An actuating lever 352 is fixedly attached at 354 (see FIG. 2) to the lever actuated control member 338 such that the actuating lever 352 and the lever actuated control member 338 form an assembly that pivots about point 340. The actuating lever enables an occupant of the seat to move the lever actuated control member from the centered position into a selected one of the fully forward and fully rearward positions.
Operation of the vertical adjustment mechanism of the present invention will now be described with reference to FIGS. 3-5.
As shown in FIG. 3, with the actuating lever 352 in a centered or locking position, the resilient coupling 322 urges the forward and rearward camming members 302, 312 into their respective locked positions. The seat cushion is then in a fully locked position with respect to its vertical orientation.
As shown in FIG. 4, a rearward pivoting of the actuating lever 352 results in a nearly rectilinear, rearward translation of the fore and aft motion transmitting member 342. The forward camming member sliding pin 310, already at the forwardmost end of the forward longitudinal slot 344, is pulled rearward by the fore and aft motion transmitting member 342 thus pivoting the forward camming member 302 clockwise about the pin 308 from the locked position into the released position.
The rearward camming member sliding pin 320 is initially at the rearwardmost end of the rearward longitudinal slot 346. Therefor, the fore and aft motion transmitting member 342 can translate rearward without disturbing the rearward camming member from its locked position.
The occupant may then either lean forward to lower the front portion of the seat cushion or lean backward to raise the forward portion of the seat cushion, the rear portion of the seat cushion all the while remaining fixed. Upon release of the actuating lever 352, the resilient coupling 322 again urges both the forward camming member 302 and the rearward camming member 312 into their respective locked positions, and the seat is again in a fully locked position.
As shown in FIG. 5, a forward pivoting of the actuating lever 352 results in a nearly rectilinear, forward translation of the fore and aft motion transmitting member 342. The rearward camming member sliding pin 320, already at the rearwardmost end of the rearward longitudinal slot 346, is pulled forward by the fore and aft motion transmitting member 342, thus pivoting the rearward camming member 312 counterclockwise about the pin 318 from the locked position into the released position.
The forward camming member sliding pin 310 is initially at the forwardmost end of the forward longitudinal slot 344. Therefor, the fore and aft motion transmitting member 342 can translate forward without disturbing the forward camming member from its locked position.
With the rearward torsion rod 206 and rearward pivoting seat support arms 230, 234 free to rotate, the torsional biasing member 238 will urge the rearward pivoting seat support arms 230, 234 upward. The occupant need only lift his/her weight off the rear of the seat cushion to allow the rear portion of the seat cushion to rise. Alternatively, the occupant need only allow his/her weight to push down on the rear portion of the seat cushion to adjust the rear portion of the seat cushion downward. Upon release of the actuating lever 352, the resilient coupling 322 again urges both the forward camming member 302 and the rearward camming member 312 into their respective locked positions, and the seat is again in a fully locked position.
Having described the invention, it will be apparent to those skilled in the art that various modifications may be made thereto without departing from the spirit and scope of this invention as defined in the appended claims. | An improved manually adjustable vehicle seat assembly is disclosed. The adjustable vehicle seat assembly includes a vehicle seat, track assemblies each with a stationary track fixed to a vehicle floor and a translating track slidably interconnected with the stationary track, a horizontal adjustment mechanism that provides an occupant of the seat with the ability to position the translating tracks horizontally relative to the stationary tracks, a seat support structure, including forward and rearward seat support arm assemblies, for supporting the seat on the translating tracks, and a vertical adjustment mechanism having forward and rearward sector gears coupled with the forward and rearward seat support arm assemblies respectively, forward and rearward locking members mounted so as to be selectively engageable with the corresponding sector gear to prevent movement of the sector gear, and seat support arm assembly coupled thereto, when engaged, forward and rearward camming members mounted so as to be selectively moved to either engage or disengage the corresponding locking member, a resilient coupling between the camming members, a lever actuated control member, an actuating lever, and a fore and aft motion transmitting member coupled with the lever actuated control member and the camming members by pin and slot connections so that upon movement of the lever actuated control member one camming member is moved so as to disengage a corresponding locking member while the other camming member continues to hold the corresponding locking member in the engaged position. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention generally pertains to a snap disc device, and more specifically pertains a snap disc device whose particular geometry provides exceptional operating characteristics.
2. Description of Related Art
The use of conventional compression springs can be limited by their physical size, as such springs are usually much longer than other types of springs. So, in applications where space is limited, other types of springs are often used, such as Bellville washers, curved disc springs, wave disc springs, and finger disc springs.
Belleville washers are resiliently compressible conical washers that provide a spring effect. For a given length, Belleville washers typically have much higher spring rates and significantly less travel than compression springs. This limits the use of Bellville washers to applications requiring relatively high forces and little travel. Belleville washers can be stacked back-to-back to provide lower spring rates and more travel, but a stack of washers will of course consume more space.
Curved disc springs have the shape of a flat washer that has been bent or bowed about a line parallel to the face of the washer. For a given size, a single curved disc springs may provide a lower spring rate than that of a Bellville washer. However, stacking curved disc springs to achieve even lower spring rates can be difficult to accomplish. Stacking the springs peak-to-peak is difficult to maintain, as the discs are normally free to rotate to a more stable arrangement of peak-to-valley.
Wave disc springs are similar to curved disc springs, but with more bends to create a wavy shape. Just as with curved disc springs, it can be difficult to maintain a stack of wave disc springs in a peak-to-peak arrangement. For a given size, wave disc springs tend to have less travel than curved disc springs.
Finger disc springs comprise an annular disc whose outer perimeter includes several fingers that are bent out of coplanar alignment with the rest of the disc. The fingers can resiliently deflect to create a spring-like effect. The fingers, however, may also interfere with being able to effectively stack finger disc springs with predictable results.
The physical structure of conventional disc springs limits their application. Current disc springs have limited use as springs and are not readily adapted for other uses such as gripping a square key.
Snap disc devices, invented by Pierre Schwab and disclosed in U.S. Pat. Nos. 4,822,959 and 5,269,499 have clover leaf shapes to create a bi-stable snap-action. However, the physical structure, operating characteristics, and/or method of pre-stressing such snap discs limits their usefulness.
SUMMARY OF THE INVENTION
To overcome the limitations of current disc springs and snap disc devices, an object of some embodiments of the invention is to provide an elastic disc that serves as a fastener by gripping the four sides of a square shaft.
Another object of some embodiments of the invention is to provide a fastener with a particular disc geometry that provides the fastener with a surprisingly high coefficient of compliance, and yet the fastener is readily stackable to lower or increase its spring rate.
Another object of some embodiments is to provide a fastener with a threaded member, wherein the fastener indicates the degree of tightness to which the threaded member compresses a bowed disc a predetermined amount of deflection against a standoff element.
Another object of some embodiments is to provide a disc-like fastener that helps inhibit a threaded fastener from unscrewing under vibration.
Another object of some embodiments is to provide a fastener with a threaded member, wherein the fastener indicates the degree of tightness to which the threaded member compresses a bowed disc a predetermined amount of deflection against a standoff element, and wherein the standoff element is a simple unitary ring.
Another object of some embodiments of the invention is to provide a fastener with a particular disc geometry that provides the fastener with a lower spring rate and more travel than a Belleville washer of similar material, thickness and diameter.
Another object of some embodiments of the invention is to provide a fastener with a particular disc geometry that provides the fastener with a higher coefficient of compliance than a Belleville washer of similar material, thickness and diameter.
Another object of some embodiments of the invention is to provide a fastener with a particular disc geometry that provides the fastener with spring characteristics that are generally between that of a Belleville washer and a compression spring.
Another object of the invention is to provide a cloverleaf shaped disc having a bowed shaped when it its normally unstressed position.
Another object of some embodiments is to provide a cloverleaf disc with radial protrusions around its outer perimeter that provide the disc with more freedom to deflect.
Another object is to provide a disc fastener that is radially symmetrical so it can be installed alone or in a stacked arrangement regardless of its rotational orientation.
Another object of some embodiments is to provide a disc fastener with ample travel and a significant spring rate even though the disk has a rather large diameter to thickness ratio.
Another object of some embodiments is to provide a disc fastener whose material thickness is less than 5% of its diameter, thereby making the disc especially useful where axial space is limited.
These and other objects of the invention are provided by a disc fastener having an outer edge and an inner edge, wherein portions of the inner edge extend radially further out than some portions of the outer edge. The disc's geometry provides a coefficient of compliance greater than 10, wherein the coefficient of compliance is defined as the disc's thickness cubed divided by a product of the disc's spring constant at 75% compression times the disc's effective outer diameter squared, wherein the thickness is expressed in mils, the spring constant is expressed in pounds per inch and the effective outer diameter is expressed in inches.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a disc fastener according to one embodiment of the invention.
FIG. 2 is a side view of the disc in FIG. 1 .
FIG. 3 is similar to FIG. 1, but of another embodiment.
FIG. 4 is a cross-sectional view taken along line 4 — 4 of FIG. 3 .
FIG. 5 is similar to FIGS. 1 and 3, but of yet another embodiment.
FIG. 6 is similar to FIG. 4, but of another embodiment.
FIG. 7 is a chart comparing various characteristics of the present invention, Bellville washers, curved washers, wave washers and finger washers.
FIG. 8 is similar to FIG. 3, but showing the disc gripping a round rod.
FIG. 9 is a front view of FIG. 8 .
FIG. 10 is similar to FIG. 8, but showing the disc of FIG. 1 gripping a square bar.
FIG. 11 is a front view of FIG. 10 .
FIG. 12 is a top view of another embodiment.
FIG. 13 is a cross-sectional view taken along line 13 — 13 of FIG. 12 .
FIG. 14 is similar to FIG. 13, but with the disc compressed 75%.
FIG. 15 is similar to FIG. 14, but with the disc at another position.
FIG. 16 is similar to FIG. 13, but of another embodiment.
FIG. 17 is similar to FIG. 16, but with the disc compressed 75%.
FIG. 18 is similar to FIG. 17, but with the disc compressed 100%.
FIG. 19 is similar to FIG. 16, but showing a different threaded fastener and showing a set of discs stacked in such a way as to provide a greater spring rate.
FIG. 20 is similar to FIG. 19, but with a set of discs stacked in such a way as to provide a lower spring rate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A fastener shown in FIGS. 1 and 2 includes a disc 10 with various design features that provide the fastener with the versatility to perform a variety of functions. Disc 10 (as shown or with some modification) can selectively serve as a variety devices including, but not limited to, a compression spring, a shaft or bar locking element, or tightness indicator for a threaded fastener.
Disc 10 is preformed so that its face surface 12 assumes a bowed or conical shape when in its unstressed position of zero percent (i.e., the disc's natural relaxed state, as shown by various discs in FIGS. 1, 2 , 3 , 4 , 5 , 12 , 13 and 16 ). A fully stressed position of 100% is where a disc is completely flattened out, as shown in FIG. 18 . An intermediate position is when a disc is compressed to a position between its unstressed position of zero percent and its fully stressed position of 100%. For example, FIGS. 14, 15 and 17 show a disc compressed to an intermediate position of 75%, wherein the disc has been compressed 75% of its fill travel distance toward its fully stressed position of 100% (e.g., if the disc's fill travel is 0.100 inches, the disc is compressed 0.075 inches to reach an intermediate position of 75%).
Referring to FIGS. 1 and 2, disc 10 includes a curved outer edge 14 and an inner edge 16 . A minimum radial point 18 on outer edge 14 is at least as close to the disc's center of gravity 20 as is a maximum radial point 22 on inner edge 16 . In some embodiments, minimum radial point 18 is preferably closer to the disc's center of gravity 20 than is maximum radial point 22 on inner edge 16 . Likewise, disc 24 of FIGS. 3 and 4 includes a curved outer edge 26 and an inner edge 28 . A minimum radial point 30 on outer edge 26 is at least as close to the disc's center of gravity 32 as is a maximum radial point 34 on inner edge 28 . Referring to FIG. 5, disc 36 also includes a curved outer edge 38 and an inner edge 40 . A minimum radial point 42 on outer edge 38 is closer to the disc's center of gravity 44 than is a maximum radial point 46 on inner edge 40 .
Discs 10 , 24 and 36 can be made of a variety of materials including, but not limited to carbon steel alloys, stainless steel alloys, copper alloys, inconel, monel, plastics and temperature responsive materials. Disc 48 of FIG. 6, for example, is made of bimetal where two intimately joined layers of material 50 and 52 have different coefficients of thermal expansion, so that disc 48 deflects as its temperature changes. Such a disc may be useful as a temperature sensor.
To create operating characteristics not available with existing fasteners, discs 10 , 24 and 36 are provided with a thickness 54 , an effective outer diameter 56 , an effective inner diameter 58 , and a 75% compression stroke 60 that produces a coefficient of compliance 62 in the range of ten to fifteen with an unusual spring rate 64 (i.e., axial compression force 66 divided by deflection 60 , as shown in FIG. 7 . Such characteristics can be achieved when the disc is made of an iron or iron alloy (e.g., steel, stainless steel, etc.) having a tensile strength of 60 to 250 psi and/or a modulus of elasticity of 25×10 6 to 35×10 6 psi. Disc 24 of FIGS. 3 and 4, for example, has an outer diameter 68 of 0.400 inches, an inner diameter 70 of 0.156 inches, a material thickness 72 of 11 mils (i.e., 0.011 inches), and a 75% deflection stroke of 0.022 inches when subjected to a compressive force of 10.4 pounds, thereby providing disc 24 with a coefficient of compliance of 13.7 (13.7=11 3 /(608×0.4 2 )). The “coefficient of compliance” pertains to a spring's degree of compliance and is defined herein as a ratio of a disc's thickness cubed (in units of cubic mils) divided by the product of the disc's effective diameter squared (in units of square inches) times the disc's spring constant (in units of pounds-force per inch of compression at the disc's intermediate position of 75%).
The “effective diameter” of a disc is defined as the diameter of the smallest circle in which the outer edge of the disc can be inscribed. Disc 24 has an effective diameter 68 , as shown in FIG. 3, and disc 36 has an effective diameter 76 , as shown in FIG. 5 . Disc 36 includes a plurality of protrusions 78 extending radially outward from the disc's outer edge 38 , whereby a distal edge 80 of each protrusion 78 defines effective diameter 76 . Protrusions 78 provide disc 36 with discrete points of contact around the disc's outer perimeter. In some applications, such points of contact allow disc 36 to flex more freely without inhibiting the disc's outer perimeter from flexing.
Returning back to the chart of FIG. 7, various embodiments of the current invention, e.g., discs 10 , 24 , 36 and another similar disc 82 , have operating characteristics that are not available with other comparably sized devices. For example, an average coefficient of compliance 84 of discs 10 , 24 , 36 and 82 is 12.3 with a range of 10.3 to 13.7. Similar embodiments can provide a coefficient of compliance ranging from 10 to 15. However, some Bellville washers 86 may provide an average coefficient of compliance 88 of 4.2 with a range of 4.0 to 4.4; some curved washers 90 may provide an average coefficient of compliance 92 of 21.3 with a range of 17 to 23; some wave washers 94 may provide an average coefficient of compliance 96 of 3.5 with a range of 3 to 5, and some finger washers 98 may provide an average coefficient of compliance 100 of 4.8 with a range of 2 to 8.5.
Besides the coefficient of compliance, other characteristics of discs 10 , 24 , 36 and 82 distinguish them from comparably sized Bellville washers, curved washers, wave washers and finger washers. Generally speaking, discs 10 , 24 , 36 and 82 have significantly greater deflection than Bellville washers 86 , they have a much lower spring rate than Bellville washers 86 , they resist a greater force of deflection than curved washers 90 , they have greater deflection than wave washers 94 , and they have a higher spring rate than finger washers 98 . It should be noted that FIG. 7 is for general comparison purposes wherein discs 10 , 24 , 36 , 82 , 86 , 90 , 94 and 98 are of a generally similar material, i.e., made of an iron or iron alloy, and/or made of a material having a tensile strength of 60 to 250 psi and/or a modulus of elasticity of 25×10 6 to 35×10 6 psi.
Such unique operating characteristics enable various embodiments of the invention to perform functions that are not readily achieved by other known devices. For instance, disc 24 can serve as an effective rod-clamping device, as shown in FIGS. 8 and 9. Here, disc 24 can be forced over a generally smooth round rod 102 , so inner edge 28 of disc 24 can grip rod 102 without rod 102 having to include an additional holding feature, such as a groove or shoulder. Two discs 24 facing in opposite directions can hold one or more members 104 at a generally fixed location along rod 102 .
In another embodiment, similar to disc 24 , disc 10 is provided with an inner edge 16 having four linear edges 106 that are able to grip four faces 108 of a square bar 110 , as shown in FIGS. 1, 2 , 10 and 11 . Two opposite facing discs 10 gripping bar 110 are able to hold bar 110 fixed relative to one or more members 112 . Disc 10 , in this case, has an inner diameter 114 defined by the largest circle 116 that can be inscribed within the inner edge 16 of disc 10 .
Referring to FIGS. 12-14, in some cases, a standoff element, such as a ring 116 , may be attached or simply placed adjacent to disc 24 to inhibit the disc from deflecting completely to its fully stressed or flat position. Here, disc 24 can be compressed between a first surface 118 (e.g., underneath an internally threaded member, such as a nut 120 ) and a second surface 122 , thereby compressing disc 24 from its unstressed position of FIG. 13 to an intermediate position of FIG. 14 . Alternatively, disc 24 may be compressed between a first surface 126 (underneath the head of an externally threaded member, such as a bolt 124 , screw, etc.) and a second surface 128 .
In some cases, the standoff element can be an integral part of the threaded member that compresses the disc. In FIGS. 16 and 17, for example, a shoulder 130 on threaded member 132 provides a standoff that inhibits disc 24 from being compressed beyond its intermediate position of FIG. 17 . Once nut 120 is tightened against shoulder 130 , further compression of disc 24 is inhibited. Of course, if shoulder 130 does not extend beyond the total thickness of members 134 and 136 , then disc 24 could be compressed to its fully stressed position of 100%, as shown in FIG. 18 .
The radial symmetry of disc 24 allows two or more discs to be stacked, as shown in FIG. 19 . The expressions, “radial symmetry” and “radially symmetrical” describe a shape, wherein the entire shape can be divided into substantially identical pie pieces. Stacking discs 24 as shown in FIG. 19 allows the discs to resist an overall greater compressive force for a given amount of deflection. To achieve greater deflection for a given amount of compressive force, discs 24 can be stacked as shown in FIG. 20 .
Although the invention is described with reference to a preferred embodiment, it should be appreciated by those skilled in the art that various modifications are well within the scope of the invention. Therefore, the scope of the invention is to be determined by reference to the claims that follow. | A bowed snap-disc includes inner and outer perimeters that provide the disc with operating characteristics not found in comparably sized discs. At certain points along its circumference, the inner perimeter extends farther from the disc's center than certain other points of the disc's outer perimeter. This provides the disc with a unique combination of spring constant, compressive force, deflection and coefficient of compliance. The disc is particularly useful as a small, flat compression spring; a shaft or bar locking element; tightness indicator for a threaded fastener; or a lock washer. | 5 |
This is a continuation, of application Ser. No. 449,136 filed Mar. 7, 1974 now abandoned.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention is concerned with a method for recovering viscous petroleum including bitumen from viscous petroleum-containing formations including tar sand deposits, and more particularly is concerned with an improved carrier gas vaporized solvent flooding method especially useful in viscous petroleum-containing formations including tar sand deposits.
II. Description of the Prior Art
There are many subterranean petroleum-containing formations in various parts of the world from which petroleum cannot be recovered by conventional means because the petroleum is too viscous to flow or be pumped. The most extreme example of viscous petroleum-containing formations are the so-called tar sand or bituminous sand deposits. The largest and most famous such formation is the Athabasca Tar Sand Deposit in the northeastern part of the Province of Alberta, Canada, which contains over 700 billion barrels of petroleum. Other extensive deposits are known to exist in the western United States and in Venezuela, and smaller deposits exist in Europe and Asia.
Tar sands are defined as sand saturated with a highly viscous crude petroleum material not recoverable in its natural state through a well by ordinary production methods. The petroleum constituent of tar sand deposits are highly bituminous in character and very viscous. The sand present in tar sand deposits is generally fine quartz sand coated with a layer of water, with the bituminous petroleum material occupying most of the void space around the water wetted sand grains. The balance of the void space is filled with connate water, and some deposits contain small volumes of gas such as air or methane. The sand grains are packed to a void volume of about 35 percent, which corresponds to 83 percent by weight sand. The balance of the material is bitumen and water, and the sum of bitumen and water is fairly consistently 17 percent by weight, with the bitumen portion thereof varying from about 2 percent to about 16 percent. One of the characteristics of tar sand deposits which differs considerably from conventional petroleum-containing formations is the absence of a consolidated material matrix within the formation. The sand grains are generally in contact although mostly uncemented and the bitumen occupies most of the void space. The API gravity of the bitumen ranges from about 6 to about 8, and the specific gravity at 60° F. is from about 1.006 to about 1.027 and the viscosity is in the millions of centipoise range at formation temperature.
The methods for recovering bituminous petroleum from tar sand deposits are classified as strip mining and in situ separation processes. Most of the recovery to date has been by means of strip mining, although this method is economically feasible at the present time only when the ratio of overburden thickness to tar sand deposit thickness is around 1 or less. Vast quantities of petroleum are known to exist in the form of tar sand deposits which are not within a range which is economically suitable for strip mining, and so there is a serious need for some form of in situ process wherein the bitumen or bituminous petroleum is separated from the sand by some means and recovered therefrom through a well or other production means drilled into the tar sand deposit.
In situ separation processes described in the literature include thermal techniques, such as fire flooding (or in situ combustion) and steam flooding, and emulsification drive processes. To be successful, an in situ separation process must accomplish two functions: the viscosity of the crude oil must be reduced and some form of oil displacement or driving mechanism must be supplied to the formation. Emulsification processes frequently also employ steam, plus a basic material such as sodium hydroxide which induces formation of an oil-in-water emulsion having a viscosity substantially lower than the viscosity of the formation petroleum. Thermal processes are restricted to formations having sufficient overburden thickness to tolerate injection of high pressure fluids. Many tar sand deposits exist in which the overburden thickness is too thin for thermal flooding and too thick for strip mining.
One other possible process for recovering bitumen from tar sand deposits by in situ separation which does not require the presence of sufficient overburden thickness to contain high pressures, is solvent flooding. Solvent flooding involves injection of a solvent into the tar sand deposit, which solvent dilutes and reduces the viscosity of the bituminous petroleum to render it mobile and recoverable by means of a well as is normally employed in conventional oil recovery operations. Although many solvents including aromatic hydrocarbons such as benzene, toluene and xylene, as well as carbon tetrachloride and carbon disulfide, readily dissolve bituminous petroleum, these materials are expensive and since huge quantities are required, solvent flooding has not been considered to be economically feasible. Paraffinic hydrocarbons such as ethane, propane, butane, pentane, etc. are more readily available and less expensive than those solvents described above, but it has always been uniformly assumed by persons skilled in the art that paraffinic hydrocarbon solvents could not be used in bituminous petroleum because of the danger of precipitating asphaltenes, which would cause formation plugging. Indeed, the asphaltic constituents of crude oil are frequently defined as pentane insoluble materials. Asphalt removal from oil by contacting the crude with propane is a well known refinery process. Furthermore, the cost of solvent flooding has always been considered prohibitive because of the vast quantities required to saturate the formation.
It can be seen from the foregoing that there is a substantial need for a method for recovering viscous petroleum such as bitumen or bituminous petroleum from tar sand formations by use of moderate quantities of readily available, inexpensive solvents in a relatively low pressure procedure that can be used in intermediate depth deposits as well as in deep deposits.
SUMMARY OF THE INVENTION
I have discovered, and this constitutes my invention, that viscous petroleum including bitumen may be recovered from viscous petroleum-containing formations including tar sand deposits by injecting into the formation a gaseous mixture of a carrier gas and a hydrocarbon solvent which is liquid at reservoir conditions. Suitable materials for the solvent include paraffinic hydrocarbons having from five to ten carbon atoms such as pentane, hexane, etc., as well as naphtha, natural gasoline, carbon disulfide, and mixtures thereof. Suitable carrier gases include nitrogen, carbon dioxide, methane, ethane, propane, butane, hydrogen, anhydrous ammonia, hydrogen sulfide, ethylene or propylene. For example, nitrogen may be passed through a vaporizer to vaporize pentane, and then the gaseous mixture injected into a subsurface tar sand deposit. Viscous petroleum or bitumen absorbs the liquid solvent from the gaseous phase until sufficient solvent is absorbed to make the petroleum sufficiently mobile that it will flow into the production well. Production may be taken from a remotely located well or from the same well as was used for injecting the gas-solvent mixture. Surprisingly, the use of paraffinic hydrocarbons such as pentane or hexane in application of this process to tar sand materials does not result in plugging of formation flow channels caused by precipitation of asphaltic materials. The carrier gas and/or the solvent may be heated prior to injection into the formation to increase the solvency rate and vapor pressure of the solvent. The solvent may be displaced by injecting water, hot water or steam into the formation.
BRIEF DESCRIPTION OF THE DRAWING
The attached drawing shows a tar sand formation being subjected to the process of my invention with provisions on the surface for recycling solvent and carrier gas produced along with the crude petroleum.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. the Process
The process of my invention comprises non-aqueous gaseous fluid injection operation necessitating at least one well drilled into and in fluid communication with the petroleum formation. A carrier gas such as nitrogen is brought in contact with and vaporizes an effective solvent which is normally liquid at reservoir conditions and the gaseous mixture is injected via the injection well into the formation.
The reasons for using a carrier gas to vaporize the normally liquid solvent are many fold. By using this procedure, the advantages of gaseous solvents and of liquid solvents can be combined. Higher molecular weight, liquid solvents are more effective solvents for high molecular weight, hydrocarbon components of viscous petroleum than lower molecular weight process gaseous solvents. Also, troubles sometimes encountered in using liquid solvents such as rapid loss of solvent injectivity due to creation of a viscous bank of the solvent-petroleum mixture which eventually becomes immobile is avoided. Injection of a permanent (non-condensible) gas with the solvent increases and maintains a high pressure which increases oil production rate and recovery. The diffusivity of gases is much higher than liquids, which speeds up the penetration rate throughout the formation and increases overall conformance. Finally, the total inventory of solvent in the formation is reduced materially when gaseous solvent mixture is used as compared to liquid solvent. This inventory reduction is especially significant in the process of my invention, since only a portion of the gas injected into the formation is solvent, the major portion thereof being the less expensive carrier gas.
The preferred method for practicing the process of my invention involves the use of a contactor vessel such as a vaporizer, in which the carrier gas can contact liquid solvent. This can be accomplished by bubbling the carrier gas through a vessel partly filled with the liquid solvent. Baffles in the vessel improve the efficiency of the vaporization step, and many other types of commercially available devices such as multi-tray vaporizers, moving film contactors, etc. may be used.
The process is best understood by referring to the illustrative embodiment in the attached drawing, in which viscous petroleum-containing formation 1 is penetrated by injection well 2 and production well 3. Perforations 4 and 5 establish fluid communication between the wells and the formation 1. On the surface, vaporizer 6 is fed by carrier gas via line 7 and by liquid solvent through line 8. Initially, all of the liquid solvent and carrier gas will be supplied from external makeup sources, although recycling of both produced solvent and carrier gas reduces inventory of these fluids. Solvent is thereafter added to vaporizer 6 only as needed to maintain the level up to a preselected level. Carrier gas is bubbled into the liquid solvent via nozzles 9, so that a uniform distribution of gas bubbles in the liquid is achieved to insure maximum gas-liquid solvent contact. The gaseous phase is saturated with solvent vapors, and only gaseous materials are allowed to exit through line 10. Baffles 11 aid in achieving efficient mixing and prevent liquid solvent from exiting the vaporizer.
The gaseous effluent from vaporizer 6, comprising carrier gas and vaporized solvent, passes via line 10 and is pumped by compressor 14 into injection well 2. The gaseous mixture of carrier gas and solvent enter the formation and flows through the flow channels in the formation. Solvent is absorbed directly into the viscous petroleum from the gaseous phase. The carrier gas serves the essential additional purpose of maintaining transmissibility by maintaining the formation flow channels open.
As the viscous petroleum gaseous solvent, the viscosity thereof decreases until flow of petroleum is initiated. Contact between solvent and viscous petroleum is achieved in a very uniform manner throughout the formation between the injection well and the production well, as contrasted to liquid solvent injection where maximum solvent-petroleum mixing occurs near the injection well, with much of the petroleum between the contact point and the production well being essentially uncontacted by solvent.
The petroleum-solvent mixture flows toward production well 3 being driven by the injected gas. The fluid enters well 3 via perforations 5, and is pumped to the surface. Some carrier gas is produced simultaneously with petroleum and solvent. It is usually desirable to separate the gas and petroleum by means such as gas stripper 12. The stripped gas is recycled through vaporizer 6. The produced fluid then passes through a solvent separator unit. Thermal distillation unit 13 accomplishes the separation in this embodiment. Solvent recycling is desirable for economic reasons. If a central surface processing plant is to be used, as will be the case for tar sand operations, for example, the separation of solvent from the petroleum may be accomplished in the central processing plant.
After the process described above has proceeded for a period of time, gas-solvent injection can be terminated and a drive fluid such as water, hot water or steam may be injected to displace the residual petroleum and solvent toward the production well.
In a slightly different embodiment, the carrier gas and/or the liquid solvent is heated, so that the gaseous mixture of carrier gas and solvent enter the formation at a temperature above ambient temperature. If desired, the temperature may be higher than the temperature of the petroleum-containing formation so as to achieve a limited amount of thermal petroleum viscosity reduction.
After completion of the oil operation, residual solvent may be recovered from the formation by any of several means. If a water, hot water or steam injection drive step is used as described above, usually no additional step is required to recover residual solvent. If no such aqueous drive fluid injection step is used, however, solvent may be recovered by injecting a gaseous material, either the same gas used as a carrier gas or any other available non-condensable gas, into the formation to scavenge by veporization the residual solvent from the formation.
The process of my invention may also be used in a push-pull, single well recovery process, wherein the gaseous mixture of carrier gas and solvent are injected into the formation for a period of time, until the gaseous mixture has penetrated for some distance into the formation, and the injection pressure has begun increasing, followed by reduction of pressure and termination of injection of gas so petroleum and absorbed solvent can flow into the well bore.
Ii. the Liquid Solvent
Any material which is essentially all liquid at the temperature and pressure in the petroleum formation, and (2) which is absorbed by the formation petroleum from the gaseous phase, and (3) as a result of such absorption the viscosity of the petroleum is reduced, may be used in the process of my invention. Surprisingly, I have found that paraffinic hydrocarbons are the preferred solvents. Any paraffinic hydrocarbon having from about five to about ten carbon atoms or more may be used. Linear or branched chain species may be used, and mixtures of numerous types are satisfactory solvents. Commercial blends such as naphtha or natural gasoline may be used. Carbon disulfide, CS 2 , alone or mixed with paraffinic hydrocarbon solvents are also effective. Aromatic hydrocarbons such as benzene have not been found to be satisfactory. This is an especially unexpected result since such materials are normally considered to be preferred solvents especially for asphaltic petroleum such as is found in tar sands.
Iii. the Carrier Gas
Any material which is essentially all gaseous at formation temperature and pressure, and which is unreactive with the liquid solvent being used, may be used as the carrier gas. Nitrogen is very suitable for use as the carrier gas in my process. Air may also be used, but precautions must be taken when using a flammable liquid solvent to avoid fire or explosion dangers. Gaseous paraffinic materials such as methane, ethane or propane, as well as gaseous, olefinic hydrocarbons such as ethylene or propylene may also be used. Carbon dioxide is another preferred carrier gas. Hydrogen sulfide may also be used if precautions are taken to prevent escape of the material into the atmosphere at the production well. Hydrogen or anhydrous ammonia may also be used. Crude materials such as natural gas, flue gas, exhaust gas, etc. may also be used, although some processing step to remove particulate matter and corrosive materials is advised. Mixtures of any two or more of the foregoing materials may also be used.
Ordinarily, there is no need to regulate the ratio of carrier gas and solvent. Generally, the preferred method of operating comprises saturating or essentially saturating the carrier gas with solvent at the operating conditions.
Iv. field Example
In order to better understand the process of my invention the following pilot field example is offered as an illustrative embodiment of my invention; however, it is not meant to be limitative or restrictive thereof.
A tar sand deposit is located at a depth of 200 feet and the thickness of the deposit is 70 feet. Since the ratio of overburden thickness to tar sand deposit thickness is greater than one, the deposit is not economically suitable for strip mining. It is determined that the most attractive method of exploiting this particular reservoir is by means of carrier gas vaporized solvent flooding.
A commercial grade natural gasoline is available at an attractive price in the area, the composition of this material being 90 percent C 6 through C 9 . This material is essentially all liquid at reservoir pressure and temperature, so it is quite suitable for use as the liquid solvent.
Flue gas available from a steam generator operating nearby in the field is passed through a filter and a scrubber to remove particulate matter and corrosive materials, and the scrubbed flue gas, which is approximately 86 percent nitrogen and 14 percent carbon dioxide, is used as the carrier gas.
A multiple baffle gas vaporizer unit capable of handling 50,000 standard cubic feet of gas per hour is installed near the injection well and connecting lines are added so that carrier gas and liquid solvent may be introduced into the vaporizer and gaseous effluent pumped to the injection well. The nitrogen-carbon dioxide carrier gas and the solvent are both heated to a temperature of 120° F. prior to introduction thereof into the vaporizer. The gaseous effluent is compressed to a pressure of 150 pounds per square inch and injected into the formation. Production of carrier gas is obtained within 20 days from the production well, which is located 100 feet from the injection well. Oil production begins 10 days after the carrier gas first appeared. Produced gas comprising the injected carrier gas and a small amount of methane is stripped from the produced fluid and recycled through the vaporizer unit. Solvent is removed from the produced fluid by distillation for recycling through the vaporizer.
After production has continued for 12 months, the gas-oil ratio begins to rise. Gas analysis indicates that the solvent content thereof is beginning to increase, indicating absorption of solvent by formation petroleum has reached an equilibrium. Gaseous fluid injection is terminated and hot water is injected into the injection well to displace additional petroleum and solvent. The petroleum production rate increases rapidly and remains high for several months, and then decreases as the injected hot water begins to break through. The injection of hot water is stopped after the water-oil ratio rises above about 50.
V. experimental Section
In order to demonstrate the operability of the process of my invention, and further to determine the magnitude of oil recovery resulting from the application of several specific embodiments thereof, the following laboratory experimental work was performed.
A glass tube measuring approximately 3/4 inch in diameter and two feet in length was filled with loosely packed tar sand material obtained from a strip mining operation in the Athabasca Tar Sand Deposit. The tube containing the tar sand material was mounted at a 45° angle. The liquid solvents to be evaluated were placed in an efficient contactor and nitrogen was bubbled through the liquid solvents at atmospheric pressure. The nitrogen carrier gas was thereby saturated with the solvent being evaluated, and the gaseous mixture was then passed through the tube packed with tar sand material. The gaseous mixture entered the tube at a pressure only slightly above atmospheric pressure. No back pressure or restriction was applied to the outlet end of the tube. The data obtained are summarized in Table I below.
Table I______________________________________Oil Recovery Using CarrierGas Vaporized SolventsRun Liquid Solvent % Recovery______________________________________A Benzene (C.sub.6 H.sub.6) 0B Carbon Disulfide (CS.sub.2) 25C Light Naphtha (equiv. to C.sub.9 H.sub.20) 28D Hexane (C.sub.6 H.sub.8) 71______________________________________
It can be seen from the data contained in Table I above that benzene (Run A) was ineffective for recovering bituminous petroleum from a tar sand material using this process. This is somewhat surprising since benzene is normally considered to be a preferred solvent for bitumen. Carbon disulfide was effective. The light naphtha was superior to carbon disulfide, which is unexpected. Hexane is the most effective solvent of those tested, which is quite surprising. No plugging due to asphaltic material precipitation was apparent during any of these tests. In the case of using carrier gas vaporized carbon disulfide, naphtha and hexane, the petroleum-solvent extract flowed out of the tube by gravity drainage alone.
While my invention has been described in terms of a number of specific illustrative embodiments, it is not so limited, since many variations thereof will be apparent to persons skilled in the related art without departing from the true spirit and scope of my invention. Similarly, while a mechanism has been proposed to explain the benefits derived from application of the process of my invention, it is not hereby asserted that this is the only mechanism responsible therefor. It is my intention that my invention be limited and restricted only by such limitations and restrictions as appear in the appended claims. | Viscous petroleum may be recovered from viscous petroleum-containing formations including tar sand deposits by injecting into the formation a gaseous mixture of a carrier gas and a solvent which is liquid at reservoir conditions, such as pentane, hexane, heptane, octane, carbon disulfide, etc., and mixtures thereof. The gaseous mixture is formed by contacting a normally liquid solvent with a carrier gas such as nitrogen and introducing the carrier gas having solvent vaporized therein into the formation. Recovery of petroleum and solvent may be from the same well as is used for injection or from a remotely located well. The carrier gas and/or solvent may be heated prior to injection to increase solvency rate and vapor pressure. In throughput operations, the gaseous solvent mixture may be followed by water, hot water or steam to displace the residual solvent from the formation. | 4 |
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/530,024 filed Sep. 7, 2006, pending, which is a continuation of U.S. patent application Ser. No. 10/713,419 filed Nov. 14, 2003, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to containers for safely collecting, storing and transporting used hypodermic needles (sharps). The present invention specifically relates to safely collecting, storing and transporting used needles in non-traditional healthcare facilities, such as public non-healthcare settings.
2. Description of the Related Art
Disposal of sharps such as hypodermic needles in non-regulated settings is a tremendous public health safety problem. All used sharps are considered hazardous bio-medical waste as they contain body fluids which have the potential to transmit diseases to anyone exposed to them through a stick or open wound. Regulated businesses, such as medical facilities, generate used sharps in the routine provision of services. Such regulated businesses have developed stringent policy procedures for the safe collection and disposal of used sharps. As a result, regulated businesses routinely require and provide convenient access to sharps disposal containers within their facilities. Because of their potentially dangerous nature, particularly with present concerns regarding accidental transmittal of infectious diseases via contact with used needles, typical sharps disposal containers are designed not only to permit disposal but also to prevent unintentional contact with sharps deposited in the container. In regulated business settings disposal of sharps into containers is managed by trained professional staff to maximize safety.
Unregulated businesses, however, generally do not have any developed policy procedures for the safe collection and disposal of used sharps, nor trained professionals to manage the disposal. Unlike regulated healthcare businesses, the disposal of sharps is not a direct result of services performed in a non-regulated business. Therefore, non-regulated businesses, including but not limited to, commercial, industrial and retail settings, are generally unprepared to safely collect and dispose of used sharps that may be generated on their premises. However, sharps are routinely used, disposed and found in non-regulated businesses. Approximately three percent (3%) of the U.S. population regularly self-inject prescription drugs using hypodermic needles. Often, self-injectors are away from home or a medical facility when a dose must be administered in non-regulated business settings and public places. In addition to legal self-injectors, an undetermined number of illicit drug users self-inject non-prescription drugs, also in public places. It is estimated that within the U.S. three billion used needles are disposed of annually in non-regulated settings and unsafely discarded into the public solid waste stream.
The present growing trend of self-injecting and providing healthcare away from regulated medical facilities significantly increases the potential for inadvertent handling of, or accidental contact with, used sharps, particularly hypodermic needles, in public places. Used needles discarded by self-injectors expose the general population to sharps unmanaged by healthcare professionals and the potential for transmittal of diseases though contact with hypodermic needles contaminated with bloodborne pathogens. In recognition of the needs of such self-injectors, and to protect employees and business customers, many commercial, industrial and retail businesses are beginning to purchase sharps collection containers to dispose of sharps found on their premises.
Sharps containers used in commercial, industrial and retail businesses are generally controlled and kept out of sight, and are used only when an employee finds a used hypodermic needle. Such an approach to safe guarding employees and customers from used sharps is reactive and inappropriate in that only the needles left in visible sight are captured by employees, who themselves are placed in a position of potential contact with hazardous bio-medical waste as they are required to retrieve used needles for disposal. It is widely known that the majority of used sharps disposed in public places are in open trash receptacles, exposing workers and the public to a dangerous health risk. Generally, non-regulated businesses in the commercial, industrial and retail sectors do not proactively provide self-injectors with a means of safely disposing of their used sharps.
It is therefore an object of the invention to provide a sharps disposal system for use by selfinjectors to safely dispose of their used sharps in such a manner where the container is safe, secure and is resistant to tampering by unauthorized individuals.
It is another object of the invention to provide a safe public sharps collection system comprised of two individual components, a lockable steel permanent wall mounted cabinet to house the sharps container and a disposable sharps container contained within the cabinet which can be safely disposed of only by authorized personnel.
It is another object of the invention to provide a secure wall mounted cabinet incorporating safety features including a sharps disposal conduit and single locking mechanism preventing unauthorized access, and a double door design to facilitate safe removal of the sharps container housed within the cabinet.
SUMMARY OF THE INVENTION
In accordance with the present invention, a cabinet for safely collecting and storing medical sharps defines an enclosure for receiving a removable sharps collection container (receptacle) therein. A bracket securely retains the sharps receptacle within the cabinet. The cabinet includes a conduit depending downward from the top thereof. The conduit is open at both ends. The lower end of the conduit interfaces with the removable receptacle thereby forming a passageway for discarded sharps to enter the sharps receptacle. The cabinet includes a single lock, double door design facilitating safe removal of the sharps receptacle housed within the cabinet.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view of a sharps disposal system in accordance with the present invention depicting the sharps disposal cabinet in an open condition;
FIG. 2 is a partially broken away section view of the sharps disposal cabinet of the present invention taken along line 2 - 2 in FIG. 1 ;
FIG. 3 is a partially broken away section view of the sharps disposal cabinet and sharps receptacle of the present invention taken along line 3 - 3 in FIG. 1 ;
FIG. 4 is a section view of a sharps disposal system in accordance with the present invention depicting the sharps disposal cabinet in a closed condition;
FIG. 5 is a section view of the sharps disposal cabinet of the present invention taken along line 5 - 5 in FIG. 4 ;
FIG. 6 is a partially broken away top plan view of the sharps receptacle housed in the sharps disposal cabinet of the present invention; and
FIG. 7 is a partially broken away side view of the sharps receptacle housed in the sharps disposal cabinet of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , a sharps idisposal system in accordance with the present invention includes a sharps disposal cabinet generally identified by the reference numeral 10 . The cabinet 10 , fabricated of heavy gauge metal, includes a cabinet body formed by sidewalls 12 , a back wall 13 , a bottom 14 , a top access door 16 and a side or front access door 17 which enclose an interior chamber 18 . A mounting bracket 20 supports the cabinet 10 on a mounting surface, such as a wall or other suitable surface.
A sharps receptacle 22 is housed within the chamber 18 of the cabinet 10 . The receptacle 22 is preferably fabricated of puncture resistant material and includes a main body defining a substantially box-like profile. The body of the receptacle 22 includes an outwardly tapering portion 23 terminating in an upstanding lip 25 which circumscribes a circular opening forming the upper end of the receptacle 22 . The open upper end of the receptacle 22 is closed by a circular lid 24 . The planar surface of the lid 24 comprises a plurality of inwardly extending flexible tabs or fingers 30 , as best shown in FIG. 2 . The fingers 30 are connected to the circumferential edge of the lid 24 and extend radially inward toward the center of the lid 24 . The fingers 30 extend across the open end of the receptacle 22 preventing the sharps deposited therein from spilling out when the receptacle 22 is removed from the cabinet 10 . A snap-on cover 26 connected to the lid 24 by a flexible tether 28 is stored within the cabinet 10 adjacent to the receptacle 22 as shown in FIG. 2 . Upon removal of the receptacle 22 from the cabinet 10 the cover 26 is snapped over the lid 24 thereby enclosing the discarded sharps therein for safe disposal.
Referring still to FIG. 1 , the top access door 16 of the cabinet 10 is secured to the back wall 13 thereof by a hinge 32 . The door 16 comprises a flat planar plate provided with a centrally located hole 34 . A conduit, such as a cylinder 36 or the like, depends downwardly from the bottom surface of the door 16 . The cylinder 36 is open at both ends. The proximal end of the cylinder 36 circumscribes the hole 34 and is welded or otherwise fixed to the door 16 . The distal end 38 of the cylinder 36 projects into the chamber 18 of the cabinet 10 upon closure of the access door 16 . The cylinder 36 is sized in length and diameter to minimize placing unintended items into the sharps disposal system of the invention and to prevent getting a finger or hand down into the sharps receptacle 22 .
Referring now to FIG. 3 , the sharps receptacle 22 is shown housed within the chamber 18 of the cabinet 10 . It is centrally located within the chamber 18 by a cradle bracket 40 fixed to the bottom 14 of the cabinet 10 . In a preferred embodiment, the cradle bracket 40 is three-sided with the open side located opposite the access door 17 . The bracket 40 is configured for frictionally engaging the bottom portion of the sharps receptacle 22 and positions the receptacle 22 to interface with the cylinder 36 upon closure of the top access door 16 . It is understood that the bracket 40 may take the form of any suitable configuration for maintaining the sharps receptacle 22 within the cabinet 10 in cooperating alignment with the cylinder 36 depending downwardly from the top access door 16 .
Referring again FIG. 1 , the access door 17 is secured to the bottom 14 of the cabinet 10 by a hinge 42 . The access door 17 comprises a flat planar plate having flange members 50 extending inwardly therefrom along opposite edges of the door 17 . Along it upper end, the top edge of the door 17 extends inwardly defining a flat first surface 52 perpendicular to the door 17 and the distal end thereof projects downwardly defining a second surface 54 which is spaced from and parallel to the planar surface of the access door 17 .
Structural reinforcement for the cabinet 10 is provided by right angle flanges 56 which are fixed along the sidewalls 12 and offset inwardly from the leading edges of the sidewalls 12 . The flanges 56 are interconnected by a cross bar 58 extending across and connected to the upper ends of 10 the support flanges 56 . A locking slot 610 is formed in the cross bar 58 . The slot 60 is shaped to match the slot 62 formed in the surface 54 of the top edge of the access door 17 . Upon closure of the door 17 , the surface 54 of the access door 17 is in facing contact with the cross bar 58 and the lock slots 60 and 62 are in alignment for receiving the lock lever 64 of a lock 66 mounted on the top access door 16 , as best shown in FIG. 4 .
Referring now to FIGS. 4 and 5 , the cabinet 10 is mounted to a mounting surface by a mounting bracket 70 . The bracket 70 is si˜bstantiallyU-shaped in cross-section as shown in FIG. 5 . It includes a flat mounting plate 72 and mounting flanges 74 integrally formed therewith. Threaded posts 76 project from the mounting plate 72 and are received through corresponding holes formed in the back wall 13 of the cabinet 10 . Wing nuts 78 secure the cabinet 10 to the mounting bracket 70 .
So that the cabinet 10 is not easily removed from its mounting surface, the width of the mounting plate 72 is less than the width of the back wall 13 of the cabinet 10 so that it overlaps the mounting flanges 74 . Thus, the bolts which secure the mounting bracket 70 (not shown in the drawings) to the mounting surface are covered and not accessible when the cabinet 10 is secured to the mounting bracket 70 .
Referring still to FIG. 4 , when the cabinet 10 is locked and the sharps receptacle 22 is contained in the chamber 18 thereof, the distal end of the cylinder 36 engages the flexible fingers 30 of the lid 24 pushing them downwardly and thereby forming an unobstructed passageway to the interior of the sharps receptacle 22 . Sharps dropped through the hole 34 in the top access door 16 fall through the cylinder 36 into the sharps receptacle 22 . The single lock, two door design of the cabinet 10 ensures that during removal of the receptacle 22 from the cabinet 10 , personnel performing the task do not at any time place their hand over the top opening in the sharps receptacle 22 . When the access door 16 is opened, the cylinder 36 rotates upwardly out of the way and the flexible fingers 30 return to their original orientation closing the opening created by the cylinder 36 in the lid 24 . The access door 17 is opened and the receptacle 22 removed from the cabinet 10 and the cover 26 is snapped over the lid 24 of the receptacle 22 , thereby enclosing the discarded sharps within the receptacle 22 for safe delivery to a facility for safely destroying the discarded sharps.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the invention may be made within the scope of the appended claims without departing from the spirit of the invention, and the scope thereof is determined by the claims which follow. | A sharps disposal system for safely collecting and disposing of medical sharps includes a cabinet defining an enclosure for receiving a removable used sharps receptacle therein. The cabinet includes a passageway through which sharps may be deposited in the sharps receptacle. A single lock, double door design facilitates safe removal and disposal of sharps deposited in the sharps receptacle. | 0 |
RELATED U.S. APPLICATION DATA
This application is a Continuation of application Ser. No. 10/429,403 filed on May 6, 2003 now abandoned and a Continuation of application Ser. No. 10/679,469, filed on Oct. 7, 2003 now abandoned, which is a Continuation In Part of application Ser. No. 09/960,483 filed on Sep. 24, 2001, now U.S. Pat. No. 6,651,685, each of the descriptions and drawings of application Ser. Nos. 10/429,403 and 10/679,469 being incorporated by reference herein.
BACKGROUND OF THE INVENTION
This invention at hand relates generally to a demountable sunshade canopy structure and in particular to sunshade canopies for ultraviolet UV sun ray protection of children's play areas.
It is increasingly acknowledged that physically challenging outdoor play structures are of a benefit to the physical and emotional development of young children. A code of safety specifications for the construction and maintenance of children's play structures has been developed by National Play and Playground Authorities, published (1996) by the National Recreation and Park Association of Arlington Va. These construction specifications describe construction features for support of children's slides, swings, climbing apparatus, etc. which minimize risk of injury to children engaged in all manner of predictable use or misuse of the play structures.
The specification requires that the play structures be mounted on a platform or on towers elevated up to six feet above a resilient (non-hardened) surface such as cork or rubber panels and the towers or the platform be supported by a very limited number of support columns. The columns are to be capped at the top without exterior fittings on which a child may be injured while climbing upon or falling from the platform or tower. The support columns are capped at the top to discourage a child from climbing or holding on while suspended from the column top. The vertical support columns have been in the past a source of injuries to children engaged in unintended use of these structures. Accordingly, the minimum of vertical columns, all free of hand-or foot holds, has become a specification for an acceptable and safe design.
Separate from the safe construction design referred to above which have and are significantly reduce playground injuries, there is a growing threat to children's health when they are engaged in outdoor play and or exercise in the sun shine.
There are numerous publications that exhibit various canopies over play areas and covers over other areas as follows:
U.S. Pat. No. 589,563 to Jensen shows a canopy to act as a tent. It is so designed that it is collapsible and has movable joints and brackets for the purpose.
U.S. Pat. No. 1,878,758 to Clayton shows a cover a mery-go-around having cover extensions that extend past the perimeter of the platform. The merry-go-around as propelled by children that are standing on the platform and hanging on to hand rails. There are no play ground devices located on the platform.
U.S. Pat. No. 1,900,274 to Brockie illustrates a collapsible play pen having vertical support columns including brackets that support hip beams. There are no cantilevered beams to extend outwardly from the brackets supporting the hip beams.
U.S. Pat. No. 2,015,321 to Shelton discloses canopy including a frame. The frame has brackets that support the frame on vertical columns including beams that extend in a horizontal direction. Hip beams are deployed by operating a central hand crank screw drive. The hip beams do not extend from the brackets on the vertical supports.
U.S. Pat. No. 5,331,992 to Gremont shows a canopy structure that employs rigid bracket to support hip beams but no cantilevered beams are disclosed.
U.S. Pat. No. 5,662,525 to Briggs discloses an elevated platform having a canopy placed there over but children's play devices are placed at a remote location.
U.S. Pat. No. 6,165,106 to McBride illustrates an elevated platform with children's play devices attached to the platform but there is no teaching that play devices may be placed on and in contact with elevated platform.
U.S. Pat. No. 6,200,060 describes a dome tent pole connector wherein the bracket my collapsibly support dome shaped hip beams.
The earth's protective atmosphere ozone layer has significantly been depleted due to release of chemical pollutants into the atmosphere during the last five decades. The result of the ozone depletion is that the solar ultraviolet UV rays are significantly more intense and comprise a serious health risk to children when playing in the now unfiltered UV sun radiation. In 1930 the risk of developing melanoma form sun exposure was 1 in 1500. Today, a person's risk of developing skin cancer at some time during their life is 1 in 75. Skin cancer is the most common cancer in the United States each year with more than one million cases diagnosed each year. Currently, this year, 47,700 Americans will be diagnosed with life threatening melanoma and 7,700 will die of this disease. The current prognosis for this disease is that approximately one out of five children in the United States will experience some form of skin cancer during their lifetime. Furthermore, exposure to the current intensity of solar UV radiation reduces the effectiveness of the immune system. This effect is of special importance to children's health.
Sources of the above statistics can be found in publications of the American Academy of dermatology, American Cancer Society, National Institutes Health, US Center for disease Control and the Australian Cancer Society.
The copending application Ser. No. 09/960,483 goes into detail how to construct a shaded canopy over a children's playground or exercise area which is incorporated herein by reference. Of particular interest are the connections of the cantilevered beams and the angled hip beams that are made to conform to the vertical support columns. These connections are simplified by constructing certain fittings that will greatly simplify those connections in a standard and more precise way and at a much lower cost.
BRIEF SUMMARY OF THE INVENTION
A demountable wind resistant sun shade canopy is suitable for mounting on playground equipment. The canopy support structure includes a plurality of fittings. The bracket fittings may be of a unitary and rigid construction. One example is the use of transverse rod connectors. The fittings, when each is fixedly mounted, provide for attachment to columns extending upwardly from children's play equipment. A cantilever beam extend outwardly from the fittings toward the perimeter of the play area to be shaded. A hip beam extending upwardly at an angle and is coupled to other hip beams and/or a ridge beam, providing a structure extending toward the inner portion of the area to be shaded. Thus, an extended-area to be shaded includes a rigid support structure which is provided over a designated area which may be dependably shaded from the sun's rays when a fabric canopy, such as a high density knitted polyethylene porous canopy cover is placed over the unique bracket fitting supporting a plurality of cantilever and hip beams support members and secured about the perimeter of the canopy cover, such as with an adjustable tension means. The hip beams may be combined by way of an apex fitting which is instrumental in forming an apex of at least four hip beams. One of the beams connected into the apex fitting may be a horizontal tube that extends toward another apex so that two distant apexes can be connected to each other to form a larger canopy to form a cover over a rectangular play area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of an existing safe play structure without a sun protective canopy, the play structure is shown mounted above a resilient ground cover;
FIG. 2 is cross-section through of the upper portion of the support of the prior art device of FIG. 1 taken along the plane 2 - 2 ;
FIG. 3 is a plane view of a specified single tower children's play area on which the innovative sun shade canopy has been erected, the play exercise devices are shown in phantom lines. From this illustration it can be seen that the perimeter of the shaded area extends beyond the basic area of the play area perimeter;
FIG. 4 is a sectional elevational view of the embodiment shown in FIG. 3 with portions of the play structures and canopy support members shown phantom;
FIG. 5 is a perspective view of a construction bracket or fitting for mounting cantilever and hip beam members to form a support structure for mounting the canopy cover;
FIG. 6 is a cross-section of the bracket or fitting shown in FIG. 5 taken along the plane 6 - 6 ;
FIG. 7 is a plan view of the connector or fitting for a four hip beam canopy support construction shown in the embodiments of the sun shade canopy illustrated in FIGS. 3 and 4 ;
FIG. 8 is a perspective view of the hip beam connector fitting of FIG. 7 ;
FIG. 9 shows a detail of the means for fastening the cover to the support structure with adjustable tension means;
FIG. 10 shows an elevation of an extended end of the cantilever member showing means for securing the canopy cover;
FIG. 11 is an elevational view of a second embodiment of the sun shade canopy structure mounted to cover a two tower specified safe children's play area;
FIG. 12 is a plan view of the embodiment shown in FIG. 11 with the children's play area devices in phantom.
FIG. 13 is a perspective view of a connector fitting using connector plates to establish certain angles between the vertical support column and the hip beam member.
FIG. 14 is a perspective view of the connector plates of FIG. 13 connected together;
FIG. 15 is a perspective view of two apex fittings being connected by a root ridge beam.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a prior art safe design of a children's play structure wherein a plurality of fixedly mounted vertical support columns 12 a , 12 b , 12 c and 12 d are shown. The columns 12 a and 12 b , etc. are mounted in foundations (not shown) beneath a resilient ground cover 14 . The ground cover may be made of rubber or cork or matted materials to soften an impact and reduce injuries to a child fallen thereon. The columns support a platform 16 from which a slide 18 , a closed chute 20 and other children's climbing devices may be positioned.
The upper ends of the conventionally designed vertical columns 12 a , 12 b , 12 c and 12 d are shown in FIG. 2 in a cross-sectional plane 2 - 2 . A column cap 22 fits over the top of column 12 d . The cap 22 is shaped with a reduced diameter lower section 24 which, when inserted into the hollow opening 26 of the vertical column comprises a secure mount for the column cap 22 . Although such conventionally designed columns are fully compatible with the invention, in order to avoid the possibility of rainwater leaking into the seam between the lower portion 24 and the column 12 d , it is preferable to have the column designed as depicted in FIG. 6 where the upper end of the column 12 a and 12 b etc. has a smaller diameter than bracket 52 so that rainwater will flow over the juncture between the two tubes without entering the seam.
FIGS. 1 and 2 are illustrative of safe children's play structures in compliance with the safety specifications developed by the National Play and Playground Authorities. At this date there are tens of thousands of such play structures erected and being erected in the United States without any provisions for effective sun shades for children using such structures.
A plan view of a first embodiment of this invention is shown in FIG. 3 wherein a canopy 30 is shown as being supported over structural members described below in subsequent Figs. which in turn are mounted above a children's exercise and play area with play devices shown in phantom lines below the canopy 30 .
FIG. 4 is a cross-sectional elevation of the embodiment shown in FIG. 3 in a plane 4 - 4 . Vertical columns 34 and 36 are fixedly mounted, respectively, in concrete foundation footings 40 and 42 . The vertical columns 34 and 36 constituting a plurality of first upright members support a platform or deck 44 at ends 44 a and 44 b fastened to the columns 34 and 36 . The columns 34 and 36 terminate at approximately four feet above the platform or deck 44 the play devices 32 and 32 a are either located on the surface and in contact with the platform or are dependent therefrom but are always within the perimeter of the shade canopy itself. The caps 22 such as shown in FIG. 2 have been removed from the upper ends of the columns 34 and 36 to expose the tops 48 and 50 , respectively. A plurality of second upright members 60 and 62 are attached to the tops 48 and 50 of columns 34 and 36 . At top ends of the second upright members there are provided transitional fittings 55 and 57 which are inserted into the tops of the second upright members. A detailed description will appear below with reference to FIGS. 13 and 14 . The letter A illustrates a drop line from the outer perimeter of the canopy to the ground, while the letter B illustrates the distance between the outer or second perimeter of the canopy and the first perimeter of the play area.
FIGS. 5 and 6 are illustrative of the structural bracket fittings 55 and 57 . More specifically, FIG. 5 depicts the bracket fitting 55 in a perspective cut-away and fragmentary view, while FIG. 6 is a view of the structural or transitional bracket 55 shown as a cross-section on plane 6 - 6 .
In preferred embodiments, the lower portion 56 of the structural bracket fitting 55 fits over the reduced diameter upper end 52 of the upper column portion 60 . In rainy weather, water will flow over the juncture of lower portion 56 and upper end 52 and will not enter the seam between the two elements where it might cause damage. The upper end of each the bracket fittings 55 and 57 is terminated with a transverse, angularly placed, cylindrical rod 64 . The rod 64 is mounted at an acute angle with the vertical cylindrical extension or transitional fitting 55 . The angle with the horizontal is normally 22 degrees but is subject to adjustments for specific applications. The rod 64 is part of the transverse rod connector. The rod 64 is transverse to the bracket fittings 55 and is a connector for the cantilever beams 80 and the hip beams 82 and the hip beams 72 and 74 ( FIG. 4 ).
FIGS. 5 and 6 further show the mounting of the cylindrical rod 64 on a plate 83 which in turn is mounted at an angle from the horizontal to bracket fitting 55 . The cylindrical rod 64 has an upper or first end 68 and a lower or second end 70 . The hip beam 72 comprises a straight section of a hollow metal steel pipe or rod. The hip beam 72 is positioned over the upper or first end of 68 of the angularly mounted cylindrical rod 64 and is secured with threaded bolts 76 passing through the hip beam 72 and the cylindrical rod 64 .
The lower or second 70 end of the solid metal rod 64 is mounted by insertion into the upper end of the cantilevered beam 80 and is secured therein by threaded means 81 . The cantilevered beam member 80 is comprised of a straight section of a hollow steel pipe or tube. The lower end of the cantilever beam is terminated with an oblong eyelet connector 84 . As is shown in FIGS. 7 and 8 , the four hip beams 72 and 74 and the counter parts 72 a and 74 a terminate in juxtaposition and are secured to each other by way of the right angle joint 86 to thereby form an apex fitting which is shown in FIG. 8 .
Referring now back to FIG. 3 , a porous knitted polyethylene canopy cover 30 is placed over the structure comprised of the hip beams 72 , 72 a , 74 and 74 a and cantilever beams members 80 , 80 a , 82 and 82 a . The canopy details are more clearly shown in FIG. 9 . The canopy cover 30 is secured about its perimeter with a tension cable 90 which in turn is secured within a cable channel 92 sewn about the canopy perimeter 94 . The tension on the cable is adjusted and maintained with a turn buckle 96 . The canopy cover 30 is provided at its four corners with a reinforced opening 98 through which the oblong connector 84 located on the extreme end of the cantilevered beam 80 and its counterpart cantilever beam members 80 and its counterpart 82 , etc., protrudes.
A second embodiment of this invention is illustrated in FIGS. 11 and 12 wherein a two tower' safe design children's play area is shown. The play and exercise devices are shown in phantom lines. A porous shade canopy cover 104 is fabricated from knitted polyethylene strips and is constructed similarly to the single tower canopy 30 . The two tower canopy cover 104 is sewn so that it provides a cable channel 106 . A tension cable 108 is threaded through the channel 106 and when positioned over the metal support structure of hip beams 110 a , 110 b , 110 c , etc., forms a sunshade canopy. A turn buckle tension means 116 is attached to the ends of cable 108 to provide adjustments and to maintain cable tension.
The canopy cover 104 is provided at each corner with a reinforced opening 98 as is shown in FIG. 9 through which the oblong eyelet connector 84 on the cantilever beam member extends.
FIG. 13 illustrates a bracket fitting 100 to be used in erecting the structure that will support the sunshade canopy. This fitting is pre-assembled and will always include the correct angle of the slanted roof structure. The explanation will apply to one column only but it is applicable to all columns when the canopy structure is assembled. To this end, the fitting includes a lower insert pipe 115 which is of a reduced diameter when compared to the upstanding vertical columns 34 , 36 ( FIG. 4 ). Therefore, when installing structure for the canopy 30 or 104 , the fitting is merely slipped into the opening of vertical columns 34 and 36 with its lower insert pipe 55 and 57 ( FIG. 4 ). With other words, it is an interfitting concept. The lower insert pipe 55 or 56 has a limiting ring 116 which limits the extent of the insert pipes 55 or 57 into either of the vertical columns 34 or 56 . Since the slant of the roof of the canopy is predetermined, a connector plate 119 is attached to the top of the insert pipe 55 by way of a welding 117 . The predetermined angle is shown at 118 . Since all the angles and distances are predetermined in the bracket fitting 100 includes a counter plate 120 which is welded to a saddle pipe 122 at 121 . The saddle pipe 122 has an outer diameter that matches the outer diameter of the cantilever pipes 80 and 82 ( FIG. 4 ) and the outer diameter of hip beams 72 and 74 ( FIG. 4 ).
In other words, there is a smooth transition between the saddle pipe and the cantilever pipes or beams when connected to each other. Therefore, the cantilever beam and the hip beam have a diameter reduced at the point of insertion into the saddle pipe. Once the connector plate 119 and the counter plate 120 are aligned with each other, the bolts 123 are passed through both of the plates 119 and 120 which will connect the two plates 119 and 120 by way of the bolts and the nuts 124 and the lock washers 125 .
FIG. 14 shows the assembled bracket or fitting 100 in combination with the upstanding vertical columns 60 and 62 ( FIG. 4 ) or 34 and the saddle pipe 122 . The reference character 110 a indicates a reduced diameter of the cantilevered pipe 110 . This way the cantilevered pipe or beam 110 can easily slip into the pipe of the saddle pipe 122 .
FIG. 15 shows a construction wherein at least two apexes 140 are combined with each other. In this construction there are at least two hip beams 141 and 142 , being the equivalents of hip beams 72 and 74 of FIG. 4 , are connected to each other including one horizontal beam or tube 143 that will receive a horizontal connector beam or tube 144 so that the distant apexes 140 can be pre-constructed and can be delivered to the construction site for assembly. | A demountable wind-resistant sunshade canopy for shading children's play areas or other actively used areas. The canopy device is removably secured over a support structure, and is comprised of a hip beams supported by columns mounted on the support structure, and the hip beams extend upwardly and inwardly toward an apex or ridge beam. Cantilevered ends of the hip beam extend beyond the support structure, providing shade for equipment, such as children's play equipment or other actively used areas. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 09/971,849, filed Oct. 4, 2001, now U.S. Pat. No. 6,947,782 B2, issued Sep. 20, 2005; which claims the benefit of U.S. Provisional Application No. 60/299,106, filed on Jun. 18, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a prosthetic medical device for connecting electrical conducting wires to a miniature implantable device to minimize risk to the living tissue.
2. Description of Related Art including Information Disclosed under 37 CFR 1.97 and 1.98
Neurological disorders are often caused by neural impulses failing to reach their natural destination in otherwise functional body systems. Local nerves and muscles may function, but, for various reasons, such as injury, stroke, or other cause, the stimulating nerve signals do not reach their natural destination. For example, paraplegic and quadriplegic animals have intact nerves connected to functioning muscles and only lack the brain-to-nerve link. Electrically stimulating the nerve or muscle can provide a useful muscle contraction.
Further, implanted devices may be sensors as well as stimulators. In either case, difficulties arise both in providing suitable, operable stimulators or sensors which are small in size and in passing sufficient energy and control information to or from the device, with or without direct connection, to satisfactorily operate them. Miniature monitoring and/or stimulating devices for implantation in a living body are disclosed by Schulman, et al. (U.S. Pat. No. 6,164,284), Schulman, et al. (U.S. Pat. No. 6,185,452), and Schulman, et al. (U.S. Pat. No. 6,208,894) all incorporated in their entirety herein by reference.
It must be assured that the electrical current flow does not damage the intermediate body cells or cause undesired stimulation. Anodic or cathodic deterioration of the stimulating electrodes must not occur.
In addition, at least one small stimulator or sensor disposed at various locations within the body may send or receive signals via electrical wires. The implanted unit must be sealed to protect the internal components from the body's aggressive environment. If wires are attached to the stimulator, then these wires and the area of attachment must be electrically insulated to prevent undesired electric signals from passing to surrounding tissue.
Miniature stimulators offer the benefit of being locatable at a site within the body where a larger stimulator cannot be placed because of its size. The miniature stimulator may be placed into the body by injection. The miniature stimulator offers other improvements over larger stimulators in that they may be placed in the body with little or no negative cosmetic effect. There may be locations where these miniature devices do not fit for which it is desired to send or receive signals. Such locations include, but are not limited to, the tip of a finger for detection of a stimulating signal or near an eyelid for stimulating blinking. In such locations, the stimulator and its associated electronics are preferably located at a distance removed from the sensing or stimulating site within the body; thus creating the need to carry electrical signals from the detection or stimulation site to the remote miniature stimulator, where the signal wire must be securely fastened to the stimulator.
Further, the miniature stimulator may contain a power supply that requires periodic charging or require replacement, such as a battery. When this is the case, the actual stimulation or detection site may be located remotely from the stimulator and may be located within the body, but removed a significant distance from the skin surface. By having the ability to locate the miniature stimulator near the skin while the stimulation site is at some distance removed from the skin, the miniature stimulator and its associated electronics can be more effectively replaced by a surgical technique or more efficiently recharged through the skin by any of several known techniques, including the use of alternating magnetic fields. If the electronics package is replaced surgically, then it is highly desirable to have the capability to reconnect the lead wires to the miniature stimulator via an easy, rapid and reliable method, as disclosed herein.
BRIEF SUMMARY OF THE INVENTION
The instant invention relates to an apparatus for connecting an electrically conductive wire to a miniature, implantable sensor or stimulator. A spring clip connector adapted to receive a doorknob electrode for communicating electrical signals between living tissue and an implantable miniature device that is configured for monitoring and/or affecting body parameters, has a prong for removably grasping the doorknob electrode to make a connection to an electrically conductive wire that has two ends, a first end for electrical coupling to a selected portion of the living tissue and a second end for attachment to the spring clip, where the spring clip is comprised of a biocompatible material.
The spring clip connector may be titanium, titanium alloy, platinum, iridium, platinum-iridium, stainless steel, tantalum, or niobium. An insulating rubber boot may surround the doorknob electrode and spring clip. The rubber boot may be silicone.
The spring clip connector may be a material selected from the group consisting of titanium, titanium alloy, platinum, iridium, platinum-iridium, stainless steel, tantalum, or niobium.
The doorknob electrode may be titanium, titanium alloy, platinum, iridium, platinum-iridium, stainless steel, tantalum, or niobium.
The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an implantable miniature stimulator having at least one electrode.
It is an object of the invention to provide a method of connecting at least one wire to a miniature stimulator in a body.
It is an object of the invention to electrically insulate the electrode of an implantable miniature stimulator that is connected to an electrical wire from the environment in which it is implanted.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 illustrates a perspective view of the miniature stimulator with a threaded connector and nut.
FIG. 2 illustrates a perspective view of the miniature stimulator with a bayonet connector and nut.
FIG. 3 illustrates a perspective view of the miniature stimulator with a pin connector and nut.
FIG. 4 illustrates a perspective view of the smooth nut with a flare nut cap.
FIG. 5 is a cross-section through the flare nut wire insertion.
FIG. 6 is a cross-sectional view of the smooth cap with flare insertion.
FIG. 7 is a longitudinal section through the protective nut showing an offset mounting hole.
FIG. 8 is a cross-section through the protective nut showing the offset mounting hole.
FIG. 9 illustrates a stimulator with a hole and pin electrode.
FIG. 10 illustrates a stimulator with a hole and pin electrode and an electrode plug.
FIG. 11 is a longitudinal cross-section of a threaded hole electrode with plug.
FIG. 12 is a longitudinal cross-section of a threaded pin electrode with nut.
FIG. 13 is a longitudinal cross-section of a threaded pin electrode with nut and spade connector.
FIG. 14 illustrates a spade connector.
FIG. 15 illustrates a spade connector attached to a wire.
FIG. 15A illustrates a detailed section of the crimp of FIG. 15 .
FIG. 15B illustrates a detailed section of an alternate crimp of FIG. 15 .
FIG. 16 is a longitudinal cross-section of an electrode hole with a plug and crush lip.
FIG. 17 illustrates a C-clamp.
FIG. 18 illustrates a pin electrode with a wire inserted.
FIG. 19 illustrates a protective nut with a crush lip.
FIG. 20 is a longitudinal section through threaded insert with a flare attachment.
FIG. 21 is a perspective view of a stimulator in combination with a flare nut.
FIG. 22 is a longitudinal section showing the flare nut with a rubber boot.
FIG. 22A is a section showing tie interaction with the rubber boot of FIG. 22 .
FIG. 23 is a top view of a disk-shaped miniature stimulator with electrodes.
FIG. 24 is a side view of a disk-shaped miniature stimulator with electrodes.
FIG. 25 illustrates a miniature stimulator annular electrode and a section through the annular nut.
FIG. 26 is an end view of the miniature stimulator with annular electrodes.
FIG. 27 is an end view of the annular nut.
FIG. 28 is a longitudinal section through a miniature stimulator with annular electrodes and a section through the annular nut.
FIG. 29 illustrates an end view of a plug with wires.
FIG. 30 is a longitudinal cross-section through a plug with wires installed in a hollow miniature stimulator.
FIG. 31 illustrates a perspective view of an electrically conductive doorknob shaped electrode with spring clip connector and wire.
FIG. 32 is a perspective view of the electrically conductive doorknob shaped electrode.
FIG. 33 is a perspective view of the spring clip connector.
FIG. 34 is a longitudinal section through the doorknob shaped connector with a wire and rubber boot.
FIG. 35 is a longitudinal section through the doorknob shaped connector with crimped connector a wire and rubber boot.
FIG. 36 is longitudinal section through the snap-on cap connector with rubber boot.
FIG. 37 is longitudinal section through the elongated snap-on cap connector with rubber boot.
FIG. 37A details the tooth interaction with the slip-on cap of FIG. 37 .
FIG. 38 is longitudinal section through the flat-bottomed slot connector with rubber boot.
FIG. 39 is a perspective view of the flat-bottomed slot connector.
FIG. 40 is a perspective view of the flat-bottomed snap-on cap.
FIG. 41 is a cross-section of the flat-bottomed slot connector in the engaged position.
FIG. 42 is a cross-section of the flat-bottomed slot snap-on cap in the disengaged position.
FIG. 43 is a hand showing placement of an implantable miniature device with a wire lead that carries electrical signals to a fingertip.
DETAILED DESCRIPTION OF THE INVENTION
An implantable miniature stimulator 2 is illustrated in FIG. 1 . FIG. 43 represents a typical placement of the implantable miniature stimulator 2 at a location that is remote from the site that is to be stimulated, in this case a fingertip, where an electrically conductive wire 38 carries the electrical signal to an electrode 39 at the stimulation site. Typical dimensions for this device are about 5 to 60 mm in length and about 1 to 6 mm in diameter. (See, for example, U.S. Pat. Nos. 6,164,284, 6,185,452, and 6,208,894 which are incorporated herein by reference in their entirety.) While element 2 is generally described as a stimulator, it is recognized that the present invention is equally applicable when element 2 is operable as a sensor or as a stimulator and a sensor. Stimulator 2 includes insulating case 4 , which typically is hollow and contains an electronics package and a power source, such as a battery, capacitor, magnetic field to electricity converter, and electrically conductive case ends 6 , each of which has an electrically conductive electrode 8 which conducts electrical signals from a stimulator and/or to a sensor, depending upon the design and function of that particular miniature stimulator 2 . Stimulator 2 may have at least one electrode, e.g., 2-8 or more, depending upon its particular design and function, although, for illustrative purposes, only two electrodes are shown in FIG. 1 . Electrically conductive electrodes 8 are shown threaded in FIG. 1 , although alternate embodiments are shown in other figures and are discussed herein.
Insulating case 4 contains the electronics, which may include a battery or other energy storage device and signal generating or receiving circuitry and is made of an electrically insulating material that is capable of being hermetically sealed and that is also biocompatible, such as plastic or ceramic. The plastic may be epoxy, polycarbonate, or plexiglass. The ceramic may be alumina, glass, titania, zirconia, stabilized-zirconia, partially-stabilized zirconia, tetragonal zirconia, magnesia-stabilized zirconia, ceria-stabilized zirconia, yttria-stabilized zirconia, or calcia-stabilized zirconia, and in a preferred embodiment, insulating case 4 is yttria-stabilized zirconia, although other insulating materials may also be used. The insulating case 4 must be a material that is biocompatible as well as capable of being hermetically sealed, to prevent permeation of bodily fluids into the case.
The electrically conductive case end 6 is preferably a biocompatible, non-corrosive material, such as titanium or a titanium alloy, although other metals such as platinum, iridium, platinum-iridium, stainless steel, tantalum, niobium, or zirconium may be used. The preferred material is Ti-6 Al-4 V. An alternate preferred material is platinum-iridium.
If any electrically conductive electrode is not being used while the stimulator is in the body, then the electrode may be insulated to prevent stimulation of nearby tissue. Protective nut 10 is either an insulator or an electrically conductive conductor. If it is an electrical conductor, then it is an extension electrode of electrically conductive case 6 . It is placed over the unused electrically conductive electrode 8 such that protective nut threaded hole 12 is tightly screwed onto threaded electrically conductive electrode 8 . In a preferred embodiment, the threads on threaded electrically conductive electrode 8 are 0 80 threads. In order to avoid growth of tissue into joints, such as the joint formed between protective nut 10 and electrically conductive case end 6 , it is preferable that any gap be less than 7 microns.
An alterative embodiment is illustrated in FIG. 2 where bayonet electrode 14 is covered by protective nut 15 that contains bayonet mount 16 . Yet another embodiment of miniature stimulator 2 is illustrated in FIG. 3 , where electrically conductive electrode 8 is now stud electrode 21 , a smooth stud, which has electrode through-hole 18 passing radially through and intersecting with the longitudinal axis of stud electrode 21 . Stud protective nut 19 is placed onto stud electrode 21 such that protective nut mounting hole 20 fits over stud electrode 21 while protective nut through-hole 22 is aligned with electrode through-hole 18 . Protective nut through-hole 22 is positioned such that it passes radially through and intersects with the longitudinal axis of protective nut 19 and such that nut 19 fits very snugly against electrically conductive case end 6 . Breakaway pin 24 is placed into protective nut through-hole 22 and into electrode through-hole 18 . After alignment of protective nut 19 onto electrode 21 is complete, the protruding portion of breakaway pin 24 is broken off and discarded.
A preferred method of attaching an electrically conductive wire 38 to a miniature stimulator 2 (see FIG. 1 ) is illustrated in FIGS. 4 , 5 , and 6 wherein flare nut 26 is comprised of protective nut 28 , which contains flare nut mounting hole 30 . Threaded flare nut mounting hole 30 is positioned over electrode 8 (see FIG. 1 ) and tightened by screwing onto the threads. Flare nut 26 also contains flare nut wire receptor 32 which has flare 34 on its extension pointed away from protective nut 28 . Because of the small diameter of wire used in this application, flare 34 is provided for ease of placement of electrically conductive wire 38 into flare 34 . Offset through-hole 36 passes through flare nut wire receptor 32 in a plane that is perpendicular to the longitudinal axis of flare nut 26 . Offset through-hole 36 preferably does not intersect with the longitudinal axis of nut 26 , but is intentionally offset to penetrate wire insulator 41 (see FIG. 6 ) and to intersect with the outer diameter of wire conductor 40 . Thus when a pin, not illustrated, is placed in offset through-hole 36 , wire conductor 40 is contacted, creating an electrically conductive path between wire conductor 40 and protective nut 28 .
The cross-sectional view of FIG. 5 illustrates the offset alignment of offset through-hole 36 with respect to the longitudinal axis of flare nut wire receptor 32 . Wire conductor 40 is intersected by offset through-hole 36 such that wire insulator 41 will be penetrated and wire conductor 40 will be contacted by a pin inserted in offset through-hole 36 . Electrically conductive wire 38 , shown in FIG. 6 is comprised of wire conductor 40 within wire insulator 41 . Alternately, wire insulator 41 may be stripped from an end portion of wire conductor 40 , to help insure good electrical contact between conductor 40 and flare nut wire receptor 32 .
In a preferred embodiment, wire conductor 40 is a highly conductive metal that is also benign in the body, such as MP35, although stainless steel or an alloy of platinum-iridium may also be used. Preferably, the wire has a diameter of approximately 0.003 inches. It is contained in wire insulator 41 to electrically isolate it from the body tissue and fluids and, in a preferred embodiment, wire insulator 41 is Teflon-coated silicone.
An alternate method of attaching an electrically conductive wire (not shown) to electrically conductive case end 6 is shown in FIG. 7 , where an electrically conductive wire is attached to smooth stud electrode 21 by placing smooth protective nut 42 over stud electrode 21 by aligning protective nut mounting hole 43 with stud electrode 21 and engaging them. Offset through-hole 44 is of a diameter that allows an insulated wire to pass therethrough and it is aligned such that when smooth protective nut 42 is pushed onto stud 21 , the electrically conductive wire is contacted and crushed, thereby making electrical contact between the electrically conductive wire and stud electrode 21 . A cross-sectional view through protective nut 42 , illustrated in FIG. 8 , shows the alignment of offset through-hole 44 with respect to protective nut mounting hole 43 . Smooth protective nut 42 is retained on stud 21 by virtue of the frictional force generated by a crushed wire present in offset through-hole 44 as protective nut 42 is placed on stud electrode 21 .
In an alternate embodiment, shown in FIG. 9 , miniature stimulator 2 has at one end threaded electrically conductive electrode 8 and at the other end threaded electrode hole 46 . Alternate embodiments contain various combinations of electrically conductive electrodes 8 and electrode holes 46 . FIG. 9 illustrates one such combination of dissimilar electrodes. As discussed previously, if an electrode is unused, then it must be covered and protected to prevent tissue damage or undesirable tissue growth into the stimulator. If threaded electrode hole 46 is unused, then it is filled with electrode plug 48 , which is screwed tightly into hole 46 , as illustrated in FIG. 10 .
A further method of attaching an electrically conductive wire 38 (not illustrated) to electrically conductive case end 6 is illustrated in FIG. 11 , where threaded electrode hole 46 mates with smooth nut 52 by inserting threaded insert 50 into threaded electrode hole 46 . As nut 52 is tightened, an electrically conductive wire, not illustrated, that has previously been inserted in smooth nut through-hole 54 is crushed between electrically conductive case end 6 and nut crush lip 56 , thereby making contact between the electrically conductive wire and electrically conductive case end 6 . Smooth nut through-hole 54 retains the wire in position and assures that the wire is secured in place until smooth nut 52 is fully tightened.
Illustrated in FIG. 12 is an alternate embodiment of a method of attaching an electrically conductive wire to a miniature stimulator 2 , wherein electrically conductive case end 6 has threaded electrically conductive electrode 8 attached thereto. Electrically conductive electrode 8 contains electrode through-hole 18 located proximate to electrically conductive case end 6 . Protective nut 10 is attached to threaded electrically conductive electrode 8 by screwing electrically conductive electrode 8 into protective nut threaded hole 12 . An electrically conductive wire, not shown, is held in place by placing it through electrode through-hole 18 . The wire makes electrical contact with electrically conductive case end 6 by virtue of being crushed between electrically conductive case end 6 and protective nut 10 by nut crush lip 56 .
A further embodiment of methods to attach an electrically conductive wire (not illustrated) to assure electrical conductivity between the electrically conductive wire and the electrically conductive case end 6 is illustrated in FIG. 13 , where spade clip 58 , which is attached to an electrically conductive wire (not illustrated), is securedly fastened between protective nut 10 and electrically conductive case end 6 .
Spade clip 58 is shown in FIG. 14 with tab 60 configured to attach to electrically conductive wire 38 . Electrically conductive wire 38 , is placed in tab 60 with wire insulator 41 stripped from an end portion of the electrically conductive wire 38 , thereby exposing wire conductor 40 for electrical contact with tab 60 . Tab 60 is wrapped around electrically conductive wire 38 so as to assure that electrically conductive wire 38 is securely attached to spade clip 58 by wrapped tab 60 , which has crimp 70 , as shown in FIG. 15 .
FIG. 15 illustrates spade clip 58 with electrically conductive wire 38 attached to spade clip 58 and retained by crimp 70 . Opening 62 in spade clip 58 is configured to approximate the diameter of electrically conductive electrode 8 (see FIG. 13 ) such that spade clip 58 fits over electrically conductive electrode 8 (not illustrated). In a preferred embodiment, tab 60 and electrically conductive wire 38 are oriented at a right angle to spade clip 58 , thus assuring that electrically conductive wire 38 is parallel to the longitudinal axis of miniature stimulator 2 , thereby minimizing stresses in the wire. FIGS. 15A and 15B illustrate detailed alternate crimp 70 attachment methods of securedly fastening wire conductor 40 to spade clip 58 .
An alternate embodiment, illustrated by cross-sectional view in FIG. 16 , has a wire (not shown) placed through smooth nut through-hole 54 , which is located proximate to smooth nut 52 . As smooth nut 52 is tightened into threaded electrode hole 46 by inserting threaded insert 50 into threaded electrode hole 46 , the wire is crushed between end crush lip 72 and cap 52 , thereby making electrical contact between the wire and electrically conductive case end 6 . The difference between the method of wire attachment illustrated in FIG. 11 and that shown by FIG. 16 is the relocation of nut crush lip 56 from the protective nut 10 of FIG. 11 to electrically conductive case end 6 , as end crush lip 72 in FIG. 16 .
Illustrated in FIGS. 18 and 19 is a further embodiment of a method of attaching an electrically conductive wire (not shown) to miniature stimulator 2 , wherein smooth electrode 76 contains no threads and also has offset electrode through-hole 75 , which is aligned to lie in a plane that is perpendicular to the longitudinal axis of miniature stimulator 2 to intersect with the outer diameter of wire conductor 38 , such that when a pin (not shown) is placed in through-hole 75 , it will contact wire conductor 40 , either by penetrating wire insulator 41 or by contacting the wire conductor 40 directly, if wire insulator 41 has been stripped from that area. Protective nut 10 , shown in FIG. 19 , illustrates nut crush lip 56 , and also illustrates offset protective nut mounting hole 77 , which aligns with offset electrode through-hole 75 , thereby allowing a pin (not shown) to pass through both offset protective nut mounting hole 77 and offset electrode through-hole 75 .
A further embodiment, illustrated by cross-sectional view in FIG. 20 , is similar to the embodiment presented in FIG. 4 , but with electrically conductive case end 6 having threaded electrode hole 46 in place of flare nut mounting hole 30 . Threaded insert 50 is screwed into threaded electrode hole 46 , thereby securing protective nut 28 to electrically conductive case end 6 . An electrical connection between electrically conductive wire 38 is made by stripping wire insulator 41 from the end of wire 38 thus exposing wire conductor 40 . Conductor 40 is inserted into flare nut wire receptor 32 using flare 34 as a guide. Wire insulator 41 is stripped such that, when wire conductor 40 is inserted fully into flare nut wire receptor 32 , wire insulator 41 extends approximately one-quarter of the length of receptor 32 into receptor 32 . Wire 38 is securedly attached inside receptor 32 by crimping receptor 32 to wire conductor 40 .
An alternate method of attaching protective nut 28 to smooth stud electrode 21 is illustrated in FIG. 21 . While the preferred method of attaching the two components is by screwing them together, as illustrated in FIGS. 4 and 20 , in the instant embodiment, electrically conductive case end 6 has stud electrode 21 attached thereto, which has no threads. Protective nut 28 slips snugly over stud electrode 21 until electrically conductive case end 6 is located touching adjoining protective nut 28 . As previously illustrated in FIG. 20 and as discussed above, wire 38 and its conductor 40 and wire insulator 41 are securely fitted inside flare nut wire receptor 32 by using flare 34 as a guide. Electrically conductive wire 38 is secured by crimping flare nut wire receptor 32 onto wire conductor 40 (see FIG. 21 ). Protective nut 28 is secured to stud electrode 21 by placing C-clip 74 (see FIG. 17 ) over protective nut 28 such that protective nut 28 is partially deformed, thereby creating a secure attachment between stud electrode 21 and protective nut 28 .
The preferred method of assuring electrical insulation between electrically conductive case end 6 , electrically conductive electrode 8 , protective nut 28 , and wire 38 , as illustrated in FIG. 22 , is to cover the electrically conductive case end 6 and other parts with rubber boot 82 . Rubber boot 82 is made of a flexible insulating material that is biocompatible, such as silicone. Its purpose is to provide electrical insulation such that stray electrical signals do not pass between surrounding tissue and any electrically conductive part of the device. Rubber boot 82 is secured to the device, preferably by tying it in place with ties 84 . A sufficient number of ties 84 are placed by the surgeon to assure that that the rubber boot 82 will not move. It is preferred that at least one tie 84 and, preferably two or more ties 84 , be placed on rubber boot 82 to secure rubber boot 82 to insulating case 4 , so as to electrically insulate electrically conductive case end 6 from the living tissue. FIG. 22A illustrates a typical tie 84 interacting with rubber boot 82 , so as to establish and maintain a hermetic seal. Alternate methods of attaching rubber boot 82 include the use of ridges inside rubber boot 82 , clamps over rubber boot 82 , silicone adhesive inside rubber boot 82 , ridges on the outside of insulating case 4 , a male notch with matching female indentation forming an O-ring seal, and the tight fit of rubber boot 82 over the device, either with or without internal ridges.
An alternate configuration to miniature stimulator 2 , previously illustrated in FIG. 1 , is miniature disk stimulator 86 , which is illustrated in FIGS. 23 and 24 . Disk 88 is preferably comprised of insulating material having at least one electrically conductive electrode 90 . Two electrodes are illustrated in FIGS. 23 and 24 , but alternate arrangements have at least one, e.g., 1 to 8 or more, electrodes. Electrode 90 is hermetically bonded to disk 88 . Electrode 90 can be one or more tabs as shown in FIG. 23 , or it can be one or more flush electrodes (not illustrated) that are mounted on the surface of disk 88 . While the tabs 90 that are illustrated in FIGS. 23 and 24 project from the surface of the insulating disk 88 , the tabs 90 can equally well not project from the surface of insulating disk 88 and may be contiguous with the surface such that they do not project above the surface. The methods of connecting a wire to the miniature stimulator that have been previously discussed are equally applicable to miniature disk stimulator 86 , as well as to other configurations. The dimensions of disk 88 are about 5 to 40 mm diameter and about 1 to 6 mm thick. Electrically conductive electrode 90 is preferably made of an electrical conductor that is biocompatible and corrosion resistant, such as platinum, iridium, platinum-iridium, tantalum, titanium or a titanium alloy, stainless steel, niobium, or zirconium. Disk 88 is made of an electrical insulator that is biocompatible, such as ceramic, glass, or plastic.
FIG. 25 illustrates an alternate annular electrode arrangement on the end of miniature stimulator 2 . At least one annular electrode may be used, e.g., four annular electrodes 92 are illustrated in FIG. 25 . Each annular electrode 92 is capable of carrying an independent electrical signal and is electrically isolated from the other electrodes. The signal from or to stimulator 2 passes along electrically conductive wires 38 , where each electrically conductive wire 38 carries an independent signal and is electrically isolated from the others. Each electrically conductive wire 38 corresponds with and is connected to one annular electrode 92 by means of its connecting to toroidal spring 98 . Alternatively, toroidal spring 98 may be a semi-circular spring. Annular cap 94 contains toroidal springs 98 . Electrically conductive wires 38 pass through holes in the end of cap 94 . The internal diameter of annular cap opening 96 approximates but is slightly larger than the outer diameter of stimulator 2 . To make a connection between annular electrode 92 and toroidal spring 98 , annular cap 94 is pushed in a longitudinal direction along the axis of stimulator 2 until it is fully engaged in a position such that electrical contact is made between annular electrode 92 and a corresponding toroidal spring 98 . Each toroidal spring 98 is preferably retained inside annular cap 94 by an annular recession inside annular cap 94 such that during engagement of stimulator 2 with annular cap 94 , the toroidal spring 98 is forced into the recession, thereby allowing room for smooth engagement of the parts. The alignment of toroidal spring 98 and annular electrode 92 is such that each toroidal spring 98 contacts only one corresponding annular electrode 92 .
FIG. 26 illustrates the case end 100 of stimulator 2 and FIG. 27 illustrates the end view of annular cap 94 . A cross-sectional view of annular electrode 92 is illustrated in FIG. 28 .
Another embodiment for making an electrical connection to miniature stimulator 2 is illustrated in FIGS. 29 and 30 . FIG. 29 illustrates an end view of electrode plug 104 (see FIG. 30 ) showing four electrically conductive wires 38 passing into the center of electrode plug 104 through potting material 106 . The potting material provides a secure, hermetic seal for wires 38 to pass into miniature stimulator core 102 , as illustrated in FIG. 30 .
FIG. 30 illustrates a longitudinal view in cross-section of miniature stimulator 2 comprising insulating case 4 , electrically conductive case end 6 , electrode plug 104 , and potting material 106 . Electrode plug 104 is made of a biocompatible material such as titanium and is attached by weld 105 to electrically conductive case end 6 , thereby forming a hermetic seal.
Another embodiment for making an electrical connection to a miniature stimulator 2 is illustrated in FIG. 31 where doorknob electrode 108 is intimately attached to electrically conductive case end 6 . The doorknob electrode is made of a material that is electrically conductive and biocompatible, such as titanium.
Spring clip 110 is preferably a clip made of titanium which has two or more, and preferably three or four prongs. Wire insulator 41 is stripped from the end of wire 38 thereby exposing wire conductor 40 . Wire conductor 40 is preferably attached to spring clip 110 by strain relief weld 112 . Strain relief weld 112 helps to relieve strain in wire conductor 40 by virtue of being oriented perpendicular to the longitudinal axis of miniature stimulator 2 . Further strain relief is provided in wire conductor 40 by virtue of it being tightly coiled inside wire insulator 41 thereby forming wire strain relief 114 . The inside of wire insulator 41 is fill material 115 , which is preferably soft silicone, to minimize infiltration of body fluids and other tissue inside wire 38 .
A perspective view of doorknob electrode 108 , showing its end attached to electrically conductive case end 6 , is illustrated in FIG. 32 . FIG. 33 illustrates a perspective view of spring clip 110 showing the four prongs that slip over doorknob electrode 108 to form an electrical connection.
FIG. 34 illustrates spring clip 110 together with electrically conductive wire 38 , which in turn is attached by strain relief weld 112 to wire conductor 40 . Spring clip 110 is shown in its attached position on doorknob electrode 108 . Rubber boot 82 is securely fastened to the device with ties 84 to completely cover electrically conductive case end 6 , doorknob electrode 108 , wire conductor 40 and a portion of wire insulator 41 , thus electrically insulating the body tissue from electrical signals.
An alternate embodiment is presented in FIG. 35 , which is similar to the connection device presented in FIG. 34 except that connector crimp 118 , which is selected from the group of biocompatible materials, and is preferably platinum metal, is placed over the end of electrically conductive wire 38 so as to cover a portion of wire insulator 41 and stripped wire conductor 40 . Connector crimp 118 is attached to electrically conductive wire 38 by crimping it onto wire 38 .
A preferred embodiment is shown in FIG. 36 in which slip-on cap 122 has a slightly larger internal diameter of a portion of slip-on cap 122 such that it slips over the outer diameter of insulating case 4 . Snap-on cap 120 has at least one flexible member 130 having a tooth 135 on each flexible member 130 . Tooth 135 engages the edge of electrically conductive slip-on cap 122 , as illustrated in FIG. 37A , and holds snap-on cap 120 tightly in place. Electrical conductivity is achieved between electrically conductive wire 38 and electrically conductive slip-on cap 122 by spring disk 125 holding enlarged end of wire 140 tightly in contact with electrically conductive slip-on cap 122 when snap-on cap 120 is in place. Rubber boot 82 provides electrical insulation by covering electrically conductive slip-on cap 122 , snap-on cap 120 , and a portion of electrically conductive wire 38 .
An alternate embodiment is shown in FIG. 37 in which snap-on cap 120 is elongated and slotted on the end opposite tooth 135 . When slotted elongated end 123 is squeezed, flexible members 130 are levered outward and tooth 135 is thereby disengaged from the edge of slip-on cap 122 . FIG. 37A illustrates the interaction of tooth 135 with slip-on cap 122 such that snap-on cap 120 is securedly fastened to slip-on cap 122 .
An alternate embodiment is shown in FIG. 38 in which electrically conductive case end 6 contains at least one angled flat 150 to allow rotatable cap tooth 136 of rotatable cap 133 to slide smoothly onto the end of electrically conductive case end 6 and to facilitate alignment of rotatable cap tooth 136 with flat-bottomed slot 145 . Electrically conductive case end 6 has at least one flat-bottomed slot 145 that engages rotatable cap tooth 136 of rotatable cap 133 to retain rotatable cap 133 on electrically conductive case end 6 . When rotatable cap 133 is rotated about its longitudinal axis by about 30° to 90°, rotatable cap tooth 136 is rotatably moved out of flat-bottomed slot 145 , thereby allowing rotatable cap 133 to be removed. These elements are shown in the perspective views of FIGS. 39 and 40 , the angled flat 150 is indicated to facilitate placement of rotatable cap 133 onto electrically conductive case end 6 in order to engage rotatable cap tooth 136 with flat-bottomed slot 145 .
A cross-sectional view, through flat-bottomed slot 145 and perpendicular to the longitudinal axis, is presented in FIGS. 41 and 42 . The view of FIG. 41 indicates the position when rotatable cap 133 is in position to engage rotatable cap tooth 136 with flat-bottomed slot 145 . The view of FIG. 42 indicates the same cross-sectional view as in FIG. 41 but rotatable cap 133 has been rotated 90° from the position illustrated in FIG. 41 to disengage rotatable cap tooth 136 from flat-bottomed slot 145 thereby allowing removal of rotatable cap 133 .
These various embodiments are of devices and methods for connecting an electrically conductive wire to a miniature, implantable stimulator in order to efficiently transmit or receive an electrical signal that is associated with the implantable stimulator.
Obviously, these methods of attaching a wire to a miniature implantable stimulator can be used in permutations and combinations not specifically discussed herein. Many 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. | Apparatus connect electrically conductive wire to a miniature, implantable sensor or stimulator device for detecting electrical signals or stimulating living tissue. The implantable device has an electrically conductive end on its case which is intimately connected to a doorknob electrode for communicating electrical signals between the living tissue and the device by a biocompatible wire. A spring clip removably attaches to the doorknob electrode so that the wire may be easily attached to the doorknob electrode during surgery. An insulating rubber boot, which may be silicone, surrounds the case end, doorknob electrode, and spring clip to isolate the living tissue from the conductive components. The components are biocompatible materials. | 7 |
This is a continuation, of application Ser. No. 170,475, filed July 21, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a system and method for recovering hydrocarbon fuel from hydrocarbon fuel bearing ores; particularly gasification recovery of oil from oil-bearing shale particularly recovery of oil from oil-bearing shale and coal gasification.
As the energy situation becomes more and more critical, it is important not only to conserve energy, but also to find every possible means of recovering energy from all sources available as economically and as efficiently as possible. In this regard, it is well-known that oil shales exist in large deposits which can be readily mined and pyrolyzed to produce shale oil and that there are large coal reserves; especially in the United States.
The term "oil shale" refers to marlstone, a limestone-like carbonaceous rock that can produce oil when heated to pyrolysis temperatures of about 800° F.-1,000° F. The oil precursor in the shale is an organic polymer substance of high molecular weight referred to as "kerogen". Oil shale is found all over the world and in at least 30 states in the United States with estimates of the amount of oil locked in those formations running into the trillions of barrels. In addition, a large amount of the oil shale formations in the United States with 25 to 30 or more gallons of oil per ton of shale can only be recovered by underground mining techniques.
Present techniques for producing oil from shale require large capital investment, pollution control, handling of raw and spent shale, and the need in some cases for large amounts of water to cool the hot kerogen vapors from the retort or kiln and to slurry and compact the spent shale back into the deposit.
In a modification of retorting applicable to underground mining referred to as in situ mining, a small portion of the rock is removed and the rest is reduced to small particles by explosives and then the particles are burned in place. The oil is collected at the bottom of the natural retort and pumped to the surface.
Regardless of the specific technique employed, in order to produce shale oil in large quantities, enormous expenditures are required with present state of the art techniques. One company estimates that it will have spent more than $100,000,000 by the time its first 9,500 barrel a day retort begins operating. Another company indicates that to produce 48,000 barrels of oil a day, it would need a half dozen 6 story tall retorts, each capable of processing 11,000 tons of shale a day. The company officials estimate that it will cost $1.3 billion to $1.5 billion for that operation. Still another company states that it has spent over $100,000,000 developing modified in situ technology for use at the shale sites and have been testing underground retorting for a number of years. The last three retorts built by this company were big enough for commercial product and were 160 feet square and almost 300 feet high. One collapsed. This company states that to scale operations up to commercial production, it would require 40 underground in situ retorts to produce the 50,000 barrels a day which was set as a goal.
There are at least six significant contributory factors to the continuing lack of economic feasibility for recovery of shale oil. These are high fixed costs of on-site construction of the necessary recovery plants (retorts and the like), the high carrying cost of the land necessary to support the large recovery plants, the uncertainties as to the technological feasibility of large plants due to problems arising from scaling up from small, successful pilot plants, the logistics of handling vast quantities of materials, the high risk premium on the cost of capital to carry out the recovery, and the environmental problems. These same factors have inhibited and largely prevented commercially-successful coal gasification.
Thus, it can be understood why no one in the last century has produced shale oil in the United States in other than small quantities, even though efforts to effect commercial production have been going on since the 1920's and particularly since the early 1970's.
As previously noted, the greatest available source of richest deposits of shale in the United States requires underground mining where it is expected that the usual mining techniques such as large room and pillar mining techniques will have to be used. This necessitates the dual problem of working to recover the shale and, further recovering the oil from the shale.
Another major problem with regard to extracting kerogen from shale is the problem of disposing of the spent shale. Having been exposed to the high temperatures in order to extract the oil, the shale expands in volume by a factor of as much as 150% and the original area mined cannot accomodate all of the expanded spent shale. Attempts to handle the shale by leaving them in dumps has not proven satisfactory. Aside from the unsightliness of such dumps, there is the problem of pollution due to the fact that rains on such dumps can produce a highly alkaline run-off. This necessitates the development of containment devices to prevent any such run-off. There is also the problem of landscaping and revegetation.
The same problems of massive capital expenditure also applies to efforts to make coal gasification a viable commercial reality in the United States even though the underlying technology exists.
SUMMARY OF THE INVENTION
Thus, the present invention relates to a system for economic extraction of hydrocarbon fuels from hydrocarbon-fuel bearing rocks; particularly oil from oil-bearing shale and coal gasification.
The system comprises means for stockpiling the hydrocarbon-fuel bearing rock, a plurality of portative retorts for processing said rock to produce a hydrocarbon fuel, means for transporting said rock from said stockpile to each of said retorts, means on each of said retorts coupled to said transport means for regulating the amount of said rock transported to a respective retort, and at least one storage device coupled to said retorts for collecting and storing said hydrocarbon fuel produced by said retorts.
The invention also relates to a method of extracting a hydrocarbon fuel from hydrocarbon-fuel bearing rock comprising the steps of stockpiling the rock, transporting said rock to a processing site, processing said rock in a plurality of portative retorts at said processing site to produce a hydrocarbon fuel, regulating the amount of rock transported to each retort, and coupling the hydrocarbon fuel produced by said retorts to at least one storage device.
The application is particularly applicable to extraction of oil from oil shale and coal gasification and will be particularly described in connection with the former.
BRIEF DESCRIPTION OF THE DRAWINGS
Numerous other aspects of this invention along with additional objectives, features, and advantages of the invention should now become apparent upon a reading of the following exposition in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic representation of the over-all mining operation;
FIG. 2 is a general schematic representation of the shale oil collection operation;
FIG. 3 is a more detailed schematic representation of an individual retort and its associated inputs and outputs;
FIG. 4 is a cross-sectional schematic representation of a room and pillar mining system in accord with the present invention; and
FIG. 5 is a cross-sectional schematic representation of a similar room and pillar mining system in accord with present conventional practice.
DETAILED DESCRIPTION
The instant invention will be described in connection with the recovery of oil from oil shale and particularly in connection with underground mining systems, it being understood that if desired, they can also be used with respect to surface mining, such as strip mining techniques. A critical feature of the system of the instant invention is the ability to utilize proven portative retorts of a size that they can be placed in and operate in, underground mines of the room and pillar type and to move as the mining operation moves. This has significant advantages in both underground as well as surface mining which are described in detail below. As used herein, the term "portative" means portable or movable either by means on the unit itself, or by means of a vehicle, such as a tractor, without any extensive disassembly.
First, the ability to process the shale underground is a tremendous advantage in that it eliminates the need to carry all of the shale to the surface to be retorted and then have to return shale back into the mine for disposal. The only disposal problem with the instant invention in underground mining is for the volume of spent shale that cannot be accomodated by the previously mined area. Thus, the problem of surface containment of spent shale is, in addition, greatly minimized.
Secondly, the problems of emissions is made simpler in that the retorts being placed in the mine and their being limited ways in which the gasses can rise therefrom to the surface, the emissions can be more readily treated to prevent pollution. Also, by having the retorts in the mine, the natural beauty of the areas where mining occurs is largely preserved. In effect, one is able to recover the oil without any of the emission problems resulting from surface retorting.
Portability; i.e., mobility, is also of importance in surface mining in that smaller, mobile units make commercial recovery possible by requiring less land, less reclamation, market entry by moderation, optimization of materials handling, and ability to mix different retort systems to obtain a desired by-product mix.
In addition, the portative retorts are of a size such that they can be produced in a factory and transported as self-contained units or in a few readily assembleable parts to the mining site. This avoids the much larger cost of on-site construction required of large retorts in remote mining areas. The savings in cost are substantial.
While underground in situ mining by the use of creating a rubble in the ground and then using the rubbleized formation for a natural retort has been attempted and is not successful in that the recoveries are low, and of course, a great deal of the oil is lost, it is known also that with room and pillar mining techniques, up to as much as 50 or 60% of shale is left in pillars and hence oil cannot be recovered therefrom. This, of course, results in higher costs and lower production. However, with the instant process, it is contemplated that as certain areas are mined, after movement of the retorts to another area for continuous recovery of additional ore, the sections serving as pillars can be collapsed and the remaining material mined by the rubbleized in situ techniques discussed above. This minimizes, again, the cost of the process and the loss in production. Further, the spent shale can be used as a structural support to eliminate the problems of surface subsidence or mine collapse as experienced by conventional in situ processing.
In short, the instant invention unites the economies of scale available with large mining operations and the economies of scale in small already proven retorts known to be successful. The instant invention unites large mine and crushing operation with a series of small, proven retorts which have been made portative and avoids the costs, uncertainties, and sub-optimization of scale-up to large size retorts.
More particularly, the retorts can be constructed in a factory and trucked to the site, avoiding on-site construction and effecting a large reduction in fixed costs; a reduction as large as 85%; small retorts have already been tested and found successful; the use of smaller portative retorts reduces the necessary amount of land needed for economic feasibility; materials handling by placing the retorts down in the mine is largely obviated; the environmental advantages and cost savings are numerous, particularly with underground mining; and by utilizing smaller, proven retorts and the above economies associated therewith, there is a much lower cost-of-capital to effect recovery of shale oil.
FIG. 1 is a schematic representation of a shale oil recovery operation of the present invention which enables recovery of the shale oil through a plurality of individual retort operational units, each of which, if desired, can be owned by an individual operator thus eliminating the requirement that the entire capital outlay be produced by one company. Further, each of the retorts is portative (mobile) in nature and can be quickly connected to or disconnected from the system or moved as the mining operation is moved.
As can be seen in FIG. 1, the oil-bearing shale is removed by a quarrying operation 10 in any well-known manner. The quarrying operation may be a strip mining operation or it may be an underground mining operation. Both methods are old and well-known and the shale produced thereby is placed on a conveyer belt 12 which carries the shale to a primary crusher 14 which has jaws or other means for reducing the size of the shale in a well-known manner. The output from crusher 14 is carried by conveyor belt 12 to a large screen 16 which separates lumps in excess of the maximum allowable size. The screened shale is then carried by conveyor belt 12 to secondary crusher 18 where the large pieces of shale are further reduced in size. The crushed shale is carried by conveyor belt 12 from secondary crusher 18 to a small screen 20 which extracts shale which is less than a minimum allowable size. The residue is carried by conveyor belt 12 to a radial stacking unit 22. The radial stacker 22 can be any of the commercially available types and stockpiles the oil-bearing shale over a large area covered by movement of the stacker in a semi-circular pattern.
A plurality of individual retorts 24 receive oil-bearing shale from stockpile 26 by means of individual conveyer belts 28. Automatic feeders 30 in stockpile 26 constantly supply the oil-bearing shale to conveyor belts 28.
Each retort 24 has an individual control 32 which is used to adjust its speed and hence the feed rate of the conveyor belt 28 coupled to that particular retort 24. Thus, the amount of shale delivered to each retort can be controlled by means of individual manual control 32. Further, each individual retort 24 has its own monitor 34 which calculates the total volume of raw shale, either in linear feet or gross weight, which is fed to the particular retort and calculates the shale fed to that particular retort. Thus, the shale is delivered in quantities as required by the individual retort and the amount of such shale delivered is measured. For each retort owned by different operators, billing can be made according to the amount of shale received. The oil-bearing shale is fed into the individual retort in the usual manner where it is heated to a temperature (about 800° F.-1,000° F.) which releases the shale oil. The residue from the burning shale is removed as an ash and sold or otherwise discarded. The shale oil is fed into a collection system and the gaseous waste by-products are also coupled to a cleansing system where they are precipitated, filtered and/or detoxified before the final wastes are released into the free atmosphere. All of the individual retorts are shown as coupled into a common collection system and by-products cleansing system, but it is also within the scope of this invention for each retort to have its own pollution control system. It is also contemplated that different retorts can be utilized to form hybrid systems that can obtain a variety of by-products dependent upon the retort used.
FIG. 2 is a schematic representation of the shale oil collection operation from the invididual retorts. Thus, as can be seen in FIG. 2, the oil-bearing shale in stockpile 26 is coupled by means of individual conveyer belts 28 to the respective retorts 24. Each of the retorts 24 is coupled to a power line 36 which provides the electrical power necessary to operate the hydraulics, suction blower and gear motors. A conventional meter unit, not shown, at each retort monitors the total power consumed by the retort. If owned by different operators, they can be billed accordingly.
The kerogen released by the heated shale flows from each retort's individual product line 38 to a common product line 40 which transfers the kerogen to a storage tank 42. As the kerogen enters the individual product line 38 from a particular retort, it flows past a volume monitor 44 which measures and records the quantity of kerogen produced and contributed by each individual retort. If individually owned, the individual retort operator is paid according to this volume figure. Further, the meter reading from this volume monitor 44 may also be used, as necessary, for computing any royalties which may be owned to the land owner and/or lease payments owed to the land owner and/or least payments owed to the retort lessor.
The gaseous wastes from each retort 24 can be collected in parallel through a gaseous waste line 46 which leads to conventional environmental cleansing/by-product extraction hardward 48. Here the gaseous wastes are precipitated, filtered, and/or detoxified before the final wastes, in the form of carbon dioxide and water, are released into the free atmosphere. As previously noted, each retort can have its own environmental cleansing/by-product extraction hardward. It is also possible to entrain the wastes in the kerogen and permit waste removal at the refinery where waste treatment facilities already exist.
Since kerogen tends to become "jello-like" in consistency when its temperature drops below 85° F., individual product lines 38 and site product line 40 as well as storage tank 42 may be heated, as by being wrapped by a tubing loop. These loops may be connected to a heat exchanger 50 associated with each retort. The heat exchanger 50 would recover the converted heat from the retorts, resulting from on-going combustion and conduct the heat by suitable means to heat the individual product lines, the site product line, as well as the kerogen storage tank. The heat of the on-going combustion in each retort is utilized to maintain the kerogen in a fluid state. Heat can also be recovered from the spent shale clinker and if desired the recovered heat can be used to distill off certain fractions of the kerogen after it has been recovered from the oil shale.
FIG. 3 is a schematic representation of the portable nature of each of the individual retorts. As can be seen in FIG. 3, conveyer belt 28 is utilized to carry the oil-bearing shale from stockpile 26 to the retort 24. Manual controls 32 associated with the individual retort 24 are utilized by the operator thereof to regulate the amount of shale desired to be processed by that particular retort 24. An electrical input line 36 is coupled through an electrical plug to retort 24 to provide the necessary electrical power for operating the hydraulics, suction blower, gear motor, and other electrical devices thereon. It is old and well-known to place a watt meter in such a line so as to measure the amount of power being consumed by the unit so that the operator can be billed accordingly.
Not depicted is the skid-mounting for the retorts. This is conventinal in nature and tractors or other similar movers can be attached to the skid-mounting to move the individual retorts to any site desired. It will be evident that other means equivalent to skid mounts can be used to make the retorts portable or, if desired, motor means on the retort itself operatively connected to motive means; i.e., wheels, continuous track, and the like, mounted on the bottom of the retorts can be used to move the retorts when desired.
The kerogen produced by retort 24 during the combustion operations is collected through line 38 which transfers the kerogen through a site product line to the kerogen storage tank. Volume monitor 44 records the quantity of kerogen produced by the individual retort, if individual operators are used. The retort operator is paid according to this volume figure. This kerogen connecting line may be coupled to retort 24 by means of a quick disconnect coupling in a manner that is old and well-known in the art.
In like manner, the gaseous wastes from retort 24 are collected by waste line 46 which leads to the environmental cleansing/by-product extraction hardware 48 as explained earlier. Again, this line may be coupled to retort 24 by means of a quick disconnect coupling in a manner that is old and well-known in the art. As previously noted, each retort may have its own environmental controls.
Finally, heat exchanger 50 may have coupled thereto an outlet line 52 for carrying heat away from the retort 24 and an inlet line 54 for providing a return flow to retort 24. Line 52 may be used to wrap line 38 and site product line 40 as well as the kerogen storage tank 42 to maintain the kerogen in a liquid state or other alternative uses as previously described.
The retorts used in the present invention can be any one of the successfully used retorts such as the Union Oil rock pump retorts (Types A and B), the Cameron and Jones kiln, or the retorts used in the Paraho, Superior, and Tosco oil shale processes as described on pages 263 to 270 of the text "The Energy Source Book", edited by McRae et al. Certain of these and other retorts are disclosed in U.S. Pat. Nos. 2,875,137 to Lieffers et al., 3,162,583 to Hemmingef et al., and 3,908,865 to Day. These retorts are cited for illustrative purposes only and not by way of limitation. It is also pointed out that these retorts must be made of a size to be portative and provided with means to make them portative.
FIG. 4 illustrates a preferred embodiment of the present invention wherein underground mining and recovery of the oil is effected. There is shown a conventional room and pillar mine 70 having sufficient pillars 71 to support the mine. Conventional mining equipment (not shown) is used to mine the shale from the mine face and the shale is conveyed, as by front-end loaders 72, to conventional crushers 73. The crushed shale is moved by conveyors 74 to a screen 99, then through a second crusher 75 (if necessary), and then the crushed ore is placed into feeder piles 76 by radial stacker 95. A plurality of conveyors 77 carry the crushed shale from piles 76 to retorts 78. The kerogen is moved by pipes 79 to storage tank 80 located on the surface. The other by-products are conveyed to recovery tank 90 by pipes 91.
The spent shale is moved by means of conveyors 85 to a portion of the mine already mined where it is disposed of and the excess spent shale is moved by means of conveyors (not shown) to an appropriate storage area where the excess spent shale is carried to the surface by suitable elevator means, such as the continuous bucket system 82, and onto surface conveyor 83 for transport to a suitable surface dump site. If desired, the spent shale can be treated with a suitable aqueous solution in tank 81 to solubilize and remove the alkaline cations therefrom prior to carrying the residue to buckets 82 for disposal as previously described. These alkaline materials can then be disposed of in the mine thereby eliminating a major problem with respect to surface deposit of the excess spent shale.
The system shown in FIG. 5 combines, again, room and pillar mining, but with surface retorting and stationary retorts. It is not as economically suitable in that all the oil shale must be conveyed to the surface, not just the excess shale as with the system of the present invention shown in FIG. 4. In this embodiment, the shale mined in mine 80 is conveyed by loader 72 to crusher 73, screened, lifted to the surface in buckets 100, and there secondarily crushed. The crushed shale is then fed to non-mobile retorts 78 and the kerogen conveyed to storage tank 80 and other recoverable by-products to recovery tank 90. The spent shale to be placed back into the already mined area of the mine can be lowered by means of buckets 103 into the mine and conveyed by means of conveyors 104 to the area where it is to be dumped. Such a system is significantly less economic. In addition, the reduced distances over which the spent shale must be transported is, by virtue of the retort mobility, greatly minimized and avoids the requirement of slurrying the shale residue as foreseen necessary in the large immobile facilities thereby avoiding the necessity of large water useage.
The use of small portative retorts is advantageous over large retorts even in surface mining in that much less land is required for economic mining as the retorts can be readily moved from place to place over the mining area.
The process of the invention is largely evident from the foregoing description of the apparatus system.
Thus, there has been disclosed an oil recovery system in which kerogen is recovered from oil-bearing shale which permits economic recovery and in a manner which allows, if desired, individual operators to share the enormous costs that are involved in the production of such shale oil and yet which allows each operator to set up a portable retort on the site of the oil-bearing shale or to purchase from the land owner or other proper individual the amount of shale necessary for continually operating the retort as many hours a day as necessary and to supply the recovered shale oil to a common collection system and to have the gaseous waste supplied to a common collection system for purification. The costs thus become managable and allow a shale oil recovery operation which could not be effectively handled by one operator.
While the instant invention has been described in detail with respect to recovery of oil from oil shale, it is also applicable to recovery of oil from tar sand and coal gasification. The applicability arises from the fact that in these other energy recovery efforts, large scale mining of the sands and coal is well-known and efficient, but the recovery of the oil from the sand and gasification of the coal have been hampered by the cost of scaling up the recovery devices; i.e., retorts, kilns, and the like. As with shale oil recovery of the instant invention, this problem can be overcome by using a sufficient number of the already proven pilot scale recovery units which are made portative and which avoid the problems, economic and mechanical, of scaling up. In short, the instant novel system of mating large scale mining techniques with small scale portative retorts to provide economic and efficient recovery of oil from oil shale can be applied to recovery of oil from tar sands and to coal gasification.
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A system for the extraction of a hydrocarbon fuel from a hydrocarbon fuel-bearing ore comprising means for mining the ore, a plurality of portative retorts for processing the mined ore to produce a hydrocarbon fuel, means for transporting the mined ore to each of said retorts, means coupled to said transport means for regulating the amount of ore transported to a respective retort, and at least one storage device coupled to the retorts for collecting and storing the hydrocarbon fuel. Also disclosed is the method of extracting a hydrocarbon fuel from a hydrocarbon fuel-bearing ore comprising the steps of mining the ore, transporting the ore to a plurality of portative retorts in which the ore is processed to produce a hydrocarbon fuel fluid, and moving the retorts in consonance with movement of the mining of said ore. | 4 |
[0001] This application is a Continuation of U.S. application Ser. No. 12/821,324, filed Jun. 23, 2010, which claims priority to Japanese Application No. 2009-151230, filed Jun. 25, 2009. The foregoing patent applications are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a fluid ejection device in which a drive signal is applied to an actuator to eject fluid, and is suitable for a fluid ejection printer adapted to, for example, eject small droplets from a nozzle of a fluid ejection head to form fine particles (dots) on a print medium, thereby printing a predetermined character, image, or the like.
[0004] 2. Related Art
[0005] In the fluid ejection printer, there is provided an actuator such as a piezoelectric element in order for ejecting a droplet from the nozzle of the fluid ejection head, and it is required to apply a predetermined drive signal on the actuator. Since the drive signal has a relatively high voltage, it is required to power-amplify a drive waveform signal forming a basis of the drive signal with a power amplifier circuit. Therefore, in JP-A-2007-168172 (Document 1), there is used a digital power amplifier circuit, which has a smaller power loss compared to an analog power amplifier circuit and can be made smaller in size, a modulator executes pulse modulation on the drive waveform signal to obtain a modulated signal, the digital power amplifier circuit performs power amplification on the modulated signal to obtain a power-amplified modulated signal, and a low pass filter smoothes the power amplified modulated signal to obtain the drive signal.
[0006] In the fluid ejection printer described in the Document 1 mentioned above, the digital power amplifier circuit continues to operate even in the case in which the voltage of the drive signal does not change. Since the piezoelectric element used as the actuator of the fluid ejection printer is a capacitive load, even in the case in which the current supply to the actuator is stopped, the voltage of the actuator is kept at the voltage applied immediately before the stoppage. In other words, since the drive signal applied to the actuator or the drive waveform signal forming a basis thereof has a portion (period) with a voltage kept constant, it is not necessary to supply the actuator with a current when the voltage of the drive signal does not change. However, in the fluid ejection printer described in the Document 1 mentioned above, there arises a problem that the digital power amplifier circuit continues to operate, and therefore, the power is consumed in the digital amplifier circuit and the low pass filter even when the voltage of the drive signal does not change.
SUMMARY
[0007] An advantage of some aspects of the invention is to provide a fluid ejection device capable of reducing power consumption and a fluid ejection printer using the fluid ejection device.
[0008] A fluid ejection device according to an aspect of the invention includes a modulator adapted to pulse-modulate a drive waveform signal forming a basis of a drive signal of an actuator to obtain a modulated signal, a digital power amplifier circuit adapted to power-amplify the modulated signal to obtain a power-amplified modulated signal, a low pass filter adapted to smooth the power-amplified modulated signal to obtain the drive signal, and a power amplification stopping section operating when holding a voltage of the actuator constant.
[0009] According to the fluid ejection device of this aspect of the invention, since the operation of the digital power amplifier circuit is stopped when keeping the voltage of the actuator constant, or in other words, keeping the voltage of the drive waveform signal constant, power consumption in the digital power amplifier circuit and in the low pass filter is reduced.
[0010] Further, the digital power amplifier circuit has a switching element, and the power amplification stopping section stops the operation of the digital power amplifier circuit by setting all of the switching elements of the digital power amplifier off.
[0011] According to the fluid ejection device of this aspect of the invention, since all of the switching elements of the digital power amplifier circuit are off, these switching elements become to be in the high-impedance state, thus the discharge from the actuator (a capacitive load) is prevented.
[0012] Further, the modulator stops an output of the modulated signal when the operation of the digital power amplifier circuit is stopped by the power amplification stopping section.
[0013] According to the fluid ejection device of this aspect of the invention, since the output of the modulated signal itself is stopped, the power consumption of the modulator and the digital power amplifier circuit is reduced.
[0014] Further, the modulator pulse-modulates the drive waveform signal using a first modulation frequency, and the modulator increases the modulation frequency of the pulse modulation from the first modulation frequency when a voltage applied to the drive waveform signal changes from varying to constant.
[0015] According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion in the drive waveform signal when stopping the operation of the digital power amplifier circuit is suppressed to enable a waveform of the drive signal to become closer to a desired form.
[0016] The modulator pulse-modulates the drive waveform signal using a first modulation frequency, and the modulator increases the modulation frequency of the pulse modulation from the first modulation frequency when a voltage applied to the drive waveform signal changes from constant to varying.
[0017] According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion of the drive waveform signal when resuming the operation of the digital power amplifier circuit is suppressed.
[0018] When, for the purpose of explaining, a period in which the modulated signal is in a high level is referred to as a first period, and a period in which the modulated signal is in a low level is referred to as a second period, the modulator sets the modulated signal to be at the high level (or the low level) for a half the time of the first period (or the second period) immediately after the voltage of the drive waveform signal changes from constant to varying.
[0019] According to the fluid ejection device of this aspect of the invention, a ripple voltage that causes distortion of the drive waveform signal when the voltage of the drive waveform signal changes from constant to varying is suppressed.
[0020] Further, the power amplification stopping section temporarily resumes the operation of the digital power amplifier circuit during a stoppage of the operation of the digital power amplifier circuit.
[0021] According to the fluid ejection device of this aspect of the invention, a voltage drop by self-discharge in the actuator due to being a capacitive load.
[0022] A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage difference data.
[0023] According to the fluid ejection device of this aspect of the invention, whether the voltage applied to the drive waveform signal is varying or not may be easily determined.
[0024] A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage data and information regarding whether the voltage of the drive waveform signal is varying or not.
[0025] According to the fluid ejection device of this aspect of the invention, determining whether the voltage applied to the drive waveform signal is varying or not is no longer required.
[0026] A memory adapted to store the drive waveform signal is further provided, and the memory stores drive waveform voltage data, and the power amplification stopping section calculates a difference between the drive waveform voltage data retrieved from the memory, and stops the operation of the digital power amplifier circuit when the difference indicates a 0.
[0027] According to the fluid ejection device of this aspect of the invention, the memory with small capacity can be adopted.
[0028] Further, the memory stores a modulation frequency by the modulator.
[0029] According to the fluid ejection device of this aspect of the invention, it becomes possible to flexibly set the modulation frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
[0031] FIG. 1 is a front view of a schematic configuration showing a fluid ejection printer using a fluid ejection device as an embodiment of the invention.
[0032] FIG. 2 is a plan view of the vicinity of fluid ejection heads used in the fluid ejection printer shown in FIG. 1 .
[0033] FIG. 3 is a block diagram of a control device of the fluid ejection printer shown in FIG. 1 .
[0034] FIG. 4 is an explanatory diagram of a drive signal for driving actuators in each of the fluid ejection heads.
[0035] FIG. 5 is a block diagram of a switching controller.
[0036] FIG. 6 is a block diagram of a drive circuit of the actuators.
[0037] FIGS. 7A and 7B are detailed block diagrams showing an example of the drive circuit shown in FIG. 6 .
[0038] FIG. 8 is an explanatory diagram of a modulated signal, a gate-source signal, and an output signal in the drive circuit shown in FIGS. 7A and 7B .
[0039] FIGS. 9A and 9B are detailed explanatory diagrams of the modulated signal shown in FIG. 8 .
[0040] FIG. 10 is a detailed explanatory diagram of the modulated signal shown in FIGS. 9A and 9B .
[0041] FIG. 11 is a waveform chart showing an example of a drive waveform signal.
[0042] FIG. 12 is an explanatory diagram of the memory contents showing a first embodiment of the invention.
[0043] FIG. 13 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 12 .
[0044] FIG. 14 is an explanatory diagram of the memory contents showing a second embodiment of the invention.
[0045] FIG. 15 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 14 .
[0046] FIG. 16 is an explanatory diagram of the memory contents showing a third embodiment of the invention.
[0047] FIG. 17 is a flow chart of arithmetic processing performed by the controller shown in FIG. 7A in accordance with the memory contents shown in FIG. 16 .
[0048] FIGS. 18A and 18B are detailed block diagrams showing another example of the drive circuit shown in FIG. 6 .
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0049] Then, as a first embodiment of the invention, a fluid ejection device applied to a fluid ejection printer will be explained.
[0050] FIG. 1 is a schematic configuration diagram of the fluid ejection printer according to the first embodiment, and in the drawing, the fluid ejection printer is a line head printer in which a print medium 1 is conveyed in the arrow direction from the left to the right of the drawing, and printed in a printing area midway of conveying.
[0051] The reference numeral 2 shown in FIG. 1 denotes a plurality of fluid ejection heads disposed above a conveying line of the print medium 1 , which are fixed individually to a head fixing plate 11 in such a manner as to form two lines in the print medium conveying direction and to be arranged in a direction intersecting with the print medium conveying direction. The fluid ejection head 2 is provided with a number of nozzles on the lowermost surface thereof, and the surface is called a nozzle surface. As shown in FIG. 2 , the nozzles are arranged to form lines in a direction intersecting with the print medium conveying direction color by color in accordance with the colors of the fluid to be ejected, and the lines are called nozzle lines, and the direction of the lines is called a nozzle line direction. Further, the nozzle lines of all of the fluid ejection heads 2 arranged in a direction intersecting with the print medium conveying direction constitute a line head covering the overall width of the print medium in a direction intersecting with the conveying direction of the print medium 1 . When the print medium 1 passes through under the nozzle surface of the fluid ejection head 2 , the fluid is ejected from a number of nozzles provided to the nozzle surface to thereby perform printing on the print medium 1 .
[0052] The fluid ejection head 2 is supplied with fluids such as ink of four colors of yellow (Y), magenta (M), cyan (C), and black (K) from fluid tanks not shown via fluid supply tubes. Then, a necessary amount of fluid is ejected simultaneously from the nozzles provided to the fluid ejection heads 2 to necessary positions, thereby forming fine dots on the print medium 1 . By executing the above for each of the colors, one-pass printing can be performed only by making the print medium 1 to be conveyed by a conveying section 4 pass through once.
[0053] As a method of ejecting a fluid from the nozzles of the fluid ejection head 2 , there can be cited an electrostatic driving method, a piezoelectric driving method, a film boiling fluid ejection method, and so on, and in the first embodiment there is used the piezoelectric driving method. In the piezoelectric driving method, when a drive signal is applied to a piezoelectric element as an actuator, a diaphragm in a cavity is displaced to cause pressure variation in the cavity, and the fluid is ejected from the nozzle due to the pressure variation. Further, by controlling the wave height and the voltage variation gradient of the drive signal, it becomes possible to control the ejection amount of the fluid. It should be noted that the invention can also be applied to fluid ejection methods other than the piezoelectric driving method in a similar manner.
[0054] Under the fluid ejection head 2 , there is disposed the conveying section 4 for conveying the print medium 1 in the conveying direction. The conveying section 4 is configured by winding a conveying belt 6 around a drive roller 8 and a driven roller 9 , and an electric motor not shown is coupled to the drive roller 8 . Further, in the inside of the conveying belt 6 , there is disposed an adsorption device, not shown, for adsorbing the print medium 1 on the surface of the conveying belt 6 . For the adsorption device there is used, for example, an air suction device for adsorbing the print medium 1 to the conveying belt 6 with negative pressure, or an electrostatic adsorption device for adsorbing the print medium 1 to the conveying belt 6 with electrostatic force. Therefore, when a feed roller 5 feeds just one sheet of the print medium 1 on the conveying belt 6 from a feeder section 3 , and then the electric motor rotationally drives the drive roller 8 , the conveying belt 6 is rotated in the print medium conveying direction, and the print medium 1 is conveyed while being adsorbed to the conveying belt 6 by the adsorption device. While conveying the print medium 1 , printing is performed by ejecting the fluid from the fluid ejection heads 2 . The print medium 1 on which printing has been performed is ejected to a catch tray 10 disposed on the downstream side in the conveying direction. It should be noted that a print reference signal output device formed of, for example, a linear encoder is attached to the conveying belt 6 . Focusing attention on the fact that the conveying belt 6 and the print medium 1 conveyed by the conveying belt 6 while being adsorbed by the conveying belt 6 are moved in sync with each other, the print reference signal output device outputs a pulse signal corresponding to the print resolution required in conjunction with the movement of the conveying belt 6 after the print medium 1 passes through a predetermined position on the conveying path, and a drive circuit described later outputs a drive signal to the actuator in accordance with this pulse signal to thereby eject the fluid of a predetermined color at a predetermined position on the print medium 1 , thus a predetermined image is drawn on the print medium 1 with the dots of the fluid.
[0055] Inside the fluid ejection printer using the fluid ejection device according to the first embodiment, there is provided a control device for controlling the fluid ejection printer. As shown in FIG. 3 , the control device is configured including an input interface 61 for reading print data input from a host computer 60 , a control section 62 configured with a microcomputer for executing arithmetic processing such as a printing process in accordance with the print data input from the input interface 61 , a feed roller motor driver 63 for controlling driving of a feed roller motor 17 coupled to the feed roller 5 , a head driver 65 for controlling driving of the fluid ejection heads 2 , and an electric motor driver 66 for controlling driving of an electric motor 7 coupled to the drive roller 8 , and further including an interface 67 for connecting the feed roller motor driver 63 , the head driver 65 , and the electric motor driver 66 , to the feed roller motor 17 , the fluid ejection heads 2 , and the electric motor 7 , respectively.
[0056] The control section 62 is provided with a central processing unit (CPU) 62 a , a random access memory (RAM) 62 c , and a read-only memory (ROM) 62 d . The CPU 62 a executes various processes such as a printing process. The random access memory (RAM) 62 c temporarily stores the print data input via the input interface 61 or data for executing, for example, the printing process of the print data, and temporarily develops a program of, for example, the printing process. The read-only memory (ROM) 62 d is formed of a nonvolatile semiconductor memory for storing the control program and so on executed by the CPU 62 a . The control section 62 obtains the print data (image data) from the host computer 60 via the input interface 61 . Then, the CPU 62 a executes a predetermined process on the print data to obtain nozzle selection data (drive pulse selection data) representing which nozzle the fluid is ejected from or how much fluid is ejected. Based on the print data, the drive pulse selection data, and input data from various sensors, drive signals and control signals are output to the feed roller motor driver 63 , the head driver 65 , and the electric motor driver 66 . In accordance with these drive signals and control signals, the feed roller motor 17 , the electric motor 7 , actuators 22 inside the fluid ejection head 2 , and so on operate individually, thus feeding, conveying, and ejection of the print medium 1 , and the printing process to the print medium 1 are executed. It should be noted that the constituents inside the control section 62 are electrically connected to each other via a bus not shown in the drawings.
[0057] FIG. 4 shows an example of a drive signal COM supplied from the control device of the fluid ejection printer using the fluid ejection device according to the first embodiment to the fluid ejection heads 2 , and for driving the actuators 22 each formed of a piezoelectric element. In the first embodiment, it is assumed that the signal has the electric potential varying around a midpoint potential. The drive signal COM is obtained by connecting drive pulses PCOM, each of which is a unit drive signal for driving the actuator 22 to eject the fluid, in a time-series manner. The rising portion of a drive pulse PCOM corresponds to a stage of expanding the volume of the cavity (a pressure chamber) communicating with the nozzle to pull-in (in other words, to pull-in the meniscus, in view of the ejection surface of the fluid) the fluid. The falling portion of the drive pulse PCOM corresponds to a stage of shrinking the volume of the cavity to push-out (in other words, to push-out the meniscus, in view of the ejection surface of the fluid) the fluid, and as a result of pushing out the fluid, the fluid is ejected from the nozzle.
[0058] By variously modifying the gradient of increase and decrease in voltage and the wave height of the drive pulse PCOM formed of trapezoidal voltage waves, the pull-in amount and the pull-in speed of the fluid, and the push-out amount and the push-out speed of the fluid can be modified, thus the ejection amount of the fluid can be varied to obtain the dots with different sizes. Therefore, even in the case in which a plurality of drive pulses PCOM are joined in a time-series manner, it is possible to select the single drive pulse PCOM from the drive pulses, and to supply the actuator 22 with the drive pulse PCOM to eject the fluid, or to select two or more drive pulses PCOM, and to supply them to the actuator 22 to eject the fluid two or more times, thereby obtaining the dots with various sizes. In other words, when the two or more droplets land on the same position before the droplets are dried, it brings substantially the same result as in the case of ejecting a larger amount of droplet, thus it is possible to increase the size of the dot. By a combination of such technologies, it becomes possible to achieve multiple tone printing. It should be noted that the drive pulse PCOM 1 shown in the left end of FIG. 4 is only for pulling in the fluid without pushing it out. This is called a fine vibration, and is used for, for example, preventing thickening in the nozzle without ejecting the fluid.
[0059] Besides the drive signal COM described above, the drive pulse selection data SI&SP, a latch signal LAT, channel signal CH, and a clock signal SCK are input to the fluid ejection head 2 from the control device shown in FIG. 3 as the control signals. The drive pulse selection data SI&SP is used for selecting the nozzle ejecting the fluid based on the print data, and at the same time, determining the connection timing of the actuators 22 such as piezoelectric elements to the drive signal COM. The latch signal LAT and the channel signal CH connects the drive signal COM and the actuator 22 of the fluid ejection head 2 based on the drive pulse selection data SI&SP after the nozzle selection data is input to all of the nozzles. The clock signal SCK is used for transferring the drive pulse selection data SI&SP to the fluid ejection head 2 as a serial signal. It should be noted that it is hereinafter assumed that the minimum unit of the drive signal for driving the actuator 22 is the drive pulse PCOM, and the entire signal having the drive pulses PCOM joined with each other in a time-series manner is described as the drive signal COM. In other words, output of a string of drive signal COM is started in response to the latch signal LAT, and the drive pulse PCOM is output in response to each channel signal CH.
[0060] FIG. 5 shows a configuration of a switching controller, which is built inside the fluid ejection head 2 in order for supplying the actuator 22 with the drive signal COM (the drive pulses PCOM). The switching controller is provided with a shift register 211 , a latch circuit 212 , and a level shifter 213 . The shift register 211 stores the drive pulse selection data SI&SP for designating the actuators 22 such as piezoelectric elements corresponding to the nozzles for ejecting the fluid. The latch circuit 212 temporarily stores the data of the shift register 211 . The level shifter 213 performs level conversion on the output of the latch circuit 212 , and then supplies the result to a selection switch 201 , thereby connecting the drive signal COM to the actuators 22 such as piezoelectric elements.
[0061] The drive pulse selection data SI&SP is sequentially input to the shift register 211 , and at the same time, the storage area thereof is sequentially shifted from the first stage to the subsequent stage in accordance with the input pulse of the clock signal SCK. The latch circuit 212 latches the output signals of the shift register 211 in accordance with the latch signal LAT input thereto after the drive pulse selection data SI&SP corresponding to the number of nozzles has been stored in the shift register 211 . The signals stored in the latch circuit 212 are converted by the level shifter 213 so as to have the voltage levels capable of switching on and off the selection switches 201 on the subsequent stage. This is because the drive signal COM has a relatively high voltage compared to the output voltage of the latch circuit 212 , and the operating voltage range of the selection switches 201 is also set to be high in accordance therewith. Therefore, the actuator 22 such as a piezoelectric element, the selection switch 201 of which is closed by the level shifter 213 , is coupled to the drive signal COM (the drive pulses PCOM) (switched on) at the coupling timing of the drive pulse selection data SI&SP. Further, after the drive pulse selection data SI&SP of the shift register 211 is stored in the latch circuit 212 , the subsequent print information is input to the shift register 211 , and the stored data in the latch circuit 212 is sequentially updated in sync with the fluid ejection timing. It should be noted that the reference symbol HGND in the drawing denotes the ground terminal for the actuators 22 such as piezoelectric elements. Further, even after the actuator 22 such as a piezoelectric element is separated from the drive signal COM (the drive pulses PCOM) (switched off), the selection switch 201 maintains the input voltage of the actuator 22 at the voltage applied thereto immediately before the separation.
[0062] FIG. 6 shows a schematic configuration of the drive circuit for the actuators 22 . The actuator drive circuit is built inside the control section 62 and the head driver 65 included in the control circuit. The drive circuit of the first embodiment is configured including a drive waveform generator 25 , a modulator 26 , a digital power amplifier circuit 28 , and a low pass filter 29 . The drive waveform generation circuit 25 generates a basis of the drive signal COM (the drive pulses PCOM), namely a drive waveform signal WCOM forming a basis of the signal for controlling the drive of the actuator 22 . The modulator 26 performs pulse modulation on the drive waveform signal WCOM generated by the drive waveform generator 25 . The digital power amplifier circuit 28 power-amplifies the modulated signal pulse-modulated by the modulator 26 . The low pass filter 29 smoothes the power-amplified modulated signal power-amplified by the digital power amplifier circuit 28 , and then supplies the result to the fluid ejection heads 2 as the drive signal COM (the drive pulses PCOM). The drive signal COM (the drive pulses PCOM) is supplied from the selection switches 201 to the actuators 22 .
[0063] FIGS. 7A and 7B show a configuration of the actuator drive circuit. FIG. 7A shows the drive waveform generator 25 and the modulator 26 , and FIG. 7B shows the digital power amplifier circuit 28 , the low pass filter 29 , and the fluid ejection heads 2 . The drive waveform generator 25 is configured including a memory 31 , a controller 32 , and a D/A converter 33 . The memory 31 stores drive waveform data of the drive waveform signal formed of digital voltage data or the like. The controller 32 converts the drive waveform data read from the memory 31 into a voltage signal, and then holds the result corresponding to a predetermined sampling period, and at the same time, instructs a triangular wave oscillator described later in a frequency and a waveform of a triangular wave signal, or a waveform output timing. The D/A converter 33 performs analog conversion on the voltage signal output from the controller 32 , and outputs the result as the drive waveform signal WCOM. It should be noted that the controller 32 also outputs an operation stop signal /Disable for stopping the operation of the digital power amplifier circuit 28 to a gate drive circuit 30 described later in the digital power amplifier circuit 28 . It is assumed that the operation of the digital power amplifier circuit 28 is stopped when the operation stop signal /Disable takes a low level.
[0064] Further, as the modulator 26 , there is used a known pulse width modulator (PWM). The modulator 26 is provided with the triangular wave oscillator 34 for outputting the triangular wave signal forming a base signal in accordance with the frequency, the waveform, and the waveform output timing instructed from the controller 32 described above. A comparator 35 compares the drive waveform signal WCOM output from the D/A converter 33 with the triangular wave signal output from the triangular wave oscillator 34 , and then outputs the modulated signal with a pulse duty cycle in which the on-duty represents that the drive waveform signal WCOM is higher than the triangular wave signal. It should be noted that the frequency of the triangular wave signal (the base signal) is defined as a modulation frequency (called, in general, a carrier frequency, for example). Further, as the modulator 26 , there can be used a well-known pulse modulator such as a pulse density modulator (PDM) besides the above.
[0065] The digital power amplifier circuit 28 is configured including a half-bridge output stage 21 and the gate drive circuit 30 . The half-bridge output stage 21 is composed of a high-side switching element Q 1 and a low-side switching element Q 2 for substantially amplifying the power. The gate drive circuit 30 controls the gate-source signals GH, GL of the high-side switching element Q 1 and the low-side switching element Q 2 based on the modulated signal from the modulator 26 . In the digital power amplifier circuit 28 , when the modulated signal is in the high level, the gate-source signal GH of the high-side switching element Q 1 becomes in the high level, while the gate-source signal GL of the low-side switching element Q 2 becomes in the low level. In other words, since the high-side switching element Q 1 is set to be in a connected state (“ON”) and the low-side switching element Q 2 is set to be in an unconnected state (“OFF”), as a result, the output Va of the half-bridge output stage 21 becomes equal to a supply voltage VDD. On the other hand, when the modulated signal is in the low level, the gate-source signal GH of the high-side switching element Q 1 becomes in the low level, while the gate-source signal GL of the low-side switching element Q 2 becomes in the high level. In other words, since the high-side switching element Q 1 is OFF and the low-side switching element Q 2 is ON, as a result, the output Va of the half-bridge output stage 21 becomes 0.
[0066] In the case in which the high-side switching element Q 1 and low-side switching element Q 2 are driven digitally as described above, although a current flows through the switching element that is ON, the resistance value between the drain and the source is small, and therefore, the loss is hardly caused. Further, since no current flows in the switching element that is OFF, no loss is caused. Therefore, the loss itself of the digital power amplifier circuit 28 is extremely small, and therefore, it is possible to use small-sized switching elements such as MOSFETs.
[0067] It should be noted that when the operation stop signal /Disable output from the controller 32 is in the low level, the gate drive circuit 30 sets both of the high-side switching element Q 1 and the low-side switching element Q 2 OFF. As described above, when the digital power amplifier circuit 28 is in operation, either one of the high-side switching element Q 1 and the low-side switching element Q 2 is ON. Setting both of the high-side switching element Q 1 and the low-side switching element Q 2 OFF is equivalent to stopping the operation of the digital power amplifier circuit 28 , which leads that the actuators 22 each formed of a piezoelectric element, the capacitive load from an electrical point of view, are kept in a high-impedance state. If the actuators 22 are kept in the high-impedance state, the charge stored in the actuators 22 as capacitive loads is held, and the charge/discharge state is maintained or restricted to a slight self-discharge state.
[0068] As the low pass filter 29 , there is used a quadratic filter composed of one capacitor C and a coil L. The modulation frequency generated by the modulator 26 , namely the frequency component of the pulse modulation, is attenuated to be removed by the low pass filter 29 , and then the drive signal COM (the drive pulses PCOM) having the waveform characteristic described above is output. It should be noted that although FIGS. 7A and 7B show a form of a circuit for the sake of easiness of understanding, the drive waveform generator 25 and the modulator 26 can also be constituted by a program executed inside the control section 62 shown in FIG. 3 . The low pass filter 29 can be configured using a stray inductance or a stray capacitance generated in the circuit wiring, the actuator, or the like, and is therefore not necessarily required to be formed as a circuit. Further, the memory 31 can also be formed inside the ROM 62 d.
[0069] FIG. 8 shows a control condition of the digital power amplification performed in the first embodiment. The upper part of FIG. 8 shows the condition of ordinary digital power amplification as a related art example, while the lower part of FIG. 8 shows a specific example of the digital power amplification control of the first embodiment. In the ordinary digital power amplification having been performed from the past, the digital power amplifier circuit is made to continue to operate constantly irrespective of whether or not the voltage of the drive signal COM varies. For example, since the digital power amplifier circuit used in the field of the audio engineering is premised on the fact that the input is varied constantly, there is no chance to stop the operation. On the other hand, since the actuator 22 such as a piezoelectric element is a capacitive load, there is no need to apply electrical current when the voltage of the drive signal COM does not vary. Despite the circumstance described above, if the high-side switching element Q 1 and the low-side switching element Q 2 of the digital power amplifier circuit 28 continues to be switched on/off, the power is consumed in the high-side switching element Q 1 , the low-side switching element Q 2 , and the coil L of the low pass filter 29 .
[0070] Therefore, in the first embodiment, as shown in the truth table of Table 1 described below, when the voltage of the drive signal COM (the same can be applied to the drive waveform signal WCOM, which has not yet been power-amplified) does not vary, the operation stop signal /Disable is set to be in the low level to stop the operation of the digital power amplifier circuit 28 , and further both of the high-side switching element Q 1 and the low-side switching element Q 2 are OFF. When setting both of the high-side switching element Q 1 and the low-side switching element Q 2 OFF, the actuators 22 as the capacitive loads are kept in the high-impedance state, and hence there is little of the self-discharge. Further, in the first embodiment, in the case of stopping the operation of the digital power amplifier circuit 28 , namely when the voltage of the drive signal COM (the drive waveform signal WCOM) does not vary, output of the modulated signal PWM is also stopped (kept in the low level). Thus, the power consumption in the modulator 26 and the gate drive circuit 30 can also be reduced.
[0000]
TABLE 1
Pulse
Modulation
Power
Signal
/Disable
Q1
Q2
Amplifier
0
1
OFF
ON
Operating
1
ON
OFF
0
0
OFF
Stopped
1
[0071] Incidentally, it is not possible to set both of the high-side switching element Q 1 and the low-side switching element Q 2 of the digital power amplifier circuit 28 OFF only by stopping the output of the modulated signal PWM (keeping the modulated signal PWM in the low level). This is because, when the modulated signal PWM is in the low level, the gate-source signal GH of the high-side switching element Q 1 becomes in the low level, but the gate-source signal GL of the low-side switching element Q 2 becomes in the high level, and consequently, the high-side switching element Q 1 becomes OFF, but the low-side switching element Q 2 becomes ON. Therefore, the gate drive circuit 30 sets both of the gate-source signal GH of the high-side switching element Q 1 and the gate-source signal GL of the low-side switching element Q 2 to be in the low level when the operation stop signal /Disable is in the low level, thereby setting both of the high-side switching element Q 1 and the low-side switching element Q 2 OFF.
[0072] FIGS. 9A and 9B show the details of the PWM modulation performed in the modulator 26 . FIG. 9A shows the state in which the voltage of the drive waveform signal WCOM gradually increases, and is then held constant, and then decreases gradually. Further, FIG. 9B shows the state in which the voltage of the drive waveform signal WCOM gradually decreases, and is then held constant, and then increases gradually. In the first embodiment, in both of the case in which the drive waveform signal WCOM increases and the case in which the drive waveform signal WCOM decreases, the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation is increased when the voltage of the drive waveform signal WCOM changes from varying to constant. Similarly, in both of the case in which the drive waveform signal WCOM increases and the case in which the drive waveform signal WCOM decreases, the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation is also increased when the voltage of the drive waveform signal WCOM changes from constant to varying. Specifically, the modulation frequency (the frequency of the triangular wave signal TRI) of the usual pulse modulation is set to be 500 kHz, and the modulation frequency (the frequency of the triangular wave signal TRI) of the pulse modulation when the voltage of the drive waveform signal WCOM changes from varying to constant or from constant to varying is set to be 1,000 kHz. According to the configuration described above, the ripple voltage of the drive signal COM in each of the transition periods can be prevented, and it becomes possible to match the voltage of the drive signal with no particular variation with the target value. It should be noted that the switching of the modulation frequency is not limited to two levels, it is also possible to increase the number of levels of the switching, or to vary the modulation frequency gradually.
[0073] Further, in the first embodiment, the period with the modulated signal PWM in either of the high level and the low level immediately after the voltage of the drive waveform signal WCOM changes from constant to varying is set to be a half of the period of the original modulated signal PWM. Specifically, since it is arranged that the modulated signal PWM becomes in the high level when the drive waveform signal WCOM is higher than the triangular wave signal TRI, and the modulated signal PWM becomes in the low level when the drive waveform signal WCOM is lower than the triangular wave signal TRI as shown in FIG. 10 , by arranging that the output of the modulated signal PWM is started from the lower apexes of the triangular wave signal TRI, the period with the high level halves. Further, by arranging that the output of the modulated signal PWM is started from the upper apexes of the triangular wave signal TRI, the period with the low level halves. For example, in FIG. 9A , the controller 32 instructs the triangular wave oscillator 34 in the wave form and the waveform output timing of the triangular wave signal TRI so that the triangular wave signal TRI is started from the upper apex simultaneously with when the voltage of the drive waveform signal WCOM starts to decrease from a constant state. In contrast, in FIG. 9B , the controller 32 instructs the triangular wave oscillator 34 in the wave form and the waveform output timing of the triangular wave signal TRI so that the triangular wave signal TRI is started from the lower apex simultaneously with when the voltage of the drive waveform signal WCOM starts to increase from a constant state. Further, according to the process described above, the ripple voltage of the drive signal COM in each of the transition periods can be prevented.
[0074] Further, in the first embodiment, in the period in which the digital power amplifier circuit 28 stops the operation thereof, the operation of the digital power amplifier circuit is temporarily resumed. Specifically, the operation stop signal/Disable is set to be in the high level to resume the operation of the gate drive circuit 30 , and at the same time, the modulated signal PWM is output from the modulator 26 to perform on/off control of the high-side switching element Q 1 and the low-side switching element Q 2 of the digital power amplifier circuit 28 . Since the operation of the digital power amplifier circuit 28 is stopped when the voltage of the drive waveform signal WCOM does not vary, the voltage of the drive signal COM supplied to the actuators 22 is also the same as the voltage before and after the operation of the digital power amplifier circuit 28 is stopped. According to the process described above, it becomes possible to prevent the voltage drop due to the self-discharge of the actuators 22 made of capacitive loads.
[0075] For example, in the case in which the drive waveform signal WCOM takes the voltage of 0V in the periods 0 through 2 , the voltage of 2V in the period 3 , the voltage of 4V in the period 4 , the voltage of 6V in the period 5 , the voltage of 8V in the period 6 , the voltage of 10V in the periods 7 through 11 , the voltage of 8V in the period 12 , the voltage of 6V in the period 13 , the voltage of 4V in the period 14 , the voltage of 2V in the period 15 , and the voltage of 0V in the periods 16 through 18 as shown in FIG. 11 , the memory 31 stores the data shown in FIG. 12 , for example. In the first embodiment, the voltage difference between the adjacent periods is stored as an output voltage difference value Vd, and at the same time, the modulation frequency (the PWM frequency in the drawing) fpwm in each of the periods is also stored.
[0076] FIG. 13 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 12 . In the arithmetic processing, firstly, a previous voltage value Vs is cleared in the step S 1 .
[0077] Then, the process proceeds to the step S 2 , and a memory address counter N is cleared.
[0078] Subsequently, the process proceeds to the step S 3 , and the waveform data (the output voltage difference value) Vd is retrieved from the memory 31 .
[0079] Then, the process proceeds to the step S 4 , and whether or not the waveform data (the output voltage difference value) Vd retrieved in the step S 3 is the waveform termination data is determined. If it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 5 .
[0080] In the step S 5 , determination of the waveform data (the output voltage difference value) Vd retrieved in the step S 3 is performed. In this case, if the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently is also 0, the process proceeds to the step S 6 on the ground that the voltage of the drive waveform signal WCOM is constant. Further, if the previous output voltage difference value Vd is not 0, and the output voltage difference value Vd retrieved presently is 0, the process proceeds to the step S 11 on the ground that the voltage of the drive waveform signal WCOM changes to constant. If the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently takes a positive value, the process proceeds to the step S 13 on the ground that the voltage of the drive waveform signal WCOM does not vary to the state of increasing the voltage occurs. Further, if the previous output voltage difference value Vd is 0, and the output voltage difference value Vd retrieved presently takes a negative value, the process proceeds to the step S 14 on the ground that the voltage of the drive waveform signal WCOM changes from varying to constant. In other cases such as the case in which the previously-output voltage difference value Vd is not 0, and the output voltage difference value Vd last retrieved is not 0, the process proceeds to the step S 15 .
[0081] In the step S 6 , determination of the modulation frequency fpwm retrieved from the memory 31 is performed. In this case, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is not 0, the process proceeds to the step S 7 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the previous modulation frequency fpwm is not 0, and the modulation frequency fpwm retrieved presently is 0, the process proceeds to the step S 8 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is also 0, the process proceeds to the step S 10 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped.
[0082] In the step S 7 , the on-duty period of the modulated signal PWM is reduced to half, and is then output, and the process proceeds to the step S 9 .
[0083] In the step S 9 , the operation stop signal /Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 12 .
[0084] Further, in the step S 8 , the process waits until the end of the modulation period, and then proceeds to the step S 10 .
[0085] Further, also in the step S 11 , the process waits until the end of the modulation period, and then proceeds to the step S 10 .
[0086] In the step S 10 , the operation stop signal /Disable is set to be in the low level, and the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 12 .
[0087] Incidentally, in the step S 13 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 15 .
[0088] Further, in the step S 14 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 15 .
[0089] In the step S 15 , the output voltage difference value Vd is added to the previous voltage value Vs to thereby obtain a present voltage value V, and the process proceeds to the step S 16 .
[0090] In the step S 16 , the present voltage value V obtained in the step S 15 is output to the D/A converter 33 , and the process proceeds to the step S 17 .
[0091] In the step S 17 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 18 .
[0092] In the step S 18 , the operation stop signal /Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 19 .
[0093] In the step S 19 , the present voltage value V is stored as an update of the previous voltage value Vs, and then the process proceeds to the step S 12 .
[0094] In the step S 12 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 20 .
[0095] In the step S 20 , the memory address counter N is incremented, and then the process proceeds to the step S 3 .
[0096] According to this arithmetic processing, the operation of the digital power amplifier circuit 28 is stopped when the voltage of the drive signal COM does not vary, and consequently, there is no need to supply the actuators 22 with the current, namely when the voltage of the drive waveform signal WCOM does not vary, thereby making it possible to reduce an amount of power consumption in the high-side switching element Q 1 and the low-side switching element Q 2 constituting the digital power amplifier circuit 28 , and the coil L inside the low pass filter 29 .
[0097] Further, by setting both of the high-side switching element Q 1 and the low-side switching element Q 2 of the digital power amplifier circuit 28 OFF, it becomes possible to set the high-side switching element Q 1 and the low-side switching element Q 2 to be in the high-impedance state, thus it becomes possible to prevent the discharge from the actuators 22 as capacitive loads.
[0098] Further, by stopping the output of the modulated signal PWM itself in the case in which the operation of the digital power amplifier circuit 28 is stopped, the power consumption in the modulator 26 and the gate drive circuit 30 of the digital power amplifier circuit 28 can be reduced.
[0099] When the voltage of the drive waveform signal WCOM changes from varying to constant, the ripple voltage caused when stopping the operation of the digital power amplifier circuit 28 is preventable by increasing the modulation frequency fpwm of the pulse modulation, so as to match the voltage of the drive signal COM having no variation with the target value.
[0100] When the voltage of the drive waveform signal WCOM changes from constant to varying, the ripple voltage caused when resuming the operation of the digital power amplifier circuit 28 is preventable by increasing the modulation frequency fpwm of the pulse modulation.
[0101] Further, the period in which the modulated signal PWM is in the high level, immediately after the voltage of the drive waveform signal WCOM has changed from constant to increasing, is set to be a half of the period in which the original modulated signal PWM is in the high level, thus the ripple voltage can be prevented.
[0102] Further, the period in which the modulated signal PWM is in the low level, immediately after the voltage of the drive waveform signal WCOM has changed from constant to decreasing, is set to be a half of the period in which the original modulated signal PWM is in the low level, thus the ripple voltage can be prevented.
[0103] Further, by temporarily resuming the operation of the digital power amplifier circuit 28 while stopping the operation of the digital power amplifier circuit 28 , it becomes possible to prevent the voltage drop due to the self-discharge of the actuators 22 formed of capacitive loads.
[0104] Further, since the drive waveform signal WCOM is stored in the memory 31 as the data of the output voltage difference value Vd, it becomes easy to determine whether or not the voltage of the drive waveform signal WCOM varies.
[0105] Further, since the modulation frequency fpwm by the modulator 26 is also stored in the memory 31 , it becomes possible to flexibly set the modulation frequency fpwm.
[0106] Then, a fluid ejection device according to a second embodiment of the invention will be explained. The fluid ejection device according to the present embodiment is applied to the fluid ejection printer similarly to the first embodiment described above, and the schematic configuration, the vicinity of the fluid ejection head, the control device, the drive signal, the switching controller, the actuator drive circuit, the modulated signal, the gate-source signals, and the output signal are substantially the same as those of the first embodiment described above. The second embodiment is different therefrom in the contents of the data stored in the memory 31 , and the arithmetic processing performed by the controller 32 using the stored data.
[0107] For example, assuming that the waveform of the drive waveform signal is substantially the same as shown in FIG. 11 of the first embodiment, the data having the contents shown in FIG. 14 is stored in the memory 31 in the second embodiment. In the second embodiment, the output voltage value (drive waveform voltage data) V of the drive waveform signal WCOM in each of the periods, drive waveform states D 0 , D 2 in each of the periods, and the modulation frequency (PWM frequency in FIG. 14 ) fpwm in each of the periods are stored in the memory 31 . The drive waveform states D 0 , D 2 are expressed with 3 bit data, wherein [000] represents that the voltage of the drive waveform signal WCOM is constant, [011] represents the voltage of the drive waveform signal WCOM changes from constant to increasing, [111] represents that the voltage of the drive waveform signal WCOM continues to vary, [010] represents a change in the voltage of the drive waveform signal WCOM from varying to constant, [101] represents that the operation of the digital power amplifier circuit 28 is temporarily resumed, [100] represents that the operation of the digital power amplifier circuit 28 is stopped, and [001] represents that that the voltage of the drive waveform signal WCOM changes from constant to decreasing.
[0108] FIG. 15 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 14 . In the arithmetic processing, firstly, the previous voltage value Vs is cleared in the step S 101 .
[0109] Then, the process proceeds to the step S 102 , and the memory address counter N is cleared.
[0110] Subsequently, the process proceeds to the step S 103 , and the waveform data (the output voltage value) V is retrieved from the memory 31 .
[0111] Then, the process proceeds to the step S 104 to determine whether or not the waveform data (the output voltage value) V retrieved in the step S 103 is the waveform termination data, and if it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 105 .
[0112] In the step S 105 , determination of the waveform states D 0 , D 2 retrieved in the step S 103 is performed. In this case, if the drive waveform states D 0 , D 2 are [101], the process proceeds to the step S 107 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the drive waveform states D 0 , D 2 are [100], the process proceeds to the step S 108 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the drive waveform states D 0 , D 2 are [000], the process proceeds to the step S 110 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped. If the drive waveform states D 0 , D 2 are [010], the process proceeds to the step S 111 on the ground that a change in the voltage of the drive waveform signal WCOM from varying to constant occurs. If the drive waveform states D 0 , D 2 are [011], the process proceeds to the step S 113 on the ground that a change in the voltage of the drive waveform signal WCOM changes from constant to increasing occurs. If the drive waveform states D 0 , D 2 are [001], the process proceeds to the step S 114 on the ground that a change in the voltage of the drive waveform signal WCOM from constant to decreasing occurs. Further, if the drive waveform states D 0 , D 2 are [11*] (* represents either one of 0 and 1), the process proceeds to the step S 116 as other states.
[0113] In the step S 107 , the on-duty period of the modulated signal PWM is reduced to half, and is then output, and the process proceeds to the step S 109 .
[0114] In the step S 109 , the operation stop signal /Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 112 .
[0115] Further, in the step S 108 , the process waits until the end of the modulation period, and then proceeds to the step S 110 .
[0116] Further, also in the step S 111 , the process waits until the end of the modulation period, and then proceeds to the step S 110 .
[0117] In the step S 110 , the operation stop signal /Disable is set to be in the low level, and the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 112 .
[0118] Incidentally, in the step S 113 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 116 .
[0119] Further, in the step S 114 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 116 .
[0120] In the step S 116 , the output voltage value V retrieved in the step S 103 is output to the D/A converter 33 , and the process proceeds to the step S 117 .
[0121] In the step S 117 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 118 .
[0122] In the step S 118 , the operation stop signal /Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 112 .
[0123] In the step S 112 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 120 .
[0124] In the step S 120 , the memory address counter N is incremented, and then the process proceeds to the step S 103 .
[0125] According to this arithmetic processing, since the drive waveform signal WCOM is stored in the memory 31 as the output voltage value (the drive waveform voltage data) V, and the memory 31 also stores the drive waveform states (information regarding whether or not the voltage of the drive waveform signal varies) D 0 , D 2 , it becomes possible to eliminate the determination itself on whether or not the voltage of the drive waveform signal WCOM varies in addition to the advantage of the first embodiment described above.
[0126] Then, a fluid ejection device according to a third embodiment of the invention will be explained. The fluid ejection device according to the third embodiment is applied to the fluid ejection printer similarly to the first embodiment described above, and the schematic configuration, the vicinity of the fluid ejection head, the control device, the drive signal, the switching controller, the actuator drive circuit, the modulated signal, the gate-source signals, and the output signal are substantially the same as those of the first embodiment described above. The third embodiment is different therefrom in the contents of the data stored in the memory 31 , and the arithmetic processing performed by the controller 32 using the stored data. For example, assuming that the waveform of the drive waveform signal is substantially the same as shown in FIG. 11 of the first embodiment, the data having the contents shown in FIG. 16 is stored in the memory 31 in the third embodiment. In the third embodiment, the output voltage value (drive waveform voltage data) V of the drive waveform signal WCOM in each of the periods, and the modulation frequency (PWM frequency in FIG. 16 ) fpwm in each of the periods are stored in the memory 31 .
[0127] FIG. 17 is a flowchart of an arithmetic processing performed in the controller 32 using the data stored in the memory 31 shown in FIG. 16 . In the arithmetic processing, firstly, the previous voltage value Vs is cleared in the step S 201 .
[0128] Then, the process proceeds to the step S 202 , and the memory address counter N is cleared.
[0129] Subsequently, the process proceeds to the step S 203 , and the waveform data (the output voltage value) V is retrieved from the memory 31 .
[0130] Then, the process proceeds to the step S 204 to determine whether or not the waveform data (the output voltage value) V retrieved in the step S 203 is the waveform termination data, and if it is the waveform termination data, the arithmetic processing is terminated, and otherwise the process proceeds to the step S 205 .
[0131] In the step S 205 , determination of the waveform data (the output voltage value) V retrieved in the step S 203 is performed. In this case, if the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is also 0, the process proceeds to the step S 206 on the ground that the voltage of the drive waveform signal WCOM stays constant. If the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is not 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is 0, the process proceeds to the step S 211 on the ground that the drive waveform signal WCOM has become constant. If the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is a positive value, the process proceeds to the step S 213 on the ground that a change in the voltage of the drive waveform signal WCOM from constant to increasing occurs. Further, if the value obtained by subtracting the last-but-one output voltage value V from the last output voltage value V is 0, and the value obtained by subtracting the last output voltage value V from the output voltage value V retrieved presently is a negative value, the process proceeds to the step S 214 on the ground that there a change in the voltage of the drive waveform signal WCOM from constant to decreasing. Otherwise the process proceeds to the step S 216 .
[0132] In the step S 206 , determination of the modulation frequency fpwm retrieved from the memory 31 is performed. In this case, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is not 0, the process proceeds to the step S 207 on the ground that the operation of the digital power amplifier circuit 28 is to be resumed temporarily. Further, if the previous modulation frequency fpwm is not 0, and the modulation frequency fpwm retrieved presently is 0, the process proceeds to the step S 208 on the ground that the operation of the digital power amplifier circuit 28 is to be stopped. Further, if the previous modulation frequency fpwm is 0, and the modulation frequency fpwm retrieved presently is also 0, the process proceeds to the step S 210 on the ground that the operation of the digital power amplifier circuit 28 continues to be stopped.
[0133] In the step S 207 , the on-duty period of the modulation signal PWM is reduced to half, and is then output, and the process proceeds to the step S 209 .
[0134] In the step S 209 , the operation stop signal /Disable is set to be in the high level to make the digital power amplifier circuit 28 and the modulator 26 operate, and the process proceeds to the step S 212 .
[0135] Further, in the step S 208 , the process waits until the end of the modulation period, and then proceeds to the step S 210 .
[0136] Further, also in the step S 211 , the process waits until the end of the modulation period, and then proceeds to the step S 210 .
[0137] In the step S 210 , the operation stop signal /Disable is set to be in the low level, and at the same time, the operations of the digital power amplifier circuit 28 and the modulator 26 are stopped, and the process proceeds to the step S 212 .
[0138] Incidentally, in the step S 213 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the high level is reduced to half of the period in which the original modulated signal is kept in the high level, and is then output, and the process proceeds to the step S 216 .
[0139] Further, in the step S 214 , by controlling the waveform and the waveform output timing of the triangular wave signal TRI as described above, the period in which the modulated signal PWM is kept in the low level is reduced to half of the period in which the original modulated signal is kept in the low level, and is then output, and the process proceeds to the step S 216 .
[0140] In the step S 216 , the output voltage value V retrieved in the step S 203 is output to the D/A converter 33 , and the process proceeds to the step S 217 .
[0141] In the step S 217 , the modulation frequency fpwm retrieved from the memory 31 is output to the modulator 26 (the triangular wave oscillator 34 ), and the process proceeds to the step S 218 .
[0142] In the step S 218 , the operation stop signal /Disable is set to be in the high level, and at the same time, the digital power amplifier circuit 28 and the modulator 26 are made to operate, and the process proceeds to the step S 212 .
[0143] In the step S 212 , the process waits until the read timing of the memory 31 , and then proceeds to the step S 220 .
[0144] In the step S 220 , the memory address counter N is incremented, and then the process proceeds to the step S 203 .
[0145] According to the arithmetic processing, since it is arranged that the drive waveform signal WCOM is stored in the memory 31 as the output voltage value (the drive waveform voltage data) V, the controller 32 calculates the difference of the output voltage value (the drive waveform voltage data) V retrieved from the memory 31 , and the operation of the digital power amplifier circuit 28 is stopped if the difference in the output voltage value (the drive waveform voltage data) V is 0, the memory 31 with small capacity can be adopted in addition to the advantages of the first and second embodiments described above.
[0146] Then, a modified example of the actuator drive circuit described above will be explained. FIGS. 18A and 18B are block diagrams showing another example of the actuator drive circuit. This actuator drive circuit is similar to the actuator drive circuit shown in FIGS. 7A and 7B described above, and the equivalent constituents are denoted by the equivalent reference numerals, and detailed explanation thereof will be omitted. In the actuator drive circuit shown in FIGS. 7A and 7B described above, the controller 32 outputs the operation stop signal /Disable to the gate drive circuit 30 , and when the operation stop signal /Disable is in the low level, both of the high-side switching element Q 1 and the low-side switching element Q 2 of the digital power amplifier circuit 28 are OFF to thereby stop the operation of the digital power amplifier circuit 28 . This is because, as described above, in the case in which only one gate drive circuit 30 is provided, and, for example, the gate-source signal GL to the low-side switching element Q 2 is obtained by inverting the gate-source signal GH to the high-side switching element Q 1 , and is then output, it is not achievable to set both of the gate-source signals GH, GL to the high-side switching element Q 1 and the low-side switching element Q 2 to be in the low level.
[0147] Therefore, in the present modified example, the gate drive circuit 30 is provided to each of the high-side switching element Q 1 and the low-side switching element Q 2 . Further, it is arranged that the comparator 35 outputs a pulse-modulated signal PWMP taking the high level when the drive waveform signal WCOM is higher than the triangular wave signal TRI, and an inverted pulse-modulated signal PWMN, so that the pulse-modulated signal PWMP is output to the gate drive circuit 30 for the high-side switching element Q 1 , and the inverted pulse-modulated signal PWMN is output to the gate drive circuit 30 for the low-side switching element Q 2 . When stopping the digital power amplifier circuit 28 , namely in the case in which the voltage of the drive waveform signal WCOM does not change, the controller 32 holds both of the modulated signals PWMP, PWMN output from the comparator 35 in the low level. Thus, the gate-source signals GH, GL output from the respective two gate drive circuits 30 are set to be in the low level, and both of the high-side switching element Q 1 and the low-side switching element Q 2 are OFF. The operation and the stop of the operation of the digital power amplifier circuit 28 are as shown in the truth table shown in Table 2 below.
[0000]
TABLE 2
Pulse
Pulse
Modulation
Modulation
Signal P
Signal N
Q1
Q2
Power Amplifier
0
0
OFF
OFF
Stopped
1
0
ON
OFF
Operating
0
1
OFF
ON
1
1
ON
ON
[0148] It should be noted that although in the first through third embodiments described above only the case in which the fluid ejection device according to an aspect of the invention is applied to the line head-type printer is described in detail, the fluid ejection device according to an aspect of the invention can also be applied to multi-pass type printer in a similar manner.
[0149] Further, the fluid ejection device according to an aspect of the invention can also be embodied as a fluid ejection device for ejecting a fluid (including a fluid like member dispersing particles of functional materials, and a fluid such as a gel besides fluids) other than the ink, or a fluid (e.g., a solid substance capable of flowing as a fluid and being ejected) other than fluids. The fluid ejection device can be, for example, a fluid like member ejection device for ejecting a fluid like member including a material such as an electrode material or a color material used for manufacturing a fluid crystal display, an electroluminescence (EL) display, a plane emission display, or a color filter in a form of a dispersion or a solution, a fluid ejection device for ejecting a living organic material used for manufacturing a biochip, or a fluid ejection device used as a precision pipette for ejecting a fluid to be a sample. Further, the fluid ejection device can be a fluid ejection device for ejecting lubricating oil to a precision machine such as a timepiece or a camera in a pinpoint manner, a fluid ejection device for ejecting on a substrate a fluid of transparent resin such as ultraviolet curing resin for forming a fine hemispherical lens (an optical lens) used for an optical communication device, a fluid ejection device for ejecting an etching fluid of an acid or an alkali for etching a substrate or the like, a fluid ejection device for ejecting a gel, or a fluid ejection recording apparatus for ejecting a solid substance including fine particles such as a toner as an example. Further, an aspect of the invention can be applied to either one of these ejection devices. | A fluid ejection device includes: a modulator adapted to pulse-modulate a drive waveform signal forming a basis of a drive signal of an actuator to obtain a modulated signal; a digital power amplifier circuit adapted to power-amplify the modulated signal to obtain a power-amplified modulated signal; a low pass filter adapted to smooth the power-amplified modulated signal to obtain the drive signal; and a power amplification stopping section operating when holding a voltage of the actuator constant. | 1 |
TECHNICAL FIELD
The invention concerns a device and a method for texturing a silicon wafer intended to constitute a photovoltaic cell.
It also concerns a silicon wafer obtained, and in particular a multicrystalline wafer.
PRIOR ART
Most photovoltaic cells (PV) are manufactured from monocrystalline or multicrystalline silicon in industrial sectors which implement the processing of silicon wafers in a clean room environment. The first step is a texturing of the surface of the wafer intended to reduce its reflectivity.
In the standard method used industrially, the crystallised ingots are cut by wire sawing into wafers which are textured by chemical attack to improve light trapping. To optimise the method, structures having the size of a few microns are generally sought. This chemical attack can be accomplished either in an acidic medium or in a basic medium.
In both abovementioned cases, the technique effectively enables the reflectivity to be reduced, but its disadvantage is that it requires the retreatment of substantial quantities of chemical effluents.
An alternative approach, based on a method of mechanical etching (a structuring tool consisting of a micro-machined metal part with V-shaped lines, and coated with an abrasive layer consisting of diamond abrasive coating) has been proposed by the University of Constance [1]. The method has demonstrated its effectiveness and its ability not to cause defects which might affect the PV cells' energy conversion rates. Furthermore, the problems of productivity (duration of process of several seconds per wafer) and of the wear and tear of the structuring tools have been resolved. However, problems of machining (notably concerning the radius of curvature of the points) and of granulometry of the diamond powders limit the method's effectiveness. In practice, the spatial resolution of the etching remains limited in standard implementations to values of the order of 50 μm.
At the other extreme in terms of scale, it is possible to cite the work accomplished by etching with an AFM point [2]. It is then possible to obtain extremely fine patterns, the surfaces of which are very clean at the submicron scale. However, the speeds of movement of the point are very slow (at best some hundred microns per second) and therefore incompatible with an industrial method.
There is therefore no simple and effective method allowing high-speed etching of silicon wafers to form textures of characteristic size of the order of some ten microns. The problem is even more complex due to the fact that cutting the ingots using a wire saw causes variations of thickness, which in the conventional method of abrasion by particles of silicon carbide are of the order of 30-40 μm [3]. Even with more sophisticated and more expensive methods using diamond particles, it appears to be difficult to go below a depth of 10 μm [3].
In addition, a chemical pretreatment is generally applied, enabling the cold-hammered zone to be eliminated following the cutting. Due to kinetics of attacks which differ depend on the crystalline grains, the effect of this pretreatment is also to increase the roughness of the wafers. In conclusion, the variations of dimensions on wafers which are ready to be textured are, except in exceptional cases, significantly greater than 10 μm.
This being so, none of techniques proposed in the literature enables a mechanical texturing of a silicon wafer with etching patterns of a depth of the order of some ten μm.
The aim of the invention is therefore to propose a solution to accomplish a texturing of a silicon wafer with uniform etching patterns of characteristic size of between 5 and 50 μm over an area likely to have flatness defects of between 5 and 50 μm at speeds compatible with the production imperatives of PV cell factories, typically of a texturing duration of a few seconds per silicon wafer.
A more general aim is to propose a solution which is simple and efficient to implement.
DESCRIPTION OF THE INVENTION
To accomplish this, the object of the invention is a device for mechanical texturing of a silicon wafer, intended to constitute a photovoltaic cell, including multiple tungsten carbide points and a support including multiple recesses, each of which is able to hold a tungsten carbide point such that it can slide, and means to keep each of the multiple points pressed against the silicon wafer with a constant force which is independent of the thickness variations of the said wafer.
The support is preferably able to hold the points such that they can slide freely. The means to maintain pressing are then advantageously constituted by the inherent weight of each of the points.
In other words, according to the invention, a texturing by mechanical etching is accomplished by using a system of self-regulation of the pressing force suitable for texturing silicon wafers which are not flat at the scale of some tens of microns.
To resolve the difficulty relating to the flatness defects, the invention uses a system in which the multiple etching points slide freely to follow the changes of level of the surface to be etched. The pressing force therefore remains equal to the weight of the point, whatever the geometric level of the surface to be etched. The vertical displacement of the points is guided by a support.
It may be considered that the principle of etching using a weighted mass is known [4], but the solution according to this document [4], U.S. Pat. No. 4,821,250A, is applied locally by a point to etch a furrow. However, the specific feature of the problem at the origin of the invention is the need to texture collectively, i.e. simultaneously over the entire surface to be etched, a silicon wafer to adhere to the specification of texturing duration.
Thus, the device according to the invention includes a structural part (support) with recesses where the points are inserted. These recesses are offset relative to one another by a distance d defining the etching interval. The recesses are separated from one another to ensure the mechanical cohesion of the assembly. The lower parts of the recesses are trapezoid, with an angle at the peak greater than that of the points, to allow them to slide vertically.
To obtain etching profiles of a depth of the order of 5-20 μm, which is typical of that which is conventionally used for PV applications, a pressing force of between 0.1 and 2 N, and preferentially 0.3 to 1 N, is preferred. And it was not in any way obvious that silicon wafers could withstand the stress, but the tests undertaken show that they are able to do so, up to pressing forces of 2 N, unless the wafers have substantial initial fractures.
Another difficulty relates to the geometrical encumbrance of the system. Indeed, the dimensions of the points (similar to parallelepipedes of base Lxl and of height H) and those of the etching zone A and B are related by the following equations:
k× ( L+el )= A and n ×(1 +e 2)= B.
The device is also specified by the constraint of the etching interval d according to:
n×d=L+el.
The references of the letters used to define the dimensions and the integers are shown in FIGS. 2 and 3 .
Length A is determined by the dimensions of the wafers to be textured, typically A=15 cm. To clarify matters, by taking reasonable values for the dimensions of the recesses and spacings, L=4 mm, 1=2 mm, el=e2=1 mm and an etching interval d of 20 μm, the above relationships give:
k= 30 ,n= 250 ,B= 0.75 m.
If such a value for B may appear high, it is perfectly acceptable for an industrial application, especially if it is possible to texture several wafers aligned in direction Y. There are also two possibilities for reducing dimension B: texturing in several stages, with offsetting of the tool in direction X, perpendicular to the etching direction Y (see the references of the directions in FIGS. 2 and 3 ).
This amounts to a redefinition of the above condition of equality:
n×d =( L+el ),
as n×d=(L+el)/j, where j is an integer.
For a given value of L, it is therefore possible to reduce n and therefore B by a factor j. However, for reasons of productivity, this solution is not realistic for values of j higher than 3.
Another option to reduce B would be to reduce dimension l, but the problem of attaining a reasonable mass without requiring an unacceptable height H is then posed.
Indeed, with a material such as silicon carbide of density ρ of the order of 3.2 kg/m 3 , reaching a force of 0.5 N with a parallelepipede of base 4×2 mm 2 would require a height of nearly 2 m, which poses obvious problems of volume of the device and of fragility of the points. This is a fundamental problem, and even maintaining B at a maximum value of 0.75 m and texturing with j=5 stages would not enable these problems to be resolved. Indeed, by keeping values L=4 mm, el=1 mm and an etching interval d of 20 μm, this results in k=30 and n=50. By keeping B=0.75 m and e2=1 mm, it would be possible to take l=1.4 cm, which should be compared with 2 mm of the previous case.
Even under these extreme conditions which are not realistic for industrial configurations, there would be a value of H greater than 28 cm, which once again would be a limit due to questions of encumbrance of the device, and of fragility of the points. The use of diamond (ρ=3.5 kg/m 3 ) poses a problem in terms of cost, and allows only a limited improvement (reduction of H of only 100).
The hard materials renowned for being compatible with silicon (diamond and silicon carbide) are not therefore suitable for implementing the invention.
To respond to this difficulty the inventors decided to test tungsten carbide as an etching material, the density of which, which is greater than 15 kg/m 3 , allows genuine technological breakdown compared to diamond or silicon carbide. And it was not in any way obvious to use this material as a material for etching silicon wafers for PV applications, since tungsten is amongst the metals which are most harmful for the lifetime of minority carriers, and therefore for the efficiency of PV cells [5]. As an example, a content of the order of one part per billion (ppb, or in equivalent fashion 5*1013 at/cm 3 ) is enough to reduce by more than 40% the efficiency of a PV cell in p-type silicon. However, the tests undertaken enabled it to be shown that the electronic properties of the wafers were not affected, thus validating the choice of tungsten carbide.
In the implementation of the invention, the lower portion of the points has the shape of a straight prism of triangular base, where the angle at the apex of the triangle is chosen such that it is in the interval 20°-60°, and advantageously 30°-45°. The upper portion of the points is preferentially a parallelepipede, but other shapes can be envisaged. For a parallelepipedic shape, the characteristic dimensions are:
length L of 2 to 15 mm, width l of 1 to 5 mm, height H of 1 to 25 cm.
Etching interval d defined as being the distance separating two adjacent points is preferably chosen to be between 5 μm and 100 μm, and preferentially between 5 μm and 40 μm.
The speed of displacement is between 5 and 100 mm/s, and preferentially 10 to 30 mm/s.
The structural part is preferably manufactured from materials of the steel or nickel-based superalloy. It should be noted that whatever the chosen configuration the number of etching points per wafer will be very high, typically always several thousands. It is therefore advantageously possible to automate the insertion of the points in their respective recesses.
In a variant of the invention a gaseous pressure is applied to the points to increase the pressing force. As an example, a pressure of 1 bar acting on an area of 10 mm 2 equates to a force of 1 N. This operating mode enables the principle to be retained of a pressing force which is independent of the geometrical level of the wafer to be etched, but the need is once again found to have points of sufficient area L×l.
Some advantages of the invention are as follows:
possibility of achieving texturing profiles other than pyramids in order to allow optimisation of the light trapping: these various profiles will be able to be attained by choosing different geometrical shapes of the points, possibility of adjusting the pressing force by altering the geometrical characteristics of the points, the points, which are wearing parts, can be manufactured using low-cost technologies of the powder metallurgy type, combined with an image processing allowing identification of defective etches from the surface of the wafer, the method allows selective replacement only of the worn points, very much shorter texturing time and possibility of simultaneously texturing several wafers positioned adjoining one another in direction Y.
The aim of the invention is therefore in particular a multicrystalline silicon wafer, intended to constitute a photovoltaic cell, the surface of which includes uniform etching patterns of a depth of between 5 and 50 μm.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
Other advantages and characteristics will be seen more clearly on reading the description given for illustrative purposes, made with reference to the following figures, among which:
FIG. 1 is a schematic transverse section view of a device according to the invention,
FIG. 2 is a top view of a device according to the invention, according to one embodiment,
FIG. 3 is a top view of a device according to the invention, according to another embodiment.
DETAILED ACCOUNT OF PARTICULAR EMBODIMENTS
As shown in FIG. 1 , a device according to the invention 1 includes a support 2 in which multiple identical points 3 are held such that they are able to slide freely.
The upper portions of recesses 20 are parallelepipedic in shape, and have an angle at the apex 200 which is trapezoid in shape in their lower portion 21 .
Upper portion 30 of the points is parallelepipedic in shape, and lower portion 31 is a straight prism of triangular shape.
In the etching position triangular portion 31 of points 3 is pressing against a silicon wafer 4 with a constant force independent of the thickness variations of wafer 4 .
The points are made of tungsten carbide, preferably using a fritting technology.
The angle at the apex of the lower triangular points portion 31 is 30° less than that 200 of lower portion 21 of support 2 .
The dimensions of the upper parallelepipedic portion 30 of points 3 are typically:
L=5 mm, l=2 mm and H=20 cm.
Recesses 20 for the points are separated by el=e2=1 mm. With a typical density of tungsten carbide ρ of the order of 15 kg/m 3 , a mass of 30 g per point 3 is found, and therefore a pressing force by the inherent weight of each point of the order of 0.3 N.
The texturing is advantageously accomplished in three stages, with an interval d of 20 μm. It can also be accomplished in a single stage using a device according to FIG. 2 , or two stages, with a device according to FIG. 3 .
In the case of texturing in three stages, structure part or support 2 is manufactured from stainless steel, with a functional zone, i.e. the zone corresponding to the zone to be etched, of dimensions A=15 cm and B=30 cm. The external dimensions of support 2 are A′=20 cm, B′=35 cm and C=15 cm. The differences between A and A′ on the one hand and B and B′ on the other hand are related to a mechanical reinforcement of support 2 around area A×B including recesses 20 of tungsten carbide etching points 3 .
The device with its points 3 held in its support 2 is positioned on two silicon wafers of dimensions 15×15 cm 2 placed end-to-end.
Support 2 is then displaced at a speed of 20 mm/s above the two end-to-end wafers to accomplish the texturing. The etching residues are eliminated by blowing with compressed air.
Light rinsing in an acidic solution can also be used.
REFERENCES CITED
[1]: P. Fath, C. Borst, C. Zechner, E. Bucher, G. Willeke, S. Narayanan, “ Progress in a novel high - throughput mechanical texturization technology for highly efficient multicrystalline silicon solar cells ”, Solar Energy Materials and Solar Cells 48 (1997) 229-236;
[2]: L Santinacci, T Djenizian, P Schwauer, T Suter, A Etcheberry and P Schmuki, “ Selective electrochemical gold deposition onto p - Si (100) surfaces ”, J. Phys. D: Appl. Phys. 41 (2008) 175301;
[3]: D. Kray, M. Schumann, A. Eyer, G. P. Willeke, R. Kübler, J. Beinert and G. Kleer, “ Solar wafer slicing with loose and fixed grains ”, Proc. 2006 IEEE 4th World Conference on Photovoltaic Energy Conversion, May 7-12 2006, Hawai, Vol. 1, 948-951;
[4]: U.S. Pat. No. 4,821,250A entitled “ Process and apparatus for the recording of an information signal”;
[5]: J. R. Davis, Jr et al. “ Impurities in silicon solar cells ”, IEEE Transactions on Electron Devices 27 (1980) 677-687. | A solution for texturing silicon wafers configured to constitute photovoltaic (PV) cells. Silicon wafers can be produced, the surface of which include uniformly engraved patterns having a depth of between 5 and 50 μm. | 8 |
BACKGROUND OF THE INVENTION
[0001] Photodynamic therapy (PDT) is an effective local therapy based on a tumor localizing photosensitizer (PS) activated by long wavelength light directed at the treatment site. Current photosensitizers have high tumor selectivity, and light can be delivered almost anywhere in the body by thin, flexible optical fibers.
[0002] Tetrapyrollic photosensitizers, e.g. porphyrins including chlorins, bacteriochlorins and other porphyrin based derivatives, including their analogs and derivatives, have recently found superior utility as photodynamic compounds for use in diagnosis and treatment of disease, especially certain cancers and other hyperproliferative diseases such as macular degeneration. These compounds have also found utility in treatment of psoriasis and papillomatosis.
[0003] Such derivatives include dimers and trimers of these compounds. Permissible derivatives also include ring variations of these compounds; provided that, the central sixteen sided four nitrogen heterocycle of these compounds remains intact. Chlorophyllins, purpurins, pheophorbides, and their derivatives are, therefore, included within “porphyrins, chlorins, and bacteriochlorins and their derivatives and analogs”. Such derivatives include modifications of substituents upon these ring structures, e.g. pyropheophorbides.
[0004] Numerous articles have been written on this subject, e.g. “Use of the Chlorophyll Derivative Purpurin-18, for Synthesis of Sensitizers for Use in Photodynamic Therapy”, Lee et al., J. Chem. Soc., 1993, (19) 2369-77; “Synthesis of New Bacteriochlorins And Their Antitumor Activity”, Pandey et al., Biology and Med. Chem. Letters, 1992; “Photosensitizing Properties of Bacteriochlorophyllin a and Bacteriochlorin a, Two Derivatives of Bacteriochlorophyll a”, Beems et al., Photochemistry and Photobiology, 1987, v. 46, 639-643; “Photoradiation Therapy. II. Cure of Animal Tumors With Hematoporphyrin and Light”, Dougherty et al., Journal of the National Cancer Institute, July 1975, v. 55, 115-119; “Photodynamic therapy of C3H mouse mammary carcinoma with hematoporphyrin di-esters as sensitizers”, Evensen et al., Br. J. Cancer, 1987, 55, 483-486; “Substituent Effects in Tetrapyrrole Subunit Reactivity and Pinacol-Pinacolone Rearrangements: VIC-Dihydroxychlorins and VIC-Dihydroxybacteriochlorins” Pandey et al., Tetrahedron Letters, 1992, v. 33, 7815-7818; “Photodynamic Sensitizers from Chlorophyll: Purpurin-18 and Chlorin p 6 “, Hoober et al., 1988, v.48, 579-582; “Structure/Activity Relationships Among Photosensitizers Related to Pheophorbides and Bacteriopheophorbides”, Pandey et al., Bioorganic and Medicinal Chemistry Letters, 1992, v 2, 491-496; “Photodynamic Therapy Mechanisms”, Pandey et al., Proceedings Society of Photo-Optical Instrumentation Engineers (SPIE), 1989, v 1065, 164-174; and “Fast Atom Bombardment Mass Spectral Analyses of Photofrin II® and its Synthetic Analogs”, Pandey et al., Biomedical and Environmental Mass Spectrometry, 1990, v. 19, 405-414. These articles are incorporated by reference herein as background art.
[0005] Numerous patents in this area have been applied for and granted world wide on these photodynamic compounds. Reference may be had, for example to the following U.S. Patents which are incorporated herein by reference: U.S. Pat. Nos. 4,649,151; 4,866,168; 4,889,129; 4,932,934; 4,968,715; 5,002,962; 5,015,463; 5,028,621; 5,145,863; 5,198,460; 5,225,433; 5,314,905; 5,459,159; 5,498,710; and 5,591,847.
[0006] One of these compounds “Photofrin®” has received approval for use in the United States, Canada and Japan. Others of these compounds have also received at least restricted approval, e.g. BPD for treatment of macular degeneration and others are in clinical trials or are being considered for such trials.
[0007] The term “porphyrins, chlorins and bacteriochlorins” as used herein is intended to include their derivatives and analogs, as described above, and as described and illustrated by the foregoing articles and patents incorporated herein by reference as background art.
[0008] Such compounds have been found to have the remarkable characteristic of preferentially accumulating in tumors rather than most normal cells and organs, excepting the liver and spleen. Furthermore, many such tumors can be killed because the compounds may be activated by light to become tumor toxic.
[0009] Such compounds are preferentially absorbed into cancer cells, and destroy cancer cells upon being exposed to light at their preferential wavelength absorbance near infrared (NIR) absorption. Further such compounds emit radiation at longer wavelengths than the preferential absorption wavelength, such that light penetrates several centimeters of tissue. It is thus possible to sense and quantitate photosensitizer concentration in subsurface tissues from measurements of diffuse light propagation.
[0010] However, for small, bulky, or buried lesions, it may be difficult to detect the malignancies and/or to properly place the optical fibers to illuminate the full extent of the tumor. Therefore the approach of guided therapy utilizing highly selective optical and radionuclide tumor imaging, allowing tumor visualization, image-guided placement of the optical fibers, and subsequent photodynamic destruction of the lesions would be extremely useful in cancer diagnosis and therapy.
[0011] Optical imaging is a rapidly evolving field. Optical contrast agents can provide planar and tomographic images with high sensitivity. For small animals, planar images are adequate, but optical tomographic reconstruction of fluorescence images is becoming feasible.
[0012] Most of the porphyrin-based photosensitizers (PS) fluoresce, and the fluorescence properties of these porphyrins in vivo has been exploited by several investigators for detection of early-stage cancers in the lung, bladder and various other sites, and to guide the activating light for treatment. However, PS are not optimal fluorophores for tumor detection or treatment guidance: (1) They have weak fluorescence compared to cyanine dyes. They have small Stokes shifts, making it difficult to separate the fluorescence from excitation light.
[0013] Fluorescent cyanine dyes with NIR excitation and emission wavelengths can have high quantum yields and excitation coefficients, and appropriate Stokes shifts. They have high extinction coefficients and appropriate Stokes shifts. We have determined that such compounds coupled with photosensitizers can be used as “Bifunctional Agents” (i. e. tumor imaging and phototherapy). See e.g. copending PCT Patent Application PCT/US05/24782.
[0014] Positron emission tomography (PET) predominately has been used to image and assay biochemical processes and circular function. However, there has been growing use of radiolabeled peptide ligands to target malignancies. Available isotope labels include 11 C (t 1/2 =20.4 min) 18 F (t 1/2 =110 min), (t 1/2 =12.8 h and 124 I (t 1/2 =4.2 days). For targeting photosensitizers, a long circulation time may be desired, as it can increase delivery of the agent into tumors. We have shown that I-124 labeled photosensitizers can be used for PET imaging and PDT. See e.g. copending U.S. patent application Ser. No. 11/353,626 filed Feb. 14, 2006.
[0015] Integrins are heterodimeric transmembrane adhesion receptors that play an important role in cell-surface mediated signaling. There are at least 24 distinct integrin receptors identified, which are assembled from 18 α and 8 β subunits. αvβ3, α5β1, αvβ5, α4β1, α2β1 are known integrins expressed by tumor cells. As an example in accordance with the invention, integrin αvβ3 is used to illustrate the invention with binding to an RGD peptide, a small peptide containing an RGD sequence [arginine(Arg)-glycine(Gly)-aspartic acid(Asp) triamino acid sequence] It is understood that longer sequences, e.g. up to ten or more amino acids, may be used containing the RGD sequence and all such peptides are referred to herein as RGD peptides. As an example of non-peptide antagonists or ligands compounds containing a 4-{2-(3,4,5,6-tetrahydropyrimidin-2-ylamino)ethyloxy}-benzoyl]amino-2-(S)-aminoethylsulfonylamino (THPAB) group are used. We are initially focusing on the specific receptor, Integrin αvβ3, as an example of such Integrins expressed by tumor cells. Integrin αvβ3 is known for its high expression in tumor cells (3) and its binding with RGD peptides.
[0016] Sequence analysis of integrin αv subunit from various organisms (human, mouse, bull, chicken, frog, zebrafish) using both T-Coffee and ClustalW multiple sequence alignment programs shows high degree of their conservations, especially among the mammals. Similar results are also observed from the sequence analysis of the integrin β3.subunit from various organisms (human, mouse, rat, chicken, frog, zebrafish). Strict conservation of the implicated ligand binding residues is clearly observed.
[0017] As for 3D structures of integrins, several crystal structures are available at PDB. For Integrin β3 subunit, there are crystal structures of Integrin β3—Talin chimera complex (1MK7,1MK9), NMR structure of the Integrin β3 cytoplasmic domain (1S4X), as well as the Integrin αIIbβ3 receptor crystal (1TXV, 1TY3, 1TY5, 1TY6, 1TY7, 1TYE) and NMR (1M8O) structures. For the Integrin αvβ3 system, the structures of the extracellular domain of Integrin αvβ3 (1JV2) as well as its complex with Mn2+ (1M1X) and with the RGD ligand (1L5G) are available. In addition, recently the N-terminal PSI (plexin-semaphorin-integrin) domain of the β subunit structure has been reported in the context of the αvβ3 receptor (1U8C). We performed a pair-wise comparison of overall structure of integrin αvβ3 and αIIbβ3. It clearly shows the conservation of ion binding residues.
[0018] Crystal structure of integrin αvβ3 RGD peptide complex was carefully examined. The RGD peptide binds at the interface of αv and β3 subunits where an intricate network of interactions involving 3 Mn cations plays an important role in recognition of RGD Asp residue (See FIGS. 1 and 2 ).
[0019] Integrins are a major group of cell membrane receptors with both adhesive and signaling functions. They influence behavior of neoplastic cells by their interaction with the surrounding extracellular matrix, participating in tumor development. An increase in its expression is correlated with increased malignancy. Significant over expression of αvβ3 is reported in colon, lung, pancreas and breast carcinomas, and the expression of integrin was significantly higher in tumors of patients with metastases than in those without metastases.
[0020] The following references are incorporated herein as background art.
1. Yihui Chen, Amy Gryshuk, Samuel Achilefu, Tymish Ohulchansky, William Potter, Tuoxiu Zhong, Janet Morgan, Britton Chance, Paras N. Prasad, Barbara W. Henderson, Allan Oseroff and Ravindra K. Pandey, A Novel Approach to a Bifunctional Photosentizer for Tumor Imaging and Phototherapy. Bioconjugate Chemistry, 2005, 16, 1264-1274. 2. Suresh K. Pandey, Amy L. Gryshuk, Munawwar Sajjad, Xiang Zheng, Yihui Chen,
[0023] Mohei M. Abouzeid, Janet Morgan, Ivan Charamisinau, Hani A. Nabi, Allan Oseroff and Ravindra K. Pandey, Multiomodality Agents for Tumor Imaging (PET, Fluorescence) and Photodynamic Therapy: A Possible See and Treat Approach. J. Med. Chem. 2005, 48, 6286-6295.
3. Xiaoyuan C. et al. Integrin avb3-Targeted Imaging of Lung Cancer. Neoplasia, 2005, 7, 271-279. Yihui Chen, Amy Gryshuk, Samuel Achilefu, Tymish Ohulchansky, William Potter, Tuoxiu Zhong, Janet Morgan, Britton Chance, Paras N. Prasad, Barbara W. Henderson, Allan Oseroff and Ravindra K. Pandey, A Novel Approach to a Bifunctional Photosentizer for Tumor Imaging and Phototherapy. Bioconjugate Chemistry, 2005, 16, 1264-1274. 4. Suresh K. Pandey, Amy L. Gryshuk, Munawwar Sajjad, Xiang Zheng, Yihui Chen, Mohei M. Abouzeid, Janet Morgan, Ivan Charamisinau, Hani A. Nabi, Allan Oseroff and Ravindra K. Pandey, Multiomodality Agents for Tumor Imaging (PET, Fluorescence) and Photodynamic Therapy: A Possible See and Treat Approach. J. Med. Chem. 2005, 48, 6286-6295. 5. Xiaoyuan C. et al. Integrin avb3-Targeted Imaging of Lung Cancer. Neoplasia, 2005, 7, 271-279.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a crystal structure of integrin RGD peptide complex. A flat arrow indicates for β strand and a cylinder for a helix. White color is used for αv subunit and a porphyrin, chlorin or bacteriochlorin, e.g. pheophorbides and pyropheophorbides gray color for β3 subunit. Integrin RGD peptide, Arg-Gly-Asp-D-Phe-N-methyl Val is located between av and β3 subunits shown in ball and stick figure. The Mn ions located near the RGD peptide are shown as spheres.
[0028] FIG. 2 shows how Asp interacts with residues from β3 subunit and Mn ions embedded in β3 subunit. Especially, the middle Mn ion is directly coordinated with Asp side chain (COO—) group. In turn, this Mn ion is coordinated by Ser 121, Ser 123, and Glu 220. These residues in turn are coordinated to two other Mn ions, which form additional coordination with other residues from β3 subunit. Asp side chain of RGD peptide also make a direct interaction with Asn 215. This network of interaction involving 3 Mn ions seems to be a very important stabilizing factor.
BRIEF DESCRIPTION OF THE INVENTION
[0029] The invention is a compound that is a conjugate of an antagonist to an integrin expressed by a tumor cell and at least one of a fluorescent dye, or a tumor avid tetrapyrollic photosensitizer, that may be complexed with an element X where X is a metal selected from the group consisting of Zn, In, Ga, Al, or Cu or a radioisotope labeled moiety wherein the radioisotope is selected from the group consisting of 11 C, 18 F, 64 Cu, 124 I, 99 Tc, 111 In and GdIII and its method of use for diagnosing, imaging and/or treating hyperproliferative tissue such as tumors and other uncontrolled growth tissues such as found in macular degeneration.
[0030] In a preferred embodiment, the compound is a tumor avid tetrapyrollic photosensitizer compound conjugated with an antagonist for an integrin expressed by a tumor cell. Such compounds have extreme tumor avidity and can be used to inhibit or completely destroy the tumor by light absoption. The tetrapyrollic photosensitizer is usually a porphyrin, chlorin or bacteriochlorin including pheophorbides and pyropheophorbides and the integrin is usually an αvβ3, α5β1, αvβ5, α4β1, or α2β1 integrin.
[0031] In a preferred embodiment, the antagonist is an RGD peptide or another antagonist that may be synthetic such as a 4-{2-(3,4,5,6-tetra-hydropyrimidin-2-ylamino)ethyloxy}-benzoyl]amino-2-(S)-aminoethyl-sulfonylamino group. The integrin is most commonly αvβ3.
[0032] The antagonist may be combined with an imaging compound such as a fluorescent dye or a structure including an element X where X is a metal selected from the group consisting of Zn, In, Ga, Al, or Cu or a radioisotope labeled moiety wherein the radioisotope is selected from the group consisting of 11 C, 18 F, 64 Cu, 124 I, 99 Tc, 111 In. Such compounds provide tumor avidity and imaging ability thus permitting selective and clear tumor imaging.
[0033] Objects of this invention include:
[0000] 1. Efficient synthetic methodologies for the preparation of αvβ3 target-specific photosensitizers.
(a) RGD conjugated photosensitizers (b) Integrin-antagonist conjugated photosensitizers.
2. Multimodality agents (photosensitizer-cyanine dye conjugates) with and without RGD peptide.
3. Target-specific PET/fluorescence imaging agent.
DETAILED DESCRIPTION OF THE INVENTION
[0036] As previously discussed, the invention is a compound that is a conjugate of an antagonist to an integrin expressed by a tumor cell and at least one of a fluorescent dye, and a tumor avid tetrapyrollic photosensitizer that may be complexed with an element X where X is a metal selected from the group consisting of Zn, In, Ga, Al, or Cu or a radioisotope labeled moiety wherein the radioisotope is selected from the group consisting of 11 C, 18 F, 64 Cu, 124 I, 99 TC, 111 In and GdIII and its method of use for diagnosing, imaging and/or treating hyperproliferative tissue such as tumors and other uncontrolled growth tissues such as found in macular degeneration.
[0037] In the case of the presence of a tetrapyrollic photosensitizer, it usually has the structural formula:
[0000]
[0000] and its complexes with X where:
R 1 is —CH═CH 2 , —CH 2 CH 3 , —CHO, —COOH, or
[0000]
where R 9 ═—OR 10 where R 10 is lower alkyl of 1 through 8 carbon atoms, —(CH 2 —O) n CH 3 , —(CH 2 ) 2 CO 2 CH 3 , —(CH 2 ) 2 CONHphenyleneCH 2 DTPA,
—CH 2 CH 2 CONH(CONHphenyleneCH 2 DTPA) 2 , —CH 2 R 11 or
[0000]
[0000] or a fluorescent dye moiety; R 2 , R 2a , R 3 , R 3a , R 4 , R 5 , R 5a , R 7 , and R 7a are independently hydrogen, lower alkyl or substituted lower alkyl or two R 2 , R 2a , R 3 , R 3a , R 5 , R 5a , R 7 , and R 7a groups on adjacent carbon atoms may be taken together to form a covalent bond or two R 2 , R 2a , R 3 , R 3a , R 5 , R 5a , R 7 , and R 7a groups on the same carbon atom may form a double bond to a divalent pendant group; R 2 and R 3 may together form a 5 or 6 membered heterocyclic ring containing oxygen, nitrogen or sulfur; R 6 is —CH 2 —, —NR 11 — or a covalent bond; R 8 is —(CH 2 ) 2 CO 2 CH 3 , —(CH 2 ) 2 CONHphenyleneCH 2 DTPA,
—CH 2 CH 2 CONH(CONHphenyleneCH 2 DTPA) 2 , —CH 2 R 11 or
[0000]
[0000] where R 11 is —CH 2 CONH—RGD-Phe-Lys, —CH 2 NHCO—RGD-Phe-Lys, a fluorescent dye moiety, or —CH 2 CONHCH 2 CH 2 SO 2 NHCH(CO 2 )CH 2 NHCOPhenylOCH 2 CH 2 NHcycloCNH(CH 2 ) 3 N; and polynuclide complexes thereof; provided that the compound contains at least one integrin antagonist selected from the group consisting of —CH 2 CONH—RGD-Phe-Lys, —CH 2 NHCO—RGD-Phe-Lys and
—CH 2 CONHCH 2 CH 2 SO 2 NHCH(CO 2 )CH 2 NHCOPhenylOCH 2 CH 2 NHcycloCNH(CH 2 ) 3 N, where X is a metal selected from the group consisting of Zn, In, Ga, Al, or Cu or a radioisotope labeled moiety wherein the radioisotope is selected from the group consisting of 11 C, 18 F, 64 Cu, 124 I, 99 Tc, 111 In and GdIII.
[0043] The complexes with X are readily made simply by heating the compound with a salt of X such as a chloride. The complex will form as a chelate of a -DTPA moiety, when present, or within the tetrapyrollic structure between the nitrogen atoms of the amine structure or both. Examples of such structures are:
[0000]
[0044] In the instance where a fluorescent dye is conjugated with the integrin antagonist (often a ligand), the fluorescent dye may be any non-toxic dye that causes the conjugate to preferentially emit (fluoresce) at a wave length of 800 to about 900 nm, e.g. indocyanine dyes. Such dyes usually have at least two resonant ring structures, often chromophores, connected together by an intermediate resonant structure of conjugated double bonds, aromatic carbon rings, resonant heterocylic rings, or combinations thereof.
[0045] Examples of such dyes include bis indole dyes wherein two indole or modified indole ring structures are connected together at their 3 2 and 2 1 carbon atoms respectively by an intermediate resonant structure as previously described. Such dyes are commonly known as tricarboclyanine dyes. Such dyes almost always have at least one, and usually at least two, hydrophilic substituents making the dye water soluble. Such water solubility facilitates entry of the structure into an organism and its cellular structures and reduces the likelihood of toxicity because of reduced storage in fatty tissues and fast elimination from the system. The intermediate resonant structure usually contains a plurality of double bonded carbon atoms that are usually conjugated double bonds and may also contain unsaturated carboxylic or heterocyclic rings. Such rings permit conjugation to a porphyrin or other structure without significantly interfering with the resonance of the intermediate structure. A preferred dye is indocyanine green.
[0046] When a radioisotope is combined with the integrin antagonist, it may be chemically combined by covalent or semi-ionic bonding or may be chelated into the compound. In such instances, the compound often includes known chelating structures such as DTPA.
Preparation of 17 2 (17 5 -N-t-Bu-ethylene-diamido) Pyropheophorbide-a 2
[0047]
[0048] Pyropheophorbide —a carboxylic acid 1 (200 mg) was obtained from spirolina algae by following the literature procedure. It was dissolved in dry dichloromethane (DCM) (5 ml), to this solution under N 2 were added in sequence triethylamine (0.3 ml), Boc-protected diethylamine (66.6 ul) and BOP (146 mg), after evacuation (2-3 times), reaction mixture was stirred at room temperature for overnight under N 2 . Reaction mixture was concentrated and chromatographed on silica (eluent: 4% Methanol in dichloromethane) and the desired compound 2 was isolated as the major product. Yield 90%. NMR (AMX400): (CDCl 3 , δ ppm): 9.35, 9.15 and 8.50 (each s, 1H, meso H); 7.80 (m, 1H CH═CH 2 ); 6.25, 6.1 (each d, 1H, CH—CH 2 ); 5.22(dd, 2H, —CH 2 exocyclic ring); 4.41(q, 1H,18H); 4.28 (d,1H, 17H); 3.75 (q,2H,CH 2 —CH 3 ); 3.62, 3.4, 3.25 (each s, 3H, ring —CH 3 ), 2.8-2.0 (several m, CH 2 —CH 2 —CO—NH—CH 2 —CH 2 —NH), 1.2 (s, 9H, Boc).
Preparation of Pyropheophorbide-Cyclo(Lys-Arg-Gly-Asp-L-Phe) conjugate
[0049]
[0050] Pyropheophorbide 2 was treated with 90% trifluroacetic acid (TFA) to remove Boc group, TFA was removed on rotaevaporator and 3 was dried under high vaccum for further reaction. 3 (15 mg) was dissolved in dry DCM, to this solution were added under N 2 Cyclo(Lys-Arg-Gly-Asp-L-Phe) (20 mg) and EDCI (12 mg), reaction mixture was stirred at room temperature for overnight under N 2 . Reaction mixture was concentrated and chromatographed on preparative silica plate (eluent: 10% Methanol in dichloromethane). The isolated compound was further treated with 90% TFA/DCM for 3-4 hrs. to get the desired pyropheophorbide . . . 4. TFA was rotaevaporated and the compound was further purified on HPLC using C-18 column (eluent: gradient 90% MeOH in water to 100% MeOH in water, flow rate 0.5 ml/min). Yield 10 mg. Mass: m/z=1161 (M+H) + .
Preparation of meso-Purpurinimide 6
[0051]
[0052] Meso-purpurinimide (60 mg) and Boc-protected diethylamine (2.24 g) were dissolved in minimum amount of DCM and the reaction mixture was stirred for 48 hrs at room temperature under N 2 . UV-VIS showed the complete shift of absorbance from 685 nm to 651 nm. To this reaction mixture, freshly prepared diazomethane (200-400 mg) was added and the reaction was monitored by TLC (5% MeOH in DCM). After 10-min UV-VIS showed the complete disappearance of peak at 651 nm and the product peak at 695 nm. Reaction mixture was immediately washed with 2% acetic acid in water and then with water (×3), compound was dried on Na 2 SO 4 , concentrated and chromatographed on silica (eluent: 2-3% Methanol in dichloromethane), the isolated compound was further treated with 90% TFA/DCM for 3-4 hrs, TFA was rotaevaporated to get the desired compound 6 as the major product. Yield 90%. NMR (AMX400): 9.54 (s, 1H, 10H); 9.16 (s, 1H, 5H); 8.4 (s, 1H, 20H); 5.34 (m, 1H,17H), 4.67 (m, 2H, N—CH 2 ), 4.34(q, 1H, 18H), 3.78, 3.58, 3.23, 3.15 (each, 3H, 12CH 3 , 17 2 CH 3 , 2CH 3 , 7CH 3 resp.) 3.74 (q,2H, 8′CH 2 ), 3.605 ( CH 2 —CH 3 ), 2.71 (m, 1H, 1×17 2 ), 2.402 (m, 2H, 2×17 1 H), 2.0 (m,1H, 17 2 H), 1.76 (d, 3H, 18CH 3 ), 1.7-1.64 (8H, 8 2 CH 2 — CH 3 , N—CH-hd 2 — CH 3 —NH 2 ), 0.11-0.1 (2H, each s, —NH).
Preparation of meso-Purpurinimide-Cyclo((Lys-Arg-Gly-Asp-L-Phe) conjugate 8
[0053]
[0054] Meso- Purpurinimide 6 (17 mg) was dissolved in dry DCM, to this solution were added under N 2 Cyclo(Lys-Arg-Gly-Asp-L-Phe) (20 mg) and EDCI (12 mg), reaction mixture was stirred at room temperature for overnight under N 2 . Reaction mixture was concentrated and chromatographed on preparative silica plate (eluent: 10% Methanol in dichloromethane). The isolated compound was further treated with 90% TFA/DCM for 3-4 hrs. to get the desired meso-Purpurinimide-Cyclo((Lys-Arg-Gly-Asp-L-Phe) conjugate 8. TFA was rotaevaporated and the compound was dried under high vacuum. Yield 19 mg. Mass: m/z=1207 (M+H) +
Preparation of Pyropheophorbide-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 8
[0055]
[0056] Pyropheophorbide —a carboxylic acid 7 (200 mg) was obtained from spirolina algae by following the literature procedure. 7(14 mg) was dissolved in dry DCM, to this solution were added under N 2 Cyclo(Lys-Arg-Gly-Asp-D-Phe) (20 mg), EDCI (12 mg) and DMAP (12 mg), reaction mixture was stirred at room temperature for overnight under N 2 . Reaction mixture was concentrated and chromatographed on preparative silica plate (eluent: 10% Methanol in dichloromethane). The isolated compound was further treated with 90% TFA/DCM for 3-4 hrs. and the solid product was washed with MeOH to get the desired pyropheophorbide-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 8, TFA was rotaevaporated and the compound was dried under vacuum. Yield 10 mg. Mass: m/z=1119.6 (M+H) +
Preparation of meso-Purpurinimide-glycine ester 10
[0057]
[0058] 58 mg of purpurin-18 was dissolved in minimum amount of toluene, to this solution HCl salt of glycine-t-Bu ester and 10-15 drops of triethylamine were added, reaction was refluxed under N 2 , after 3 hrs UV-VIS showed the complete disappearance of peak at 696 nm of starting material and new peak at 705 nm, Reaction mixture was concentrated and chromatographed on silica (eluent: 2% Methanol in dichloromethane). and the desired meso- Purpurinimide-glycine ester 10 was isolated as the major product. Yield 90%. NMR (AMX400): 9.64 (s, 1H, 10H), 9.39 (s, 1H, 15H), 8.58 (s,1H, 20H), 7.84 (d, 1H, 3CH—CH 2 ), 6.16 (d,1H, 3CH═CH 2 ), 5.4(m,1H,17H), 4.46 (m, 2H, N—CH 2 — CH 2 —CO 2 H), 4.31 (q, 1H, 18H), 3.84 (s, 3H, 7CH 3 ); 2.68 and 2.39 (each m, 1H+2H, 2×17 1 H); 1.99 (m, 1H, 1×17 2 H); 1.74 (d, 3H, 18CH 3 ), 1.64 (t, 3H, 8 2 CH 3 ); 0.07 and −0.16 (each br, 1H, 2NH).
Preparation of meso-Purpurinimide-glycine-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 12
[0059]
[0060] MMeso-Purpurinimide-glycine ester 10 (17 mg) was dissolved in dry DCM, to this solution were added under N 2 Cyclo(Lys-Arg-Gly-Asp-D-Phe) (20 mg), EDCI (12 mg) and DMAP (12 mg), reaction mixture was stirred at room temperature for overnight under N 2 . Reaction mixture was concentrated and the solid powder was washed with MeOH. The isolated compound was further treated with 90% TFA/DCM for 3-4 hrs. to get the desired meso- Purpurinimide-glycine-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 12, TFA was rotaevaporated, washed with MeOH and dried under vaccum. Yield 20 mg. Mass: m/z=1220 (M+H) + .
Preparation of Mono-I-Cypate
[0061]
[0062] Cypate 13 (260 mg, 0.4 mM) was dissolved in dry DMF (10-15 ml), to this solution were added under N 2 m-I-benzylamine (92 mg, 0.4 mM), EDCI (92 mg, 0.48 mM) and HoBt(64.75 mg, 0.48 mM), reaction mixture was stirred at room temperature for overnight under N 2 . After overnight reaction, DMF was removed under high vaccum, reaction mixture was washed with brine (×3) and water (×3), dried over Na 2 SO 4 and concentrated. Purification was done on Si column using MeOH/DCM as an eluant. Yield 57 mg (17%). Mass: m/z=839 (M+H) + . NMR (AMX400): 7.25-8.03 (m, 16H, aromatic), 6.28-6.80 (m, 4H, —CH), 2.47-3.0 (m, 10H, CH 2 ), 1.88 (s, 12H, CH 3 ).
Preparation of Mono-I-Cypate-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 16
[0063]
[0064] Mono-I-Cypate(30 mg) was dissolved in dry DCM, to this solution were added under N 2 Cyclo(Lys-Arg-Gly-Asp-D-Phe) (20 mg), EDCI (12 mg) and DMAP (12 mg), reaction mixture was stirred at room temperature for overnight under N 2 . After overnight stirring, reaction mixture was concentrated and chromatographed on preparative silica plate (eluent: 13% Methanol in Dichloromethane). The isolated compound was further treated with 90% TFA/DCM for 3-4 hrs. and the oily product was further analyzed and purified on an HPLC (Waters, Delta 600 with 996 photodiode array detector) Ana. Column: Waters Symm-C-81, 4.6×150 mm, 5μ: Semiprep Column: Waters Symm- C-18, 7.8×150 mm, 7μ: using Acetinitrile/Water as an eluant (gradient: 30% to 100% ACN) to get the desired mono-I-Cypate-Cyclo(Lys-Arg-Gly-Asp-D-Phe) conjugate 16 , Yield 24 mg. Mass: m/z=1424 (M+H) + .
Pyro-IA (methyl ester)(19)
[0065] To a solution of Methyl 3-[4-{2-(3,4,5,6-tetrahydropyrimidin-2-ylamino)ethyloxy}-benzoyl]amino-2-(S)-aminoethylsulfonylaminopropionate (17) (47 mg, 0.1 mmol) and pyrocarboxylic acid (18) (60 mg, 0.11 mmol) in anhydrous DMF (5.0 mL) under nitrogen atmosphere, PyBOP (65 mg, 0.12 mmol) and anhydrous triethylamine (0.3 mL) was added and resultant reaction mixture was stirred for overnight at room temperature. Reaction mixture was then rotary evaporated down to dryness and desired product (19) was obtained after purifying crude reaction mixture first over prep silica TLC plate (eluant: 10% MeOH in CH2Cl2) followed by short silica column (eluant: 8% MeOH in CH2Cl2). Yield=50 mg (50%)
[0066] 1 H-NMR(10% CD 3 OD in CDCl 3 ; 400 MHz): δ 9.39, 9.28 and 8.56(all s, 1H, meso-H); 7.95(dd, J=11.4, 18.2, 1H, 3-vinyl); 7.73(d, J=8.8, 2H, ArH); 6.84(d, J=8.8, 2H, ArH); 6.28(d, J=17.6, 1H, 3-vinyl); 6.18(d, J=11.6, 1H, 3-vinyl); 5.26(d, J=20, 1H, 13 2 -CH 2 ); 5.06(d, J=20, 1H, 13 2 -CH 2 ); 4.51(m, 1H, 18-H); 4.30-4.20(m, 2H, CH & 17-H); 4.00(t, J=5.0, 2H, OCH 2 ); 3.85(m, 1H, CONHC H 2 ); 3.67 (s, 3H, ring CH 3 ); 3.62(m, 2H, 8-C H 2 CH 3 ); 3.60(m, 1H, CONHC H 2 ); 3.58(s, 3H, OCH 3 ); 3.42(t, J=5.0, 2H, SO 2 C H 2 ); 3.38(s, 3H, ring CH 3 ); 3.37-3.31(m, 6H, 3×NHC H 2 ); 3.19(s, 3H, ring CH 3 ); 3.14(m, 2H, 3×NCH 2 ); 2.66, 2.45, 2.28, 2.20 (all m, 4H, 17 1 and 17 2 -H); 1.93(t, J=5.6, 2H, CH 2 ); 1.80(d, J=7.2, 3H, 18-CH 3 ); 1.68(t, J=7.8, 3H, 8CH 2 C H 3 ). Mass for C 52 H 62 N 10 O 8 S: 986.45 (Calculated); 986.6 (Found, M + ).
Pyro-Integrin Antagonist-IA (20)
[0067] To a solution of Pyro-IA (methyl ester) (19)(40 mg) in dry THF (10 mL) under argon atmosphere, a solution of LiOH (80 mg, in 5+4 mL: H2O+MeOH respectively) was added and reaction mixture was stirred for 45 min. Reaction was then carefully neutralized with cation exchange resin. Resin was filtered out and reaction mixture was rotary evaporated down to dryness. No further attempt was made to purify the product.
[0068] Yield=35 mg (90%). 1 H-NMR(25% CD 3 OD in CDCl 3 ; 400 MHz): δ 9.39, 9.28 and 8.56(all s, 1H, meso-H); 7.95(dd, J=11.4, 18.2, 1H, 3-vinyl); 7.73(d, J=8.8, 2H, ArH); 6.84(d, J=8.8, 2H, ArH); 6.28(d, J=17.6, 1H, 3-vinyl); 6.18(d, J=11.6, 1H, 3-vinyl); 5.26(d, J=20, 1H, 13 2 -CH 2 ); 5.06(d, J=20, 1H, 13 2 -CH 2 ); 4.51(m, 1H, 18-H); 4.30-4.20(m, 2H, CH & 17-H); 4.00(t, J=5.0, 2H, OCH 2 ); 3.85(m, 1H, CONHC H 2 ); 3.67 (s, 3H, ring CH 3 ); 3.62(m, 2H, 8-C H 2 CH 3 ); 3.60(m, 1H, CONHC H 2 ); 3.42(t, J=5.0, 2H, SO 2 C H 2 ); 3.38(s, 3H, ring CH 3 ); 3.37-3.31(m, 6H, 3×NHC H 2 ); 3.19(s, 3H, ring CH 3 ); 3.14(m, 2H, 3×NCH 2 ); 2.66, 2.45, 2.28, 2.20 (all m, 4H, 17 1 and 17 2 -H); 1.93(t, J=5.6, 2H, CH 2 ); 1.80(d, J=7.2, 3H, 18-CH 3 ); 1.68(t, J=7.8, 3H, 8-CH 2 C H 3 ). Mass for C 52 H 62 N 10 O 8 S: 972.4 (Calculated); 972.6 (Found, M + ).
Purpurinimide-Gly-IA (methyl ester)(22)
[0069] To a solution of Methyl 3-[4-{2-(3,4,5,6-tetrahydropyrimidin-2-ylamino)ethyloxy}-benzoyl]amino-2-(S)-aminoethylsulfonylaminopropionate (17) (20 mg, 0.04 mmol) and glycine purpurinimide (21) (20 mg, 0.03 mmol) in anhydrous DMF (3.0 mL) under nitrogen atmosphere, PyBOP (20 mg, 0.04 mmol) and anhydrous triethylamine (0.1 mL) was added and resultant reaction mixture was stirred for overnight at room temperature. Reaction mixture was then rotary evaporated down to dryness and desired product (22) was obtained after purifying crude reaction mixture first over prep silica TLC plate (eluant: 10% MeOH in CH2Cl2) followed by short silica column (eluant: 8% MeOH in CH2Cl2). Yield=15 mg (45%)
[0070] 1 H-NMR(10% CD 3 OD in CDCl 3 ; 400 MHz): δ 9.07, 8.94 and 8.58(all s, 1H, meso-H); 7.82(dd, J=11.4, 18.2, 1H, 3-vinyl); 7.70(d, J=8.8, 2H, ArH); 6.75(d, J=8.8, 2H, ArH); 6.26(d, J=17.6, 1H, 3-vinyl); 6.16(d, J=11.6, 1H, 3-vinyl); 5.25(d, J=7.2, 1H, 17-H); 5.10(dd, J=8.6, 16.0, 2H, NCH 2 ); 4.42(dd, J=4.4, 7.6, 1H, CH); 4.35(q, J=6.8, 1H, 18-H); 3.89(m, 2H, OCH 2 ); 3.85(m, 1H, CONHC H 2 ); 3.80 (m, 2H, NHC H 2 ); 3.72, 3.52, 3.36, 3.33 and 2.85(all s, all 3H, for 3×ring CH 3 & 2×OCH 3 ); 3.67(m, 1H, CONHC H 2 ); 3.35(m, 4H, 2×NHC H 2 ); 3.26 (m, 4H, 8-C H 2 CH 3 and SO 2 C H 2 ); 3.15(m, 2H, NCH 2 ); 3.62(m, 2H, 8-C H 2 CH 3 ); 2.68, 2.38, 1.98 (all m, 4H, 17 1 and 17 2 -H); 1.83(t, J=5.6, 2H, CH 2 ); 1.80(d, J=7.2, 3H, 18-CH 3 ); 1.41(t, J=7.8, 3H, 8-CH 2 C H 3 ). Mass for C 55 H 65 N 11 O 11 S: 1087.46 (Calculated); 1087.8 (Found, M + ).
Purpurinimide-Gly-IA (23)
[0071]
[0072] To a solution of Purpurinimide-Gly-IA (methyl ester)(22) (15 mg) in dry THF (7 mL) under argon atmosphere, a solution of LiOH (30 mg, in 4+3 mL: H 2 O+MeOH respectively) was added and reaction mixture was stirred for 45 min. Reaction was then carefully neutralized with cation exchange resin. Resin was filtered out and reaction mixture was rotary evaporated down to dryness. No further attempt was made to purify the product. Yield=12 mg (85%)
[0073] 1 H-NMR(25% CD 3 OD in CDCl 3 ; 400 MHz): δ 9.07, 8.94 and 8.58(all s, 1H, meso-H); 7.82(dd, J=11.4, 18.2, 1H, 3-vinyl); 7.70(d, J=8.8, 2H, ArH); 6.75(d, J=8.8, 2H, ArH); 6.26(d, J=17.6, 1H, 3-vinyl); 6.16(d, J=11.6, 1H, 3-vinyl); 5.25(d, J=7.2, 1H, 17-H); 5.10(dd, J=8.6, 16.0, 2H, NCH 2 ); 4.42(dd, J=4.4, 7.6, 1H, CH); 4.35(q, J=6.8, 1H, 18-H); 3.89(m, 2H, OCH 2 ); 3.85(m, 1H, CONHC H 2 ); 3.80 (m, 2H, NHC H 2 ); 3.36, 3.33 and 2.85(all s, all 3H, for 3×ring CH 3 ); 3.67(m, 1H, CONHC H 2 ); 3.35(m, 4H, 2×NHC H 2 ); 3.26 (m, 4H, 8-C H CH 3 and SO 2 C H 2 ); 3.15(m, 2H, NCH 2 ); 3.62(m, 2H, 8-C H 2 CH 3 ); 2.68, 2.38, 1.98 (all m, 4H, 17 1 and 17 2 -H); 1.83(t, J=5.6, 2H, CH 2 ); 1.80(d, J=7.2, 3H, 18-CH 3 ); 1.41(t, J=7.8, 3H, 8-CH 2 C H 3 ). Mass for C 55 H 65 H 11 O 11 S: 1059.43 (Calculated); 1059.8 (Found, M + ). | A compound that is a conjugate of an antagonist to an integrin expressed by a tumor cell and at least one of a tumor avid tetrapyrollic photosensitizer, a fluorescent dye, and a radioisotope labeled moiety wherein the radioisotope is 11 C, 18 F, 64 Cu, 124 I, 99 Tc, 111 In or GdIII and its method of use for diagnosing, imaging and/or treating hyperproliferative tissue such as tumors. Preferably the photosensitizer is a tumor avid tetrapyrollic photosensitizer, e.g. a porphyrin, chlorin or bacteriochlorin, e.g. pheophorbides and pyropheophorbides. Such conjugates have extreme tumor avidity and can be used to inhibit or completely destroy the tumor by light absoption. The integrin is usually αvβ3, α5β1, αvβ5, α4β1, or α2β1. Preferably, the antagonist is an RGD peptide or another antagonist that may be synthetic such as a 4-{2-(3,4,5,6-tetra-hydropyrimidin-2-ylamino)ethyloxy}-benzoyl]amino-2-(S)-amino-ethyl-sulfonylamino group. Such compounds provide tumor avidity and imaging ability thus permitting selective and clear tumor imaging. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 37 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/190,640, filed Mar. 20, 2000.
FIELD OF THE INVENTION
The present invention relates to fabric bag-type containers for use in a non-immersion fabric care process for dry clean only fabrics. The outer shell of the bags are made from fabric such that the bags resist melting at higher temperatures than conventional non-fabric plastic bags and/or the bags are more pliable and/or supple than conventional non-fabric plastic bags and/or the bags retain more of their pliability and/or suppleness than conventional non-fabric plastic bags after being subjected to heat and/or the bags produce less noise during use than the conventional non-fabric plastic bags and/or the bags retain their shape and/or resist wrinkling during use better than the conventional non-fabric plastic bags. The bags of this invention are used in fabric care or “refreshment” processes are conducted in a hot air environment, preferably dryers, in the presence of a cleaning/refreshment composition.
BACKGROUND OF THE INVENTION
Certain delicate fabrics are not suitable for conventional in-home immersion cleaning processes. Home washing machines, which provide excellent cleaning results for the majority of fabrics used in today's society, can, under certain conditions, shrink or otherwise damage silk, linen, wool and other delicate fabrics. Consumers typically have their delicate fabric items “dry-cleaned”. Unfortunately, dry-cleaning usually involves immersing the fabrics in various hydrocarbon and halocarbon solvents that require special handling and must be reclaimed, making the process unsuitable for in-home use. Hence, dry-cleaning has traditionally been restricted to commercial establishments making it less convenient and more costly than in-home laundering processes. But, excluding cost and convenience, dry-cleaning processes remain generally superior to in-home, immersion laundering processes for the care of fine fabrics.
Attempts have been made to provide in-home dry-cleaning systems that combine the fabric cleaning and refreshing of in-home, immersion laundering processes with the fabric care benefits of dry-cleaning processes. One such in-home system for cleaning and refreshing garments comprises a substrate sheet containing various liquid or gelled cleaning agents, and a non-fabric plastic bag. The garments are placed in the bag together with the sheet, and then tumbled in a conventional clothes dryer. However, due to the properties of the non-fabric plastic bag, this in-home system is not suitable for hot or high heat dryers nor is it suitable for most conventional laundromat dryers which operate at higher temperatures than most in-home conventional dryers.
Further, conventional non-fabric plastic bags tend to lose their shape and/or become wrinkled during use in dryers.
Further yet, conventional non-fabric plastic bags are relatively rigid and/or tend to lose their pliability during use in dryers.
Still further yet, conventional non-fabric plastic bags tend to be relatively noisy during filling of the bag with garment(s) and/or during use in dryers and/or after being subjected to heat.
Accordingly, there is a need for a fabric care containment bag that is suitable for use in in-home dry-cleaning processes and/or laundromat dry-cleaning processes which resists melting at higher temperatures than conventional fabric care containment bags; namely, non-fabric plastic fabric care containment bags; a fabric care containment bag that is more pliable and/or supple than conventional non-fabric plastic fabric care containment bags; a fabric care containment bag that retains more of its pliability and/or suppleness than conventional non-fabric plastic fabric care containment bags after being subjected to heat; a fabric care containment bag that produces less noise during use than the conventional non-fabric plastic fabric care containment bags; a fabric care containment bag that retains its shape and/or resists wrinkling during use better than the conventional non-fabric plastic fabric care containment bags; and a fabric care kit comprising such a fabric care containment bag.
SUMMARY OF THE INVENTION
The present invention fulfills the needs identified above by providing a fabric bag that can be used in in-home and laundromat (commercial) dry-cleaning processes, especially when a hot or high heat dryer is used.
It has been surprisingly found that fabric bags, especially polyester bags, more preferably woven polyethylene terephthalate fabric bags provide improved performance over non-fabric plastic bags, as detailed below.
In one aspect of the present invention, a fabric containment bag that is heat resistant up to at least 230° C., preferably 240° C., more preferably 250° C. is provided.
In another aspect of the present invention, a fabric containment bag that is more pliable and/or supple than conventional non-fabric plastic fabric care containment bags is provided.
In yet another aspect of the present invention, a fabric containment bag that retains more of its pliability and/or suppleness than conventional non-fabric plastic fabric care containment bags after being subjected to heat is provided.
In still yet another aspect of the present invention, a fabric containment bag that produces less noise during use than the conventional non-fabric plastic fabric care containment bags is provided.
In still yet another aspect of the present invention, a fabric containment bag that retains its shape and/or resists wrinkling during use better than the conventional non-fabric plastic fabric care containment bags is provided.
In still yet another aspect of the present invention, a fabric care containment bag that substantially resists degradation (i.e., closure failure, fabric damage, damage to bag, such as holes, tears, seam damage, etc.) for at least 50 uses, preferably at least 75 uses, more preferably at least 100 uses.
In still yet another aspect of the present invention, a kit for cleaning and/or refreshing fabrics comprising a fabric containment bag in accordance with the present invention and a stain removing system comprising an absorbent stain receiving article and/or a stain removing composition in accordance with the present invention, and optionally instructions for using the fabric containment bag and stain removing system to clean and/or refresh a fabric article, is provided.
In still yet another aspect of the present invention, a kit for cleaning and/or refreshing fabrics comprising a fabric containment bag in accordance with the present invention and a cleaning and/or refreshing composition in accordance with the present invention and optionally instructions for using the fabric containment bag and cleaning and/or refreshing composition to clean and/or refresh a fabric article, is provided.
In still yet another aspect of the present invention, a kit for cleaning and/or refreshing a fabric article in need of cleaning and/or refreshing comprising a fabric containment bag in accordance with the present invention, and one or more absorbent articles comprising a carrier which releasably contains water and optionally non-water fabric cleaning/refreshment ingredients and instructions for using the fabric bag and one or more absorbent articles to clean and/or refresh a fabric article, the instructions comprising the following steps:
(a) place the fabric article to be cleaned and/or refreshed into the fabric bag; (b) place one or more absorbent articles into the fabric bag; (c) place the fabric containment bag containing the fabric article and one or more absorbent articles into an automatic clothes dryer; and (d) operating the automatic clothes dryer such that the fabric article is cleaned and/or refreshed.
It has also now been unexpectedly discovered that certain fabric bags, specifically, those with more than two side walls, form a three dimensional interior void space when they are closed. This three dimensional void space allows the fabric bag to resist collapsing on the fabric articles that are treated within the bag. That is, the fabric bag retains its “billowed” configuration better than conventional envelope style non-fabric plastic bags. Even more surprisingly, the fabric bags of this invention, by virtue of their enhanced three dimensional configuration, tumble more efficiently in a conventional clothes dryer. Specifically, the fabric bags tend to maintain a position in the center of the tumbling drum of a clothes dryer resisting the centrifugal forces that tend to pull common envelope style non-fabric bags to the side walls of the drum where they collapse. By virtue of their design, the fabric bags of this invention tend to maintain their three dimensional shape such that the fabric articles inside the bag are free to tumble, while at the same time being in the controlled environment of a vapor venting fabric bag.
In still yet another aspect of the present invention, a vapor-venting fabric containment bag comprising:
i) an open configuration and a closed configuration; ii) a VVE rating of at least about 40, preferably at least about 60 and less than about 90, preferably less than about 80, as measured in the Vapor Venting Ev Evaluation Test is provided.
When the bag is in its closed configuration the bag comprises at least three flexible side walls. Further, when the bag is in its closed configuration a three dimensional interior void space is formed whereby the bag resists collapsing. Preferably, the bag comprises at least four side walls configured in the form of a tetrahedron. In another aspect, the bag comprises at least six side walls configured in the form of a cube.
In still yet another aspect of this invention there is provided a process for cleaning or refreshing fabrics by contacting the fabrics with a fabric cleaning/refreshment composition comprising water in a vapor-venting fabric containment bag as described above. In one preferred embodiment, the process is carried out in a hot air clothes dryer at a temperature from about 40° C. to about 240° C., whereby malodors present on the fabrics are vented from the bag by means of the vapor-venting closure.
There is also provided herein a kit for cleaning and/or refreshing fabrics, comprising a package that contains one or more absorbent articles comprising a carrier which releasably contains water and optional non-water fabric cleaning/refreshment ingredients, and a vapor-venting fabric containment bag, and optionally a stain removing system, as described above. In a preferred embodiment, the kit further comprises from one to about ten of the absorbent articles which are disposable after a single use.
All percentages, ratios and proportions herein are by weight, unless otherwise specified. All documents cited are, in relevant part, incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
While this specification concludes with claims that distinctly define the present invention, it is believed that these claims can be better understood by reference to the Detailed Description Of The Invention and the drawings, wherein:
FIG. 1 is a schematic representation of a two sided envelope style fabric bag in accordance with the present invention; the bag is also shown with fold lines for optionally configuring the bag such that a six sided cube is formed as shown in FIG. 2 ;
FIG. 2 is a schematic representation of the fabric bag of FIG. 1 after it has been folded along the marked fold lines to form a six sided cube;
FIG. 3 is a schematic representation of the bag of FIG. 2 inside a rotating drum of a conventional clothes dryer;
FIG. 4 is a schematic representation of a two sided envelope style fabric bag in accordance with the present invention; the bag is also shown with fold lines for optionally configuring the bag such that a five sided three dimensional bag is formed as shown in FIG. 5 ;
FIG. 5 is a schematic representation of the bag of FIG. 4 after it has been folded along the marked fold lines to form a five sided three dimensional bag;
FIG. 6 is a schematic representation of a fabric sheet of bag material in accordance with the present invention; the fabric sheet of bag material is shown with fold lines for optionally configuring the fabric sheet of bag material such that a four sided three dimensional bag is formed as shown in FIG. 7 ;
FIG. 7 is a schematic representation of the sheet of FIG. 6 after it has been folded along the marked fold lines to form a four sided three dimensional bag;
FIG. 8 is a schematic representation of a two sided envelope style fabric bag in accordance with the present invention; the bag is shown with fold lines for optionally configuring the bag such that a four sided three dimensional bag is formed as shown in FIG. 9 ;
FIG. 9 is a schematic representation of the bag of FIG. 8 after it has been folded along the marked fold lines to form a four sided three dimensional bag;
FIG. 10 is a schematic representation of a fabric sheet of bag material in accordance with the present invention; the fabric sheet of bag material is shown with fold lines for optionally configuring the fabric sheet of bag material such that a cylinder is formed as shown in FIG. 11 ;
FIG. 11 is a schematic representation of the fabric sheet of FIG. 10 after it has been formed into a cylinder; and
FIG. 12 is a schematic representation of the cylinder of FIG. 11 and ultimately the fabric sheet of FIG. 10 after it has been folded along the marked fold lines to form a four sided three dimensional bag.
FIG. 13 is a schematic representation of a two sided envelope style fabric bag in accordance with the present invention; the bag is shown with fold lines for optionally configuring the fabric bag such that a four sided three dimensional bag is formed as shown in FIG. 14 ;
FIG. 14 is a schematic representation of the bag of FIG. 13 after it has been folded along the marked fold lines to form a four sided three dimensional bag.
DETAILED DESCRIPTION OF THE INVENTION
It will be appreciated from the disclosures herein that the present invention provides the user with a fabric bag, preferably a woven fabric bag, more preferably a woven polyester fabric bag, most preferably a vapor venting fabric containment bag and/or a three dimensional fabric bag, that can be used for cleaning and refreshing fabrics, especially garments, in a simple, readily available apparatus such as a conventional hot air clothes dryer. The fabric bags and processes of the invention can be used with any type of fabric/garment, including “Dry Clean Only” (DCO) garments. In a preferred embodiment, the user is provided with an article which comprises an absorbent core which releasably contains a cleaning/refreshment composition. In one embodiment, this core with its load of liquid composition is substantially enrobed in an outer cover sheet, which has openings through which the composition is permeable in the vapor state, but which constitutes a barrier through which liquid can flow in, but would be somewhat restrained in the core against flow outward. The liquid-loaded core can also be enrobed in low-density non-water absorbent fabric or non-fabric sheet comprising fibers such as nylon, polyester, polypropylene and the like. In addition, the user can, optionally, also be provided with a separate portion of a spot removal (“pre-spotting”) composition.
When treating a fabric (such as a soiled, wrinkled or malodorous garment) in the present manner, the item is first inspected for heavily spotted areas. If none are found, the item being treated is placed in the fabric bag of this invention together with the cleaning/refreshment article herein and tumbled in a hot air clothes dryer in the manner disclosed, i.e., the “in-dryer” step.
If heavily spotted areas are found, it is preferred to treat them individually before the in-dryer step. The pre-spotting steps of this invention are discussed in detail below.
Containment Bag
It has now been discovered that high water content compositions can be loaded onto a carrier substrate such as a cloth or fabric or non-fabric towelette and placed in a bag environment in a heated operating clothes dryer, or the like, to remove malodors from fabrics as a dry cleaning alternative or “fabric refreshment” process. The warm, humid environment created inside this bag volatilizes malodor components in the manner of a “steam distillation” process, and moistens fabrics and the soils thereon. This moistening of fabrics can loosen pre-set wrinkles, but overly wet fabrics can experience setting of new wrinkles during the drying stage toward the end of the dryer cycle. Proper selection of the amount of water used in the process and, importantly and preferably, proper venting of the bag in the present manner can minimize wrinkling. Moreover, venting of the bag permits any volatilized malodorous materials removed from the fabrics to be removed from the bag thus preventing undesirable re-depositing onto the fabrics.
The preferred design of the venting ability of the bag achieves a proper balance of the above effects. A tightly-sealed, vapor impermeable “closed” bag will not purge malodors and will overly moisten the fabrics, resulting in wrinkling. An overly “open” bag design will not sufficiently moisten the fabrics or soils to mobilize heavier malodors or to remove pre-existing fabric wrinkles. Further, the bag must be “closed” enough to billow and create a void volume under water vapor pressure, wherein the fabrics can tumble freely within the bag and be exposed to the vapors. By allowing the fabric articles to tumble freely, wrinkle removal is improved and wrinkle resistance/prevention is enhanced.
Preferably the bag must be designed with sufficient venting to trap a portion of water vapors (especially early in the dryer cycle) but to allow most of the water to escape by the end of the cycle. Said another way, the rate of vapor release is, preferably, optimized to secure a balance of vapor venting and vapor trapping. A preferred bag design employs a water vapor impermeable fabric, preferably a fabric plastic fabric, more preferably a fabric polyethylene terephthalate fabric, with a closure, preferably a zipper, but other closures such as a closure flap like that of a large envelope that employs a hook-and-loop VELCRO®-type fastener can be used.
The fabrics, when removed from the bag, will usually contain a certain amount of moisture. This will vary by fabric type. For example, silk treated in the optimal range shown on the graph may contain from about 0.5% to about 2.5%, by weight, of moisture. Wool may contain from up to about 4%, by weight, of moisture. Rayon also may contain up to about 4% moisture. This is not to say that the fabrics are, necessarily, frankly “damp” to the touch. Rather, the fabrics may feel cool, or cool-damp due to evaporative water losses. The fabrics thus secured may be hung to further air dry, thereby preventing wrinkles from being re-established. The fabrics can be ironed or subjected to other finishing processes, according to the desires of the user.
The present invention thus provides fabric bags, and in a preferred embodiment three dimensional vapor-venting fabric containment bags which are intended for use in fabric cleaning/refreshment operations. The bags are preferably designed for multiple uses and reuses, preferably at least 50 uses, more preferably at least 75 uses and most preferably at least 100 uses, and are especially adapted for use by the consumer in any conventional hot air clothes dryer apparatus, such as those found in the home or in commercial laundry/cleaning establishments. The bags herein are preferably designed to vent water and other vapors which emanate from within the bag when used in the manner described herein. The vapors released from the bag are exhausted through the air vent of the dryer apparatus.
The bag herein is most preferably formed from fabric which is heat resistant up to at least about 204° C.-260° C., preferably up to about 230° C., more preferably up to about 240° C. and most preferably up to about 250° C. Polyethylene terephthalate is a preferred fabric for forming the bag. Other suitable materials known to those of ordinary skill in the art can also be used for the fabric, such as fabric nylon.
As described more fully below, the preferred fabric bags are provided with a vapor-venting closure which provides one or more gaps through which vapors are released from the bag, in-use. For example, if the closure is a zipper, preferably the material, such as fabric attached to the teeth of the zipper allows for sufficient vapor venting of the bag. In a preferred embodiment, the type of closure and material comprising the closure preferably is chosen to permit sufficient vapor venting of the bag in accordance with the present invention. The closure preferably is selected to provide controlled vapor release from the bag under the indicated operating conditions.
Alternatively, the bag can be provided with a series of holes or other fenestrations which provide vapor venting. However, such venting is not as effective as the vapor-venting closure.
In another embodiment, the edge of one wall of the bag is notched along a substantial portion of its width to facilitate and optimize vapor venting.
In one embodiment, the present invention comprises a fabric bag, preferably a vapor-venting fabric containment bag comprising an open end, a closed end and at least three flexible side walls having inner and outer surfaces, the open end of the bag having a closure, preferably a zipper-like closure.
In yet another embodiment, the present invention encompasses a fabric bag, preferably a vapor-venting fabric containment bag comprising an open end, a closed end and at least three flexible side walls having inner and outer surfaces, the open end of the bag having a section of one side wall extending beyond the open end to provide a flexible flap, the flap having first fastening device affixed thereto, the flap being foldable to extend over a portion of the outside surface of the opposing side wall, the flap being affixable to the outer surface of the opposing wall of the bag by engaging the first fastening device on the inside face of the flap with a second fastening device present on the outside face of the opposing side wall, the first and second fastening devices, when thus engaged, forming a fastener, thereby providing a closure for the open end of the bag. The first and second fastening devices are disposed so as, when engaged, to provide vapor-venting along the closure, especially at the lateral edges of the closure. The first and second fastening devices can form a mechanical fastener or an adhesive fastener.
In an alternate mode, the flap can be folded to provide the closure, tucked inside the opposing side wall, and secured there by a fastener. In this mode, vapors are vented along the closure and especially at the lateral edges of the closure. In yet another mode, the side walls are of the same size and no flap is provided. Fastening devices placed intermittently along portions of the inner surfaces of the side walls are engaged when the lips of the side walls are pressed together to provide closure. One or more vapor-venting gaps are formed in those regions of the closure where no fastening device is present.
While the fastening devices herein can comprise chemical adhesives, the bag is preferably designed for multiple uses. Accordingly, reusable mechanical fasteners are preferred for use herein. Any reusable mechanical fastener or fastening means can be used, as long as the elements of the fastener can be arranged so that, when the bag is closed and the fastener is engaged, a vapor-venting closure is provided. Non-limiting examples include: bags wherein the first and second fastening devices, together, comprise a hook and loop (VELCRO®-type) fastener; hook fasteners such as described in U.S. Pat. No. 5,058,247 to Thomas & Blaney issued Oct. 22, 1991; bags wherein the first and second fastening devices, together, comprise a hook and string type fastener; bags wherein the first and second fastener devices, together, comprise an adhesive fastener; bags wherein the first and second fastening devices, together, comprise a toggle-type fastener; bags wherein the first and second fastening devices, together, form a snap-type fastener; as well as hook and eye fasteners, ZIP LOK®-style fasteners, zipper-type fasteners, and the like, so long as the fasteners are situated so that vapor venting is achieved. Other fasteners can be employed, so long as the vapor-venting is maintained when the bag is closed, and the fastener is sufficiently robust that the flap does not open as the bag and its contents are being tumbled in the clothes dryer. The fastening devices can be situated that the multiple vapor-venting gaps are formed along the closure, or at the lateral edges, or so that the gap is offset to one end of the closure.
Turning now to the drawings wherein FIG. 1 is a schematic representation of a two sided envelope style fabric bag 10 . The bag 10 is shown with fold lines inscribed thereon for optionally configuring the bag 10 such that a six sided cube is formed as described below and as shown in FIG. 2 . Letters A-P have been used to indicate fold lines and intersection points on side wall 12 of bag 10 . The points on the opposite side wall 14 of envelope bag 10 , which correspond to the interior points M, N, O and P are labeled M′, N′, O′ and P′, respectively. Envelope bag 10 is sealed and/or sewn along edges ALKJ, ABCD and DEFG. Edges JIHG and JI′H′G are a part of side walls 12 and 14 , respectively, and these edges define bag opening 13 .
When bag 10 is folded along the lines shown (for example, lines LMNE, AM, and CNOH) a six sided cube is formed as shown in FIG. 2 as bag 11 . It is highly preferred that the edge lines MM′, NN′, OO′ and PP′ be sealed and/or sewn, for example either mechanically or adhesively so that the bag maintains its cube-like configuration. The triangular shaped tips (for example, AMM′ and JPP′) can be removed or they can be folded against one of the side walls. Alternatively, the triangular shaped tips can be left sticking out to help bag 11 align within the rotary drum of a conventional dryer as shown in FIG. 3 .
Specifically, FIG. 3 shows a six sided bag 11 according to this invention inside of a rotary drum 20 of a conventional clothes dryer (not shown). While not wanting to be bound by any one theory, it is believed that bag 11 and rotary drum 20 both rotate about axis 22 as illustrated by arrow 24 . This is in sharp contrast to a conventional envelope style bag which is believed to by drawn to the side walls of the rotary drum by centrifugal forces created as the drum spins about its axis. Once pressed against the side of the drum, an envelope style bag is prone to collapsing. This in turn restricts the interior space of the bag within which the fabric articles have to tumble. As discussed above, a collapsed bag provides sub-optimal cleaning and refreshing for fabric articles.
FIG. 4 is a schematic representation of a two sided envelope style fabric bag 30 . The bag 30 is shown with fold lines inscribed thereon for optionally configuring the bag 30 such that a five sided three dimensional bag if formed and described below and as shown in FIG. 5 . Letters A-J have been used to indicate fold lines and intersection points on side wall 32 of bag 30 . The points on the opposite side wall 34 of envelope bag 30 , which correspond to the interior points I and J are labeled I′ and J′, respectively. Envelope bag 30 is sealed and/or sewn along edges ABC, CDEF and FGH. There are two edges AH, which are part of side walls 32 and 34 , respectively, and these edges define bag opening 33 .
When bag 30 is folded along the lines shown (for example, lines AID and CI) a five sided bag 31 is formed as shown in FIG. 5 . It is highly preferred that the edge lines II′ and JJ′ be sealed and/or sewn, for example, either mechanically or adhesively, so that the bag maintains its three dimensional configuration. The triangular shaped tips (CII′ and FJJ′) can be removed as shown or they can be folded against one of the side walls. Alternatively, the triangular shaped tips can be left sticking out to help the bag align within the rotary drum of a conventional dryer.
FIG. 6 is a schematic representation of a fabric sheet 40 of bag material. The fabric sheet 40 of bag material is shown with fold lines inscribed thereon for optionally configuring the fabric sheet 40 such that a four sided three dimensional bag is formed as described below and as shown in FIG. 7 . Letters A-F have been used to indicate fold lines and intersection points on sheet 40 . Sheet 40 is folded along lines DB, BE and EC, then edges ED and EF are sealed and/or sewn together, and edges AD and CF are sealed and/or sewn together to form a tetrahedral bag 42 , as shown in FIG. 7 . Edges BC and BA define bag opening 43 , as shown in FIG. 7 .
FIG. 8 is a schematic representation of a two sided envelope style fabric bag 50 . The fabric bag 50 is shown with fold lines inscribed thereon for optionally configuring the fabric bag 50 such that a four sided three dimensional bag is formed as described below and as shown in FIG. 9 . Letters A-F have been used to indicate fold lines and intersection points on side walls 52 and 54 of bag 50 . The fold lines present on side wall 52 are EC and ED. Analogous fold lines are present on side wall 54 ; namely, F-C and F-D. Bag 50 is sealed and/or sewn along edges AD, DC and BC. There are two edges AEB and AFB, which are part of side walls 52 and 54 , respectively, and these edges define bag opening 53 . When bag 50 is folded along the lines shown (for example, lines ED and EF) a tetrahedral bag 51 is formed as shown in FIG. 9 .
FIG. 10 is a schematic representation of a fabric sheet 60 of bag material. The fabric sheet 60 of bag material is shown with fold lines inscribed thereon for optionally configuring the fabric sheet 60 such that a cylinder is formed as described below and as shown in FIG. 11 . Letters A-G, C′, E′, F′, and G′ have been used to indicate fold lines and intersection points on sheet 60 . Letter D′ has been used to indicate a mid-point on edge F′G′.
As shown in FIG. 11 , the fabric sheet 60 can be formed into a cylinder shape 61 by contacting and preferably sealing and/or sewing fold line EE′ to fold line CC′ such that a fold line between point CE and C′E′ is formed.
An example of one method for forming the tetrahedral fabric bag 62 , as shown in FIG. 12 , is by forming the cylinder 61 , as shown in FIG. 11 . The cylinder 61 comprises a first opening 63 and a second opening 64 . The second opening 64 is closed by sealing and/or sewing along seal line DC-E. After forming seal DC-E, the cylinder 61 is stretched along stretch line BA such that point D′ and C′-E′ about come in contact with each other, such that the bag opening 63 ′ of the tetrahedral fabric bag 62 is formed by edges BC′-E′A and BD′A. This method substantially produces the tetrahedral fabric bag 62 , as shown in FIG. 12 .
Another example of a method for forming the tetrahedral fabric bag 62 , as shown in FIG. 12 , is by folding the fabric sheet 60 along fold lines CA, AD, DB, BE, then fold lines CC′ and EE′ are sealed and/or sewn together and fold lines CD and DE are sealed and/or sewn together to form the tetrahedral fabric bag 62 . Edges BC′-E′A and BD′A define bag opening 63 ′, as shown in FIG. 12 .
FIG. 13 is a schematic representation of a two sided envelope style fabric bag 70 . The fabric bag 70 is shown with fold lines inscribed thereon for optionally configuring the fabric bag 70 such that a four sided three dimensional bag is formed as described below and as shown in FIG. 14 . Letters A-F have been used to indicate fold lines and intersection points on side walls 72 and 74 of bag 70 . The fold lines present on side wall 72 are EC and ED. Analogous fold lines are present on side wall 74 ; namely, FC and FD. Bag 70 is sealed and/or sewn along edges AD, DC and BC. There are two edges AEB and AFB, which are part of side walls 72 and 74 , respectively, and these edges define bag opening 73 . When bag 70 is folded along the lines shown (for example, lines ED and EC) a tetrahedral fabric bag 71 is formed as shown in FIG. 14 . Another method for forming the tetrahedral fabric bag 71 shown in FIG. 14 is closing a closure, such as a zipper, from E to F or F to E. By closing such a closure between EF, the fabric bag 70 automatic configures itself into the tetrahedral fabric bag 71 as shown in FIG. 14 .
The construction of the preferred, heat-resistant vapor-venting bags used herein to contain the fabrics in a hot air laundry dryer or similar device preferably employs thermal resistant films to provide the needed temperature resistance to internal self-sealing and external surface deformation sometimes caused by overheated clothes dryers. In addition, the bags are resistant to the chemical agents used in the cleaning or refreshment compositions herein. By proper selection of bag material, unacceptable results such as bag melting, melted holes in bags, and sealing of bag wall-to-wall are avoided. In a preferred mode, the fastener is also constructed of a thermal resistant material. The method of assembling the bags can be varied, depending on the equipment available to the manufacturer and is not critical to the practice of the invention.
The dimensions of the containment bag can vary, depending on the intended end-use. For example, a relatively smaller bag can be provided which is sufficient to contain one or two silk blouses. Alternatively, a larger bag suitable for handling a man's suit can be provided. Typically, the bags herein will have an internal volume of from about 10,000 cm 3 to about 25,000 cm 3 . Bags in this size range are sufficient to accommodate a reasonable load of fabrics (e.g., 0.2-5 kg) without being so large as to block dryer vents in most U.S.-style home dryers. Somewhat smaller bags may be used in relatively smaller European and Japanese dryers.
The bags herein are preferably flexible, yet are preferably durable enough to withstand multiple uses. The bags also preferably have sufficient stiffness that they can billow, in-use, thereby allowing its contents to tumble freely within the bag during use.
The inner surface or parts thereof of the fabric bag of the present invention preferably comprises a moisture barrier that inhibits the drying of the fabrics such that the fabrics do not become too dry before the operation is complete. Preferred moisture barriers include inner coating layers, preferably made of plastic, more preferably selected from the group consisting of polybutylene terephthalate, polypropylene, nylon and mixtures thereof. The moisture barrier is preferably made from a material that resists melting up to at least about 155° C., more preferably up to about 180° C., even more preferably up to about 195° C., most preferably up to about 209° C. This inner coating layer is preferably extruded onto the inner surface or parts thereof of the fabric bag. Nonlimiting examples of coating processes include extrusion coating of the fabric components of the fabric bag; knife-coating of the fabric components of the fabric bag; adhesive-laminating of the coating to the fabric components of the fabric bag. Without being bound by theory, it is believed that this inner coating layer functions as a moisture barrier to prevent the fabrics contained within the fabric bag from over-drying during use.
Process for Making Bag
The fabric bags and/or fabrics making up the fabric bags of the present invention can be made by any suitable process, especially textile processes such as conducted in textile mills, known to those of ordinary skill in the art. Preferably, the fabrics are woven from polyester fibers, preferably 150 denier plain weave fibers. Nonlimiting examples of such fibers are commercially available from DUPONT under the trade name DACRON®.
Vapor Venting Evaluation
A preferred containment bag in accordance with the present invention is a vapor-venting containment bag. In its broadest sense, the preferred vapor-venting containment bag used in this invention is designed to be able to vent at least about 40%, preferably at least about 60%, up to about 90%, preferably no more than about 80%, by weight, of the total moisture introduced into the bag within the operating cycle of the clothes dryer or other hot air apparatus as measured according to the Vapor-Venting Evaluation Test described herein. (Of course most, if not all, of organic cleaning solvents, if any, will also be vented during use together with the water. However, since water comprises by far the major portion of the cleaning/refreshment compositions herein, it is more convenient to measure and report the venting as water vapor venting.)
It will be appreciated by those knowledgeable about the operation of hot air clothes dryers and similar apparatus that the rate of venting will usually not be constant over the entire operating cycle. All dryers have a warm-up period at the beginning of the operating cycle, and this can vary according to the specifications of the manufacturer. Most dryers have a cool-down period at the end of the operating cycle. Some venting from the containment bag can occur during these warm-up and cool-down periods, but its rate is generally less than the venting rate over the main period of the drying cycle. Moreover, even during the main period of the cycle, many modern dryers are constructed with thermostat settings which cause the air temperature in the dryer to be increased and decreased periodically, thereby preventing overheating. Thus, an average, rather than constant, dryer operating temperature in the target range of from about 50° C. to about 85° C. is typically achieved.
Moreover, the user of the present containment bag may choose to stop the operation of the drying apparatus before the cycle has been completed. Some users may wish to secure fabrics which are still slightly damp so that they can be readily ironed, hung up to dry, or subjected to other finishing operations.
Apart from the time period employed, the Vapor-Venting Equilibrium (“VVE”) for any given type of vapor-venting closure will depend mainly on the temperature achieved within the dryer—which, as noted above, is typically reported as an average “dryer air temperature”. In point of fact, the temperature reached within the containment bag is more significant in this respect, but can be difficult to measure with accuracy. Since the heat transmittal through the walls of the bag is rather efficient due to the thinness of the walls and the tumbling action afforded by conventional clothes dryers, it is a reasonable approximation to measure the VVE with reference to the average dryer air temperature.
Moreover, it will be appreciated that the vapor-venting from the containment bag should not be so rapid that the aqueous cleaning/refreshment composition does not have the opportunity to moisten the fabrics being treated and to mobilize and remove the soils/malodors therefrom. However, this is not of practical concern herein, inasmuch as the delivery of the composition from its carrier substrate onto the fabrics afforded by the tumbling action of the apparatus occurs at such a rate that premature loss of the composition by premature vaporization and venting is not a significant factor. Indeed, the preferred bag herein is designed to prevent such premature venting, thereby allowing the liquid and vapors of the cleaning/refreshment composition to remain within the bag for a period which is sufficiently long to perform its intended functions on the fabrics being treated.
One embodiment of a vapor-venting containment bag comprises an open end, a closed end and flexible side walls having inner and outer surfaces, the open end of said bag having a section of one side wall extending beyond said open end to provide a flexible flap, said flap having first fastening device, said flap being foldable to extend over a portion of the outside surface of the opposing side wall, said flap being affixable to the outer surface of the opposing side wall of the bag by engaging said first fastening device with a second fastening device present on said opposing side wall, thereby providing a closure for the open end of the bag, said first and second fastening devices being disposed so as, when engaged, to provide at least one vapor-venting gap along said closure.
Another such vapor-venting containment bag comprises an open end, a closed end and flexible side walls having inner and outer surfaces, the side walls being of equal length, wherein the first side wall is notched over part of its width, whereby said opposing side wall thereby extends beyond said notched portion of said first side wall, thereby providing a flexible flap, said flap being foldable over said notched portion to provide a vapor-venting gap when said bag is closed.
In another mode, there is provided a vapor-venting bag with the aforesaid VVE ratings whose side walls are fenestrated. A combination of vapor-venting closure and fenestrations can also be used to achieve the desired VVE.
In yet another embodiment, such a vapor-venting containment bag comprises open end, a closed end and flexible side walls having inner and outer surfaces, the side walls being of equal length, and a closure that substantially closes the open end, but does not completely close the open end such that sufficient vapor-venting from the bag is achieved.
In still another embodiment, such a vapor-venting containment bag comprises open end, a closed end and flexible side walls having inner and outer surfaces, the side walls being of equal length, and a closure that completely closes the open end of the bag, but the closure permits sufficient vapor-venting in accordance with the present invention.
The vapor-venting containment bag facilitates venting of malodors from the bag via the vapor-venting feature and/or providing any fabrics within the vapor-venting containment bag, wrinkle removal and/or wrinkle resistance benefits.
Thus, different from art-disclosed processes, the vapor-venting containment bag of the present invention provides, in a process for cleaning/refreshing fabrics in a mechanical apparatus by placing said fabrics in a fabric vapor-venting containment bag together with a cleaning/refreshment composition and operating said apparatus with heating, such that during venting of water vapors from said bag during said process malodors are released from the bag and fabric wrinkling is minimized. These benefits are optimally secured when the VVE rating of said bag is at least about 40. The process can be conducted in any apparatus, but is conveniently conducted with heating and tumbling in a hot air clothes dryer.
The following Vapor-Venting Evaluation Test (VVET) illustrates the foregoing points in more detail. Larger or smaller containment bags can be used, depending on the volume of the dryer drum, the size of the fabric load, and the like. As noted above, however, in each instance the containment bag is designed to achieve a degree of venting, or VVE “score”, of at least about 40% (40 VVE), preferably at least about 60% (60 VVE), up to about 90% (90 VVE).
Vapor-Venting Evaluation Test
Materials:
Fabric Bag to be evaluated for VVE.
Carrier Substrate (15″×11″; 38.1 cm×27.9 cm) HYDRASPUN® carrier substrate sheet from Dexter with (10444) or without (10244) Binder
Wool Blouse: RN77390, Style 12288, Weight approx. 224 grams
Silk Blouse: RN40787, Style 0161, Weight approx. 81 grams
Rayon Swatch: 45″×17″ (114.3 cm×43.2 cm), Weight approx. 60 grams
Pouch: 5″×6.375″ (12.7 cm×16.2 cm) to contain the Carrier Substrate and water
De-ionized Water; Weight is variable to establish VVE.
Pretreatment of Fabrics:
1. The wool, silk, and rayon materials are placed in a Whirlpool dryer (Model LEC7646DQO) for 10 minutes at high heat setting, with the heating cycle ranging from about 140° F.-165° F. to remove moisture picked up at ambient condition.
2. The fabrics are then removed from the dryer and placed in sealed nylon or plastic bags (minimum 3 mil. thickness) to minimize moisture pick up from the atmosphere.
Test Procedure:
1. Water of various measured weights from 0 to about 40 grams is applied to the carrier substrate a minimum of 30 minutes before running a vented bag test. The substrate is folded, placed in a pouch and sealed.
2. Each fabric is weighed separately and the dry weights are recorded. Weights are also recorded for the dry carrier substrate, the dry pouch containing the substrate, and the dry containment bag being evaluated.
3. Each garment is placed in the bag being evaluated for vapor venting along with the water-containing substrate (removed from its pouch and unfolded).
4. The bag is closed without expressing the air and placed in the Whirlpool Dryer for 30 minutes at the high heat setting, with tumbling per the standard mode of operation of the dryer.
5. At the end of 30 minutes the bag is removed from the dryer and each fabric, the carrier substrate, the bag and the pouch are weighed for water weight gain relative to the dry state. (A possible minor loss in weight for the containment bag due to dryer heat is ignored in the calculations.)
6. The weight gain of each garment is recorded as a percent of the total moisture applied to the carrier substrate.
7. The remaining unmeasured moisture divided by the total moisture is recorded as percent vented from the dryer bag.
8. When a series of total applied moisture levels are evaluated, it is seen that above about 15-20 grams of water the % vented becomes essentially constant, and this is the Vapor-Venting Equilibrium value, or VVE, for the particular bag venting design.
It can be seen from examining a series of VVET results at various initial moisture levels that the water at lower initial levels is being disproportionately captured by the garment load, the headspace, and the nylon bag, such that venting of water and volatile malodors begins in earnest only after the VVE value is achieved. Since this occurs only when about 15-20 grams or more of water is initially charged, it is seen that a VVE of greater than about 40 is needed to avoid excessive wetting of garments, leading to unacceptable wet-setting of wrinkles, as discussed herein.
Malodor and/or Wrinkle Removal
The overall process herein optionally comprises a spot removal step on isolated, heavily stained areas of the fabric. Following this localized stain removal step, the entire fabric can be cleaned/refreshed in the fabric containment bag, preferably the vapor-venting containment bag. This latter step provides a marked improvement in the overall appearance and refreshment of fabrics, especially with respect to the near absence of malodors and wrinkles, as compared with untreated fabrics.
One assessment of this step of the process using the vapor-venting fabric containment bag herein with respect to malodors comprises exposing the fabrics to be tested to an atmosphere which contains substantial amounts of cigarette smoke. In an alternate mode, or in conjunction with the smoke, the fabrics can be exposed to the chemical components of synthetic perspiration, such as the composition available from IFF, Inc. Expert olfactory panelists are then used to judge odor on any convenient scale. For example, a scale of 0 (no detectable odor) to 10 (heavy malodor) can be established and used for grading purposes. The establishment of such tests is a matter of routine, and various other protocols can be devised according to the desires of the formulator.
For example, garments to be “smoked” are hung on clothing hangers in a fume hood where air flow has been turned off and vents blocked. Six cigarettes with filters removed are lighted and set in ashtrays below the garments. The hood is closed and left until the cigarettes have about half burned. The garments are then turned 180.degree. to get even distribution of smoke on all surfaces.
Smoking is then continued until all cigarettes are consumed. The garments are then enclosed in sealed plastic bags and allowed to sit overnight.
After aging for about one day, the garments are treated in the cleaning/refreshment process using the venting bag. The garments are removed promptly from the containment bag when the dryer cycle is finished, and are graded for malodor intensity. The grading is done by an expert panel, usually two, of trained odor and perfume graders. The malodor intensity is given a grade of 0 to 10, where 10 is full initial intensity and 0 is no malodor detected. A grade of 1 is a trace detection of malodor, and this grade is regarded as acceptably low malodor to most users.
In the absence of perfume ingredients in the cleaning cloth composition, the grading of residual malodor intensity is a direct indication of degree of cleaning or removal of malodorous chemicals. When perfumed compositions are used, the grading panelists can also determine a score for perfume intensity and character (again on a 0 to 10 scale), and the malodor intensity grading in this case would indicate the ability of the residual perfume to cover any remaining malodorous chemicals, as well as their reduction or removal.
After the garment odor grading taken promptly after the cleaning/refreshment process, the garments are hung in an open room for one hour and graded again. This one-hour reading allows for an end-effect evaluation that would follow cool-down by the garments and drying of the moisture gained in the dryer cycle treatment. The initial out-of-bag grading does reflect damp-cloth odors and a higher intensity of warm volatiles from the bag, and these are not factors in the one-hour grades. Further garment grading can be done at 24 hours and, optionally, at selected later times, as test needs dictate.
Likewise, fabric wrinkles can be visually assessed by skilled graders. For example, silk fabric, which wrinkles rather easily, can be used to visually assess the degree of wrinkle-removal achieved by the present processes using the vapor-venting bag. Other single or multiple fabrics can optionally be used. A laboratory test is as follows.
De-Wrinkling Test
Materials:
As above for VVET.
De-ionized Water, Weight range (0-38 grams)
Pretreatment of Fabrics:
The silk fabric is placed in a hamper, basket, or drum to simulate normal conditions that are observed after wearing. These storage conditions produce garments that are severely wrinkled (well defined creases) and require a moist environment to relax the wrinkles.
Test Procedure:
1. One silk fabric is placed in a containment bag being tested.
2. Water (0-38 grams) is applied to the carrier substrate a minimum of 30 minutes before running the test, placed in a pouch and sealed.
3. The silk garment is placed in the test containment bag along with the water-containing substrate (removed from its pouch and unfolded).
4. The bag is closed and placed in a Whirlpool Dryer (Model LEC7646DQO) for 30 minutes at high heat (48-74 C cycle).
5. At the end of 30 minutes, the dryer bag is removed from the dryer IMMEDIATELY and the silk garment is placed on a hanger.
6. The silk garment is then visually graded versus the Control Garment from the same Pretreatment Of Fabrics.
In laboratory tests of the foregoing type, the in-dryer, non-immersion cleaning/refreshment processes herein typically provide malodor (cigarette smoke and/or perspiration) malodor grades in the 0-1 range for smoke and somewhat higher for perspiration malodors, thereby indicating good removal of malodor components other than those of sufficiently high molecular weights that they do not readily “steam vaporize” from the fabrics. Likewise, fabrics (silks) have wrinkles removed to a sufficient extent that they are judged to be reasonably suitable for wearing with little, or no, ironing.
Perfume—As noted above, various treatment agents can be applied to the fabrics during the present process. One type of agent comprises various perfume materials. However, the perfumer should select at least some perfume chemicals which are sufficiently high boiling that they are not entirely vented from the bag along with the water vapors during the drying process herein.
A wide variety of aldehydes, ketones, esters, acetals, and the like, perfumery chemicals which have boiling points above about 50.degree. C., preferably above about 85.degree. C., are known. Such ingredients can be delivered by the process herein and caused to permeate the garments of the containment bag during the processes herein. Non-limiting examples of perfume materials with relatively high boiling components include various essential oils, resinoids, and resins from a variety of sources including but not limited to orange oil, lemon oil, patchouli, Peru balsam, Olibanum resinoid, styrax, labdanum resin, nutmeg, cassia oil, benzoin resin, coriander, lavandin and lavender. Still other perfume chemicals include phenyl ethyl alcohol, terpineol and mixed pine oil terpenes, linalool, linalyl acetate, geraniol, nerol, 2-(1,1-dimethylethyl)-cyclohexanol acetate, orange terpenes and eugenol. Of course, lower boiling materials can be included, with the understanding that some loss will occur due to venting.
Cleaning And Refreshing Processes
As discussed briefly above, the cleaning and refreshing processes of this invention include the following steps. The cleaning/refreshment composition is loaded on the substrate which is preferably encased in a coversheet, and the substrate is placed in a bag according to this invention with the fabrics to be treated. The bag is closed and placed in a heated operating clothes dryer, or the like, to remove malodors from the fabrics.
In more detail, the cleaning and refreshing process herein can be conducted in the following manner. Modifications of the process can be practiced without departing from the spirit and scope of the present invention.
(i) optionally, conducting a pre-spotting process according to the description below, on localized stained areas of the fabric; (ii) placing the entire fabric together with the substrate that releasably contains a cleaning/refreshment composition in a fabric containment bag in accordance with the present invention; (iii) placing the bag in a device to provide agitation, e.g., such as in a hot air clothes dryer and operating the dryer with heat and tumbling to moisten the fabric; and (iv) removing the fabric from the bag. (v) promptly hanging the fabrics to complete drying and/or to prevent re-wrinkling.
More specifically, the cleaning and refreshment process is conveniently conducted in a tumbling apparatus, preferably in the presence of heat. The substrate containing the releasably absorbed shrinkage reducing composition and cleaning/refreshment composition is placed along with the fabrics to be treated in a nylon or other heat-resistant, and preferably vapor-venting bag. The bag is closed and placed in the drum of an automatic hot air clothes dryer at temperatures of 40° C.-150° C. The drum is allowed to revolve, which imparts a tumbling action to the bag and agitation of its contents concurrently with the tumbling. The tumbling and heating are carried out for a period of at least about 10 minutes, typically from about 20 minutes to about 60 minutes. This step can be conducted for longer or shorter periods, depending on such factors as the degree and type of soiling of the fabrics, the nature of the soils, the nature of the fabrics, the fabric load, the amount of heat applied, and the like, according to the needs of the user.
In more detail, a pre-spotting process can be conducted in the following manner. Modifications of the process can be practiced without departing from the spirit and scope of the present invention.
1. Place a stained area of the fabric over and in contact with the absorbent stain receiving article, preferably a poly-HIPE or TBAL stain receiver described herein or, less preferably, an ordinary folded paper towel (e.g., preferably white or non-printed—to avoid dye transfer from the towel—BOUNTY® brand) on any suitable surface such as a table top, in a tray, etc. 2. Apply enough spot cleaning composition from a dispenser bottle with a narrow spout which directs the composition onto the stain (without unnecessarily saturating the surrounding area of the fabric) to saturate the localized stained area—about 10 drops; more may be used for a larger stain. 3. Optionally, let the composition penetrate the stain for 3-5 minutes. 4. Optionally, apply additional composition—about 10 drops; more may be used for larger stains. 5. Use the treatment member, such as the distal tip on the dispenser bottle to work the stain completely out. Contact can be maintained for a period of 1-60 seconds for lighter stains and 1-5 minutes, or longer, for heavier or more persistent stains. 6. Optionally, blot the fabric, e.g., between paper towels, to remove excess composition. Or, the treated area can be blotted with a dampened sponge or other absorbent medium to flush the fibers and remove excess composition.
Cleaning/Refreshment Composition
The cleaning/refreshment composition preferably comprises water and a member selected from the group consisting of surfactants, perfumes, preservatives, bleaches, auxiliary cleaning agents, organic solvents and mixtures thereof. The preferred organic solvents are glycol ethers, specifically, methoxy propoxy propanol, ethoxy propoxy propanol, propoxy propoxy propanol, butoxy propoxy propanol, butoxy propanol and mixtures thereof. The surfactant is preferably a nonionic surfactant, such as an ethoxylated alcohol or ethoxylated alkyl phenol, and is present at up to about 2%, by weight of the cleaning/refreshment composition. Typical fabric cleaning refreshment/compositions herein can comprise at least about 80%, by weight, water, preferably at least about 90%, and more preferably at least about 95% water.
The Examples below give specific ranges for the individual components of preferred cleaning/refreshment compositions for use herein. A more detailed description of the individual components of the cleaning/refreshment compositions, that is, the organic solvents, surfactants, perfumes, preservatives, bleaches and auxiliary cleaning agents can be found in U.S. Pat. No. 5,789,368, which issued on Aug. 4, 1998 to You et al. and in U.S. Pat. No. 5,591,236, which issued on Jan. 7, 1997 to Roetker. The entire disclosure of the You et al. and the Roetker patents are incorporated herein by reference. Additionally, cleaning/refreshment compositions are described in co-pending U.S. patent application Ser. No. 08/789,171, which was filed on Jan. 24, 1997, in the name of Trinh et al. The entire disclosure of the Trinh et al. Application is incorporated herein by reference.
It is especially preferred that the cleaning/refreshment compositions of this invention include a shrinkage reducing composition, which is preferably selected from the group consisting of ethylene glycol, all isomers of propanediol, butanediol, pentanediol, hexanediol and mixtures thereof, and more preferably selected from the group consisting of neopentyl glycol, polyethylene glycol, 1,2-propanediol, 1,3-butanediol, 1-octanol and mixtures thereof. The shrinkage reducing composition is preferably neopentyl glycol or 1,2-propanediol, and is more preferably 1,2-propanediol. The ratio of shrinkage reducing composition to cleaning/refreshment composition is preferably from about 1:2 to about 1:5, preferably from about 1:2 to about 1:4, more preferably from about 1:3 to about 1:4, and most preferably about 1:3.6.
In addition to the above ingredients, the cleaning/refreshment composition may optionally comprise a bleaching agent, preferably hydrogen peroxide.
Substrate
When used in the in-dryer step of the present process, the cleaning/refreshment composition is releasably absorbed an absorbent substrate, herein after referred to as a “substrate”. The substrate releasably contains the composition. By “releasably contains” means that the composition is effectively released from the substrate onto the soiled fabrics as part of the non-immersion cleaning and fabric refreshment processes herein. This release occurs mainly by volatilization of the composition from the substrate through the vapor-permeable coversheet, or by a combination of vapor and liquid transfer, although bulk liquid transfer is desirably minimized by means of the coversheet herein.
The substrate can be in any desired form, such as powders, flakes, shreds, and the like. However, it is highly preferred that the substrate be in the form of an integral pad or “sheet” that substantially maintains its structural integrity throughout the process. The substrates and sheets of this invention are sometimes referred to in the literature as “carriers” or “absorbent carrier sheets”; it is understood that all of these labels refer to liquid absorbing materials that can be used to conveniently transport liquids. Such substrates are described in detail in U.S. Pat. No. 5,789,368, to You et al. which was incorporated herein by reference above. The manufacture of these sheets forms no part of this invention and is already disclosed in the literature. See, for example, U.S. Pat. No. 5,009,747, Viazmensky, et al., Apr. 23, 1991 and U.S. Pat. No. 5,292,581, Viazmensky, et al., Mar. 8, 1994, which are incorporated herein by reference.
A preferred substrate herein comprises a binderless (or optional low binder), hydroentangled absorbent material, especially a material which is formulated from a blend of cellulosic, rayon, polyester and optional bicomponent fibers. Such materials are available from Dexter, Non-Wovens Division, The Dexter Corporation as HYDRASPUN®, especially Grade 10244 and 10444. The manufacture of such materials forms no part of this invention and is already disclosed in the literature. See, for example, U.S. Pat. No. 5,009,747, Viazmensky, et al., Apr. 23, 1991 and U.S. Pat. No. 5,292,581, Viazmensky, et al., Mar. 8, 1994, incorporated herein by reference. Preferred materials for use herein have the following physical properties.
Grade
Optional
10244
Targets
Range
Basis Weight
gm/m 2
55
35-75
Thickness
microns
355
100-1500
Density
gm/cc
0.155
0.1-0.25
Dry Tensile
gm/25 mm
MD
1700
400-2500
CD
650
100-500
Wet Tensile
gm/25 mm
MD*
700
200-1250
CD*
300
100-500
Brightness
%
80
60-90
Absorption Capacity
%
735
400-900
H 2 O
Dry Mullen
gm/cm 2
1050
700-1200
*MD—machine direction; CD—cross direction
As disclosed in U.S. Pat. Nos. 5,009,747 and 5,292,281, the hydroentangling process provides a nonwoven material which comprises cellulosic fibers, and preferably at least about 5% by weight of synthetic fibers, and requires less than 2% wet strength agent to achieve improved wet strength and wet toughness.
The substrate is intended to contain a sufficient amount of the cleaning/refreshment composition to be effective for the intended purpose. The capacity of the substrate for such compositions will vary according to the intended usage. The size of the substrate should not be so large as to be unhandy for the user. Typically, the dimensions of the substrate will be sufficient to provide a macroscopic surface area (both sides of the substrate) of at least about 360 cm 2 , preferably in the range from about 360 cm 2 to about 3000 cm 2 . For example, a generally rectangular substrate may have the dimensions (X-direction) of from about 10 cm to about 35 cm, and (Y-direction) of from about 18 cm to about 45 cm.
Coversheet
The coversheets employed herein are distinguished from the substrate, inasmuch as the coversheets are relatively non-absorbent to the cleaning/refreshment composition as compared with the substrate. The coversheets are constructed from hydrophobic fibers which tend not to absorb, “wick” or otherwise promote the transfer of fluids. While fluids can pass through the void spaces between the fibers of the coversheet, this occurs mainly when excessive pressure is applied to the article. Thus, under typical usage conditions the coversheet provides a physical barrier which keeps the absorbent substrate, which is damp from its load of shrinkage reducing composition and cleaning/refreshment composition, from coming into direct contact with the fabrics being treated. Yet, the coversheet does allow vapor transfer of the shrinkage reducing composition and cleaning/refreshment composition from the substrate through the coversheet and into the containment bag, and thus onto the fabrics being treated. If desired, the coversheet can be provided with macroscopic fenestrations through which the lint, fibers or particulate soils can pass, thereby further helping to entrap such foreign matter inside the article, itself.
Such fibrous, preferably heat resistant and, most preferably, hydrophobic, coversheets are described in detail in U.S. Pat. No. 5,789,368, to You et al. which was incorporated herein by reference above. Additionally, co-pending U.S. provisional application 60/077,556, which was filed on Mar. 11, 1998, in the name of Wise et al., describes certain improvements to the coversheets of this invention. The entire disclosure of the Wise et al. application is incorporated herein by reference. Suitable combinations of the coversheets described in You et al. with the improvements described in Wise et al. can be employed, according to the desires of the manufacturer, without departing from the spirit and scope of the invention.
Spot Cleaning Composition
The user of the present process can be provided with various spot cleaning compositions to use in the optional pre-spotting procedure of this invention. These compositions are used to remove localized stains from the fabrics being treated, either before or after the cleaning and refreshing process defined herein. Necessarily, the spot cleaning composition must be compatible with the fabric being treated. That is, no meaningful amount of dye should be removed from the fabric during the spot treatment and the spot cleaning composition should leave no visible stains on the fabric. Therefore, in a preferred aspect of this invention there are provided spot cleaning compositions which are substantially free of materials that leave visible residues on the treated fabrics. This necessarily means that the preferred compositions are formulated to contain the highest level of volatile materials possible, preferably water, typically about 95%, preferably about 97.7%, and surfactant at levels of about 0.1% to about 0.7%. A preferred spot cleaning composition will also contain a cleaning solvent such as butoxy propoxy propanol (BPP) at a low, but effective, level, typically about 1% to about 4%, preferably about 2%.
Preferred spot cleaning compositions are exemplified below, and are described in U.S. Pat. No. 5,789,368, to You et al. which was incorporated herein by reference above. Additionally, spot cleaning compositions are described in U.S. Pat. No. 5,630,847, which issued on May 20, 1997, to Roetker. The entire disclosure of the Roetker patent is incorporated herein by reference.
Treatment Member
In one embodiment, a treatment member is provided to assist in removing localized stains from fabrics. In a preferred aspect of this invention, the spot cleaning composition is provided in a dispenser, such as a bottle, and the dispenser has a distal tip that can serve as the treatment member. Additionally, the treatment member can comprise an absorbent base material which can be, for example, a natural or synthetic sponge, an absorbent cellulosic sheet or pad, or the like. In contact with and extending outward from this base material can be multiple protrusions. Specific examples of treatment members can be found in U.S. Pat. No. 5,789,368, to You et al. which was incorporated herein by reference above.
Absorbent Stain Receiving Article
An absorbent stain receiving article, sometimes referred to herein as a stain receiver, can optionally be used in the optional pre-spotting operations herein. Such stain receivers can be any absorbent material which imbibes the liquid composition used in the pre-spotting operation. Disposable paper towels, cloth towels such as BOUNTY™ brand towels, clean rags, etc., can be used. However, in a preferred mode the stain receiver is designed specifically to “wick” or “draw” the liquid compositions away from the stained area. One preferred type of stain receiver consists of a nonfabric pad, such as a thermally bonded air laid fabric (“TBAL”). Another highly preferred type of stain receiver for use herein comprises polymeric foam, wherein the polymeric foam comprises a polymerized water-in-oil emulsion, sometimes referred to as “poly-HIPE”. The manufacture of polymeric foam is very extensively described in the patent literature; see, for example: U.S. Pat. No. 5,260,345 to DesMarais, Stone, Thompson, Young, LaVon and Dyer, issued Nov. 9, 1993; U.S. Pat. No. 5,550,167 to DesMarais, issued Aug. 27, 1996, and U.S. Pat. No. 5,650,222 to DesMarais et al., issued Jul. 22, 1997, all incorporated herein by reference. Typical conditions for forming the polymeric foams of the present invention are described in co-pending U.S. patent application Ser. No. 09/042,418, filed Mar. 13, 1998 by T. A. DesMarais, et al., titled “Absorbent Materials for Distributing Aqueous Liquids”, the disclosure of which is incorporated herein by reference. Additional disclosure of conditions for forming the polymeric foams for use in the present invention are described in co-pending U.S. Provisional Patent Application Ser. No. 60/077,955, filed Mar. 13, 1998 by T. A. DesMarais, et al., titled “Abrasion Resistant Polymeric Foam And Stain Receivers Made Therefrom”, the disclosure of which is incorporated herein by reference. Notwithstanding the above described preferred types of stain receivers, latex bonded air laid nonfabrics (“LBAL”) and multi-bonded air laid nonfabrics (“MBAL” combined latex and thermal bonded) stain receiver may also be used.
The various stain receivers described herein, and described in the references incorporated herein by reference, preferably comprise a liquid impermeable backsheet. The backsheet can be made of, for example, a thin layer of polypropylene, polyethylene and the like. The backsheet provides protection for the surface that the stain receiver rests on from the spot cleaning composition. For example, spot cleaning processes are typically performed on a hard surface, such as a table top. The stain receiver is placed on the table and the fabric to be treated in placed on the stain receiver. Spot cleaning composition is applied to the stained area of the fabric and then drawn into the stain receiver. But in the absence of a back sheet, the spot cleaning composition can leak onto the table top, possibly causing damage thereto.
The following Examples further illustrate the invention, but are not intended to be limiting thereof.
EXAMPLE I
Cleaning and Refreshing Compositions
Fabric cleaning/refreshment compositions according to the present invention, for use in a containment bag, are prepared as follows:
Ingredient
% (wt.)
Emulsifier (TWEEN 20)*
0.5
Perfume
0.5
KATHON ®
0.0003
Sodium Benzoate
0.1
Water
Balance
*Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.
Additionally, preferred compositions for use in the in-dryer cleaning/refreshment step of the process herein are as follows.
Ingredient
% (wt.)
Range (% wt.)
Water
99.0
95.1-99.9
Perfume
0.5
0.05-1.5
Surfactant
0.5
0.05-2.0
Ethanol or Isopropanol
0
Optional to 4%
Solvent (e.g. BPP)
0
Optional to 4%
pH range from about 6 to about 8.
Additionally, preferred compositions for use in the in-dryer cleaning/refreshment step of the process herein are as follows:
Ingredient
% (wt.)
% (wt.)
% (wt.)
% (wt.)
Water
97.63
98.85
77.22
96.71
Perfume
0
0.38
0.38
0
Surfactant
0.285
0
0
0.285
Ethanol or Isopropanol
0
Solvent (e.g. BPP)
2.0
0
0
2.0
KATHON ®
0.0003
0
0
0
Emulsifier (TWEEN 20)*
0
0.5
0.38
0
Amine Oxide
0.0350
0
0
0.0350
MgCl 2
0.045
0
0
0
MgSO 4
0
0
0.058
0
Hydrogen Peroxide
0
0
0
0.6
Citric Acid
0
0
0
0.05
Proxel GXL
0
0.08
0.08
0
Bardac 2250
0
0.2
0.2
0
1,2-Propanediol
0
0
21.75
0
*Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.
Besides the other ingredients, the foregoing compositions can contain enzymes to further enhance cleaning performance, as described in the Trinh et al. patent incorporated herein above.
EXAMPLE II
Preparation of a Substrate Comprising a Cleaning/Refreshment Composition
A 10¼ in.×14¼ in. (26 cm×36 cm) substrate in the form of a sheet is prepared from HYDRASPUN® material, manufactured by the Dexter Corp. The substrate sheet is covered on both sides with a topsheet and a bottomsheet of 8 mil (0.2 mm) Reemay fabric coversheet material. The coversheet (i.e., both topsheet and bottomsheet) are bonded to the substrate sheet by a Vertrod® or other standard heat sealer device, such as conventional sonic sealing devices, thereby bonding the laminate structure together around the entire periphery of the sheet. The edges of the sheet around its periphery are intercalated between the topsheet and bottomsheet by the bond. As noted above, the width of the bond is kept to a minimum and is about 0.25 in. (6.4 mm).
The bonded laminate sheet thus prepared is folded and placed in a pouch. Any plastic pouch which does not leak would be suitable. For example, a foil laminated pouch of the type used in the food service industry can be employed. Such pouches are well-known in the industry and are made from materials which do not absorb food flavors. In like manner, the formulator herein may wish to avoid absorption of the perfume used in the cleaning/refreshment composition by the pouch. Various pouches are useful herein and are commercially available on a routine basis.
The folded substrate/coversheet sheet is placed in the pouch. The folds can be of any type, for example, an accordion-style fold or rolled and then the roll is folded in half. This size is not critical but is convenient for placement in a pouch.
5 grams of a shrinkage reducing composition and 18 grams of the cleaning/refreshment composition are poured onto the substrate sheet/coversheet in any order, more preferably the shrinkage reducing composition and the cleaning/refreshment composition are mixed before pouring onto the substrate. The compositions are allowed to absorb into the substrate. The pouch is sealed immediately after the liquid product is introduced into the pouch and stored until time-of-use.
EXAMPLE III
Spot Cleaning Compositions
A spot cleaning composition for use for use in the present invention, preferably with a dispenser as defined above, and with a TBAL or poly-HIPE foam stain receiver, is prepared as follows:
% (Wt.)
INGREDIENT
(Nonionic)
Range % (Wt.)
Hydrogen peroxide
1.000
0-2
Amino tris(methylene phosphonic acid)*
0.040
0-0.06
Butoxypropoxypropanol (BPP)
2.000
1-6
Neodol 23 6.5
0.250
0-1
Kathon preservative
0.0003
Optional**
Water
96.710
Balance
pH target = 7;
range = 6-8
*Stabilizer for hydrogen peroxide
**Sufficient to provide a preservative function.
Another example of a preferred, high water content, low residue spot cleaning composition for use in the pre-spotting step herein is as follows.
INGREDIENT
Anionic Composition (%)
Hydrogen peroxide
1.000
Amino tris(methylene phosphonic acid)*
0.0400
Butoxypropoxypropanol (BPP)
2.000
NH 4 Coconut E 1 S
0.285
Dodecyldimethylamine oxide
0.031
Magnesium chloride
0.018
Magnesium sulfate
0.019
Hydrotrope, perfume, other minors,
0.101
Kathon preservative
0.0003
Water (deionized or distilled)
96.507
Target pH
6.0
*Stabilizer for hydrogen peroxide
Preferably, to minimize the potential for dye damage as disclosed hereinabove, H 2 O 2 -containing pre-spotting compositions comprise the anionic or nonionic surfactant in an amount (by weight of composition) which is less than the amount of H 2 O 2 . Preferably, the weight ratio of surfactant:H 2 O 2 is in the range of about 1:10 to about 1:1.5, most preferably about 1:4 to about 1:3. | The present invention relates to improved bag-type containers for use in a non-immersion fabric care process for dry clean only fabrics. The outer shell of the bags are made from fabric such that the bags resist melting at higher temperatures than conventional non-fabric plastic bags and/or the bags are more pliable and/or supple than conventional non-fabric plastic bags and/or the bags retain more of their pliability and/or suppleness than conventional non-fabric plastic bags after being subjected to heat and/or the bags produce less noise during use than the conventional non-fabric plastic bags and/or the bags retain their shape and/or resist wrinkling during use better than the conventional non-fabric plastic bags. The bags of this invention are used in fabric care or “refreshment” processes are conducted in a hot air environment, preferably dryers, in the presence of a cleaning/refreshment composition. | 3 |
PRIORITY CLAIM
[0001] This application claims the benefit of previously filed U.S. Provisional Patent Application entitled “ELECTRONIC SKI CONTROL,” assigned U.S. Ser. No. 61/386,627, filed Sep. 27, 2010, and U.S. Provisional Patent Application entitled “ELECTRONIC SKI CONTROL,” assigned U.S. Ser. No. 61/425,352, filed Dec. 21, 2010, both of which are incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] The present subject matter relates to propulsion control systems. More particularly, the present subject matter relates to electronic propulsion control systems for small watercraft.
BACKGROUND OF THE INVENTION
[0003] Propulsion control systems are extensively used to provide a means to control neutral, forward and reverse signals to the transmission and to control the throttle position of the engine of all types of watercraft. Typical propulsion control systems use mechanical cables to shift the transmissions into and out of neutral, forward and reverse and also make use of mechanical cables to increase engine RPM. Some propulsion control systems make use of electronic switches to shift the transmission into and out of neutral, forward and reverse with a mechanical cable to increase engine RPM while others may use mechanical cables to shift the transmissions into and out of neutral, forward and reverse and use electronic position sensors to increase engine RPM while still others may use any combination of mechanical cable and electronic means.
[0004] Some propulsion control systems utilize an individual handle to control the shifting of the transmission and a separate handle for throttling the engine while other propulsion control systems such as systems on recreational ski watercraft utilize a single handle to control shifting and throttling. Propulsion control systems that utilize a single handle to control shifting and throttling require a means to throttle and rev the engine independently of the shifting the transmission into and out of neutral, forward and reverse. Such systems utilize a mechanical means to disengage the shift mechanism from the handle. For single handle propulsion control systems that utilize mechanical cables for shifting and throttling and a mechanical means to disengage the shift mechanism from the handle require an increase in the number of components needed for the assembly and are extremely susceptible to mechanical failure, wearing out of parts, tolerance issues between mating parts at the manufacturing and assembly levels, etc.
[0005] Single handle propulsion control systems also require a mechanical means to lock the handle in the neutral shift position to prevent accidental shifting of the transmission into gear and acceleration of the watercraft.
[0006] In light of such deficiencies recognized herewith in the known propulsion control systems, it would be desirable to provide a propulsion control systems that significantly improves operational reliability and at the same time provides significant simplification of required components.
[0007] Prior watercraft control systems have been disclosed in the following U.S. Pat. Nos.: 6,414,607 to Gonring, et al. entitled “Throttle position sensor with improved redundancy and high resolution,” 6,485,340 to Kolb et al., entitled “Electrically controlled shift and throttle system,” 6,704,643 to Suhre, et al. entitled “Adaptive calibration strategy for a manually controlled throttle system,” and 6,587,765, 6,751,533, and 6,965,817 all to Graham, et al. and all entitled “Electronic control system for marine vessels.”
[0008] The complete disclosures of the herein referenced patent related publications are fully incorporated herein for all purposes.
[0009] While various configurations of propulsion control systems have been developed, no design has emerged that generally encompasses all of the desired characteristics as hereafter presented in accordance with the subject technology.
SUMMARY OF THE INVENTION
[0010] In view of the recognized features encountered in the prior art and addressed by the present subject matter, an improved electronic propulsion control system for small watercraft has been developed. It should be understood that the present subject matter equally encompasses both methodologies and corresponding apparatuses.
[0011] In an exemplary configuration, watercraft control circuitry is provided to enable operation of the watercraft in both normal and override modes.
[0012] In one form, the present subject matter provides an interlock circuit that permits an operator to operate the throttle of a watercraft in an override mode without engaging the watercraft's transmission.
[0013] In accordance with aspects of certain embodiments of the present subject matter, a failsafe configuration is provided that inhibits engagement of the watercraft's transmission upon failure of certain control circuit components.
[0014] In accordance with certain aspects of other embodiments of the present subject matter, methodologies have been developed to positively indicate to an operator when the circuitry is operating in an override mode.
[0015] In accordance with aspects of still further embodiments of the present subject matter, override mode operation is automatically terminated when an operator selects a neutral throttle position.
[0016] One present exemplary embodiment relates to a propulsion control system for watercraft, comprising a handle assembly movable among at least respective forward, neutral, and reverse positions thereof; a cam configured for rotation about an axis upon movement of such handle assembly, such cam including a central portion and at least one lobe extending from such central portion; a plurality of switches positioned proximate such cam for operation thereby upon contact by such at least one lobe, such plurality of switches configured to provide respective forward, neutral, and reverse signals when contacted by such at least one lobe; an actuator configured for rotation about an axis upon movement of such handle assembly; a sensor positioned proximate such actuator for operation thereby, such sensor configured to provide an output corresponding to the rotational angle of such actuator; and a manual override switch configured to inhibit such forward and reverse signals when such handle assembly is moved from such neutral position thereof.
[0017] In one variation of the foregoing, such actuator may comprise a permanent magnet. In another present variation, such manual override switch may comprise a normally open manually operated switch.
[0018] In still further variations, such sensor output may be configured to comprise a continuous output; and such system may further comprise a self-sealing circuit configured to continue inhibiting such forward and reverse signals until such handle assembly is returned to such neutral position thereof. In some of such variations, a given such system may further comprise an indicator for providing a visual indication upon operation of such manual override switch. In some, such visual indicator may comprise a light emitting diode.
[0019] In still further present system variations, such sensor output may be configured to comprise a continuous output; and such system may further comprise an interlock circuit configured to inhibit such forward and reverse signals upon failure of at least one of such plurality of switches configured to provide such forward and reverse signals.
[0020] In other present variations, such sensor output may be configured to comprise a continuous output; and such system may further comprise a handle locking mechanism configured to mechanically retain such handle assembly in such neutral position until manually released. In alternatives of such, a release cup may be positioned proximate a manually engageable end of such handle assembly. In some of such alternatives, such handle locking mechanism may comprise a dead bolt releasable by operation of such release cup.
[0021] In yet other present alternatives, present systems may further comprise at least one switch located in a handle portion of such handle assembly, such at least one switch configured for control of a watercraft associated mechanism. In certain such systems, such watercraft associated mechanism may correspond to one of trim tabs, wedge hydrofoils, surf tabs, and drives.
[0022] In other present alternatives, some of the foregoing systems may further comprise an emergency stop switch configured to kill one or more engines of an associated watercraft.
[0023] Yet another present exemplary embodiment in accordance with the present subject matter may relate to a propulsion control system for watercraft, comprising a handle assembly, a cam, a plurality of switches, and a manual override switch. Preferably such handle assembly is movable among at least forward, neutral, and reverse positions thereof, such cam is preferably configured for rotation about an axis upon movement of such handle assembly, and with such cam including a central portion and at least one lobe extending from such central portion.
[0024] Further, such plurality of switches are preferably positioned proximate such cam for operation thereby upon contact by such at least one lobe, with such plurality of switches configured to provide respective forward, neutral, and reverse signals when operated by such at least one lobe. Still further, such manual override switch is preferably configured to inhibit such forward and reverse signals when such handle assembly is moved from such neutral position thereof.
[0025] In further alternative arrangements of the foregoing, such manual override switch may comprise a normally open manually operated switch.
[0026] In other present alternatives, such a system may further comprise a self-sealing circuit configured to continue inhibiting such forward and reverse signals until such handle assembly is returned to such neutral position thereof. In variations thereof, such system may further comprise an indicator for providing a visual indication upon operation of such manual override switch. In some embodiments, such visual indicator may comprise a light emitting diode.
[0027] In other present alternatives, a present exemplary system as the foregoing may in some instances further comprise an interlock circuit configured to inhibit such forward and reverse signals upon failure of at least one of such plurality of switches configured to provide such forward and reverse signals.
[0028] In other variations, such system may further comprise a handle locking mechanism configured to mechanically retain such handle assembly in such neutral position until manually released. In some, such an exemplary present system may further comprise a release cup positioned proximate a manually engageable end of such handle assembly. In still others, such handle locking mechanism may comprise a dead bolt releasable by operation of such release cup.
[0029] It is to be understood by those of ordinary skill in the art from the complete disclosure herewith that the present subject matter equally relates to system subject matter, as well as corresponding and/or associated methodology. For example, one present exemplary method for controlling watercraft propulsion may comprise configuring a handle assembly for movement among at least respective forward, neutral, and reverse positions thereof; associating first and second actuators with such handle assembly for rotation about an axis upon movement of such handle assembly; positioning a plurality of switches proximate such first actuator for operation thereby; positioning a sensor proximate the second actuator and configured to provide an output corresponding to the rotational angle of such second actuator; generating respective forward, neutral, and reverse signals upon actuation of selected of the plurality of switches; and selectively inhibiting the forward and reverse signals when the handle assembly is moved from its neutral position.
[0030] In alternatives of the foregoing exemplary method, such sensor output may be continuous; and such selectively inhibiting may comprise manually operating a normally open switch. In some present variations, the present method may yet further comprise continuously inhibiting such forward and reverse signals until the handle assembly is returned to its neutral position.
[0031] In others, present methodology may alternatively further comprise activating a visual indicator concurrently with inhibiting the forward and reverse signals. In some, such activating of a visual indicator may comprise activating a light emitting diode.
[0032] In yet other present variations, present methodology may alternatively in some instances further comprise inhibiting the forward and reverse signals upon failure of at least one of the selected switches configured to provide such forward and reverse signals.
[0033] Yet another present exemplary methodology embodiment relates to a method for controlling watercraft propulsion, comprising configuring a handle assembly for movement among at least respective forward, neutral, and reverse positions thereof; associating an actuator with the handle assembly for rotation about an axis upon movement of such handle assembly; positioning a plurality of switches proximate the actuator for operation thereby; generating respective forward, neutral, and reverse signals upon actuation of selected of such plurality of switches; and selectively inhibiting the forward and reverse signals when the handle assembly is moved from its neutral position.
[0034] Alternatives of such methodology may relate to such selectively inhibiting functionality comprising manually operating a normally open switch.
[0035] In others, present methodology may further comprise continuously inhibiting such forward and reverse signals until the handle assembly is returned to its neutral position. In others, present methodology may further comprise activating a visual indicator concurrently with inhibiting the forward and reverse signals. In some, such activating of a visual indicator may comprise activating a light emitting diode.
[0036] Other alternative present methodologies may further comprise inhibiting the forward and reverse signals upon failure of at least one of such selected switches configured to provide such forward and reverse signals. In yet others, present methodology may further comprise locking the handle assembly in its neutral position until manually released.
[0037] Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referred and discussed features, elements, and steps hereof may be practiced in various embodiments and uses of the present subject matter without departing from the spirit and scope of the present subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like.
[0038] Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matter may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly shown in the figures or stated in the detailed description of such figures). Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0040] FIG. 1 illustrates a front view of the Electronic Ski Control Assembly in accordance with present technology and shows the full range of motion of the assembly;
[0041] FIG. 2 illustrates a side view of the Electronic Ski Control Assembly taken along line A-A in FIG. 1 ;
[0042] FIG. 3 illustrates a rear section of the Electronic Ski Control Assembly in Neutral position taken along line B-B of FIG. 2 ;
[0043] FIG. 4 illustrates a rear section of the Electronic Ski Control Assembly in Forward Idle position taken along line B-B of FIG. 2 ;
[0044] FIG. 5 illustrates a rear section of the Electronic Ski Control Assembly in Forward wide open throttle (WOT) position taken along line B-B of FIG. 2 ;
[0045] FIG. 6 illustrates a rear section of the Electronic Ski Control Assembly in Reverse Idle position taken along line B-B of FIG. 2 ;
[0046] FIG. 7 illustrates a rear section of the Electronic Ski Control Assembly in Reverse wide open throttle (WOT) position taken along line B-B of FIG. 2 ;
[0047] FIG. 8 illustrates an exploded side section of the Electronic Ski Control Assembly in Neutral position;
[0048] FIG. 9 illustrates an assembled side section of the Electronic Ski Control Assembly in Neutral position;
[0049] FIG. 10 illustrates an electrical schematic of the ski control circuit as employed in the Electronic Ski Control Assembly in accordance with present technology;
[0050] FIG. 11 illustrates a detailed view of an exemplary printed circuit board supporting various components of the ski control circuit
[0051] FIGS. 12A , 12 B, 12 C, and 12 D are respective Front View, Right View, Back View, and Left View of a further embodiment of the Electronic Ski Control Assembly;
[0052] FIGS. 13A , 13 B are respective Front View and sectional view along line A-A of Front View FIG. 13A ;
[0053] FIGS. 14A , 14 B are respective Right View and sectional view along line B-B of Front View FIG. 14A in Neutral position;
[0054] FIG. 15 is a partially exploded view of the final assembly of an Electronic Ski control in accordance with a further embodiment;
[0055] FIG. 16 is an exploded view of the Main Assembly of an Electronic Ski control in accordance with a further embodiment;
[0056] FIG. 17 illustrates a front view of the Electronic Ski Control Assembly in accordance with a further embodiment of the present technology and shows the full range of motion of the assembly
[0057] FIGS. 18A , 18 B, 18 C, and 18 D respectively illustrate a rear section of the Electronic Ski Control Assembly along line B-B of FIG. 14A showing Forward Idle, Forward wide open throttle (WOT), Reverse Idle, and Reverse wide open throttle (WOT) positions; and
[0058] FIG. 19 illustrates a back view of the Electronic Ski Control Assembly in accordance with a further embodiment of the present technology and shows the full range of motion of the assembly.
[0059] Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features, elements, or steps of the present subject matter. It should be appreciated that the various illustrations are not drawing to the same scale but are variously sized to better comprehend selected aspects of components illustrated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] As discussed in the Summary of the Invention section, the present subject matter is particularly concerned with electronic propulsion control systems for small watercraft.
[0061] Selected combinations of aspects of the disclosed technology correspond to a plurality of different embodiments of the present subject matter. It should be noted that each of the exemplary embodiments presented and discussed herein should not insinuate limitations of the present subject matter. Features or steps illustrated or described as part of one embodiment may be used in combination with aspects of another embodiment to yield yet further embodiments. Additionally, certain features may be interchanged with similar devices or features not expressly mentioned which perform the same or similar function.
[0062] Reference will now be made in detail to the presently preferred embodiments of the subject electronic ski control. With reference to FIG. 1 , the present technology provides an electronic ski control that allows for two different modes of operation, hereafter called normal mode and override mode. The normal mode of operation is defined as a mode of watercraft operation where the operator moves the throttle handle assembly 50 forward with the intent of engaging the forward gears on the watercraft transmission, causing the watercraft to propel in the forward direction. Similarly, the operator moves the throttle handle assembly 50 in reverse with the intent of engaging the reverse gears on the transmission, causing the watercraft to propel in the reverse direction. The override mode of operation is defined as a mode of watercraft operation where the operator moves the throttle handle assembly 50 forward or reverse with the intent of revving the engine without placing the transmission into forward or reverse gear. The override mode is typically used to provide a higher level of fuel into the engine for purposes of starting or warming up the engine without actually moving the watercraft.
[0063] When the operator wishes to enter the override mode, he or she will press override switch 129 in the neutral throttle position. After entering override mode, the operator can move the throttle handle forward or in reverse, that is, out of neutral, and the transmission will not receive signals to engage the transmission gears. Such operation is otherwise fully described herein.
[0064] With further reference to FIG. 1 , it will be seen that there is illustrated a frontal illustration of the throttle assembly 10 in the neutral position and also illustrating in phantom lines the Forward Idle, Forward wide open throttle (WOT), Reverse Idle, and Reverse WOT positions. With reference also to FIG. 8 , the throttle mechanism is typically engaged by the watercraft operator by grasping throttle handle assembly 50 , pulling up the release cup 66 to disengage the mechanical interlock and moving the throttle handle assembly 50 out of neutral and into either forward or reverse directions. Forward Idle and Reverse Idle handle positions are provided with mechanical detents.
[0065] The operation of the mechanical interlock mechanism will now be explained with reference to FIGS. 8 and 9 . Throttle handle assembly 50 is provided with a release cup 66 that is attached to wire 65 that, in turn, is attached to lock bar 63 . Lock bar 63 has a compression spring 64 pushing it in a downward or locked position. A dead bolt 62 engages spherical pocket 71 and is deadheaded against lock bar 63 . In the locked position, if one tries to rotate the handle assembly 50 , the lock bar 63 prevents the dead bolt 62 from camming out of the spherical pocket 71 .
[0066] When the release cup 66 is lifted, this in turn pulls wire 65 attached to lock bar 63 in an upward direction allowing dead bolt 62 to slide in an axial direction and cam out of pocket 71 . At such point, the release cup 66 may be released from grasp and the handle assembly 50 may be rotated in either forward or reverse directions. The force of the compression spring 64 places a constant force on lock bar 63 in turn forcing dead bolt 62 in a constant locking position. In such manner, as the handle is rotated back to the neutral position, dead bolt 62 is forced back into spherical pocket 71 , thus locking handle assembly 50 in the neutral position.
[0067] To move the watercraft in the forward direction, handle assembly 50 must be rotated in the forward idle direction as shown in FIG. 1 . At such position, the transmission has been switched to forward gearing and the engine is at idle. Moving the handle assembly 50 out of idle to the forward WOT position propels the watercraft to maximum forward speed.
[0068] To move the watercraft in the reverse direction, the handle assembly 50 must be rotated in the reverse idle direction as shown in FIG. 1 . At such position, the transmission has been switched to reverse gearing and the engine is at idle. Moving the handle assembly 50 out of idle to the reverse WOT position propels the watercraft to maximum reverse speed.
[0069] With continued reference to FIG. 8 , it is noted that handle assembly 50 is assembled to base assembly 200 by fitting slot 68 over shaft 106 . The handle assembly may be held in place by screw 51 , force fit, or other mechanical assembly means. A logo nameplate 52 may then be applied to handle 60 after screw 51 is tightened.
[0070] With reference to FIGS. 8 and 11 , shaft 106 is provided with slot 150 that engages cam 105 with cam keyway 107 . The interaction of keyway 107 and slot 150 locks cam 105 to shaft 106 and therefore handle assembly 50 . By such interaction, movement of handle assembly 50 causes cam 105 to move rotationally in unison. Cam 105 is provided with two lobes, 108 and 109 . Such lobes are used to engage switches 120 , 122 and 124 by means of their respective actuators 121 , 123 , and 125 . Switches 120 , 122 , 124 are used to send neutral, forward and reverse signals, respectively, to the watercraft's engine control module (ECM). Such interaction is otherwise fully described herein.
[0071] Switches 120 , 122 , and 124 are mounted to printed circuit board 100 that in turn is mounted to shift/throttle assembly 200 with screws 101 , 102 , 103 , and 104 . Printed circuit board 100 is also provided with control relays 126 , 127 , 128 , fuse 133 and connectors 131 and 132 . Such components may be mounted to printed circuit board 100 by means of through hole and/or surface mount technology. It should be appreciated that those of ordinary skill in the art can easily assemble the control system described herein with discrete switches, relays, fuses, wiring, etc. Assembling such components onto a printed circuit board significantly reduces assembly time and significantly increases reliability, but is neither required to perform the control circuit's operation nor is a specific requirement of the present technology.
[0072] With reference to the schematic diagram of FIG. 10 and for purposes of the present discussion, normally open switch contacts 120 a , 122 a , 124 a are electrical contacts that are electrically open when switches 120 , 122 , 124 are not mechanically contacted or closed. Normally closed switch contacts 120 b , 122 b , 124 b are electrical contacts that are electrically closed when switches 120 , 122 , 124 are mechanically contacted or closed. Mechanical contact with actuators 121 , 123 , 125 on switches 120 , 122 , 124 , respectively, will cause the respective normally open contacts 120 a , 122 a , 124 a to electrically close and the normally closed contacts 120 b , 122 b , 124 b to electrically open.
[0073] Similarly, normally open relay contacts 126 a , 127 a , 128 a on relays 126 , 127 , 128 , respectively, are electrical contacts which are electrically open when the respective relay coils 126 c , 127 c , 128 c are not energized. Normally closed relay contacts 126 b , 127 b , 128 b on relays 126 , 127 , 128 , respectively, are electrical contacts which are electrically closed when the respective relay coils 126 c , 127 c , 128 c are not energized. Energizing coils 126 c , 127 c , 128 c on relays 126 , 127 , 128 will cause the respective normally open contacts 126 a , 127 a , 128 a to close and the normally closed contacts 126 b , 127 b , 128 b to open.
[0074] For purposes of this discussion, the mechanical interaction of handle assembly 50 and therefore cam 105 and its lobes 108 and 109 and switches 120 , 122 and 124 will be described first. The electrical interaction of switches 120 , 122 , and 124 , relays 126 , 127 , 128 and the watercraft's control system will be described later.
[0075] Returning now to the operation of the throttle, FIGS. 3 and 11 illustrate throttle handle assembly 50 and cam 105 in the neutral position. In such position, cam lobe 109 is contacting switch actuator 121 causing normally open contact 120 a and normally closed contact 120 b in switch 120 to change state to closed and open, respectively. In the previously described normal mode, the operator can move the throttle handle assembly 50 forward (clockwise) as illustrated in FIG. 4 . Before entering the forward position, cam lobe 109 releases contact with switch actuator 121 causing normally open contact 102 a and normally closed contact 120 b in switch 120 to change back to the normal state, open and closed, respectively.
[0076] Upon further clockwise movement of handle assembly 50 , cam lobe 108 contacts switch actuator 123 causing normally open contact 122 a and normally closed contact 122 b in switch 122 to change state to closed and open, respectively. Further clockwise movement of the throttle is possible as illustrated in FIG. 5 .
[0077] Returning the throttle handle assembly 50 to the neutral state (moving it in reverse or counter clockwise) will reset switch 122 and its respective contacts 122 a , 122 b when cam lobe 108 releases switch actuator 123 and therefore switch 122 . After switch 122 is reset to the normal state, cam lobe 109 engages switch actuator 121 and therefore switch 120 causes its contacts 120 a , 120 b to change state.
[0078] In the normal state, the operator can also move the throttle handle assembly 50 backward (counter clockwise) as illustrated in FIG. 6 . Before entering the reverse position, cam lobe 109 releases contact with switch actuator 121 causing normally open contact 120 a and normally closed contact 120 b in switch 120 to change back to the normal state, open and closed, respectively.
[0079] Upon further counter clockwise movement of handle assembly 50 , cam lobe 108 contacts switch actuator 125 causing normally open contact 124 a and normally closed contact 124 b in switch 124 to change state to closed and open, respectively. Further counter clockwise movement of the throttle is possible as illustrated in FIG. 7 .
[0080] Returning the throttle handle assembly 50 to the neutral state (moving it forwards or clockwise) will reset switch 124 and its respective contacts 124 a , 124 b when cam lobe 108 releases switch actuator 125 and therefore switch 124 . After switch 124 is reset to the normal state cam lobe 109 engages switch 120 and causes its contacts 120 a , 120 b to change state.
[0081] Returning to FIG. 3 (neutral state) and the electrical schematic FIG. 10 , we can see that the interaction of cam 105 and its lobes 108 and 109 with switches 120 , 122 , and 124 cause various interactions with relays 126 , 127 , and 128 which, in turn, will energize and de-energize forward, reverse, and neutral outputs of connector 132 at pins 1 , 2 , 3 .
[0082] For purposes of this discussion, the electrical operation of the “normal” mode of watercraft operation will be described first, followed by a description of the “override” mode of watercraft operation.
[0083] Turning to the mechanical illustration of FIG. 3 together with the electrical schematic of FIG. 10 the throttle assembly is in the neutral position. Cam lobe 109 is engaging switch 120 which closes normally open contact 120 a . Switch 120 is connected to 12V+ at pin 1 . The closure of normally open contact 120 a energizes pin 3 of switch 120 , which in turn, energizes pin 1 of connector 131 . Pin 1 of connector 131 is used in the override mode of operation, to be described later.
[0084] Forward Normal Mode
[0085] When the handle assembly 50 is moved forward as shown in FIGS. 4 and 5 , the first event is for switch 120 to be released, which opens normally open contact 120 a , thereby de-energizing pin 3 of switch 120 , and then closes normally closed contact 120 b , thereby energizing pin 2 of switch 120 . Pin 2 of switch 120 is electrically connected to the movable contact of relay 126 , which is the common electrical contact in normally open relay contact 126 a and normally closed relay contact 126 b . In the normal mode of operation, relay coil 126 c is de-energized, and therefore normally open contact 126 a is open and normally closed contact 126 b is closed. Since the normally closed contact 126 b is closed, and the movable contact of relay 126 is energized, pin 4 of relay 126 is energized.
[0086] Pin 4 of relay 126 is electrically connected to common contact (pin 1 ) of switch 122 . As the handle assembly 50 continues to move forward, cam lobe 108 contacts switch 122 causing it to change state. Such state change of switch 122 causes the normally open contact 122 a of switch 122 to close. Such in turn energizes the normally closed contact 127 b of relay 127 . Since normally closed contact 127 b is closed, the movable contact of relay 127 is therefore energized. Forward interlock relay 127 is used as an interlock with the reverse circuit and will be described later. The movable contact of relay 127 is connected to pin 2 which is electrically connected to (and therefore energizes) pin 1 of connector 132 (denoted as the forward output).
[0087] In summary, when in the normal mode of operation, moving forward, 12V+ follows the following path: pin 2 of switch 120 : pin 2 of relay 126 : pin 4 of relay 126 : pin 1 of switch 122 : pin 3 of switch 122 : pin 4 of relay 127 : pin 2 of relay 127 : pin 1 of connector 132 . Pin 1 of electrical connector 132 is connected to the watercraft's control circuit and signals the watercraft that the operator intends the watercraft to move forward by engaging the transmission in the normal mode of operation.
[0088] When the handle assembly 50 is moved in reverse, cam lobe 108 will release switch 122 ; the opening of switch 122 will de-energize pin 3 of switch 122 , which, in turn de-energizes pin 4 of relay 127 and therefore pin 1 of connector 132 .
[0089] Further reverse movement of throttle handle assembly 50 will cause cam lobe 109 to contact switch 120 , de-energizing relay contacts of relay 126 .
[0090] Reverse Normal Mode
[0091] When the handle assembly 50 is moved in reverse as shown in FIGS. 6 and 7 , the first event is for switch 120 to be released, which opens normally open contact 120 a , thereby de-energizing pin 3 of switch 120 , and then closes normally closed contact 120 b which energizes pin 2 of switch 120 . Pin 2 of switch 120 is electrically connected to the movable contact of relay 126 , which is the common electrical contact in normally open relay contact 126 a and normally closed relay contact 126 b . In the normal mode of operation, relay coil 126 c is de-energized, and therefore normally open contact 126 a is open and normally closed contact 126 b is closed. Since the normally closed contact 126 b is closed, and the movable contact of relay 126 is energized, pin 4 of relay 126 is energized. Pin 4 of relay 126 is electrically connected to common contact (pin 1 ) of switch 124 .
[0092] As the handle assembly 50 continues to move in reverse, cam lobe 108 contacts switch 124 causing it to change state. Such state change of switch 124 causes the normally open contact 124 a of switch 124 to close. Such in turn energizes the normally closed contact 128 b of relay 128 ; since normally closed contact 128 b is closed, the movable contact of relay 128 is therefore energized. Reverse interlock relay 128 is used as an interlock with the forward circuit and will be described later. The movable contact of relay 128 is connected to pin 2 which is electrically connected to (and therefore energizes) pin 2 of connector 132 (the reverse output).
[0093] In summary, when in the normal mode of operation, moving in reverse, 12V+ follows the following path: pin 2 of switch 120 : pin 2 of relay 126 : pin 4 of relay 126 : pin 1 of switch 124 : pin 3 of switch 124 : pin 4 of relay 128 : pin 2 of relay 128 : pin 2 of connector 132 . Pin 2 of electrical connector 132 is connected to the watercraft's control circuit and signals the watercraft that the operator intends the watercraft to move in reverse by engaging the transmission in the normal mode of operation.
[0094] When the handle assembly 50 is moved forwards, cam lobe 108 will release switch 124 . The opening of switch 124 will de-energize pin 3 of switch 124 , which, in turn de-energizes pin 4 of relay 128 and therefore pin 2 of connector 132 . Further forward movement of throttle handle assembly 50 will cause cam lobe 109 to contact switch 120 , de-energizing relay contacts of relay 126 .
[0095] Forward/Reverse Electrical Interlock
[0096] While moving forward or reverse, the forward of reverse interlock relays 127 , 128 are employed to ensure that both forward output (pin 1 connector 132 ) and reverse output (pin 2 connector 132 ) are not energized simultaneously.
[0097] In FORWARD operation: when the handle assembly 50 is moved forward (clockwise), cam 108 actuates switch 122 . Such operation energizes pin 3 of switch 122 that in turn energizes the normally closed contact 127 b of relay 127 . In addition to being electrically connected to pin 4 of relay 127 , pin 3 of switch 122 is also electrically connected to relay coil 128 C of reverse interlock relay 128 at pin 5 . When relay coil 128 c is energized, it causes normally open relay contact 128 a and normally closed relay contact 128 b to change state to closed and open, respectively.
[0098] If there was a failure of cam 105 or its related mounting mechanism or a failure of switch 124 or its actuator 125 which would cause switch 124 to change state simultaneously to switch 122 , i.e., forward switch 122 and reverse switch 124 are simultaneously actuated, normally open contact 124 a would close, energizing pin 3 of switch 124 and therefore normally closed relay contact 1288 at pin 4 , relay 128 . As previously stated, when going forward, normally closed relay contact 128 b is open. When normally closed relay contact 128 b is open, electrical current cannot flow to the movable contact of relay 128 and therefore output pin 2 of connector 132 will not be energized. The fact that pin 2 of connector 132 cannot be energized results in the fact that the watercraft's control system will not receive a reverse signal simultaneous to getting a forward signal.
[0099] In addition to the reverse output being locked out when switch 124 becomes actuated simultaneous to switch 122 being actuated due to the aforementioned failure modes, the interaction of the reverse switch 124 and relay 127 will also turn off forward output pin 1 on connector 132 through the following relay interaction.
[0100] When switch 124 (reverse) is actuated, normally open contact 124 a also energizes relay coil 127 c . When relay coil 127 c becomes energized, normally closed contact 127 b opens. The opening of 127 b will de-energize the movable contact of relay 127 , and therefore will de-energize the forward output, pin 1 of connector 132 . The net effect of the aforementioned failure modes causing both forward switch 122 and reverse switch 124 to be simultaneously actuated is that there will be no electrical output at either pin 1 connector 132 (forward) or pin 2 connector 132 (reverse).
[0101] In REVERSE operation: when the handle assembly 50 is moved in reverse (counter clockwise), cam 108 actuates switch 124 . Such operation energizes pin 3 of switch 124 that in turn energizes the normally closed contact 128 b of relay 128 . In addition to being electrically connected to pin 4 of relay 128 , pin 3 of switch 124 is also electrically connected to relay coil 127 C of forward interlock relay 127 at pin 5 . When relay coil 127 c is energized, it causes normally open relay contact 127 a and normally closed relay contact 127 b to change state to closed and open, respectively.
[0102] If there was a failure of cam 105 or its related mounting mechanism, or a failure of switch 122 or its actuator 123 which would cause switch 122 to change state simultaneously to switch 124 , i.e., reverse switch 124 and forward switch 122 are simultaneously actuated, normally open contact 122 a would close, energizing pin 3 of switch 122 and therefore normally closed relay contact 127 B at pin 4 , relay 127 . As previously stated, when going in reverse (reverse), normally closed relay contact 127 b is open. When normally closed relay contact 127 b is open, electrical current cannot flow to the movable contact of relay 127 (and therefore output pin 1 of connector 132 ) will not be energized. The fact that pin 1 of connector 132 cannot be energized results in the fact that the watercraft's control system will not receive a forward signal simultaneous to getting a reverse signal.
[0103] In addition to the forward output being locked out when switch 122 becomes actuated simultaneous with switch 124 being actuated due to the aforementioned failure modes, the interaction of the forward switch 122 and relay 128 will also turn off reverse output pin 2 on connector 132 through the following relay interaction.
[0104] When switch 122 (forward) is actuated, normally open contact 122 a also energizes relay coil 128 c . When relay coil 128 c becomes energized, normally closed contact 128 b opens. The opening of 128 b will de-energize the movable contact of relay 128 and therefore will de-energize the reverse output, pin 2 of connector 132 . The net effect of the aforementioned failure modes causing both reverse switch 124 and forward switch 122 to be simultaneously actuated is that there will be no electrical output at either pin 2 connector 132 (reverse) or pin 1 connector 132 (forward).
[0105] In summary and simply stated, any time forward switch 122 and reverse switch 124 are simultaneously actuated, neither forward output (pin 1 , connector 132 ) or reverse output (pin 2 , connector 132 ) will be energized.
[0106] Neutral Operation
[0107] Returning now to the neutral state ( FIG. 3 ) and the electrical schematic ( FIG. 10 ), it can be seen that in the neutral position, cam lobe 109 actuates switch 120 causing it to change state. Such causes normally open contact 120 b to close, energizing pin 3 of switch 120 . Pin 3 of switch 120 is electrically connected to pin 3 , connector 132 through series resistance. This series resistance is used to limit current exiting the neutral output, as typical watercraft control systems have a high impedance load on the neutral input. Pin 3 connector 132 is connected to the watercraft's control system and is used to signal the watercraft that the throttle is in the neutral position. Upon leaving the neutral position, cam lobe 109 releases switch 120 and therefore pin 3 of electrical connector (neutral output) is de-energized. Generally, in operation, neutral switch 120 will disengage prior to forward switch 122 or reverse switch 128 engagement. Similarly, forward switch 122 and reverse switch 128 will disengage prior to neutral switch 120 engagement. If neutral switch 120 is disengaged, operation of override switch 129 will have no effect. In an exemplary configuration, the operating voltage of the circuit may range from about 9-14 VDC and the maximum current supplied to the engine control module (ECM) may be about 10 mA.
[0108] Override Circuit
[0109] Periodically, it becomes necessary to move the throttle forward or in reverse with the intent of not engaging the transmission gears in either direction. Such mode is typically used to provide a higher level of fuel into the engine for purposes of starting or warming up the engine without actually moving the watercraft. Typically, such mode is used when the watercraft is docked and it is critical, from a safety point of view, that the transmission not be engaged while in such mode. Such mode is called the override mode, and is entered by the operator pressing switch 129 while in the neutral position and then pushing the throttle forward or reverse.
[0110] When the throttle is in the neutral position, (as shown in FIG. 3 ), pin 3 of switch 120 is energized. Such pin (in addition to being resistively connected to pin 3 , connector 132 ) is connected to pin 1 of electrical connector 131 . Electrical connector 131 is used to connect to override switch 129 (at pin 1 , 2 ) and override LED indicator 130 (at pin 3 , 4 ). When override switch 129 is closed, pin 2 of connector 131 becomes energized, and in turn relay coil 126 c becomes energized, causing relay 126 to change state.
[0111] As previously stated, in the normal, i.e., non-override mode, normally closed contact 126 b is used to electrically connect normally closed contact 120 b (neutral switch) to forward and reverse switches 122 and 124 , respectively. If normally closed contact 126 b opens, electrical current cannot go from pin 2 of switch 120 to forward and reverse switches 122 and 124 , which, in turn, cannot feed the forward and reverse outputs at pin 1 and 2 connector 132 .
[0112] When relay 126 changes state due to actuation of override switch 129 while in the neutral position, normally open contact 126 a of relay 126 closes. As previously stated, the movable contact of relay 126 is electrically connected to normally closed switch contact 120 b at pin 2 . When the throttle handle assembly 50 is in the neutral state illustrated in FIG. 3 , switch 120 , pin 2 is open, that is, it is not electrically connected to anything.
[0113] Normally open contact 126 a is connected to pin 3 of relay 126 , which is electrically connected relay coil 126 c at pin 5 through forward biased diode 180 . When the throttle handle assembly 50 is moved out of the neutral position as illustrated in FIGS. 4 and 5 or 6 and 7 , normally closed contact 120 b closes. Such energizes pin 2 of switch 120 that, in turn, energizes pin 2 of relay 126 which (through the now closed relay contact 126 a ) will energize relay coil 126 C through forward biased diode 180 .
[0114] In summary, while in neutral, the action of pressing override switch 129 energizes relay coil 126 c . Such causes relay contacts 126 a and 126 b to change state, which results in relay coil 126 c being electrically connected to pin 2 of switch 120 through the now closed contact 126 a . Upon moving the throttle handle 50 out of the neutral position, switch contacts 120 b now energize relay coil 126 c through relay contacts 126 a . The operator can now release the override switch 129 and the relay coil 126 c will remain energized, through its own contact 126 a and neutral switch 120 b . Such self-sealed mode will remain until the operator moves the throttle handle assembly 50 back into the neutral position.
[0115] As previously noted, normally open contact 126 a of relay 126 is electrically connected to relay coil 126 c through forward biased diode 180 . In addition, normally open contact 126 a of relay 126 is resistively connected to pin 3 of electrical connector 131 . Also connected to pin 3 of electrical connector 131 is an LED 130 override indicator. Such LED 130 indicates to the operator that the watercraft is operating in the override mode. Typically, LED 130 override indicator may be blue in color, but, of course, other colors may be selected without limitation. LED 130 is wired with anode connected to pin 3 of electrical connector 131 and cathode to pin 4 of electrical connector 131 . Pin 4 of electrical connector is connected to ground.
[0116] When the throttle is in the neutral position, and the override button 129 is pressed, relay coil 126 c becomes energized. Such also energizes the cathode of diode 180 , to reverse bias it. Diode 180 serves to block electrical current from flowing to pin 3 of electrical connector 130 , which therefore prohibits turning on override indicator LED 130 . It is not desirable to illuminate override indicator LED 130 when the throttle 50 is in the neutral position and the override button 129 pressed, because this can be confusing to the operator. The override mode is not truly (i.e., fully) entered until the throttle moves to the forward or reverse positions, and the forward and reverse outputs at pins 1 and 2 of electrical connector 132 are not energized due to relay coil 126 c being energized.
[0117] Once the throttle is moved from the neutral position (forward or reverse) in override mode, electrical current flows from pin 2 of switch 120 through the now closed relay contact 126 a , through forward biased diode 180 , to override indicator LED 130 connected to pins 3 , 4 of electrical connector 131 and illuminating LED 130 .
[0118] Once in override mode, relay coil 126 c remains energized and override indictor LED 130 will remain illuminated until the throttle returns to the neutral position. When relay coil 126 c is energized, electrical current cannot flow to either of forward or reverse switches 122 and 124 , respectively, and therefore forward and reverse outputs at pins 1 , 2 of electrical connector 132 will not energize. In summary, once in override mode, the operator can move the throttle in the forward or reverse direction to increase the RPM of the engine without worrying about the transmission engaging in forward or reverse.
[0119] When the operator moves the handle assembly 50 out of override mode (forward or reverse) and back into neutral, the system is reset to the normal mode of operation through the following process. The action of moving the throttle into neutral will cause switch 120 to change state. Such will de-energize pin 2 of switch 120 which in turn will de-energize the movable contact of relay 126 (currently connected to contact 126 a and therefore pin 3 ) which will de-energize relay coil 126 c (through now non-biased diode 180 ). When relay coil 126 c de-energizes, contacts 126 a and 126 b change state, which, in turn will turn off led override indicator so that the watercraft is now in the normal mode of operation, in neutral, as shown in FIG. 3 .
[0120] Throttle Control Operation
[0121] Throttle control is further explained herein with reference to FIGS. 8 and 9 . A magnet actuator 72 may be relatively rigidly attached to the end of the shaft 106 such as by means of a screw or similar 74 . The magnet actuator 72 is preferably keyed to the shaft 106 in the same manner as cam 105 ; thus, the present magnet actuator and shaft rotate as one unit. A position sensor 73 is preferably rigidly attached to the enclosure 76 such as by means of two push nuts 75 . Such position sensor may preferably be a non-contacting magnetic type sensor that is designed for continuous output corresponding to the rotation angle of the magnetic actuator.
[0122] Such arrangement provides dual (that is, redundant) output signals to the engine at idle to WOT handle assembly 50 positions in forward and reverse. In accordance with the present subject matter, the position sensor 73 may be programmed (calibrated) during assembly of the Electronic Ski Control to allow more precise settings than standard preprogrammed position sensors and to eliminate mechanical manufacturing variations. Outputs may also be varied based on customer criteria or specialized needs (for example, such as half scale redundancy, inverse redundancy, or similar).
[0123] Handle Switches
[0124] The Electronic Ski Control may optionally in accordance with the present subject matter also be equipped with one or more switches in the knob 67 of handle assembly 50 (see FIGS. 8 and 9 ) used to control water craft mechanisms such as trim tabs, wedge hydrofoils, surf tabs, drives, etc. Wire leads from the switches may be integrated into the assembly wiring harness that exits from the assembly.
[0125] Emergency Stop Switches
[0126] The Electronic Ski Control may also be equipped with single or dual engine emergency stop switches (kill switches) mounted on the face 201 of the base plate of base assembly 200 (see FIG. 1 ). Such switches provide for an engine stop, such as in case of emergency. Wire leads from the switches may be integrated into the assembly wiring harness that exits from the assembly.
[0127] Mechanical Shift Mechanism
[0128] A further embodiment provides for push/pull shift cable functionality described in the Background of the Invention above, with a mechanical shift override which replaces the electronic shift control and electronic override modes while retaining other existing features.
[0129] With reference to FIGS. 12A , 12 B, 12 C, and 12 D, there are respectively illustrated Front View, Right View, Back View, and Left View of a further embodiment of the Electronic Ski Control Assembly showing an overview of the mechanical embodiments of the transmission shift and override features. Generally the operational features of this further embodiment remain the same as those previously described except that the function provided by the three switches illustrated in FIGS. 3-7 and their corresponding circuitry illustrated in FIG. 10 has been provided by mechanical elements.
[0130] More specifically, with reference to FIG. 12C , assembly generally 1200 is provided with a fixed arm 1202 including a clamp assembly 1204 configured to retain the outer shell of a cable (not separately illustrated) that may be mechanically coupled for push and/or pull operation of a transmission control of a watercraft. The cable includes an inner core that slides within the shell. The inner core may be attached to lever 1206 by way of cable pivot 1208 .
[0131] With brief reference to FIG. 15 , such various components may be seen with corresponding reference numbers in the 1500 series. For example, fixed arm 1502 together with clamp assembly 1504 may be employed to retain the outer shell of a control cable (not separately illustrated) while an inner core of the cable may be secured by way of cable pivot 1508 to a transmission controlling lever arm not visible in FIG. 15 ,
[0132] With reference now to FIG. 16 , there is illustrated an exploded view of the Main Assembly generally 1600 of an Electronic Ski control in accordance with a further embodiment of the present technology. As may be seen, arm 1602 corresponds to an extension of a cover plate for the assembly and cooperates with the previously mentioned clamp assembly (not illustrated in FIG. 16 ) to retain a transmission control cable outer shell. Also seen is lever 1606 , the end portion of which is coupled to an inner core of the control cable via a cable pivot (item 1508 in of FIG. 15 ). Lever 1606 is operated via cooperative engagement of a shift gear 1620 and drive gear 1630 .
[0133] Shift gear 1620 has coupled thereto a shaft 1622 , the flattened end 1622 of which is configured to fit into a rectangular slot 1618 in one end of lever 1606 . Drive gear 1630 may be rotated by operation of a handle sub-assembly ( FIG. 15 ) by way of shaft 1640 .
[0134] In normal operation, an inner shaft 1612 is inserted in an axial opening of shaft 1640 and has attached to one end thereof a drive pin 1616 which is normally biased by override spring 1652 so as to maintain drive pin 1616 in position within slots 1632 of drive gear 1630 . As more clearly seen in FIG. 18A , operational movement of handle sub-assembly 1802 produces rotation of drive gear 1830 as a result of rotation of shaft 1840 so long as drive pin 1816 is retained within slots 1832 formed in drive gear 1830 .
[0135] In override mode, an operator would push button 1510 which is retained on the end of shaft 1512 by means of, for example, screw 1514 ( FIG. 15 ) in the same manner that an operator would activate override switch 129 ( FIG. 1 ) of the first embodiment of the present technology. By operation of button 1510 , drive pin 1816 disengages from slots 1832 in drive gear 1830 , thereby preventing movement of lever 1606 and, consequently, inhibiting movement of any connected transmission controlling cable.
[0136] With further reference to FIG. 16 , it will be seen that cut magnet 1660 is configured with a central opening 1662 that receives flattened end portion 1624 of shaft 1640 . In this manner, operation of the handle sub-assembly also produces rotation of cut magnet 1660 and, consequently, operation of magnetically operated potentiometer 1664 whose output is coupled to the electronic throttle control in a manner similar to that of position sensor 73 ( FIG. 8 ) to control engine speed. It should be appreciated that rotation of cut magnet 1660 and, consequently, operation of potentiometer 1664 , is not affected by operation of the override mechanism wherein drive pin 1616 is disengaged from drive gear 1630 . In such manner, full throttle control is maintained while transmission control is overridden to permit, for example, starting operation of the engine or other engine “revving” operations.
[0137] While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art. | The present subject matter is directed to electronic circuitry and associated hardware configured to electronically control directional signals, i.e., neutral, forward and reverse signals, to the transmission of a watercraft. The circuitry provides for electronic control of the throttle position of the watercraft engine and electronic override of the transmission shifting circuitry to allow throttling up (i.e., revving) of the engine without placing the transmission into gear. In an alternative embodiment, directional control is effected by operation of a lever mechanism and override functionality is effected by manual disengagement of a drive mechanism for the directional control while maintaining operation of the electronic throttle control. | 1 |
FIELD OF THE INVENTION
This invention relates to a process for producing thermoplastic coated photographic paper by extrusion coating, and more particularly to a process for producing thermoplastic coated paper at high speed with good bond and few gel imperfections.
BACKGROUND OF THE INVENTION
This invention relates to a method for manufacturing resin coated paper support appropriate for use in photographic applications. Specifically, a technique is described where the polymeric resin layer can be laminated onto the paper base at high speed.
The maximum speed at which a polymeric coating can be applied to a photographic paper base is often limited by the bond strength between the paper and the polymer. As speed increases, the strength of the bond between the polymer and the paper tends to decrease. This is a key consideration in the manufacture of photographic paper supports, since chemicals used in the aqueous photographic processing will tend to penetrate into the support between the polymer and the paper if the bond is poor. This will leave unsightly marks around the edges of the paper after processing.
It is therefore necessary to compromise between a high speed production process and a high quality photographic product. One way to overcome this is to increase the temperature of the polymer. This method is appropriate as long as the temperature is not too high that decomposition of the polymer results in deleterious physical properties or photoactive substances which will fog the emulsion. Griggs (U.S. Pat. No. 3,582,337) claims polymer extrusion temperatures of from 304° C. to 343° C. to be used at speeds of between 61 and 305 m/min. Unfortunately, though these temperatures are adequate to assure reasonable bond, thermal degradation in the polyolefin results in occasional product imperfections (as mentioned in U.S. Pat. No. 5,503,968), which are not tolerable by today's discerning customers. These imperfections have since been reduced by the addition of antioxidants such as 4,4'-butylidene-bis(6-tert-butyl-meta-cresol). These antioxidants are adequate for reducing spot imperfections, however they also degrade bond considerably. Thus, it is no longer possible to run at the speeds claimed by Griggs and still achieve good bond at these temperatures.
Another way to overcome poor bond is to use corona discharge treatment as described in U.S. Pat. No. 3,411,908. This technique is applied to the paper base before laminating. The corona discharge technique tends to "activate" the surface resulting in better bond once the polymer is applied. Another technique which has been used is the application of flame as described in U.S. Pat. No. 5,147,678. This approach uses the flame caused by the burning of natural gas which impinges on the paper support. Again, this technique activates the paper, giving it better bond after the polymer is applied. One possible disadvantage of this technique is the possibility that flame treatment dries out the paper. Since moisture is necessary to facilitate the curing of the hardener in the photographic emulsion, this reduced moisture can diminish productivity in the sensitizing operation. Honma (U.S. Pat. No. 4,481,289) describes the use of ozone which can be applied to the molten polymer. This method activates the polymer instead of the paper support, again increasing the bond after the polymer is laminated onto the paper. In this application, Honma claims a maximum polymer extrusion temperature of 300° C. A maximum speed of 183 m/min is demonstrated which Lee (U.S. Pat. No. 5,503,968) points out is rather slow in today's environment. Lee describes a synergistic effect when flame is used in conjunction with ozone and demonstrates that speeds of greater than 400 m/min are possible. Unfortunately, as described above, this may have the disadvantage of drying the paper.
There is a great need for a polymer coating process which can be run at speeds greater than 305 m/min without drying the paper, creating gels, or creating photoactive products which will fog the photographic emulsion.
SUMMARY OF THE INVENTION
This invention describes a method for manufacturing a photographic support which includes providing a support and laminating a surface of the support with a polymer resin formulation containing from 0.001 to 1 weight percent antioxidant at a temperature of from 305° to 360° C. while exposing the polymer resin formulation to an ozone containing gas at a rate of greater than 0.1 mg/m 2 of said support.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the preparation of a thermoplastic coated paper for photographic paper base in accordance with this invention, a thermoplastic resin is prepared from any coatable polyolefin material known in the photographic art. Representative of these materials are polyethylene, polypropylene, polystyrene, polybutylene, and copolymers thereof. The polyolefin can be copolymerized with one or more copolymers including polyesters, such as, polyethylene terephthalate, polysulfones, polyurethane's, polyvinyls, polycarbonates, cellulose esters, such as cellulose acetate and cellulose propionate, and polyacrylates. Specific examples of copolymerizable monomers include vinyl stearate, vinyl acetate, acrylic acid, methylacrylate, ethylacrylate, acrylamide, methacrylic acid, methylmethacrylate, ethyl-methacrylate, methacrylamide, butadiene, isoprene, and vinyl chloride. Preferred polyolefins are film forming and adhesive to paper. For the emulsion side resin, Polyethylene of low density, between 0.91 g/cm 3 and 0.94 g/cm 3 is preferred. Polyethylene having a density in the range of from about 0.94 grams/cm 3 to about 0.98 grams/cm 3 is most preferred for the back side layer. The polyolefin to be applied to the side of the paper whereupon the photographic emulsion will be applied includes a suitable optical brightener such as those described in Research Disclosure Issue N. 308, December 1989, Publication 308119, Paragraph V, Page 998, in an amount of from about 0.001 to about 0.25 percent by weight based on the total weight of the polyolefin coating, including any white pigment present, with 0.01 to about 0.1 percent being the most preferred. Any suitable white pigment may be incorporated in the polyolefin layer, such as, for example, titanium dioxide, zinc oxide, zinc sulfide, zirconium dioxide, white lead, lead sulfate, lead chloride, lead aluminate, lead phthalate, antimony trioxide, white bismuth, tin oxide, white manganese, white tungsten, and combinations thereof. The pigment is used in any form that is conveniently dispersed within the polyolefin. The preferred pigment is titanium dioxide in the anatase crystalline form. Preferably, the white pigment should be employed in the range of from about 3 to about 35 percent by weight, based on the total weight of the polyolefin coating. Anatase titanium dioxide at from about 5 to about 20 percent is most preferred.
In addition to the brightener mixture and the white pigment, the polyolefin coating must contain an antioxidant such as 4,4'-butylidene-bis(6-tert-butyl-meta-cresol), di-lauryl-3,3'-thiodipropionate, N-butylated-p-aminophenol, 2,6-di-tert-butyl-p-cresol, 2,2-di-tert-butyl-4-methyl-phenol, N,N-disalicylidene-1,2-diaminopropane, tetra(2,4-tert-butylphenyl)-4,4'-diphenyl diphosphonite, octadecyl 3-(3',5'-di-tert-butyl-4'-hydroxyphenyl propionate), combinations of the above, and the like, in concentrations of from 0.001% to 1%. Heat stabilizers may be included, such as higher aliphatic acid metal salts such as magnesium stearate, calcium stearate, zinc stearate, aluminum stearate, calcium palmitate, sodium palmitate, zirconium octylate, sodium laurate, and salts of benzoic acid such as sodium benzoate, calcium benzoate, magnesium benzoate and zinc benzoate; calcium stearate of concentrations between 0.1 and 1.0% with 0.4-0.6% being most preferred. Addition of antistatic agents; lubricants; dyes; and the like, is well known to those skilled in the art. Additionally, emulsion side resins can contain one or more pigments, such as the blue, violet or magenta pigments described in U.S. Pat. No. 3,501,298, or pigments such as barium sulfate, colloidal silica, calcium carbonate and the like, with the preferred colorant combination consisting of cobalt aluminate and quinacridone, present in concentrations of between 0.02 to 0.5% and 0.0005 to 0.05% respectively, with the most preferred concentrations being from 0.1 to 0.2% and 0.001 to 0.003% respectively.
The back side resin also can consist of any extrudable polymer known in the photographic art, and contains from 0.01 to 1% of an antioxidant such as those previously mentioned.
The paper base material employed in accordance with the invention can be any paper base material which has heretofore been considered useful for a photographic support. The weight and thickness of the support can be varied depending on the intended use. A preferred weight range is from about 20 g/m 2 to about 500 g/m 2 , with about 100-200 g/m 2 being the most preferred. Preferred thickness (those corresponding to commercial grade photographic paper) are from about 20 μm to about 500 μm with the most preferred thickness being from 100-200 μm. It is preferred to use a paper base material calendered to a smooth surface. The paper base material can be made from any suitable paper stock preferably comprising hard or softwood. Either bleached or unbleached pulp can be utilized as desired. The paper base material can also be prepared from partially esterified cellulose fibers or from a blend of wood cellulose and a suitable synthetic fiber such as a blend of wood cellulose and polyethylene fiber.
As is known to those skilled in the art, the paper base material can contain, if desired, agents to increase the strength of the paper such as wet strength resins, e.g., the amino-aldehyde or polyamide-epichlorohydrin resins, and dry strength agents, e.g., starches, including both ordinary starch and cationic starch, or polyacrylamide resins. In a preferred embodiment of this invention, the amino-aldehyde or polyamide-epichlorohydrin and polyacrylamide resins are used in combination as described in U.S. Pat. No. 3,592,731. Other conventional additives include water soluble gums, e.g., cellulose ethers such as carboxymethyl cellulose, sizing agents, e.g., aldyl ketene dimers, sodium stearate which is precipitated on the pulp fibers with a polyvalent metal salt such as alum, aluminum chloride or aluminum salts.
Prior to the polyolefin extrusion step, the paper is treated with a corona discharge to improve the adhesion of the polyolefin to the paper support as described in U.S. Pat. No. 3,411,908.
The emulsion side polymer is melted and extruded through a coathanger die, horseshoe die, T-die or other die at a temperature of from 305° C. to 360° C., and exposed to an ozone stream with an ozone concentration of greater than 0.03 g/m 3 , at an application rate of greater than 1 mg/m 2 . The polymer is then brought into contact with the paper and laminated between a metallic chill roll and a polymer backing roll as is well known in the art.
The invention will be further illustrated by the following examples. In the bond tests used in the examples, the technique used to measure bond strength is TAPPI Std T 539 cm-88.
EXAMPLE 1
(Control)
The back side resin, consisting of 99.9% polyethylene of density 0.945 g/cc, is melted in a single screw extruder and is forced through a coat hanger die at a melt temperature of 330° C., and laminated with photographic grade paper support where the thickness of the paper is 165 μm, and the thickness of the polymer layer is 25 μm. The paper leaves the laminator at 310 m/min with poor bond.
EXAMPLE 2
Same as Example 1, except the melt curtain is treated with ozone at a rate of 60 mg/m 2 of support. The bond is very good.
EXAMPLE 3
Same as example 2, except the paper leaves the laminator at 350 m/min. The bond is still very good.
EXAMPLE 4
Same as example 2 except the melt temperature is 310° C. The bond is still very good.
EXAMPLE 5
Same as example 4 except the paper leaves the laminator at 350 m/min. The bond is still very good.
EXAMPLE 6
Same as example 2 except an emulsion side resin is used, consisting of 85.68% polyethylene of density 0.925 g/cc, 12.5% anatase TiO 2 , 3.0% ZnO, 5% calcium stearate, 0.1%, 4,4'-butadiene-bis(6-tert-butyl-meta-cresol), and 0.05% bis(benzoxazolyl)-stilbene, and the a silver halide emulsion is coated on the resin. The emulsions were chemically and spectrally sensitized as described below.
Blue Sensitive Emulsion (Blue EM-1, prepared similarly to that described in U.S. Pat. No. 5,252,451, column 8, lines 55-68): A high chloride silver halide emulsion was precipitated by adding approximately equimolar silver nitrate and sodium chloride solutions into a well-stirred reactor containing gelatin peptizer and thioether ripener. Cs 2 Os(NO)Cl 5 dopant was added during the silver halide grain formation for most of the precipitation, followed by a shelling without dopant. The resultant emulsion contained cubic shaped grains of 0.76 μm in edge length size. This emulsion was optimally sensitized by the addition of a colloidal suspension of aurous sulfide and heat ramped up to 60° C. during which time blue sensitizing dye BSD-1, 1-(3-acetamidophenyl)-5-mercaptotetrazole and potassium bromide were added. In addition, iridium dopant was added during the sensitization process.
Green Sensitive Emulsion (Green EM-1): A high chloride silver halide emulsion was precipitated by adding approximately equimolar silver nitrate and sodium chloride solutions into a well-stirred reactor containing gelatin peptizer and thioether ripener. Cs 2 Os(NO)Cl 5 dopant was added during the silver halide grain formation for most of the precipitation, followed by a shelling without dopant. Iridium dopant was added during the late stage of grain formation. The resultant emulsion contained cubic shaped grains of 0.30 μm in edge length size. This emulsion was optimally sensitized by addition of green sensitizing dye GSD-1, a colloidal suspension of aurous sulfide, heat digestion followed by the addition of 1-(3-acetamidophenyl)-5-mercaptotetrazole and potassium bromide.
Red Sensitive Emulsion (Red EM-1): A high chloride silver halide emulsion was precipitated by adding approximately equimolar silver nitrate and sodium chloride solutions into a well-stirred reactor containing gelatin peptizer and thioether ripener. The resultant emulsion contained cubic shaped grains of 0.40 μm in edge length size. This emulsion was optimally sensitized by the addition of a colloidal suspension of aurous sulfide followed by a heat ramp, and further additions of 1-(3-acetamidophenyl)-5-mercaptotetrazole, potassium bromide and red sensitizing dye RSD-1. In addition, iridium dopant was added during the sensitization process.
Coupler dispersions were emulsified by methods well known to the art, and the following layers were coated on a polyethylene resin coated paper support, that was sized as described in U.S. Pat. No. 4,994,147 and pH adjusted as described in U.S. Pat. No. 4,917,994. The polyethylene layer coated on the emulsion side of the support contained a mixture of 0.1% (4,4'-bis(5-methyl-2-benzoxazolyl) stilbene and 4,4'-bis(2-benzoxazolyl) stilbene, 12.5% TiO 2 , and 3% ZnO white pigment. The layers were hardened with bis(vinylsulfonyl methyl) ether at 1.95% of the total gelatin weight.
______________________________________Layer 1: Blue Sensitive LayerGelatin 1.530 g/m.sup.2Blue Sensitive Silver (Blue EM-1) 0.280 g Ag/m.sup.2Y-1 1.080 g/m.sup.2Dibutyl phthalate 0.260 g/m.sup.22-(2-butoxyethoxy)ethyl acetate 0.260 g/m.sup.22,5-Dihydroxy-5-methyl-3-(1-piperidinyl)-2-cyclo- 0.002 g/m.sup.2penten-1-oneST-16 0.009 g/m.sup.2Layer 2: InterlayerGelatin 0.753 g/m.sup.2Dioctyl hydroquinone 0.094 g/m.sup.2Dibutyl phthalate 0.282 g/m.sup.2Disodium 4,5 Dihydroxy-m-benzenedisulfonate 0.065 g/m.sup.2SF-1 0.002 g/m.sup.2Layer 3: Green Sensitive LayerGelatin 1.270 g/m.sup.2Green Sensitive Silver (Green EM-1) 0.263 g A g/m.sup.2M-1 0.389 g/m.sup.2Dibutyl phthalate 0.195 g/m.sup.22-(2-butoxyethoxy)ethyl acetate 0.058 g/m.sup.2ST-2 0.166 g/m.sup.2Dioctyl hydroquinone 0.039 g/m.sup.2Phenylmercaptotetrazole 0.001 g/m.sup.2Layer 4: UV InterlayerGelatin 0.484 g/m.sup.2UV-1 0.028 g/m.sup.2UV-2 0.159 g/m.sup.2Dioctyl hydroquinone 0.038 g/m.sup.21,4-Cyclohexylenedimethylene bis(2-ethyl- 0.062 g/m.sup.2hexanoate)Layer 5: Red Sensitive LayerGelatin 1.389 g/m.sup.2Red Sensitive Silver (Red EM-1) 0.187 g Ag/m.sup.2C-3 0.424 g/m.sup.2Dibutyl phthalate 0.414 g/m.sup.2UV-2 0.272 g/m.sup.22-(2-butoxyethoxy)ethyl acetate 0.035 g/m.sup.2Diocty1 hydroquinone 0.004 g/m.sup.2Potassium tolylthiosulfonate 0.003 g/m.sup.2Potassium tolylsulfinate 0.0003 g/m.sup.2Layer 6: UV OvercoatGelatin 0.484 g/m.sup.2UV-1 0.028 g/m.sup.2UV-2 0.159 g/m.sup.2Dioctyl hydroquinone 0.038 g/m.sup.21,4-Cyclohexylenedimethylene bis(2-ethyl- 0.062 g/m.sup.2hexanoate)Layer 7: SOCGelatin 1.076 g/m.sup.2Polydimethylsiloxane 0.027 g/m.sup.2SF-1 0.009 g/m.sup.2SF-2 0.004 g/m.sup.2Tergitol 15-S-5 ™ 0.003 g/m.sup.2DYE-1 0.018 g/m.sup.2DYE-2 0.009 g/m.sup.2DYE-3 0.007 g/m.sup.2______________________________________
The paper/polyethylene bond was very good.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | This invention describes a method for manufacturing a photographic support which includes providing a support and laminating a surface of the support with a polymer resin formulation containing from 0.001 to 1 weight percent antioxidant at a temperature of from 305° to 360° C. while exposing the polymer resin formulation to an ozone containing gas at a rate of greater than 0.1 mg/m 2 of said support. | 6 |
I. FIELD OF THE INVENTION
[0001] The present invention relates generally to detecting and logging signals from a TV remote control that can later be reviewed.
II. BACKGROUND OF THE INVENTION
[0002] Television filtering devices known as V-chips have been provided that can be used to prevent certain programs from being displayed on a TV. A parent, for example, can instruct the V-chip not to display programs with certain ratings. In this way, a parent can ensure that certain programs will not be viewed by a child when the parent is away.
[0003] It will readily be appreciated that V-chips depend on the ratings of programs. These ratings are not assigned by the parent, but rather by the broadcaster or content provider or some other external agency, meaning that all parents in essence are at the mercy of the rating discretion that is exercised by a third party or unknown entity. It happens that many programs which are given normally acceptable ratings, e.g., “general audience” ratings, might in fact be highly objectionable to some parents. Violent cartoons, music shows featuring profane, infantile chants, and the like all might be given ratings that skirt under the levels set by the parents for blocking objectionable content through V-chip or similar blocking technology.
[0004] As recognized herein, one way to empower parents to address the above problem is to provide them with a way to review what their child has viewed while alone. As further understood herein, tracking a child's channel selections can be challenging if not impossible with existing TVs.
SUMMARY OF THE INVENTION
[0005] An interceptor includes a processor and an infrared interceptor receiver receiving TV channel commands originating from a TV remote control. The receiver communicates the commands to the processor. In response, the processor accesses a database to correlate the commands to TV programs and to generate a log of programs displayed on a TV, with the log being displayed on an output device.
[0006] In some embodiments the processor and receiver are in an interceptor housing that is separate from the TV. Thus, the TV includes a TV wireless command receiver separate from the interceptor receiver. In another embodiment the processor and receiver are in a TV housing, with the processor being implemented by a TV processor and with the receiver being implemented by a TV wireless command receiver. In still other embodiments, the interceptor housing does not implement a set-top box, while in still other embodiments the interceptor housing does implement a set-top box.
[0007] If desired, in non-limiting implementations in response to detecting a power on signal originated by the remote control, the processor sends a command to the TV to cause the TV to tune to a predetermined channel. An extender may be provided for receiving IR signals from a TV remote control and relaying the signals in RF to an extender on the interceptor. The extender on the interceptor transforms the signals from RF to IR.
[0008] In another aspect, a method for logging television use includes receiving channel change signals from a TV remote control, correlating the channel change signals to TV programs, and displaying a log of the programs to a user. If desired, the log can be displayed only upon input of proper authentication information.
[0009] In another aspect, a system includes a TV defining a TV chassis and a remote control configured for sending wireless command signals to the TV. A set-top box communicates with the TV and defines a STB housing. An interceptor is in a housing that can be separate from the TV chassis and set-top box housing and that receives signals from the remote control. The interceptor logs the signals.
[0010] The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a non-limiting hardware block diagram of a system in accordance with present principles, with portions of the STB and TV cutaway for clarity; and
[0012] FIG. 2 is a flow chart of non-limiting logic in accordance with present principles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] Referring initially to FIG. 1 , a system is shown, generally designated 10 , which includes a television 12 defining a TV chassis 13 and receiving, via a set-top box (STB) 14 defining a STB housing 15 , audio video TV programming from a head-end 16 , such as a cable or satellite head-end, over a wired or wireless link 17 . The STB 14 and TV 12 are examples of receivers. “Set-top box” also includes set-back boxes. While the STB 14 is shown separately housed from the chassis 18 of the TV 12 , it is to be understood that the functionality of the STB 14 may be incorporated into the chassis 18 .
[0014] As shown, the STB 14 includes a STB processor 20 and a computer readable medium 22 such as volatile or non-volatile solid state storage, disk storage, tape storage, or other type of electronic storage medium or logic circuitry that typically can be executed by the processor 20 . The STB 14 typically includes a wireless receiver such as an infrared (IR) receiver 24 for receiving channel, volume, and other commands from a hand-held wireless transceiver 26 on a TV remote control 28 . The receiver 24 communicates with the STB processor 20 . Likewise, a TV wireless receiver 30 may be provided on the TV housing and may communicate with the TV processor discussed below for sending commands from the remote control 28 to the TV processor.
[0015] Additionally, as shown the TV 12 typically includes a TV processor 32 and data storage medium 34 . Video may be presented on a display 36 of the TV 12 , e.g., a flat panel matrix display, cathode ray tube, or other appropriate video display.
[0016] A wireless interceptor 38 is shown that includes an interceptor receiver 40 communicating with an interceptor processor 42 . The interceptor processor 42 may communicate with an electronic storage medium 44 , which can bear data and logic executable by the interceptor processor 42 . If desired, a display 46 may be provided on the interceptor 38 .
[0017] Furthermore, an extender receiver 48 can be provided on the interceptor 38 in non-limiting embodiments, and the extender receiver 48 can communicate wirelessly by, e.g., radiofrequency with an extender 50 that may be physically positioned near, e.g., just in front of, the TV receiver 30 to receive IR command signals, transform them into RF, and send the transformed signals to the extender receiver 48 of the interceptor 38 for conversion, back to IR if desired. The process can be reversed between the receiver 48 and extender 50 . In any case, this facilitates hiding the interceptor 38 from view of children if desired.
[0018] As also shown in FIG. 1 , the interceptor 38 may communicate with a database 52 to obtain channel-by-channel program information correlated by time. The database 52 may be accessed over the Internet or it may be stored on, e.g., the TV medium 34 and/or STB medium 22 in electronic program guide (EPG) format.
[0019] It is to be understood that the logic shown herein is implemented on one or more of the TV 12 , and/or STB 14 , and/or interceptor 38 . It is to be further understood that the interceptor 38 may be physically integrated with the TV 12 or STB 14 , and thus in some implementations the logic set forth below may be executed by the STB processor 20 and/or the TV processor 32 , with a physically separate interceptor omitted. It, may now be understood that the interceptor 38 may be provided as shown as a standalone device in an interceptor housing 39 that does not require retrofitting of existing TVs and STBs, and thus may not communicate at all with the TV 12 . In other embodiments the interceptor 38 may communicate with the TV 12 only for purposes of displaying a channel history on the TV display 36 , and in still other embodiments the TV processor 32 and/or STB processor 20 can be programmed to execute the logic set forth below.
[0020] Turning now to FIG. 2 , to synchronize the interceptor 38 with the channel of the TV (or equivalently, when the channel is being controlled by signaling the STB 14 , the channel of the STB), when the interceptor detects a power-on signal at block 54 from the remote 28 to the TV 12 (or STB 14 ), the interceptor 38 commands the TV 12 (or STB 14 ) to tune to a predetermined channel at block 56 . The interceptor 38 may be provided with an IR or RF transmitter for this purpose, as appropriate.
[0021] Since the interceptor 38 is now synchronized with the TV 12 (or STB 14 ) by forcing the TV/STB into a state known to the interceptor 38 , all later channel up/down commands snooped from the remote control 28 can be used to ascertain the accessed channel. The interceptor 38 checks whether it has missed a transmission (and hence made an error for the previous log entry) by comparing sequence numbers in the transmitted packets.
[0022] For example, if the present sequence number of packets from the remote control 28 that the interceptor 38 has sniffed/snooped from the wireless medium is #4324, and the last sequence number interceptor 38 saw was #4322, then the interceptor 38 can assume it has missed a transmitted command, in which case it may resynch with the TV/STB by repeating the process at block 56 . In addition, if the interceptor 38 detects an “acknowledge” packet sent from the TV/STB to the remote control 28 but did not see the packet that is being acknowledged, the interceptor 38 may similarly assume it has missed a packet from the remote control to the TV/STB, and resynchronize accordingly.
[0023] If desired, to prevent bypassing the interceptor 38 by manually changing channels using the “channel up/down” buttons on the TV chassis 13 and/or on the STB housing 15 , a keyword protected menu option of disabling the “channel up/down” buttons on the TV chassis/STB housing may be provided. Or, the channel up/down buttons on the chassis 13 /housing 15 may be mechanically disabled by, e.g., depositing adhesive onto them.
[0024] Alternate synchronization methods may be used. For example, in addition to or in lieu of the above, the interceptor 38 may also perform speech recognition on the TV sound, and then compare the recognized speech to a database containing soundtrack/closed captioned information of the program it thinks is being watched, to confirm that the user is watching the same channel. If a discrepancy exists, the interceptor 38 may either try to resynchronize by finding which program is actually being watched (by comparing speech recognition of TV sound with soundtrack of the channel obtained from a database or closed caption information), or the interceptor 38 may simply force the TV/STB into a known channel by transmitting a “tune to channel x” command to the TV.
[0025] Once synchronized, the logic can move to block 58 to receive IR (or RF) wireless channel signals from the remote 28 . The channel signals can include channel up/down signals as well as channel number signals. The signals preferably are timestamped at block 60 , so that when each channel is tuned to and the length of time it is tuned to, along with the channel number itself, preferably is recorded in a data log.
[0026] At block 62 , the database 52 preferably is accessed to correlate the channel numbers to associated programs by, e.g., program name and/or rating and/or other program metadata. The log showing the times and channel numbers/programs to which the TV/STB were tuned can be presented at block 64 on, e.g., the TV display 36 or the display 46 of the interceptor 38 . The display of the log may be permitted only upon receipt of proper authentication information, e.g., a parental password, so that only authorized people can view the log.
[0027] In non-limiting implementations, recognizing that Internet Protocol addresses can be tracked, data from the International Standard Audiovisual Number (ISAN) system, which may be part of the program metadata, can be used to create the log.
[0028] In another implementation, the log generated by the interceptor 38 can be provided for a fee to third parties such as TV ratings agencies.
[0029] When the present interceptor logic is implemented by the STB 14 (e.g., in a set-back box implementation), tuning data can be obtained using a universal serial bus (USB) link from the TV 12 to the STB 14 , and since a broadband connection may also be provided between the two components, the STB 14 can implement the logic of FIG. 2 , and also to provide this viewer preference data to third parties if the user chooses.
[0030] While the particular TV REMOTE CONTROL SIGNAL LOG is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. | An interceptor detects command signals from a TV remote control and logs the signals. The signals can be correlated not just to channel number but also to programs by accessing a program/channel database. A log of channels/programs that have been viewed by, e.g., a child can thus be obtained and viewed by a parent. | 7 |
FIELD OF THE INVENTION
This invention relates to purification of oxygenated gaseous effluents polluted by nitrogen oxides.
BACKGROUND OF THE INVENTION
Residual gases coming from production of nitric acid, apparatus for pickling of metals with acids, thermal decomposition of nitrates, etc. contain a high concentration of nitrogen oxides NO 2 , which are polluting compounds because of their corrosive action and the contamination of the air that they cause.
To combat industrial pollution it is necessary to have means for eliminating toxic wastes, including nitrogen oxides produced in combustions of any origin.
It has been known for seveal decades, especially from the teaching of German patent No. 1,088,938, that oxygen is eliminated during catalytic reduction of nitrogen oxides with fuels. With this process, fuel consumption is high and the great amount of released heat causes an accelerated degradation of the catalyst and a loss of its activity.
It has been proposed to subject the oxygenated gaseous effluents containing nitrogen oxides to a selective reaction with ammonia, the presence of oxygen not interfering with this type of reduction. According to French patent 1,205,311, this reaction is catalyzed by metals of the platinum group or metals of the iron group according to French patent 1,233,712. However, these catalysts as described, after a certain period of use, undergo, in the presence of ammonia and nitrogen dioxide NO 2 , a change involving a reduction of their catalytic efficiency.
Further, it is known to submit the oxygenated gaseous effluents containing nitrogen oxides to a selective reduction in the presence of vanadium pentoxide deposited on alumina, especially from French patent 1,412,713. However, catalysts comprising a transition metal oxide as an active component do not promote the reduction of nitrous oxide (N 2 O).
In the technical field of purification of gaseous effluents polluted by nitrogen oxides, by selective reduction of said oxides with ammonia leading to the production of nonpolluting nitrogen and water products, French patent 2,413,128 describes catalytic compositions containing as active elements, iron and chromium in the form of oxides associated with alumina and at least one promoter selected from rare earth oxides alone or in combination and rare metals accompanying platinum ores. These catalysts are applicable with satisfactory results in a purification process at a temperaure between 120° and 350° C.
It was desirable to extend the zone of using the process of reduction of nitrogen oxides to the higher temperatures. Actually, in many cases the effluents to be treated had a temperature greater than 300° C.; and it was advisable to avoid resorting to heat exchangers to cool then heat the gases to achieve a gain in investment and a saving in operation.
Further, the fact of performing the selective reduction by ammonia at higher temperature makes possible the purification of effluents containing, besides nitrogen oxides, sulfur oxides; these latter do not combine, at this temperature level, with ammonia to form ammonium sulfate which causes a deactivation of the catalyst.
French application 2,568,789 proposed a reduction process, denitrification of ammonia of residual gases in the presence of a zeolite of the type of substitution with hydrogen and/or iron, at a surface velocity of 5 m/h or less with a ratio of the ammonia NH 3 concentration to the nitrogen dioxide NO 2 concentration of 1.3 or more, in particular 1.6 or more.
The catalyst, seeming to have been tested only on a laboratory scale, was prepared by immersion of a natural or synthetic zeolite in hydrochloric acid, an aqueous solution of ferric chloride or an aqueous solution of ferric nitrate Fe(NO 3 ) 3 , then calcination at about 500° C. The tests were conducted in the presence of mordenite with substitution with H, Fe obtained by replacing 42% of equivalent of Na, K and Ca contained in the mordenite with hydrogen and 35% of equivalent for iron.
A resistant catalyst was sought making it possible to obtain equivalent purification performances in extensive fields of application and at all nitrogen oxides contents, by using a lower NH 3 /NO x ratio, while performing the reaction of reduction of nitrogen oxides at high temperature and at volumetric speeds of circulation of gases which can be high.
SUMMARY OF THE INVENTION
According to the present invention, the catalytic compositions for selective reduction of nitrogen oxides contained in the oxygenated gaseous effluents, by ammonia, contain, as active material, mordenite in ammonium or acid form with a residual sodium content less than 1000 ppmw (parts per million by weight) in a proportion between 70 and 95% of the total weight of the catalytic composition, the complement comprising a binder.
The basic mordenite is in sodium form and its catalytic activity is very slight in the reduction of nitrogen oxides by ammonia. Preparation of the catalytic compounds of the invention resort to techniques of exchange of the mordenite.
The exchange of sodium ions Na + with ammonium ions NH 4 + is performed by treatment of the sodium mordenite with a solution of ammonium nitrate in a stirred reactor. The rate of exchange is limited by thermodynamics, and the speed of reaction is a function of the temperature of the medium. In the case of mordenite, the reaction is very rapid, in particular, at a temperature close to 100° C., the thermodynamic equilibrium is reached in less than 10 minutes. The exchange treatment is performed during a period slightly greater than 10 minutes at a temperature on the order of 100° C. Obtaining a very low sodium content implies an elimination of the extracted sodium to shift the thermodynamic equilibrium.
After the ion exchange phase, the mordenite is partially separated by filtering, then subjected to a washing operation with demineralized water.
Then the partially exchanged mordenite is subjected to a second exchange treatment with an ammonia nitrate solution, under the same conditions as above, followed by a separation by filtering and washing with demineralized water.
It has been found that two cycles each corresponding to a sequence--exchange-filtering-washing--are sufficient to lower the sodium content below 1000 parts per million by weight.
The product obtained is then subjected to drying at a temperature on the order of 120° C. for a period of 10 to 20 hours, after which it is subjected for several hours to an operation of mixing with a binder.
The binder used is an element of the group consisting of kaolinite clay (Si 2 Al 2 O 5 (OH) 4 ), bentonite, alumina, alone or in combination.
The catalytic composition obtained is packaged in a suitable form, such as pellets, or preferably extrudates.
Then drying is performed for several hours at a temperature between 100° and 120° C.
Then to obtain the acid mordenite, the product obtained after the previous drying is subjected to a heat treatment under a strong flow of dry air, at a minimum of 1 to 2 Nm 3 h -1 /l of catalyst, in a crosswise bed, with progressive raising of the temperature of 50° to 100° C./h to a temperature between 450° to 550° C., maintaining this temperature level for 5 to 10 hours.
The specific surface measured according to the BET method, nitrogen adsorption at the temperature of liquid nitrogen--of catalytic compositions in acid form is between 200 and 300 m 2 /g and the diameter of macropores--measured on a mercury porosimeter--between 40 and 15,00 Å essentially.
The catalytic compositions of the invention are applicable with great success in a process of purification, in the presence of ammonia, of oxygenated gaseous effluents containing nitrogen oxides (NO x ) at a temperature between 300° and 550° C., under a pressure of at least 0.1 MPa absolute, with an hourly volume velocity HVV of circulation of gases, which can be brought up to 80,000 h -1 , and a ratio of the ammonia concentration to the nitrogen oxide concentration NH 3 /NO x at most equal to 1.25.
The purification process can be performed in the presence of a mordenite according to the invention in ammonium form in a temperature zone of 300° to 375° C., or in acid form in a zone of 300° to 550° C.
Increase of pressure has a favorable influence on the activity of the purification catalysts, also the process of reduction of nitrogen oxides is advantageously performed at the highest pressure possible; very satisfactory results are obtained for pressures between 0.15 MPa and 1 MPa.
The process of reduction of nitrogen oxides in the presence of catalytic compositions with a base of ammonium or acid mordenite with a residual sodium content of less than 1000 ppmw, leads to quite remarkable purification efficiencies and yields with slight amounts of ammonia added to the oxygenated effluent to be treated relative to the content of said effluent in nitrogen oxides. It is possible to obtain very satisfactory results with ratios expressed in moles NH 3 /moles NO x between 1.05 and 1.2; a ratio of 1.1 can be advantageously selected.
According to a variation of the present invention in the catalytic composition comprising, as an active material, exchanged mordenite representing 70 to 95% of the total weight of said composition rounded out by a binder, the mordenite is exchanged with copper ions.
The mordenite used is the so-called industrially synthesized "small-pore" variety. This form is called small-pore in contrast with the "large-pore" form which is also synthetic. In both cases, the same structure is involved, but with different adsorption properties. The large-pore form adsorbs benzene (kinetic diameter 6.6 10 -10 m, whereas the small-pore form adsorbs only molecules with kinetic diameter less than about 4.4 10 -10 m. These two types of zeolites are also distinguished by morphological differences. The small-pore type mordenite cystallizes as needles, whereas the large-pore type mordenite crystallizes as spherulites.
The small-pore mordenite, of elementary formula Na 7 ((AlO 2 ) 7 (SiO 2 ) 40 ), 24H 2 O, shows an Si/Al ratio measured by fluorescence X of about 6; the sodium content which results from this Si/Al structure ratio is close to 5.2% by weight (relative to the dry product 1000° C.). The volume of the crystalline lattice (orthorhombic system) is close to 2770 Å 3 .
This small-pore mordenite is synthesized in its sodium form and its catalytic activity, in this form, like those of other sodium zeolites, is very slight.
It has been found that substitution by exchange of sodium ions totally or partially with copper ions makes it possible to obtain a very high-performance catalyst for catalytic reduction with ammonia of nitrogen oxides contained in the oxygenated gaseous effluents.
This catalytic composition contains as active material, a so-called small-pore mordenite adsorbing only molecules with a kinetic diameter less than about 4.4·10 -10 m, and crystallizes as needles, exchanged with copper cations, representing between 1 and 5% of the total weight of said composition, the complement being made up by a binder.
The presence of copper in the active exchanged mordenite, in the form complexed by ammonia Cu(NH 3 ) 4 2+ , was found to be very advantageous.
The binder used is an element of the group consisting of kaolinite clay (Si 2 Al 2 O 5 (OH) 4 ), bentonite, alumina, alone or in combination.
The catalytic compositions are packaged in a suitable form, such as pellets or extrudates.
These catalytic compositions can be obtained directly from the sodium form without prior transformation to the ammonium or acid form; however, it has been found that the catalytic activity is reinforced if the ammonium form is selected as starting product.
Copper cations are introduced by exchange with sodium Na + or ammonium NH 4 + ions. This exchange reaction can be performed on the zeolite in the form of powder or on it after shaping with a suitable binder.
When the starting product consists of small-pore mordenite, in powder, in sodium or ammonium form, it is subjected to at least two cation exchange cycles by being put in contact with a copper tetramine solution at a temperature between 20° and 80° C., preferably 40° to 60° C., followed by separation of the exchanged mordenite by filtering and washing with demineralized water, then drying at controlled temperature to obtain the separation of water under the gentlest conditions possible, then the resulting material is mixed with a suitable binder, and the catalytic composition is shaped.
When the exchange reaction is used on the packaged product, the small-pore mordenite powder in sodium or ammonium form is mixed with a suitable binder, after adjustment of the moisture, shaping and drying. The preshaped products are subjected to a heat treatment between 300° and 500° C., said preforms are then subjected to at least one cation exchange treatment by being put in contact with a copper tetramine solution, at a temperature between 20° and 80° C., preferably 40° to 60° C., followed by separation by filtering, washing with demineralized water, then drying of the catalytic composition at controlled temperature to obtain separation of water under the gentlest conditions possible.
Introduction of copper cations in its form complexed by ammonia Cu(NH 3 ) 4 2+ is achieved by means of a solution of copper tetramine, resulting from the reaction of copper nitrate and ammonia.
The rate of exchange between sodium Na + and ammonium NH 4 + ions with copper cations Cu ++ can be increased either by multiplying the number of exchange cycles or by raising the temperature of this exchange.
It has been found that the exchange of small-pore mordenite with copper ions Cu ++ leads to obtaining very remarkable catalysts.
The catalytic compositions can be used for purification, in the presence of ammonia, of oxygenated gaseous effluents contaning nitrogen oxides (NO) x , at a temperature between 225° and 400° C., under pressure of at 0.1 MPa absolute with an hourly volume velocity HVV of circulation of gases, which can be raised and reach 80,000 h -1 , and a ratio of ammonia concentration to nitrogen oxides concentration NH 3 /NO x at most equal to 1.25.
Excellent yields are obtained in this type of purification, with molar ratios NH 3 /NO x between 1.05 and 1.2; a ratio of 1.15 can advantageously be chosen.
The influence of the pressure is comparable to that observed with ammonium mordenite without copper cations.
The advantage of copper exchanged catalytic compositions resides in the performance of the purification operation at low temperature. Very satisfactory results are obtained at 250° C., whereas it is necessary to operate above 300° C. with preceding other catalysts.
The copper exchanged catalytic compositions make it possible to combine very high purification yields greater than 98% with amounts of ammonia very close to stoichiometry and especially very slight contents of residual ammonia after reaction, which represents an undeniable advantage for this type of catalyst.
The purification process used on the catalytic compositions of the invention are particularly well suited for depollution of residual gas rejected into the atmosphere in the production of nitric acid.
The process is extremely flexible, suited to purification of gaseous effluents with any nitrogen oxide contents, even in the presence of sulfur oxides. The efficiency of the process is remarkable even at high NO x contents on the order of 20000 ppm and also at slight nitrogen oxide contents on the order of 100 ppmv.
These catalytic compositions are resistant industrial products which do not undergo any mechanical deterioration or loss of activity after very long periods of operation.
DETAILED DESCRIPTION OF THE INVENTION
Examples are given below of the preparation of the catalytic composition and its use, which illustrate the invention in a nonlimiting way.
EXAMPLE 1
Preparation of Catalyst No. 1
Into a reactor with 150 liters of useful volume are introduced 100 liters of ammonium nitrate solution at 300 grams per liter, and 25 kg, figured in dry material, of small-pore sodium mordenite, of the elementary formula Na 7 ((AlO 2 ) 7 (SiO 2 ) 4O ), 24H 2 O, and with an initial sodium content of 5.9% by weight of dry product.
The suspension is stirred for 15 minutes at 100° C. The mordenite is recovered by filtering on a band filter of 0.1 m 2 of filtering surface and washed on the filter with 100 liters of demineralized water. At the filter output, the water content of the drained mass is 55% by weight. The sodium content, relative to dry material, of the mordenite is 4000 ppmw.
The drained mass is picked up and retreated under the same ion exchange and filtering conditions. After washing with 300 liters of demineralized water to eliminate all the extracted sodium, the product is dried at 120° C. in an oven for 10 hours. A very pulverulent powder is obtained whose residual sodium content is 900 ppmw of dry material.
Then, the powder is mixed for four hours with a binder made up of 75% by weight of kaolinite clay and 25% by weight of bentonite, at a rate of 20% by weight, of dry material, relative to the total weight.
The mixture obtained is subjected to extrusion, and the extrudates of 4.8 millimeters in diameter are subjected to drying at 120° C. for 3 hours.
EXAMPLE 2
This example illustrates use of catalyst No. 1 in ammonium form, under various operating conditions, by using residual gases of an industrial nitric acid unit. The results are given in table I below.
The process of reduction by ammonia of nitrogen oxides contained in residual gases is performed under a pressure varying from 0.17 to 0.6 MPa absolute, at an average temperature of the catalytic bed of 325° C.; the hourly volume velocity HVV expresses the delivery of gas entering on the catalyst in N1/h divided by the volume of the catalyst.
The content of nitrogen oxides NO x is expressed in ppmv (parts per million by volume); the NO x content of the gases at the input of the catalyst, expressed in ppmv, is carried in column 1 of the table; the reduction yield, expressed in %, corresponding to the ratio of the difference between NO x content of the gases as input and the NO x content of gaes as output, to the NO 2 content of gases as input, is carried in column 6. The amount of ammonia added to the incoming gas expressed in moles NH 3 /moles NO x appears in column 5. The hourly volume velocity HVV is carried in column 4, pressure P in MPa absolutes in column 3 and the average temperature of the catalyst T in °C. in column 2.
TABLE 1______________________________________No.sub.x input average P abs HVV NH.sub.3 Yieldppmv T °C. MPa h.sup.-1 NO.sub.x %______________________________________1 500 325 0.17 5000 1.1 98.2" " 0.17 15000 1.1 92.9" " 0.3 10000 1.1 98.2" " 0.3 20000 1.1 95.8" " 0.45 45000 1.1 91.1" " 0.45 95000 1.1 94.4" " 0.6 95000 1.1 96.8" " 0.6 40000 1.1 95.1" " 0.6 60000 1.1 90.53500 325 0.25 5000 1.1 98.4" " " 7500 " 98.1" " " 10000 " 97.1" " " 19500 " 95.5" " " 15000 " 93.2______________________________________
EXAMPLE 3
A sample of catalyst No. 1 is charged in a test reactor, then subjected to a heat treatment under dry air (in crosswise fixed bed) at an hourly velocity HVV of 20,000 h -1 with progressive raising of the temperature from 75° C. per hour to 500° C. and this temperature level is kept during 10 hours.
The specific surface, measured according to the BET method, of catalyst No. 2 in acid form is 240 m 2 /g, its microporous volume 0.285 cm 3 /g with a distribution of the diameter of the pores between 40 and 5000 A (for 98.9% of the microporous volume) and its microporous volume, determined by nitrogen adsorption, is 0.25 cm 3 /g.
As in the preceding example, catalyst No. 2 is used under various operating conditions, using residual gases of an industrial nitric acid unit.
The process of reduction by ammonia of the nitrogen oxides contained in the residual gas is performed under a pressure varying from 0.17 to 0.6 MPa absolute, at an average temperature of the catalytic bed of 450° C.
The results given in Table II below were obtained after more than six months of operation of catalyst No. 2.
TABLE II______________________________________NO.sub.x input average: P abs HVV NH.sub.3 Yieldppmv T °C. MPa h.sup.-1 NO.sub.x %______________________________________1500 450 0.17 3000 1.1 98.2" " 0.17 15000 1.1 95.3" " 0.3 10000 1.1 98.7" " 0.3 20000 1.1 97.7" " 0.45 15000 1.1 98.7" " 0.45 25000 1.1 98.2" " 0.45 40000 1.1 96.8" " 0.6 25000 1.1 98.8" " 0.6 40000 1.1 97.9" " 0.6 60000 1.1 93.1______________________________________
EXAMPLE 4
Preparation of Catalysts Numbers 3, 4, 5 and 6
The powder is used which was obtained during production of catalyst No. 1. The powder is then mixed for 4 hours with a binder, at a rate of 20% by weight of dry material relative to the total weight.
The composition of the binder is the following:
catalyst No. 3 kaolinite clay 100% by weight
catalyst No. 4 kaolinite clay 40% by weight--bentonite 60% by weight
catalyst No. 5 bentonite 100 by weight
catalyst No. 6 Condea alumina 100% by weight
Shaping and heat treatment are the same as for catalyst No. 2.
The main characteristics of catalytic compositions Nos. 3 to 6 are given in Table III below.
TABLE III______________________________________ Specific Macro- % Macroporous surface porous Diameter of volumeCata- m.sup.2 g.sup.-1 volume macropores betweenlyst BET method (m.sup.3 g.sup.-1 A 40 and 1500 A______________________________________3 260 0.334 37.5-15000 98.04 250 0.252 37.5-30000 95.95 283 0.265 37.5-40000 89.16 238 0.303 37.5-37500 98.7______________________________________
EXAMPLE 5
This example illustrates the use of catalysts Nos. 3, 4, 5 and 6 under two operating conditions, using residual gases of an industrial nitric acid unit, as in example 2. The results are given in table IV below:
TABLE IV______________________________________ NO.sub.x input average Pabs HVV NH.sub.3 YieldCatalyst ppmv T °C. MPa h.sup.-1 NO.sub.x %______________________________________3 1500 450 0.45 45000 1.1 98.9 " " " 25000 1.1 95.44 1500 450 0.45 15000 1.1 97.7 " " " 25000 1.1 97.05 1500 450 0.45 45000 1.1 98.2 " " " 25000 1.1 93.56 1500 450 0.45 15000 1.1 98.0 " " " 25000 1.1 95.8______________________________________
EXAMPLE 6
Catalyst No. 7
6.6 kg of small-pore sodium mordenite, characterized above, is intimately mixed with 1.9 kg of alumina gel. The losses to firing at 1000° C. of these products are 9.7 and 20.7% respectively.
The mixture thus obtained after adjustment of the moisture is shaped by extrusion through a die.
In this case the equipment is of the gear type and the extrudates have a diameter of 3 mm for an average length of 8 mm. The mordenite content is 80% (dry material). The rods are dried in an oven at 60° C. for 3 hours, then at 120° C. for 3 hours. They are then treated in a muffle furnace in plates at 350° C. for 2 hours.
The strength of these extrudates measured on rolls is between 1.1 and 1.6 kg/mm. 150 cm 3 extrudates of sodium mordenite are placed in a stainless steel basket (mesh 2/10 mm) whose geometry is adjusted to that of a 0.5-liter beaker. Their charging density is close to 0.65.
500 cm 3 of a copper tetramine solution is prepared from 70 g of crystallized Cu(NO 3 ) 2 6H 2 O dissolved in 100 cm 3 of demineralized water by addition of 250 cm 3 of ammonia concentrated at 25% NH 3 . First, the formation of a copper hydroxide precipitate is observed which, after agitation, disappears. The solution is clear blue. The copper is complexed by NH 3 in the form Cu(NH 3 ) 4 2+ . It is rounded out with demineralized water to have a solution volume of 0.5 liter.
The stainlss steel basket containing the extrudates is placed in a 0.5-liter beaker. 250 cm 3 of cupric solution is poured in. Its level is above that of the extrudates. The unit is brought to 40° C. and the exchange reaction is maintained for 2 hous. The basket is then removed; the extrudates are washed by soaking in demineralized water and the exchange operation is performed again with 200 cm 3 of fresh cupric solution. The product is washed 3 times by soaking then dried in an oven at 60° C. for 3 hours, then at 120° C. for 2 hours.
The copper content of the extrudates is 3% (of dry product) which represents, considering a content of Al 2 O 3 binder of 20%, an exchange rate of the sodium of 53%.
The exchange rate can be increased either by increasing the number of exchanges or the reaction temperature.
EXAMPLE 7
Catalyst No. 8
150 g of small-pore sodium mordenite is introduced in the form of powder (PAF: 9.7%) in a 500 cm 3 beaker containing 300 cm 3 of copper tetramine solution prepared according to the procedure described in example 6.
The suspension is stirred with a bar magnet and the temperature is adjusted to 40° C. The exchange period is 2 hours.
The mordenite partially exchanged with Cu ++ is recovered by filtering with a filtering funnel and washed with 1 liter of demineralized water.
A second exchange is performed under the same conditions. The product after filtering and washing is dried at 60° C. for 2 hours, then at 120° C. for 2 hours.
This product is intimately mixed with a binder consisting of 75% kaolinite clay and 25% bentonite. The mordenite content of the product (dry) is 80%. This powder is then shaped in pellets with a diameter of 3 mm.
The rate of exchange of sodium with copper is 48%.
EXAMPLE 8
Catalyst No. 9
6.9 kg of small-pore mordenite in ammonium form is used according to the preparation described above.
The sodium content is close to 400 ppm and the loss to firing (PAF) at 1000° C. is 13%.
The product is intimately mixed with 1.9 kg of alumina gel (PAF: 20.7%) then extruded through a die 3 mm in diameter. The mordenite content is 80% by weight. The exchange as described in example 6 is reproduced.
The copper content is 3% which represents an exchange rate of 53%.
EXAMPLE 9
This example illustrates the use of the catalysts prepared according to the procedures described in the three preceding examples tested on a fixed bed, in a catalytic unit, under various operating conditions; the gaseous effluent to be treated comes directly from an industrial nitric acid unit.
The volume of catalyst used is 37.5 cm 3 , which is brought to 350° C. under a gas current rich in nitrogen (96% N 2 -4% O 2 ) of 750 N1/h at a rate of rise in temperature of 100° C./h. The mixture (N 2 -O 2 ) is then replaced by the effluent to be treated which is mixed with an amount of ammonia which is a function of the content of the nitrogen oxides. The reduction process is performed under a pressure varying from 0.104 to 0.45 MPa absolute. The hourly volume velocity (HVV) expresses the delivery of gas entering on the catalyst N1/h divided by the volume of the catalyst (1). The NO x content is expressed in ppmv (parts by million by volume). It is 1500 ppm for the group of tests made whose results are presented below.
The amount of ammonia added to the entering gas is expressed by the molar ratio NH 3 /NO x . The residual ammonia content after the reaction is expressed in ppm. The temperature indicated is the average temperature of the catalytic bed. The reduction yield, expressed in %, corresponds to the ratio of the difference between the content of NO x of the gases as input and the content of NO x of the gases as output, to the NO x content of the gases as input.
TABLE V______________________________________CATALYST No. 7: NO.sub.x input: 1500 ppmAverage Pabs HVV Yield NH.sub.3 outputT °C. MPa h.sup.-1 NH.sub.3 /NO.sub.x % ppmv______________________________________350 0.104 5000 1.15 99.7 0" " 10000 1.18 98.4 0" " 15000 1.15 94 0" 0.3 15000 1.16 98.5 0" " 25000 1.15 97.5 0" " 35000 1.16 94.5 2" " 40000 1.15 91.6 6" 0.45 20000 1.16 99 0" " 30000 1.15 98 0" " 40000 1.15 96.1 0" " 50000 1.15 93.6 13300 0.104 5000 1.17 98.8 0" " 10000 1.14 96.8 0" " 15000 1.14 80 0" 0.3 15000 1.17 97.9 0" " 25000 1.15 93.9 3" " 30000 1.15 89.6 4" 0.45 15000 1.16 98.7 0" " 25000 " 97.4 0" " 35000 " 94 2" " 45000 " 90 3______________________________________
TABLE VI______________________________________CATALYST No. 8: NO.sub.x input: 1500 ppmvAverage Pabs HVV Yield NH.sub.3 outputT °C. MPa h.sup.-1 NH.sub.3 /NO.sub.x % ppmv______________________________________350 0.104 10000 1.18 98.8 0" " 20000 1.14 94 0" " 25000 1.14 91.5 0" 0.3 15000 1.18 99 0" " 25000 1.14 98 0" " 35000 1.15 94.2 0" " 40000 1.14 89.8 7" 0.45 15000 1.16 99.2 0" " 35000 1.16 91.8 1" " 50000 1.16 95.1 5" " 60000 1.16 93 6300 0.104 10000 1.14 97.8 0" " 15000 1.15 95.2 0" " 20000 1.16 92 6" 0.3 15000 1.15 98.2 6" " 25000 1.14 94.4 15" " 30000 1.16 91 23" 0.45 15000 1.43 99 0" " 35000 1.15 91.4 80" " 50000 1.15 94 25" " 60000 1.16 91.9 10______________________________________
TABLE VII______________________________________CATALYST No. 9: NO.sub.x input: 1500 ppmvAverage Pabs HVV Yield NH.sub.3 outputT °C. MPa h.sup.-1 NH.sub.3 NO.sub.x % ppmv______________________________________350 0.45 15000 1.16 99.4 0" " 35000 1.14 99 0" " 50000 1.14 98.6 0" " 60000 1.13 97.1 0250 0.45 10000 1.15 98.8 0" " 20000 1.16 96.4 0" " 25000 1.15 92.9 0______________________________________
While the invention is described above in relation to certain specific embodiments, it will be understood that many variations are possible, and that alternative materials and reagents can be used without departing from the invention. In some cases such variations and substitutions may require some experimentation, but such will only involve routine testing.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and therefore such adaptations and modifications are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation. | A catalytic composition for selective reduction of nitrogen oxides comprising, as active material, mordenite in ammonium or acid form, with a residual sodium content less than 1000 ppmw, representing 70 to 95% of the total weight of the catalytic composition, the remainder comprising a binder. The active material can also be in the form of small-pore mordenite exchanged with copper ions.
The catalytic composition can be used for the purification of effluents with containing any nitrogen oxide, in particular for depolluting residual gases rejected into the atmosphere during the production of nitric acid. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an integral fiber optic printhead and, more particularly, to a printhead comprising a single fiber optic faceplate substrate.
2. Description of the Prior Art
Light emitting diode arrays are well known in the art for recording an image on a photosensitive medium such as a photographic film or paper or, alternatively, a photocopying receptor such as a selenium drum or a zinc oxide paper. In order to achieve high resolution, a large number of light emitting diodes are arranged in a linear array and means are included for providing a relative movement between the linear array and the photosensitive medium so as to effect a scanning movement of the linear array over the surface of the photosensitive medium. Thus, the photosensitive medium may be exposed to provide a desired image one line at a time as the LED array is advanced relative to the photosensitive medium either continuously or in a stopping motion. Each LED in the linear array is used to expose a corresponding pixel in the photosensitive medium to a value determined by image defining electronic signal information. Since the light emitted from each LED rapidly diverges upon emission from the diode, an optical system is needed to transmit the light from the LED to the surface of the photosensitive medium without substantial divergence. One such proposed optical system for use in such a printhead comprises an array of graded index lenses made up of closely packed rows of optical fibers as disclosed in U.S. Pat. No. 4,447,126, entitled "Uniformly Intense Imaging by Close Packed Lens Array", by P. Heidrich et al., issued May 8, 1984. Another apparatus disclosed for mounting an imaging lens array formed of a plurality of gradient index optical fibers onto a printhead having a linear array of light emitting diodes is suggested by U.S. Pat. No. 4,715,682, entitled "Mount for Imaging Lens Array on Optical Printhead", by K. Koek et al., issued Dec. 29, 1987. Although arrays of gradient index optical fibers have been suggested for use as the imaging lens in such printheads, critical alignment and assembly problems still exist so as to effect the precise connection between the optical fiber array and the LED array. Not only must the LED arrays be precisely aligned to the optical fiber arrays but electrical connections must also be made from remotely stationed control circuits which modulate the current furnished to drive the LED's during exposure.
Therefore, it is a primary object of this invention to provide an integral printhead structure in which LED arrays and the driver circuits therefor can be mounted on a singular substrate.
It is a further object of this invention to provide an integral printhead structure in which light emitting diode arrays are more easily connected to a fiber optic lens array which can further act as a substrate to accommodate the mounting and connection of additional support circuitry.
Other objects of the invention will be in part obvious and will in part appear hereinafter. The invention accordingly comprises a structure and system possessing the construction, combination of elements and arrangement of parts which are exemplified in the following detailed disclosure.
SUMMARY OF THE INVENTION
Apparatus for selectively exposing a plurality of longitudinally spaced areas across the face of a photosensitive medium comprises an elongated coherent fiber optic faceplate substrate. The fiber optic faceplate has a substantially planar light receiving surface oppositely spaced apart with respect to a substantially planar light emitting surface. The light emitting surface is stationed to accommodate the close proximity placement of the photosensitive medium to receive the light emitted therefrom. There is also provided at least one elongated array comprising a plurality of light emitting diodes. Each of the light emitting diodes is closely spaced with respect to an adjacent diode and has a light emitting surface fixedly stationed in close light transmitting proximity to the light receiving surface of the fiber optic faceplate. Conductive interconnecting lines are selectively deposited on the light receiving surface of the fiber optic faceplate to accommodate select electrical connection to the light emitting diodes. Means are also provided for electrically connecting the light emitting diodes to select ones of the conductive interconnecting lines. There are also preferably provided a plurality of drive control circuits for controlling the energization of the light emitting diodes. The drive control circuits are also fixedly stationed with respect to the light receiving surface of the fiber optic faceplate in spaced relation with respect to the light emitting diodes. There are also provided means for electrically connecting the driver control circuits to select ones of the conductive interconnecting lines. In the preferred embodiment, the means for electrically connecting the light emitting diodes and the driver control circuits to selected ones of the conductive interconnecting lines comprises connections made by the so-called flip chip/solder bumping process.
DESCRIPTION OF THE DRAWINGS
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and its method of operation, together with other objects and advantages thereof will be best understood from the following description of the illustrated embodiment when read in conjunction with the accompanying drawings wherein:
FIG. 1 is a plan view of the integral fiber optic printhead of this invention;
FIG. 2 is a cross-sectional view taken across the lines 2--2 of FIG. 1; and
FIG. 3 is an enlarged cross-sectional view showing a portion of the integral fiber optic printhead of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-3, there is shown at 10 the printhead assembly of this invention comprising a fiber optic faceplate 12. The fiber optic faceplate 12 is configured in an elongated parallelepiped shape having a substantially planar light receiving surface 14 in spaced parallel relation to a substantially planar light emitting surface 16. The fiber optic faceplate comprises a plurality of individual glass fibers which are stacked together, pressed and heated under pressure to form a uniform structure with a plurality of light transmitting passages extending between the light receiving and light emitting surfaces 14, 16. Fiber optic faceplates are well known in the art as taught in U.S. Pat. No. 4,179,596, entitled "Method For Processing Fiber Optic Electronic Components of Electronic Vacuum Device", by C. Bjork, issued Dec. 18, 1979, and now incorporated by reference herein. The above-described method is only exemplary, and it will be readily understood that other methods may also be utilized.
Disposed on the light receiving surface 14 of the fiber optic faceplate 12 are three elongated arrays 18, 20 and 22 comprising, respectively, pluralities of light emitting diodes (LED's) 24, 26 and 28 aligned in side-by-side relationship with respect to each other along the length of each respective array. Each of the LED's 24, 26 and 28 is preferably selected to emit radiation in one of three distinct wavelength ranges as for example red, blue and green. As will be well understood, other wavelength ranges could also be utilized. The LED's 24, 26 and 28 are of conventional construction well known in the art. A plurality of LED driver circuits 32 are also mounted on the light receiving surface 14 of the fiber optic faceplate 12. Driver circuits 32 are electrically connected to select ones of the LED's 24, 26 and 28 by means of conductive interconnecting lines 40. The conductive interconnecting lines 40 may comprise any suitably conductive metal such as gold, aluminum, etc. deposited on the light receiving surface 14 of the fiber optic faceplate 12 by any well-known technique such as sputtering or evaporation with the excess metallization being thereafter removed by well-known photoresist and etching techniques to provide selective interconnects between the LED's 24, 26 and 28 and respective ones of the driver circuits 32.
Referring specifically to FIG. 3, there is shown an enlarged cross-sectional view of one of the LED's 24. Light emitting diode 24 has metallized contacts as shown at 38 deposited in any well-known manner and a narrow central light emitting area as shown generally at 34. The metallized contacts 38 are electrically connected to respective ones of the conductors 40 by a conventional solder bumping process. The driver circuits 32 can be interconnected to respective ones of the conductors 40 by the same solder bumping process used to connect the LED's or by conventional wire bonding techniques. Since the electrical connections to the fiber optic faceplate substrate 12 are made on the underlying surface of the active elements, the connection technique is generally referred to as the flip chip/solder bumping process. Although the flip chip/solder bumping process is preferred for connecting the active components to selective conductors 40 on the fiber optic faceplate substrate 12, the invention is by no means so limited and other conventional techniques such as wire bonding may also be utilized.
During the operation of the printhead 10 of this invention, a photosensitive sheet 30 is moved relative to the light emitting surface 16 of the fiber optic faceplate substrate 12 to effect a raster line exposure thereof. The radiant energy emitted by the light emitting area of each diode 34 diverges slightly in the space 42 between the underlying surface of the light emitting area and the light receiving surface 14 of the fiber optic faceplate 12. Once incident to the light receiving surface 14 radiation is transmitted in a collimated beam 44 by the fused glass fibers of the fiber optic faceplate 12 until exiting from the light emitting surface 16 to expose the photosensitive sheet 30. As will be readily understood, the radiation emitted by the light emitting diodes 24, 26 and 28 are all transmitted in collimated beams 44 without substantial divergence by respective ones of the diffused optical fibers of the faceplate 12 to expose discrete pixel areas on the photosensitive sheet 30. Transmission of the radiation from the light emitting diodes without substantial divergence operates to contain the size of the discrete areas exposed on the photosensitive so that the resolution of the reproduced image is substantially determined by the size and spacing of the LED's 24. The driver circuits 32 operate to control or modulate the flow of current through respective ones of the LED's 24, 26 and 28 in a manner as is fully described in U.S. Pat. No. 4,525,729, entitled "Parallel LED Exposure Control System", by M. Agulnek et al., issued June 25, 1985, and now incorporated in its entirety by reference herein.
Thus, there is provided a simple and economical construction in which a single fiber optic substrate operates to transmit light from light emitting diode arrays in collimated beams to expose well-defined pixel areas of a photosensitive sheet while simultaneously providing a substrate onto which other conductors and LED driver circuitry may be deposited by standard techniques.
Other embodiments of the invention including additions, subtractions, deletions, and other modifications of the preferred disclosed embodiments of the invention will be obvious to those skilled in the art and are within the scope of the following claims. | An intgeral printhead includes a single fiber optic faceplate substrate to which are connected light emitting diode arrays, driver circuits for selectively controlling the energization of the light emitting diodes and interconnecting conductive lines all disposed on the same fiber optic faceplate substrate which thereby provides the optical lens system for the light emitting diodes and a supporting substrate to which the active components are mounted and electrically interconnected by the conductive lines. | 1 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of my copending application Ser. No. 096,551, filed Sept. 15, 1987, and now U.S. Pat. No. 4,829,946.
1. Field of the Invention
The present invention relates to new and useful improvements in fuel injected two-stroke cycle gasoline engines. More particularly, the present invention relates to new and useful improvements in exhaust valves for such engines which will delay the opening of the exhaust port every cycle during the expansion stroke and, if desired, advance closing of the exhaust port every cycle during the compression stroke while, at the same time, opening the exhaust port permitting proper scavenging of the cylinder. In addition, the present invention also permits varying the opening and closing of the exhaust port relative to the piston position according to engine speed.
2. Description of the Prior Art
It has been know in the past to provide speed-controlled exhaust valves which will remain partially closed at slow speeds of the engine, delaying communication between the combustion chamber and exhaust passage beyond the usual opening of the exhaust port by the piston, and move upward, fully exposing the exhaust passage to the combustion chamber through the exhaust port at high engine speeds. Such valves, however, do not provide the advantages of longer expansion and compression strokes while also permitting maximum scavenging.
With the foregoing in mind, a principal object of the present invention is to provide a novel exhaust control valve for fuel injected two-stroke cycle engines which will vary the exhaust opening according to a selected pattern during each stroke of the piston.
An additional object of the present invention is to provide an engine with an improved use of fuel, an improved power stroke, and improved emissions results.
Another object of the present invention is to provide a novel exhaust control valve for fuel injected two-stroke cycle engines which, in addition to varying the exhaust opening during each cycle, will further change the exhaust opening with changes of engine speed.
A further object of the present invention is to provide a novel reciprocating exhaust control valve driven in timed relation to the piston movement to delay opening of the exhaust passage during each expansion stroke and advance closing of the exhaust passage during each compression stroke, while opening the exhaust passage sufficiently to permit proper scavenging.
Still a further object of the present invention is to provide a novel exhaust control valve for fuel injected two-stroke cycle engines which may be easily incorporated into an engine and will operate reliably and efficiently.
SUMMARY OF THE INVENTION
An exhaust control valve for fuel injected two-stroke cycle engines is provided within the exhaust passage of the engine positioned in close proximity to the piston skirt. The valve is interconnected with the engine crankshaft and reciprocates upward and downward in timed relation to the piston movement to delay opening of the exhaust passage during the expansion stroke of the piston and advance closing of the exhaust passage during the compression stroke of the piston. After the exhaust passage is initially opened, the valve is moved upward out of the stream of exhaust gases passing through the exhaust port, opening the exhaust port, so as not to interfere with scavenging of the combustion chamber. In addition, an adjustable drive connection is provided between the crankshaft and the valve to permit modification of the position of the valve relative to the piston with a change in engine speed and also to permit modification of the total movement of the valve relative to the piston with change in engine speed and throttle setting.
The fuel injection system operates continuously or in timed relationship with the movement of the piston and the concurrent movement of the exhaust valve. In the preferred embodiment the fuel is delivered into the air intake passage of the engine either upstream or downstream from air intake valves, such as reed valves. The entire system provides the improved fuel control of a fuel injection system with the improved combustion and scavenging of the exhaust valve of the present invention.
DESCRIPTION OF THE DRAWINGS
The operation of the present invention should become apparent from the following description when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a longitudinal sectional view, partially in elevation, of a fuel injected two-stroke cycle engine incorporating the present invention, with the fuel provided downstream of the reed valves in the engine's inlet passage;
FIG. 2 is a transverse sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a chart showing piston position and exhaust valve position relative to crankshaft rotation;
FIG. 4 is a representation of the exhaust control valve drive mechanism at high speed of the engine;
FIG. 5 is a representation of the exhaust control valve drive mechanism at slower speeds of the engine;
FIG. 6 is a side elevational view of the exhaust control valve drive mechanism;
FIG. 7 is an exploded view of the elements of the exhaust control valve drive mechanism;
FIG. 8 is a side elevational view of a modified exhaust control valve mechanism; and
FIG. 9 is a longitudinal sectional view, partially in elevation, of another embodiment of a fuel injected two-stroke cycle engine incorporating the present invention, with the fuel provided upstream of the reed valve in the engine's air inlet passage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the illustrated embodiment of the present invention, the exhaust control valve is shown in conjunction with a single cylinder fuel injected two-stroke cycle, variable speed, crankcase compression engine as used, for example, on motorcycles. This exhaust control valve, however, has many useful applications in other than the engine shown.
The engine 10 includes a cylinder 11, a cylinder head 12 and a crankcase housing 13, with the piston, connecting rod and crankshaft not shown. The cylinder 11 includes a combustion chamber 14, an inlet passage 15 terminating in the inlet port 16, transfer passages 17, 17 terminating in transfer ports 18, 18 and an exhaust port 19 leading to the exhaust passage 20. In the inlet there are reed valves 21, a supplement transfer passage 22 and a booster port 23, similar to those described in my prior U.S. Pat. No. 3,905,341.
In this type of engine, the piston skirt, not shown, serves as the valve means for opening and closing the inlet port 16, booster port 23, transfer ports 18 and exhaust port 19. In the conventional engine of this type, as the piston is moving toward its bottom dead center position, the upper edge of the piston starts to open the exhaust port 19 at about the 90° position of the crankshaft, 0° being the crankshaft position at top dead center and 180° being the crankshaft position at bottom dead center. Upon continued further downward movement of the piston, the transfer ports and booster port start to open at approximately the 120° position of the crankshaft. When the piston reaches bottom dead center, all of these above ports are fully uncovered or open. Similarly, on the compression stroke of the piston, the transfer and booster ports are closed by the piston at the 240° position of the crankshaft and the exhaust port is closed by the piston at the 270° position of the crankshaft. Thus, in the conventional engine of this type, the effective expansion stroke of the piston and the effective compression stroke of the piston each occur during only a 90° rotation of the crankshaft.
In accordance with the present invention, valve means are provided to delay fluid communication between the combustion chamber 14 and the exhaust passage 20 during the expansion stroke until after the piston has initially uncovered the upper edge of the exhaust port, but permit such fluid communication prior to the transfer ports being opened. Similarly, this same valve means can shut off fluid communication between the combustion chamber and the exhaust passage prior to the piston closing of the exhaust port. This increases the effective length of the expansion and compression strokes, thereby increasing the power output of the engine.
In the embodiment of the invention shown, this valve means comprises a flat valve plate 24 pivotally mounted at one end within a recess 25 in the exhaust passage 20. This mounting is accomplished by means of a pivotal valve shaft 26 fixed to and rotatable with valve plate 24 and extending through bushings, not shown, mounted in the cylinder 11 at both sides of exhaust passage recess 25. The valve plate 24 extends forwardly from the valve shaft 26 and terminates near the exhaust port 19. When closing at or just short of the exhaust port 19, the forward edge 24a of the valve plate 24 is concave when viewed from above, as in FIG. 2, and has a radius of curvature equal to or slightly greater than that of the combustion chamber. This forward edge of the valve plate may also be tapered or curved upward or rearward so that it can rest in the exhaust passage recess 25.
An important feature of the present invention is the provision of means to move the valve plate 24 in timed relation to movement of the piston. In the position as shown in FIG. 1, the valve plate 24 is between the top of the exhaust port 19 and the top of the transfer ports 18, and upon rotation of the crankshaft, will move upward. The upper edge of the downward moving piston is, as shown in phantom lines at P, at a position just about passing the upward moving valve plate. This would be, in the embodiment shown, at about the 105 to 110°-125° position of the crankshaft depending on engine revolutions per minute (r.p.m.) and throttle position. In the illustrated position of the piston and valve plate, a seal is provided between the skirt of the piston and the forward edge of the valve plate, preventing the expanding products of combustion in the combustion chamber from entering the exhaust passage 20. While the upper portion of the exhaust port 19 is uncovered by the piston P, the expanding gases in the combustion chamber cannot enter the exhaust passage due to the fact that the valve plate provides a barrier, with possibly slight leakage, between the area of the combustion chamber 14 above the piston and the exhaust passage 20. With this arrangement, the effective expansion force on the piston is extended from 90° rotation of the crankshaft to approximately 105 to 110-125° rotation of the crankshaft. This increases the length of the power stroke of the piston by more than twenty percent. Although a seal is not possible when the exhaust valve is located further downstream in the exhaust port, beneficial results are still obtained by impeding the flow of combustion products and causing a high temperature stream of exhaust upon the opening of the valve. This is believed to provide better operation of air pollution devices, such as catalytic converters, in their normal orientation.
Movement of the valve plate 24 is controlled by rotation of the crankshaft of the engine. To this end, the valve shaft 26 is fixed to the valve plate 24 and extends, at one end, outwardly beyond the cylinder 11. An operating link 27 is attached to the valve shaft and, by means of a connecting link 28, is interconnected with the crankshaft of the engine.
As illustrated, a pinion 29 is carried by an extension 30 of the engine crankshaft. This pinion in turn drives a gear 31 in a one-to-one relationship, which gear is carried by a shaft 32. At the end of the shaft 32 is a rotatable drive plate 33 to which the lower end of the connecting link 28 is attached. A drive connection, more fully described hereafter, is provided between the gear 31 and the drive plate 33 to cause the plate 33 to rotate with the gear 31. Thus, the valve plate 24 is driven from the crankshaft of the engine in timed relation to movement of the piston.
During downward movement of the piston, the valve plate 24 is moving upward as shown in FIG. 1. When the forward edge 24a of the valve plate is higher than the upper edge of the piston, products of combustion may exit from the combustion chamber into the exhaust passage. With continued rotation of the crankshaft, the valve plate continues rising until it is completely within the exhaust passage recess 25, thereby permitting unrestricted flow of exhaust gases through the exhaust passage.
At high engine speeds, it may be necessary to advance opening of the exhaust passage to allow adequate time for scavenging. One method of advancing opening of the exhaust passage is shown in FIG. 4 through 7, inclusive. As illustrated, the gear 31 is provided with a diametrical recess 36 in the face adjacent the drive plate 33, while the adjacent drive plate face is provided with an S-shaped recess 37. A pair of hardened drive balls 38 ar provided engaged within each recess 36, 37, at opposite sides of the shaft 32 and cause the drive plate 33 to rotate with the gear 31. A torsion spring 39 surrounding the shaft 32 normally urges the drive plate 33 in the counterclockwise direction relative to the gear 31, as viewed in FIG. 5, forcing the balls 38 inwardly toward the shaft 32. When the engine approaches high speed, centrifugal force will drive the balls radially outward against the torsion of the spring 39, rotating the drive plate 33 clockwise relative to the gear 31, as shown in FIG. 4. This will advance upward movement of the valve plate during the expansion stroke of the piston, opening the exhaust passage earlier than at slow or moderate speeds of the engine, allowing more time for scavenging the chamber 14.
A modified drive for the valve 24 is illustrated in FIG. 8. In this embodiment, the drive plate also has a concave forward edge 24b but is rounded upward, instead of tapered, to provide constant clearance with the piston over a longer period of relative movement between the piston and valve plate. A rotatable drive plate 40 fixed to the crankshaft or driven by the crankshaft has a cam track recess 41 in its face, within which a cam roller 42, carried by the lower member 43 of a bifurcated linkage 43, 44 is received. The upper link member 44 of the bifurcated linkage is connected to the operating link 27 to cause reciprocation of the valve plate 24 upon rotation of the drive plate 40. An idler link 45 is provided connected to the pivotal connection 46 of the link members 43 and 44. This idler link 45 can be moved horizontally to the right or left, with respect to FIG. 8, in accordance with variations in the engine speed and thus advance opening of the exhaust passage at high engine speed and retard the same at low engine speed.
It also should be appreciated that a cam controlled drive train may be employed in the present invention to control valve element movement. This permits fine-tuning of the valve member movement for each particular engine or each particular use of an engine through merely substituting cams. Additionally, it may be possible in some applications to substitute electronic "cams" which receive electronic signals from the crankshaft and drive a synchronous motor which controls the movement of the valve element.
The chart of FIG. 3 illustrates with the graph A a plot of piston position versus crank angle. Graph B is a plot of the movement of the valve plate during the time the exhaust passage is open to the combustion chamber at low and moderate engine speeds, while graph C is a plot of movement of the valve plate when the exhaust passage is open at high engine speeds and maximum throttle. While plot B shows the exhaust passage being opened at 105° of crank angle and closed at 255° of crank angle at low speed and wide open throttle. There is flexibility in the design, and the exhaust passage can be designed to open anywhere between a 90° and 120° crank angle and close anywhere up to a 270° crank angle.
As is shown in FIG. 1, the exhaust valve of the present invention may be operated with a fuel injection system 50. Any appropriate fuel injection system may function quite well with the present invention. An example of one such system is described in U.S. Pat. No. 4,446,833 issued to Matsushita et al.
The fuel injection system 50 shown in FIG. 1 provides fuel to the air inlet 15 downstream from reed valves 21 via fuel injection nozzle 52. As is known, fuel is pumped to the fuel injection nozzle 52 from a fuel tank 54 and through a fuel filter 56 by a fuel pump 58. Fuel is provided to the nozzle 52 through conduit 60. In order to assure relatively constant fuel pressure, a fuel control valve 62 is provided with a fuel return conduit 64 which returns excess fuel to the fuel tank 54.
The fuel injection nozzle 52 is controlled in the conventional manner by an electromagnetic controller 66 which regulates the amount of fuel released relative to the air flow through the engine. In the preferred embodiment, this control is accomplished through use of a pressure sensor device 68 measuring the pressure in the inlet passage 15, as shown. It also may be placed in a transfer passage 17, or alternatively in the crankcase 13, of the engine. The sensor 68 provides an electrical signal to a central processor 70 which provides a signal conversion. The processor 70 also receives a signal from the crankshaft 36 in angular degrees from a rotational sensor 72. Through use of known control programs, the processor 70 may calculate appropriate fuel discharge parameters relative to the pressure and/or pressure changes in the engine. Fuel discharge commands are then conveyed to the electromagnetic controller 66 to control fuel release by the nozzle 52. As is known, mechanical systems can also be configured to provide similar control of the fuel injection nozzle 52. Also, without departing from the present invention, fuel injector control can be accomplished by the conventional means of measuring the flow of air through the air inlet 15 and providing an appropriate fuel discharge. Also without departing from the present invention, fuel may be injected anywhere in the intake passage, into the crankcase, or into the combustion chamber.
FIG. 9 illustrates another embodiment of the fuel injection system 50 of the present invention which differs from the system 50 of FIG. 1 in the orientation of fuel injection nozzle 52a. As is shown, the fuel injection nozzle 52a may be oriented upstream from the reed valve elements 21. In all other respects this system 50a functions the same as that of fuel injection system 50.
To maximize the effectiveness of the exhaust valve 24 of the present invention, the injection of fuel should occur after the transfer ports 16 have been covered on the upward movement of the piston P. Ideally fuel should be dispensed with the piston at or approaching near top dead center (TDC) position. Fuel may also be dispensed continuously from the fuel injector nozzle throughout the cycle or during other portions of the cycle.
It should be appreciated that the present invention functions equally well when included in known "supercharged " or "blower scavenged" engines which provide fuel and air under pressure from the intake passage, through modified transfer passages, directly to the combustion chamber. However, due to the lower transfer ports of, and the pressure generated by, a high pressure blower scavenged engine, it may be necessary to advance closing of the exhaust valve, perhaps as early as when the piston is at bottom dead center position. Similarly, it may be desirable to open the exhaust passage later. As is true with all embodiments of the present invention, the optimal point of opening or closing of the exhaust valve depends in large part on many factors peculiar to individual engine design. These include the type of charge to the engine, the size of the engine, the scavenging flow, and the configuration and shape of the engine. Additionally, it is believed that it may be desirable to adjust the degree of valve movement with engine speed and throttle opening, with the valve remaining substantially closed at low engine speeds and closed throttle and providing full movement at high speeds and wide open throttle. This may be accomplished in any suitable manner, which may include another mechanism in the linkage between the crankshaft and the valve which controls the extent of valve movement in accordance with engine speed and throttle opening or by switching electronic cams, as discussed, during operation.
While particular embodiments of the present invention have been illustrated and described herein, it should be apparent that changes and modifications may be incorporated and embodied therein within the scope of the following claims. | An exhaust control valve for two-stroke cycle engines used in conjunction with a fuel injection system is disclosed. This valve is within the exhaust passage and, for each revolution of the engine, delays opening of the exhaust passage to the combustion chamber during the expansion stroke of the piston for a preselected number of degrees of rotation of the crankshaft while permitting the necessary opening of the exhaust port to give complete blow down before the scavenging cycle. The valve also permits advanced closing of the exhaust port to eliminate short circuiting of the fresh charge out the exhaust port. A fuel injection system, providing fuel either upstream or downstream from valves in the engine's air intake passage, is provided to operate in timed relation to the piston strokes and the exhaust valve. Also disclosed are means for modifying opening of the exhaust valve at high engine speeds to improve scavenging. | 5 |
[0001] [0001] CROSS-REFERENCE TO RELATED APPLICATIONS Patent Date of number patent First Author Title 2737411 Mar. 6, 1956 Ralph Potter Inflatable streamlining apparatus for vehicle bodies 4006932 Feb. 8, 1977 Alan McDonald Inflatable drag reducer for land vehicles 4142755 Mar. 6, 1979 Edgar Keedy Vehicle drag reducer 4214787 Jul. 29, 1980 Frank Chain Drag reducing apparatus.. 4236745 Dec. 2, 1980 Grover Davis Retractable streamlining device for vehicles 4257641 Mar. 24, 1981 Edgar Keedy Vehicle drag reducer 4401338 Aug. 30, 1983 Kenneth Caldwell Streamlining device for vehicles 4451074 May 29, 1984 Barry Scanlon Vehicular airfoils 4508380 Apr. 2, 1985 Mithra Sankrithi Truck afterbody drag reducing device. 4601508 Jul. 22, 1986 Paul D. Kerian Streamlining appendage for vehicles 4688841 Aug. 25, 1987 Mark Moore Drag reduction device for tractor-trailers 4702509 Oct. 27, 1987 Morris Elliott Long-haul vehicle streamline apparatus 4741569 May 3, 1988 Paul F. Stuphen Inflatable Drag Reducer for land transport vehicles 4978162 Dec. 18, 1990 Francois P. Labbe Drag reducer for rear end of vehicle. 5058945 Oct. 22, 1991 Morris Elliott Long-haul vehicle streamline apparatus
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] There were no direct or indirect federally sponsored research money or support given for the development of this application or idea.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Does not apply.
BACKGROUND OF THE INVENTION
[0004] It is well known that air resistance is the major external resistive force that fast moving vehicles must overcome. Assuming a vehicle is not on an incline and there are no inclement weather conditions (i.e., no wind, rain or snow), total external resistive force (ƒ t ) can be estimated as the sum of road friction (ƒ r ) plus air friction (ƒ a ). These latter forces are in turn the result of several factors defined as:
ƒ r =μN and ƒ a =1/2 CAρυ 2 . Thus ƒ t =μN +1/2 CAρυ 2
[0005] Where:
[0006] μ=coefficient of friction between two objects; for rubber and concrete this is approximately 1.0.
[0007] N=Newton (assuming gravitational force N=mass (in Kg)* 9.8 meters/second 2 )
[0008] C=drag coefficient (this is related to aerodynamics, for a sphere it is 0.5).
[0009] A=cross-sectional area of the vehicle's forward moving surface.
[0010] ρ=density of air (at sea level it is approximately 1.293 kg/m 3 )
[0011] υ=velocity of vehicle
[0012] The power, P, required to overcome this total external resistive force and thus maintain a constant velocity, can be expressed as:
P=ƒ t υ
[0013] If one's objective is to maximize efficiency then any or all of the three mutable factors (C, A, υ) could be reduced. Economic incentives are likely to mitigate against reduction of A or υ, thus C may be an excellent candidate for reduction attempts. Given the political uncertainties related to fuel accessibility, one would expect an interest in practical means by which to reduce C.
[0014] More specifically, this invention seeks to reduce C, the coefficient of air drag for trucks, by making the rear end of the vehicle more streamlined. This need has been recognized for many years and devices proposed to achieve this goal were first patented over forty years ago. However, such devices have had major practical limitations that can be summarized as follows 1) many are very complicated and would require considerable adaptation of the truck which may be expensive 2) many employ a rigid device that would perhaps be difficult to maneuver in docking stations 3) many attempt to provide flexibility by using inflatable structures so necessitate an impervious yet light material and a very dependable pump, plus ensure such an inflated device could maintain the desired shape even under modem high speed conditions.
BRIEF SUMMARY OF THE INVENTION
[0015] The Drag-Dropper is a collapsible structure made of rigid components that may be unfolded to form a modified pyramid to streamline the posterior aspect of trucks. The exact dimensions of the apparatus may be varied such that small to large trucks including semi-tractor-trailers may be fitted. As safety is always the foremost priority, the design has structural redundancy to reduce if not eliminate destruction during operation even if one of several essential components were to fatigue simultaneously from material failure. Likewise, the dimensions seek to maximize posterior drag reduction without additional functional length of the vehicle that would obstruct the driver's rear vision, and the apex is intentionally far above the height of most passenger vehicles in the event of a collision involving a trailing vehicle.
[0016] The exact material composition, dimensions and means by which it is affixed to the trailer may change and all such variations when crafted in the described design comprise the scope of this patent application.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0017] Please note: 1) none of these figures are drawn to scale 2) figures which share the same perspective in a figure (e.g., 1 A and 1 B, 2 A and 2 B) have items labeled just once to avoid clutter 3) “left” and “right” are given in terms of the a truck driver's right and left if s/he were seated in the drivers seat looking through the windshield 4) all perspectives are given regarding what a viewer might see if s/he was positioned behind, to the left, right or above the truck; all of these assume the viewer is in those locations but looking towards the back of the truck unless otherwise stated 5) dashed lines indicate an obstructed view of a line 6) 's' shaped curves (whether on its side or in the standard position) indicate the structure has been truncated to save room 7) the “side” of the truck that these pictures refer to are the two vertical sides that run from the front to the back of the truck 8) the term “assembled” refers to the Drag-Dropper in a position such that the panels are all opened and located behind the truck; the term “quasi-assembled” refers to the right and left panels being parallel to the truck sides but one or both of the top and bottom panels are folded 9) since the components of the device can assume several positions, the default one will be with the panels behind the truck in either an assembled position or quasi-assembled position (defined in point 8), 10) all views from above assume that, if the viewer was in the prone position, then her/his head would be closer to the front of the truck than her/his feet would be.
[0018] [0018]FIG. 1: The series of figures shows: 1 a ) a stationary semi-truck trailer without a Drag-Dropper 1 b ) a stationary semi-truck trailer with a Drag-Dropper in the assembled position, 1 c ) a moving semi-truck trailer without a Drag-Dropper and the associated air-current and drag depiction 1 d ) a moving semi-truck trailer with a Drag-Dropper and the associated air-current and drag depictions.
[0019] [0019]FIG. 2: This series of figures shows the dimensions and angles of an assembled Drag-Dropper from several perspectives: 2 a ) as would be seen by a viewer positioned above the Drag-Dropper 2 b ) as would be seen by a viewer standing behind the truck 2 c ) as would be seen by a viewer on the right side of the truck.
[0020] [0020]FIG. 3: Each panel which comprises the sides of the Drag-Dropper are depicted as if it was lying flat on the ground so that the dimensions only specify the lengths and not the distance to given points when they are assembled: 1 a ) left panel 1 b ) right panel 1 c ) top panel 1 d ) bottom panel.
[0021] [0021]FIG. 4: The Drag-Dropper as seen by a viewer on the left side of the truck when the Drag-Dropper is in the 4 a ) storage position and 4 b ) quasi-assembled position.
[0022] [0022]FIG. 5: The Drag-Dropper as seen by a viewer on the left side of the truck with the Drag-Dropper in the storage position with the Panel-brace in the 5 a ) inactive position and 5 b ) active position.
[0023] [0023]FIG. 6: Series of figures depict positions of the left horizontal-pole and left panel as would be seen by a viewer above the truck. The horizontal-poles traverse when folding from the assembled position ( 6 a ) to the storage position ( 6 f ).
[0024] [0024]FIG. 7: Two figures which show a more detailed component composition and dimensions of the Drag-Dropper as would be seen by a viewer above the truck when it is in the 7 a ) assembled and 7 b ) storage positions.
[0025] [0025]FIG. 8: Series of figures depict the positions of each panel of the Drag-Dropper as it is assembled, as would be seen by a viewer standing behind the truck. 8 a ) panels in the storage position 8 b ) right and left panels are parallel to the vertical sides of the truck, top panel is in the assembled position 8 c ) left and top panels are in the assembled positions, bottom panel is still folded against the right panel which is still parallel to the vertical sides of the truck 8 d ) left, top and right panels in the assembled positions; the bottom panel is still folded against the side of the right panel 8 e ) all panels are in the assembled position.
[0026] [0026]FIG. 9: Two figures that depict components of the left and top panels and their relations as would be seen by a viewer positioned behind the truck. 9 a ) the left panel is parallel to the vertical side of the truck and the top panel is in the folded position against the left panel and 9 b ) the left panel is parallel to the vertical side of the truck and the top panel is open.
[0027] FIGS. 10 : Series of figures that depict the various positions the top panel traverses as it goes from the folded positions ( 10 a and 10 e ) to the open positions ( 10 d and 10 h ) as would be seen from a viewer standing on the left side of the truck (top four figures) or behind the truck (bottom four figures). Top and bottom figures are synchronized in position.
[0028] FIGS. 11 : Figures depicting the Lock-Rod in various perspectives. 11 a ) As seen by a viewer behind the truck with the right panel still parallel to the vertical side of the truck when in the “locked position” but without the right panel in place, 11 b ) As seen by a viewer behind the truck with the right panel still parallel to the vertical side of the truck when in the “guiding position” but without the right panel in place 11 c ) As seen by a viewer behind the truck with the right panel still parallel to the vertical side of the truck when in the “guiding position” attached to the right panel, which in turn is parallel to the side of the truck 11 e ) As seen by a viewer behind the truck with the right panel still parallel to the vertical side of the truck when in the “locked position” attached to the right panel, which in turn is parallel to the side of the truck 11 d ) As seen by a viewer on the left side of the truck with the right panel still parallel to the vertical side of the truck when in the “guiding position” attached to the right panel, which in turn is parallel to the side of the truck 11 f ) As seen by a viewer on the left side of the truck with the right panel still parallel to the vertical side of the truck when in the “locked position” attached to the right panel, which in turn is parallel to the side of the truck. The following letters indicate dimensions of the following components: A=width of top block, B=length of the top block, C=height of the top block, D=height of hinge, E=height of the bottom block, F=width of the lock-rod, G=width of the bottom block, H=width of the handle and I=width of the lock-rod.
[0029] FIGS. 12 : Figures depict what a viewer positioned on the left side of the truck (FIGS. 12 a and 12 b ) or above the Drag-Dropper (FIGS. 12 c and 12 d ) would see when the right panel swings from being parallel to the truck side ( 12 a and 12 c ) to the right panel being in the assembled position ( 12 b and 12 d ). The top panel is in the assembled position. FIGS. 12 a and 12 c are synchronized, as are 12 b and 12 d.
[0030] FIGS. 13 : Series of figures depict how the Lock-Rod is used to guide and lock the top panel in place. 13 a ) The right and left panel are parallel to the truck sides, the top and bottom panels are folded; the Lock-Rod is in the “guiding position”. 13 b ) All components are as in FIG. 13 a except the left panel has swung inwards (though not yet in the assembled position) 13 c ) all components are as in FIG. 13 a except the left panel has now swung into the assembled position 13 d ) all components are as in FIG. 13 c except the Lock-Rod has now been inserted into the guide hole of the top panel and the top panel is opening into the assembled position 13 e ) components in same position as in 13 d except the top panel is almost in the assembled position 13 f ) the top panel is in the assembled position and the Lock-Rod has now been rotated counter-clockwise position so the wide block is pointing towards the viewer and has locked the top panel in the assembled position. The slits in the top panel depicted in FIGS. 13 e and 13 f are intentionally greater than would occur in actual life to facilitate viewing.
[0031] FIGS. 14 : Right panel and the folded bottom panel as seen by a viewer standing on the left side of the truck ( 14 a ) and the behind the truck ( 14 b ). Shows the dimensions and relative sizes.
[0032] FIGS. 15 : Left panel without the top panel attached so that the peg-ledge, pegs and the handle-window can be seen. 15 a ) as seen by a viewer standing behind the truck with the left panel behind the truck but in the parallel position (i.e., quasi-assembled position) 15 b ) as seen by a viewer standing behind the truck with the left panel beside the truck (in the storage position) 15 c ) as seen by a viewer standing on the right side of the truck.
[0033] FIGS. 16 : Series of figures that depict the various positions the bottom panel traverses as it goes from the folded positions ( 16 a and 16 e ) to the open positions ( 16 d and 16 h ) as would be seen from a viewer standing on the left side of the truck (top four figures) or behind the truck (bottom four figures). Vertical pairs of figures (e.g., 16 a & 16 e ) are synchronized in position. FIGS. 17 : Bottom panel in the assembled position as seen from the top of the truck with the locking mechanism in the unlocked ( 17 a ) and locked ( 17 b ) positions.
[0034] [0034]FIG. 18: Series of figures as seen from the top of the truck with the bottom panel in the assembled position as the locking mechanism goes from the unlocked ( 18 a ) to the locked position ( 18 e ).
[0035] [0035]FIG. 19: Several perspectives of the handle-lock which projects off the “locking arm” on the bottom panel. FIGS. 19 a , 19 c and 19 e are synchronized in the unlocked position; FIGS. 19 b , 19 d and 19 f are synchronized in the locked position. 19 a ) as viewed looking at the left brace head-on such that the handle is behind the left brace but can be seen jutting above the left brace; 19 b ) as viewed looking at the left brace head-on such that the handle is behind the left brace and not viewable since in the locked position 19 c ) as viewed if a viewer is on the left side of the truck and the Drag-Dropper is assembled, here with the lock in the unlocked position 19 e ) as viewed if a viewer is on the left side of the truck and the Drag-Dropper is assembled, here with the lock in the locked position 19 f ) as viewed if the viewer is looking along a plane parallel to the left panel and can perceive where the handle juts through the window in the left panel; apparatus in the unlocked position. 19 g ) same as in 19 f but apparatus in the locked position.
[0036] [0036]FIG. 20: Views of the left panel-brace in various positions. FIGS. 20 a , 20 b , 20 c and 20 f are viewed as by a viewer is standing on the left side of the truck; FIGS. 20 d and 20 e are viewed by a viewer standing at the front of the truck and looking towards the back but is able to see the bolt insertions. FIGS. 20 b and 20 c demonstrate the panel-brace may swing in the plane parallel to the truck side. FIGS. 20 e and 20 f demonstrate the panel-brace may swing in the plane perpendicular to the truck side.
[0037] [0037]FIG. 21: Views of the lower aspect of the left panel-brace as it enters the lock-box. FIGS. 21 a , 21 b , 21 c show the figures as seen by a viewer standing on the left side of the truck. FIGS. 21 d , 21 e and 21 f show the left panel as seen by the a viewer standing at the front of the tuck and looking towards the back. Figures are synchronized in their vertical positions to depict how the spring-loaded pin locks (e.g., synchronized pairs are 21 a & 21 d , 21 b & 21 e , 21 c & 21 f ) when going from the panel-brace not having yet entered the lock-box (FIGS. 21 a & 21 d ); entered the lock-box with the pin in the retracted position (FIGS. 21 b & 21 e ) and with the pin in the locked position (FIGS. 21 c & 21 f ).
[0038] [0038]FIG. 22: Views of the left upper swivel brace. FIGS. 22 a , 22 b and 23 c depict the swivel brace as would be seen from a viewer above the Drag-Dropper with the left panel behind the truck and parallel to the truck side ( 22 a ), left panel behind the truck in the assembled position ( 22 b ), left panel beside the truck in the stored position ( 22 c ). FIG. 22 d is the swivel brace as seen by a viewer standing on the left side of the truck with the left panel behind the truck in either the parallel or assembled position. FIGS. 22 e and 22 f is the right swivel brace as seen by a viewer who is located at the front of the truck and looking toward the back when the arm from the horizontal pole is ( 22 f ) or is not ( 22 e ) connected. (This L-arm is always connected in the actual apparatus, but is removed in these figures to illustrate component parts and relationships).
[0039] [0039]FIG. 23: Views of the left Pivot-Rod from various perspectives. FIGS. 23 a and 23 b are seen by the viewer standing on the left side of the truck when the stubs point towards either the back of the truck ( 23 a ) or directly at the viewer ( 23 b ). FIG. 23 c and FIGS. 23 d depict the left Pivot-rod as seen by a viewer standing behind the truck when the stubs point towards the viewer ( 23 c ) or are perpendicular to the side of the truck as might be seen when the panels of the Drag-Dropper are being rotated from the assembled or quasi-assembled position to the storage positions ( 23 d ). FIGS. 23 a & 23 c are synchronized, as are FIGS. 23 b & 23 d.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The Drag-Dropper may be conceptualized as being comprised of three component sets: 1) four panels that, when assembled, create a modified pyramid shape 2) structures internal to the assembled Drag-Dropper that assist in locking the panels together and 3) support structures external to the assembled Drag-Dropper that connect it to the trailer. Each of these will be described with regard to their size, relationships and function.
[0041] Section 1: Four Panels that when Assembled, Create a Modified Pyramid Shape.
[0042] The panels have two basic shapes: those that comprise the vertical sides of the Drag-Dropper (FIG. 3 a and FIGS. 3 b ) and those that cover the top and bottom (FIG. 3 c and FIGS. 3 d ). (The narrower side of the trapezoid like structure of the side panels will be referred to as the vertex; the corresponding point of the triangles for the top and bottom panels that contact those vertices when in the assembled position will also be referred to as vertices.) The lengths of their sides is as depicted in FIG. 3 and when assembled they form a structure as depicted in FIG. 2: the vertical sides have a 30° inward deflection from the vehicle's sides, the bottom and top panels deflect 20° from the top and bottom sides of the trailer, respectively. When in the assembled position the Drag-Dropper projects 78″ behind the vehicle (FIG. 2 c ) and its tip is elevated at least 33″ above the bottom of the trailer edge. Importantly, the assembled panels do not form a single point as in a classical pyramid but rather the point is distributed over at least 24″ to avoid excessive pressure in the event of a collision.
[0043] The width of each panel and its components are dependent upon the material composition so are not specified here exactly. However, it is expected that each panel width is at least 0.5″.
[0044] The assembly of the panels must follow a specific order such that the internal locking mechanisms can function. This sequence is illustrated in FIG. 8:
[0045] 1) the Drag-Dropper with the panels in the storage position ( 8 a )
[0046] 2) the left and right panels are swung so they extend behind the truck but remain parallel to the vertical sides of the truck, then the top panel is unfolded from the left panel ( 8 b )
[0047] 3) the left panel is rotated inward 30° such that the top edge of the top panel is flush against the truck trailer ( 8 c ).
[0048] 4) the right panel rotates inward 30° such that the right and left panels connect at their vertices ( 8 d )
[0049] 5) the bottom panel is unfolded from the right panel, thus completing the assembled position ( 8 e ).
[0050] The left panel has a small hole which allows the handle of the bottom panel to project through it and a small brace that the handle locks to. The top panel has a small hole in it which allows the locking-bar to pass through it. All of these points will be described more below.
[0051] To disassemble the Drag-Dropper one would reverse the sequence of events.
[0052] The composition of the panels may be one of several materials, but the recommended material is impermeable and rigid (e.g., fiberglass) so the shape is not distorted by wind but can collapse in the event of a posterior collision exceeding a pre-specified force.
[0053] Section 2: Structures Internal to the Assembled Drag-Dropper that Assist in Locking the Panels Together
[0054] There are a number of components attached to the four basic panels to help ensure the assembled Drag-Dropper maintains a secure structure and to assist in reaching this position. There are two permanent connections that secure two pairs of panels and two mobile mechanisms which connect two other pairs of panels. Each will be described in detail.
[0055] Permanent connections: A spring-loaded hinge connects the edges of the left panel and top panel as shown in FIGS. 9 and 10. The spring forces the top panel to unfold and is strong enough to support the weight of the top panel; however it is not excessive and can be easily overcome when the driver pulls on a rope attached to the tip of the top panel when s/he wishes to refold the top panel. Analogously, a hinge (without a spring) permanently connects the edges of the right panel and the bottom panel as shown in FIGS. 14 and 16. When released, the bottom panel lowers to its unfolded position (FIG. 16). The exact width of the hinge and spring-hinge are dependent upon the material used but would be expected to be less than 0.5″.
[0056] Mobile connections: The means by which the top panel attaches to the right panel and the means by which the left panel attaches to the bottom panel are somewhat more complex and involve mobile and stationary components so will be described separately. The next two paragraphs describe how the top and right panels connect; the subsequent two paragraphs describe how the left and bottom panels connect.
[0057] Connection of the top panel and right panel: A vertical pole, called the “locking-rod” is depicted in FIGS. 11, 13 and 14 . This pole is comprised of a top block that is permanently attached to the upper corner of the right panel, has a hinge on its underside that allows rotation in the plan perpendicular to the right panel; the other side of the hinge is a slender shaft that extends into the “bottom block” which is in turn connected to a longer, slender pole which has a handle on its bottom end. The top-block is shaped as a cube but the dimensions of the bottom block are all unequal so that, when viewed from an observer behind the truck, the resulting width is narrow when the handle points towards the observer (FIGS. 11 a , 11 e ) but is wide when the handle is pointed to the left of the truck (FIG. 11 c ). Similarly, when viewed from the left of the truck, the bottom-bock appears narrow when the handle points towards the observer ( 11 d ) or wide when the handle points towards the vertex of the right panel ( 11 f ).
[0058] The locking rod works to secure the top panel and right panel together as depicted in FIG. 13 and as described here: the top panel is unfolded slowly and the distal end (with the handle) of the locking-rod is inserted through a small rectangular hole in the top panel; the handle of the locking-rod is turned towards the left truck side so that the bottom-block's dimensions are concordant with the rectangle's hole (the so-called “guiding position”) and as the top panel unfolds its right tip slides up the locking-rod until it rests just below the top-block. The locking rod is then swung back towards the right panel then the handle is turned counter-clockwise which rotates the top-block into the so called “locking position” such that the top-panel is locked in the unfolded position. As with other elements in the mobile components, the size of the locking-rod and its respective dimensions are dependent upon the material composition. However, an optimal approach would involve the pole width of less than 0.5″, top-block's cube dimension of 2″ and the bottom-block's dimensions of 2″×4″×2″; additionally, the dimensions in FIG. 14 would depend upon the material used but their relative sizes are approximated here.
[0059] Connection of the top and right panel: A series of short, rigid cylinders (pegs) are permanently affixed in a vertical position to a ledge (so called peg-ledge) that is in turn attached to the left panel and runs along the lower edge of the left panel (FIG. 15). The peg-ledge extends out at least 3″ and each peg is at least 1″ and has a central hollow as seen by an observer standing at the right side of the truck ( 15 c ). The bottom panel has an equal number of circular holes as there are pegs on the peg-ledge (in this example I have made 7 pegs and 7 peg-holes) which have a slightly larger diameter and when unfolded the holes in the bottom panel surround the pegs such that the pegs project through the bottom panel (FIG. 14).
[0060] The bottom panel has a special apparatus called the locking-arm that has locking-fingers extend from it in a parallel manner and can be pulled in a plane parallel to the bottom-panel by a handle that projects through a small window in the left panel (FIG. 17). The locking-arm is affixed to the bottom-panel by guide-bars which allow it to be moved in a plane towards or away from the edge with the holes. Once the bottom panel has been lowered such that the pegs from the left panel project into the bottom panel, the locking arm is pulled towards the left panel such that the fingers pass through the hollow parts of the pegs (FIG. 18) and then the handle is folded against the external component of the left panel (FIG. 17 b , 18 e ) such that it connect with an external brace on the left panel and can be locked with a pad-lock (FIG. 19).
[0061] To disassemble the Drag-Dropper, the above sequence of steps is done in reverse. Importantly, only one pad-lock is required to secure the structure and, though one could use an alternative method, given the very dangerous consequences of structural collapse if the handle was tampered without the knowledge of the driver, this is a necessary safety component.
[0062] Section 3: Support Structures External to the Assembled Drag-Dropper that Connect it to the Trailer.
[0063] There are three external components which can be grouped as 1) those that secure the panels of the Drag-Dropper to the horizontal poles 2) the apparatus used to swing the panels of the Drag-Dropper from the quasi-assembled position to the storage position and 3) the panel-brace which secures the panels while in the storage position. One paragraph will be given to describe each of these in this order.
[0064] Apparatus to secure the panels to the horizontal poles: The swivel brace depicted in FIG. 22 comprises a simple bolt that passes through two steel trapezoids in turn mounted on a plate that attaches to the right or left panels. There may be any number of these swivel braces (I have drawn in 4 for each of the left and right panels) and the distal tip of a horizontal pole is permanently connected to these when the bolt is passed through a hole in the horizontal pole then welded in place. When the swivel brace is attached to the panel and the horizontal pole, it may assume several angles that allow the panels to move 30° inward when being assembled (FIG. 22 b ) and facilitate the vertices of the right and panel to be flush against the side of the truck when in the storage position (FIG. 22 c ).
[0065] Apparatus used to swing the panels: The pivot-rod is a vertical rod secured to the trailer by anchors and that has a number of stubs projecting perpendicular from it, the latter of which are hollow and accept the proximal tips of the horizontal poles (FIG. 23). The exact number of stubs can vary depending upon the size of the vehicle, and the length of the horizontal poles can also vary so that the pivot-rod could be located close to the back door (in the case where the back-door is opened vertically as in a roll-up door) or significantly far from the back doors (in the case where the back-door is swung open and lies against the sides of the truck. The horizontal poles chosen for a given installment may be short or long depending upon the location of the pivot rod, but each has a right-angle (so called L-arm as in FIG. 22) just prior to attachment with the swivel joint; the distance of this L-arm may be varied upon the size of the vehicle but generally should be short so the panels make contact just inside the edge of the side walls (but far enough in so air can not accidentally enter the interior of the assembled Drag-Dropper). The horizontal poles would be securely affixed to the stubs and the anchors of the pivot-rods would by a securely affixed to the trailer when the Drag-Dropper and its supporting structures are installed on the truck. When swung into the storage position (FIGS. 4 , 6 , 7 ) the panels move in a semi-circle whose center is the pivot-rod and radius is sum of the length of the stubs, horizontal pole and the length of the panels.
[0066] Apparatus used to secure the panels in the storage position: In the event that the truck is used for frequent stops rather than longer-hauls, the driver may wish to leave the Drag-Dropper in the storage position and can secure it in this position using the panel-brace. The panel brace is secured to the truck by its top end to a “top component” (which entails a bolt that is inserted through a top-plate which is connected with a hinge to an inner plate and is mounted with bolts or other means to the truck-side (FIGS. 5 & 20 )). This top component allows the pole of the panel-brace to move in both the planes parallel to the truck side (FIGS. 20 b and 20 c ) and perpendicular to it (figure e) so that it may be moved from a neutral position (FIG. 5 a ) to one in which it overlays the panels (FIG. 5 b ) and can secure them. The mobile end of the panel brace has a “foot” that inserts into a lock-box (FIGS. 5 & 21). Since the swivel brace (described two paragraphs above this one) allows the vertex of the panel to move, the optimal secured storage position is one in which the vertices of the panels are against the truck wall (FIG. 7) so that air is deflected away from the panels and pushes them against the walls rather than getting between the panels and the walls which could result in material fatigue and potentially dismemberment of the panel from a moving vehicle. The exact dimensions of the panel-brace and its components are dependent upon the material used, but the pole of the panel-brace should be at least 1″ in diameter and the top components' hinge-plates should be at least 2″×2″×0.5″. | The Drag-Dropper is a collapsible structure made of rigid components that may be unfolded to form a modified pyramid to streamline the posterior aspect of trucks. The exact dimensions of the apparatus may be varied such that small to large trucks including semi-tractor-trailers may be fitted. As safety is always the foremost priority, the design has structural redundancy to reduce if not eliminate destruction during operation even if one of several essential component were to fatigue simultaneously from material failure. Likewise, the dimensions seek to maximize posterior drag reduction without additional functional length of the vehicle that would obstruct the driver's rear vision, and the apex is intentionally far above the height of most passenger vehicles in the event of a collision involving a trailing vehicle.
The exact material composition, dimensions and means by which it is affixed to the trailer may change and all such variations when crafted in the described design comprise the scope of this patent application. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to electrical generators, and more particularly to a system for monitoring the vibration of an electrical generator.
U.S. Pat. No. 5,146,776, Sep. 15, 1992, titled Method for Continuously Calibrating an Optical Vibration Sensor, discloses a system for automatically calibrating a fiber optic vibration monitor (FOVM) employing a cantilever-mounted grid attached to a generator. The grid interrupts a light beam at a frequency directly proportional to the sensor's vibrational amplitude at a singular driving frequency (i.e., 120 Hz). The system disclosed in the patent is illustrated in FIG. 1. A generator 10, optical vibration sensor 12, and computer 14 constitute the vibration sensing system 16. The patent teaches how troublesome conditions of the generator can be detected at an early stage by measuring the vibration amplitude of a generator end-winding. This allows maintenance to be scheduled to avoid damage to the generator and minimize down time.
Briefly, the system may be described as follows: The optical vibration sensor 12 is mounted directly to an end-winding 17 of the generator 10. The massive exciter-end and turbine-end end-turns of the generator are consolidated into semi-ridged baskets to prevent damaging effects of the 120 Hz vibration coupled into the system from the rotor field. The sensor monitors the end-turn vibration to provide warning signals when destructive levels of vibration exist or when the vibration level is increasing. The vibration may then be controlled through load management or change in coolant gas temperature until an outage can be scheduled for the generator.
FIG. 2 illustrates the optical vibration sensor 12 in more detail. The optical vibration sensor 12 receives light from an optical fiber cable 18. The sensor includes a housing 20 and an optical-to-digital conversion unit 22. The housing 20 includes an internal reed 24 and a grid assembly 26. The internal reed 24 and the grid assembly 26 are designed to have a natural resonant frequency above 120 Hz. Preferably, the resonant frequency is approximately 132 Hz for a 60 Hz generator application. See U.S. Pat. No. 4,321,464, Mar. 23, 1982, or U.S. Pat. No. 4,218,614, Aug. 19, 1980, for further details of the sensor 12.
The following discussion assumes the generator is producing 60 Hz electrical power, although the principles are the same for a 50 Hz unit.
As the internal reed vibrates, the grid assembly 26 moves up and down, causing light pulses to be produced. The number of light pulses produced in a given time interval is proportional to the amplitude of the 120 Hz (100 Hz in Europe) vibration being measured. The grid assembly 26 has evenly spaced grid openings separated by 10 mils. Thus, the number of light pulses produced in a given time interval is a function of the resonant frequency of the sensor and the distance the grid swings from its equilibrium position. The light pulses are output from the casing 20 through the optical fiber cable 18 to the optical-to-electrical conversion unit 22. The optical-to-electrical conversion unit 22 converts the light pulses into a digital signal according to a conventional method. For example, a photodiode can be utilized to convert the light pulses to an electrical signal which can then be converted into a digital frequency output signal. The output signal waveform takes the form of a frequency modulated sine wave. The signal is, furthermore, slightly frequency-modulated by the mixing of the 120 Hz excitation with the resonant frequency of the sensor.
The system employs curve fitting of the beat signal peaks to a trigonometric function of the form sin(2πf B t) to determine the beat frequency f B . The beat frequency is then used to calibrate the system. In particular, the system computes an amplification factor
M.sub.0 =(120/f.sub.0).sup.2 /(1-(120/f.sub.0).sup.2),
where the sensor's resonant frequency is given by
f.sub.0 =120 Hz+f.sub.B.
Thus, the resonant frequency f 0 of the optical vibration sensor determines the amplification factor M 0 . To obtain the actual displacement of the generator due to vibration at 120 Hz, the measured amplitude (i.e., as determined by the light pulse signal) must be divided by the amplification factor. Note that the equation for M 0 results from the correlation between the light pulse frequency and the amplitude of the grid, which can be expressed, for the grid-reed geometry employed by the assignee (Westinghouse), as:
Amplitude of vibration=f LP ×1 mil/180 Hz, where f LP is the light pulse frequency (Hz). This equation is true for a grid assembly having a grid spacing of 10 mils.
In sum, the system employs the amplitude of the signal at the "extrema" to determine the beat frequency. Such a beat frequency is discernable from FIG. 3A, which depicts a waveform representative of an ordinary sensor signal. The extrema are the furthest points in the grid's motion as it oscillates about its equilibrium position. The largest wavelengths in the frequency modulated output signal (i.e., the points in the waveform where the zero crossings are spread apart the most) correspond to the extrema, since the extrema are where the grid comes momentarily to rest before reversing direction.
The present invention addresses the problem that occurs when the beat amplitude becomes large enough to cause a fold-over, distorting the beat frequency. This problem also occurs in connection with a small beat amplitude when the signal at the extrema occurs near the peak signal values. An illustration of a small fold-over phenomenon is shown in FIG. 3B. Very large fold-overs often occur in the field. However, the waveform extrema for such large fold-overs are difficult to visualize and thus are not depicted. As discussed above, to determine the actual displacement of the generator due to vibration at 120 Hz, the amplification factor M 0 must be determined. To determine the amplification factor, the resonant frequency of the sensor (f 0 +f B ) must be accurately determined. However, when fold-overs occur, they distort the beat signal determined from the extrema such that it becomes extremely difficult to determine the beat frequency, making it practically impossible to accurately determine the resonant frequency of the sensor. Moreover, the resonant frequency drifts (changes) with temperature and with age of the sensor. Therefore, one cannot assume that the resonant frequency of the sensor is whatever it was designed to be. It must be measured in the field, while the generator is operating.
SUMMARY OF THE INVENTION
Accordingly, a primary object of the present invention is to provide a system for determining FOVM sensor beat frequency in environments with a high beat amplitude. Another object of the present invention is to provide such a system which will also determine FOVM sensor beat frequency in environments wherein the beat amplitude is small but the signal at the extrema occurs near the peak signal values.
According to the present invention, methods (or apparatus) for determining a beat frequency in a vibration sensing system attached to equipment comprise the steps of (or means for): (a) generating a vibration signal indicative of a vibrational frequency and amplitude of the equipment; and (b) obtaining a beat frequency from the vibration signal by storing and processing time interval data representing the time intervals between zero crossings of the vibration signal.
In one preferred embodiment of the present invention, the equipment is an electrical generator having a 120 HZ end-turn vibration, the vibration signal is obtained with a vibration sensor attached to the generator, and the vibration signal includes a mechanical vibration signal resulting from the 120 Hz end-turn vibration of the electrical generator and the resonant frequency of a vibration sensor. Further, in the preferred embodiment, step (b) comprises calculating time interval data by summing clock counts between consecutive zero crossings of the vibration signal, finding positions of extrema time intervals corresponding to fold-overs in the time interval data, compensating for said fold-overs by changing the number of zero crossing time intervals summed about the extrema affected by said fold-overs, and performing a Fourier transform on the time interval data to obtain transformed time interval data which has a peak value at a point corresponding to the beat frequency.
Other features of the present invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of an FOVM as applied to an electrical generator.
FIG. 2 is a more detailed depiction of the optical vibration sensor 12.
FIGS. 3A-3H are waveform diagrams demonstrating the improved performance provided by a system, in accordance with the present invention, for determining FOVM sensor beat frequency.
FIGS. 4A-4D collectively are a flow diagram of one preferred implementation of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention provides a method for use in an FOVM system for measuring the motion of the grid at the extrema. The method employs the change in length of the time period defined by the signal zero crossings on either side of the extrema (i.e., the time interval extrema).
FIG. 3C depicts an exemplary sensor waveform (voltage amplitude over two cycles). The extremum intervals for an upper extremum and a lower extremum are also shown. The upper extremum is represented by the "x" (position extremum) or the line "A" (time interval extremum) and the lower extremum interval is represented by the "o" or the line "B." It should be noted that the upper extrema can be represented equally well by the distance X (i.e., the distance from 0 to x) or the time interval A in FIG. 3C. Likewise, the lower extrema can be represented by the distance O or the time interval B. The time interval representation will be used herein for the following reason. If the position representation of the extrema is used, no fold-over occurs when X reaches P (the top of the graph) and is reflected back (note that X can never exceed A). If the time interval representation of the extrema is used, fold-over occurs when X=0 and A suddenly changes from a large value to a small value, or vice versa. While the two representations are certainly different ways of defining the extrema, they are nearly equivalent. However, the position representation does not behave in a linear manner, while the time interval representation does. Therefore, if the beat amplitude is slowly increased, X would increase and reach P and then get smaller. This change in X is nonlinear with beat amplitude. That is, X tends to "hang-up" at P as the beat amplitude is increased. This is caused by the full intensity of light being received by the optical sensor for positions of the grid around the position at which light passes through. At a lower extremum, this occurs for the stop between two adjacent slits, i.e., the stop can move but it still blocks light for a certain small swing of the grid.
Thus, as a beat causes the grid to oscillate about an average position at each extremum, this time interval changes in a manner analogous to the change in amplitude of the signal at the extremum. A fold-over occurs when the beat amplitude or vibrational amplitude causes the sensor signal (i.e., waveform) to cut the zero amplitude axis and thereby define a new extremum time interval in a discontinuous manner. The same discontinuity occurs in the method disclosed in U.S. Pat. No. 5,146,776 when the signal experiences fold-over at upper and lower peaks.
FIG. 3D illustrates a discontinuous change in the extremum time interval as the upper extrema pass from interval A to interval B. These discontinuities create problems in determining the sensor beat frequency.
Preferred embodiments of the present invention collect and process only signal zero crossing times and do not digitize the complete sensor signal. This greatly reduces data acquisition requirements and permits a highly accurate measurement. An existing Blade Vibration Monitor (BVM) 32 MHz card (zero crossing card) may be used for this purpose. The BVM card is able to determine the signal zero crossing times to within 30 billionths of a second, permitting a very accurate measurement of the beat frequency. Data files are typically 12,000 entries long. To achieve the same accuracy, the direct digitization procedure disclosed in the patent would require a 320,000 entry data file. Most of this data would be discarded. However, considerable time and expensive hardware are required to accomplish this. Therefore, the present invention minimizes the required data and reduces hardware cost and computer processing time.
The algorithm described below determines the beat frequency in the FOVM sensor when a high beat frequency amplitude causes one or more additional grid slits to pass light. This phenomenon causes fold-over. Two types of extrema, upper and lower, are generated in the sensor signal each sensor cycle. An extremum time interval is determined by the signal zero crossings on either side of each extremum. The upper extremum interval occurs when the grid momentarily comes to rest at the very top of its path. Likewise, the lower extremum interval occurs when the grid momentarily comes to rest at the bottom of its path.
At low beat amplitude, the beat causes a small modulation in the extremum time intervals. A plot of lower extremum intervals vs. sensor cycles results in a sinewave with a frequency equal to that of the beat. When the beat amplitude gets larger (or smaller), causing an additional (or loss of) two zero crossings, this procedure of extracting the beat frequency becomes confused by the sudden appearance of an unexpected small (or large) extremum interval, resulting in a large discontinuity in the beat signal.
FIG. 3E depicts the extremum time interval, referred to herein as "DELTA()," at the lower extrema occurring once each sensor cycle for 450 sensor cycles. This highly chaotic and discontinuous waveform shows no harmonic beat signal. FIG. 3F depicts a Fourier Transform of this data. The beat frequency expected at 12.6 Hz is lost in the noise generated by the fold-overs (added zero crossings) at the extrema.
According to the present invention, the extremum interval DELTA() is expanded by summing over the appropriate number of adjacent intervals to account for beat amplitude increase or decrease when fold-over occurs. The algorithm described below determines when a fold-over has occurred and extends the measured time interval DELTA() by adding to that interval at the extrema the correct number of intervals on either side of the extremum interval. The algorithm may be implemented with computer software written, e.g., in the QUICK BASIS (by Microsoft) programming language. DELTA() at a minimum is one center time interval but may be that center time interval plus one, two, three, or more time intervals on either side of the center time interval. Determining how many intervals about the extremum interval to sum over is complicated by the following:
It is known when two additional zero crossings have been added (or lost) between adjacent extrema but, without specific knowledge of the waveform, it is not known which extrema, upper or lower, were responsible. According to the present invention, the FOVM collects and processes only signal zero crossing times and does not digitize the complete sensor signal. This greatly reduces data acquisition requirements and permits a more highly accurate measurement. A 32 MHz clock zero crossing board may be used for this purpose.
It is important to determine the correct starting parameters for the summing intervals. The state of each extremum can be determined by only one parameter, referred to herein as "J%()." J%() is the number of time intervals (zero crossings plus one) between the extremum in question and the previous extremum. The summing parameter "S1()" specifies the number of intervals to be summed over at each extremum. The number of intervals to be summed over is equal to 2*S1()+1. Incorrect starting values of the summing parameter (i.e., values of S1(1) and S1(2)) will lead to disaster.
The odd DELTA() are the correct expanded time intervals for each upper extremum and the even DELTA() are the correct expanded time intervals for each lower extremum. (Note that "DELTA()" represents DELTA(1), DELTA(2), . . . DELTA(N), where N=450 in FIG. 3E.)
FIG. 3G depicts a plot of DELTA() for the lower extrema for the same data used in FIG. 3E. Unlike FIG. 3E, however, the extrema intervals DELTA() are expanded by the addition of the correct number of adjacent time intervals. The beat is clearly and unambiguously seen. FIG. 3H shows a Fourier Transform of the lower extrema beat signal. The beat frequently of 12.6 Hz is clearly identified. The sensor natural frequency is thus 120 Hz+12.6 Hz=132.6 Hz and the sensor correction factor can thus be easily found. The same procedure performed for the upper extrema would achieve identical results (this would be useful, e.g., as a check).
One preferred embodiment of a computer implemented algorithm in accordance with the present invention will now be described with reference to the flow diagram of FIGS. 4A-4D. A zero crossing I/O card produces a one-dimensional data array Z() (e.g., with approximately 10,000 entries) representing the absolute time (clock count) at which the FOVM sensor voltage crossed the zero volt level. Z() is therefore an array of monotonically increasing numbers representing zero crossing times as clock counts. There are 10,000 storage locations in the Z() array in one exemplary embodiment of the invention.
The blocks of the flow diagram correspond to steps 1-5 as follows:
Step-1=Blocks 100-106
Step-2=Blocks 108-138
Step-3=Blocks 140-144
Step-4=Blocks 146-174
Step-5=Blocks 176-200
Briefly, steps 1-5 perform the following functions: Step-1 calculates time intervals (clock counts) between consecutive zero crossing. The respective clock counts are stored in the X() array. Step-2 finds positions of extrema time intervals in the X() array (K of them), finds the number of intervals that occur between adjacent extrema (represented by J%()), and finds the minimum number of intervals that occur between any two neighboring extrema. This minimum number is represented by the variable MIN. As the beat amplitude increases, more time intervals about the extrema time interval must be summed. Step-3 finds the first point (START) in the series of extrema where the beat amplitude is a minimum and subsequently only one time interval is required to form the corrected time interval data (represented by DELTA()), i.e., there is no fold-over. Step-4 comprises a forward chain that determines the number of intervals about each extremum interval to sum over from the point START to K. Note that S1(START)=S1(START+1)=0 (since there is no fold-over). Step-5 comprises a backward chain from K-1 to 0 that determines whether the number of time intervals to be summed over should change based on the number of interval counts J%() between extrema occurring after the last extremum of this type, i.e., upper or lower.
Step-1
Referring now to FIG. 4A, at block 100 the variable "I" is set to 1. At block 102, X(I) is set to Z(I +1)-Z(I). At step 104, I is compared to 10,000. If I is not equal to 10,000, the program branches to block 106; otherwise it proceeds to block 108. At block 106, I is set to I+1.
Step-2
At block 108, I is set to 5, TOT is set to 0 , K is set to 1, and MIN is set to 100. At block 110, "SKIP1" is set to X(I)+X(I+1) and SKIP2 is set to X(I+3)+X(I+4). At block 112, SKIP1 is compared to SKIP2. If SKIP1 is less than SKIP2, the program proceeds to block 114; otherwise it proceeds to block 116. At block 114, I is set to I+1 and the program branches back to block 110. Thus, blocks 110-114 look ahead to ensure that the time intervals are increasing in length. This ensures that the symmetric point in the time interval array X() that occurs between extrema is not detected.
At block 116, J is set to 1. At block 118, T1 is set to the absolute value of (X(I+J)-X(I-J)) divided by the quantity (X(I+J)+X(I-J)). At block 120, T1 is compared to a trigger variable "TR," which in preferred embodiments is equal to 0.1. If T1 is less than TR, the program branches to block 122; otherwise it proceeds to block 124. At block 122, TOT is set to TOT+1. At block 124, J is set to J+1. At block 126, J is compared to the number 5. If J is less than 5, the program branches back to block 118; otherwise it proceeds to block 128. At block 128 TOT is compared with the number 3. If TOT is less than 3, the program branches back to block 114 (FIG. 4A); otherwise it proceeds to block 130. At block 130, the variable EX(K) is set to I. At block 132, J%(K) is set to EXT(K)-EXT(K-1)-1. At block 134, J%(K) is compared to MIN. If J%(K) is less than MIN, the program branches to block 136; otherwise it proceeds to block 138. At block 136, MIN is set to J%(K). At block 138, the index I is set to the integer value of (I+J%(K)/2+2). The program then branches back to block 116 (FIG. 4A), i.e., if I is less than 10,000 (the test to determine whether I is less that 10,000 is not depicted in the drawings).
The following points should be noted in connection with the above description of Step-2 (comprising blocks 108-138): Block 118 calculates a symmetry parameter T1. With decision block 120, corresponding time intervals on either side of the Ith interval are judged symmetric. With block 122, the program counts the number of corresponding time intervals about the Ith interval that are symmetric. With block 126, the program tests four corresponding time intervals about the Ith time interval for symmetry. With block 128, the program assures that three of four corresponding interval are judged symmetric for the Ith time interval to be judged in extremum. With block 130, the program identifies the location of the extremum just found (i.e., the Kth extremum) in the time interval array X(). This is called the upper extrema. With block 132, the program determines the minimum number of time intervals that occur between extremum K and the previous extremum K-1. With blocks 134-136, the program records the number of time intervals that has been measured between the extremum. This number is assigned to the variable MIN. With block 138, the index I is incremented to skip over the next symmetric time interval that occurs between extrema. After steps 1 and 2 have been completed, the position EXT(K) of all K extrema in the time interval array X(I) have been found. The odd K are arbitrarily identified as upper extrema and even K are identified as lower extrema. The number of time intervals that occur between extrema is also calculated and stored in the variable array J%(K). The minimum value stored in the J%() array is stored in the variable MIN.
Step-3
Referring again to FIG. 4B, Step-3 begins at block 140 by setting START to 0. At block 142, START is set to START+1. At block 144, J%(START), J%(START+1), and MIN are compared. If the three are not equal to one another, the program branches back to block 142; otherwise it proceeds to block 146. In this manner, the program finds the first time that two adjacent extrema equals MIN.
Step-4
At block 146, the index I is set to START and DELTA(I) is set to X(I). At block 148, I is set to START+1 and DELTA(I) is set to X(I). In this manner, the first two corrected time intervals (DELTA()) have a sum index S1() equal to 0. The program is only required to sum over the center interval for these two extrema. At block 150, I is set to I+1, Q is set to 0, and DELTA(I) is set to 0. At block 152 (FIG. 4C), J%(I-1) is compared to J%(I). If the former is greater than the latter, the program branches to block 154; otherwise it proceeds to block 156. At block 154, the sum index S1(I) is set to S1(I-2)-1. At block 156, J%(I-1) is compared to J%(I). If the former is less than the latter, the program branches to block 158; otherwise it proceeds to block 160. At block 158, S1(I) is set equal to S1(I-2)+1. At block 160, the sum index S1(I) is set to S1(I-2). Thus, blocks 150-160 determine whether the number of intervals to be summed over (i.e., the sum index, S1()) should be changed based on the number of interval counts (J%()) between extrema occurring before the last extremum of this type, i.e., upper or lower. Block 154 decrements the sum index S(1) by 1 if the interval count J%() decreases. Block 158 increments the sum index S1() by 1 if the interval count J%() increases. Block 160 leaves the sum index S1() unchanged, i.e., if the interval count neither decreases nor increases.
At block 164, S1(I) is compared to 0. If it is equal to 0, the program branches to block 172; otherwise it proceeds to block 166. At block 166, the variable Q is set equal to Q+1. At block 168, DELTA(I) is set equal DELTA(I)+ X(I+Q)+X(I-Q). At block 170, Q is compared with S1(I). If the two are equal, the program proceeds to block 172; otherwise it branches back to block 166. Therefore, blocks 164-170 sum up the two S1() time intervals on either side of the center time interval (this may be done more than once for a multiple fold-over). At block 172, DELTA(I) is set equal to DELTA(I)+X(I). Block 172 adds in the center time interval. At block 174, I is compared with K. If I is less than K, the program branches back to block 150 (FIG. 4B); otherwise it proceeds to block 176 (FIG. 4D). Thus, the program returns to the start for analysis of the next higher extremum if I is less than K; otherwise it exits to begin the backward chain.
Referring to FIG. 4D, the program at block 176 sets the index I to START. At block 178, I is set to I-1, Q is set to 0, and DELTA(I) is set to 0. At block 180, J%(I+2) is compared with J%(I+1). If the former is greater than the latter, the program branches to block 182; otherwise it proceeds to block 184. At block 182, S1(I) is set equal to S1(I+2)-1. At block 184, J%(I+2) is compared with J%(I+1). If the former is less than the latter, the program branches to block 186; otherwise it proceeds to block 188. At block 186, S1(I) is set equal to S1(I+2)+1. At block 188, S1(I) is set equal to S1(I+2). Thus, blocks 180-188 determine whether the number of time intervals to be summed over should change based on the number of interval counts between extrema occurring after the last extremum of this type, i.e., upper or lower. With block 182, the program decrements the sum index S1() if the interval count J%() increases. With block 186, the program increments the sum index S1() if the interval count J%() decreases. With block 188, the sum index S1() is unchanged, i.e., if the interval count neither increases nor decreases.
At block 190, S1(I) is compared with 0. If it is equal to 0, the program proceeds to block 192; otherwise it branches to block 194. At block 192, DELTA(I) is set equal to DELTA(I)+X(I). At block 194, Q is set equal to Q+1. At block 196 DELTA(I) is set equal to DELTA(I)+X(I+Q)+X(I-Q). At block 198, Q is compared with S1(I). If the two are equal, the program branches to block 192; otherwise it loops back to block 194. Thus, blocks 190-198 sum up the two S1(I) time intervals on either side of the center time interval I, and repeats this process if a multiple fold-over exists. Block 192 adds in the center time interval I. At block 200, I is compared with 1. If I is greater than 1, the program branches back to block 178; otherwise it ends. Thus, the program returns to start the next lower extremum until it reaches the front end, which is when I=1.
To perform a Fourier Transform or Fast Fourier Transform (FFT), the program lets the number of sensor cycles captured be K=1024, which corresponds to 8.53 seconds of data. The dependent variable DELTA(2I), I=1-512, has the units of time. However, this is not important, since only the variation in time (frequency) of this signal is used. The variable 2I is therefore also representative of time. The time interval between 2I=2 and at 2I=4 is 1/120of a second. This is for the lower extrema.
For the upper extrema, the dependent variable DELTA (2I-1), I=1-512, is the time interval between data points 2I-1=1 and 2I-1=3, which again is 1/120of a second. A Fourier Transform or FFT on DELTA(2I) and then on DELTA(2I-1) will yield identical sensor beat frequency F B with a resolution of 0.117 Hz. The sensor natural frequency F N equals 120 Hz+F B . The sensor correction factor "CF" is given by the expression,
C.sub.F =(F.sub.N.sup.2 -F.sub.0.sup.2)/(F.sub.I.sup.2 -F.sub.0.sup.2),
where F 0 is the excitation or driving frequency applied to the sensor (typically 120 Hz) and F I is the sensor design frequency (typically 132.5 Hz).
Many features and advantages of the present invention are apparent from this specification and thus it is intended by the appended claims to cover all such features and advantages which fall within the true spirit and scope of the present invention. | A method for determining a beat frequency in a vibration sensing system attached to an electrical generator comprises the steps of (a) generating a vibration signal indicative of a vibrational frequency and amplitude of the generator; and (b) obtaining a beat frequency from the vibration signal by storing and processing time interval data representing the time intervals between zero crossings of the vibration signal. A generator 10, optical vibration sensor 12, and computer 14 constitute the vibration sensing system 16. The computer is programmed to analyze the time interval data to obtain the beat frequency. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. patent application Ser. No. 14/212,619 filed Mar. 14, 2014 (now U.S. Pat. No. 9,381,630).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND
Frictionally and/or adhesively bonded joints of pipe are commonly used with many types of underground pipelines. Conventionally available joints of pipe include male and female type jointing.
It is necessary that large forces be used to cause the male end of one joint of pipe to be inserted into the female end of a second joint of pipe so that a proper seal can be made between the two joints of joined piping, along with overcoming frictional forces between the joints of pipe and the ground surface in contact with the joints of pipe.
The large forces necessary to join multiple joints of pipe together are especially difficult to create in confined spaces such as ditches or digouts where the joints of pipe are placed before being joined and which will be filled so that the pipeline will be below or underground.
Conventionally available methods for joining pipes include hammering the one joint into another.
While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner.
In one embodiment is provided a method and apparatus including a pulling and pulled portions detachably connectable to two pipe joints to be joined which are located in a ditch or dugout, which apparatus pulls one joint relative to the second joint causing socketing of the joints together at a joint area.
In one embodiment is provided cables or chains which detachably connect the pulling and pulled portion of the method and apparatus.
As force is applied by the gas controlled cylinders the joints of pipe are pulled together and one joint is socketed into the other at the joint between them.
In one embodiment each pipe is encircled by a clamping belt.
In one embodiment the gas controlled cylinders include a frictional enhancing material suitable for gripping each joint of pipe, such as rubber.
In one embodiment the pulling section includes a pair of gas controlled cylinders each having extension/retraction rods. In this embodiment each gas controlled cylinder will be detachably connected to a first joint of pipe with diametrically opposed positions on the first joint of pipe.
In various embodiments chains or cables or like pulling members can be connected to the extension/retraction rods of each gas controlled cylinder, and also to a pulled section which pulled section is detachably connected to a second joint of pipe.
In one embodiment the gas controlled cylinders can be actuated causing retraction of the extension/retraction rods into the gas controlled cylinders, said retraction causing the male end of the first joint of pipe to be pulled into the female end of the second joint of pipe.
In various embodiments pulling can be made at time when each joint of pipe is resting in a ditch.
In various embodiments multiple pulls of separate joints of pipe can be made without relocating pulling section when it is detachably connected to the first joint of pipe. In various embodiments at least 2, 3, 4, 5, 6, 7, 8, 9, and 10 separate joints of pipe pulled together without removing the pulling section from its detachable connection to the first joint of pipe. In various embodiments, a range of multiple pulls can be made between any two of the above referenced multiple joints of pipe being pulled without removing the pulling section from its detachable connection to the first joint of pipe.
In various embodiments pulls can be made between a plurality of joints of pipe having a minimum joint length of at least about 10, 12, 14, 15, 16, 18, 20, 22, 25, 30, 35, 40, 45, and/50 feet without removing the pulling section from its detachable connection to the first joint of pipe. In various embodiments, multiple pulls of joints of pipe having lengths falling with a range between any two of the above referenced minimum joint lengths can be made without removing the pulling section from its detachable connection to the first joint of pipe.
In various embodiments the method and apparatus includes a pulling section having a clamping belt with a plurality of pulling cylinders, with at least one of the pulling cylinders being laterally adjustable relative to the clamping belt. In various embodiments both of the pulling cylinders are laterally adjustable relative to the clamping belt. In various embodiments the apparatus includes two clamping belts with wherein at least one of the pulling cylinders has lateral adjustability, and in other embodiments two of the clamping cylinders have lateral adjustability. In various embodiments lateral adjustability can be provided by a loop connection with the at least one clamping belt. In various embodiments lateral adjustability can be provided by a sliding connection, and in other embodiments by a slot connection with the clamping belt.
In various embodiments the method and apparatus includes a pulled section having a clamping belt with a plurality of connectors, with at least one of the connectors being laterally adjustable relative to the clamping belt. In various embodiments both of the clamp connectors are laterally adjustable relative to the clamping belt. In various embodiments the apparatus includes two clamping belts with wherein at least one of the connectors has lateral adjustability, and in other embodiments two of the connectors have lateral adjustability. In various embodiments lateral adjustability can be provided by a loop connection with the at least one clamping belt. In various embodiments lateral adjustability can be provided by a sliding connection, and in other embodiments by a slot connection with the clamping belt.
In various embodiments lateral adjustability can be used to attach to joints of multiple diameters of piping with same system by adjusting length of belt clamp and relative lateral position of connectors to belt.
In various embodiments the pulling and/or pulled sections includes a belt having lateral adjustability to accommodate multiple diameter joints of pipes to be pulled. In various embodiments the pulling and/or clamping units include a belt having lateral adjustability used to attach to joints of multiple diameters of piping with same system by adjusting length of belt for pulling section and relative lateral position of cylinders to belt. In various embodiments the diameters of pipe which can be accommodated include 6, 8, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 42, 48, 60, 72, 84, 96, 108, and/or 120 inch diameters of joints of pipe. In various embodiments, the lateral adjustability is such that it can accommodate a multiple diameters of pipe falling within a range of between any two of the above referenced diameters of joints of pipe.
In various embodiments pulling cylinders are located at 180 degrees from each other around the joint of pipe. In various embodiments pulling cylinders are spaced about 90, 100, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270 degrees from each other. In various embodiments, the pulling cylinders can be spaced within a range of between any two of the above referenced degree spacing.
In various embodiments the method and apparatus includes the steps of, after making a pull, and during the time the pipe string remains resting in a ditch, removing the pulling portion of the apparatus from the joint of pipe to which it was connected before making the pull.
In various embodiments, the pulling section is removed without having to lift resting pipe. In various embodiments, the pulling section is removed without digging out around resting pipe. In various embodiments, the pulling section is removed by sliding at least one clamping belt relative to at least one of the cylinders. In various embodiments, the clamp belt of the pulling section removed from ditch separately from both gas controlled cylinders (clamp detached from at least the separately removed cylinder/clamp detached from both cylinders). In various embodiments, the clamp belt and gas controlled cylinder can be removed from the ditch separately from other gas controlled cylinder (clamp detached from at least the separately removed cylinder/clamp detached from both cylinders)
In various embodiments, the pulled can be removed when pipe resting in ditch, clamping section removed from pipe. In various embodiments, the pulled section is removed without digging out around resting pipe. In various embodiments, the pulled section is removed by sliding at least one clamping belt relative to at least one of the connectors. In various embodiments, the clamp belt of the pulled section removed from ditch separately from both connectors. In various embodiments, the clamp belt and connector can be removed from the ditch separately from other connector for the pulled section (first connector detached from clamping belt separately removed from the clamping belt and/or second connect; and/or both connectors detached from the clamping belt and separately removed).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a side view of first and second joints of pipe to be attached using the method and apparatus.
FIG. 2 is a top perspective view of the pulling and pulled section of the method and apparatus.
FIG. 3 is a perspective view of the control system for the pulling section.
FIG. 4 is a side perspective view of first and second joints of pipe to be attached shown in FIG. 1 , but now showing more clearly the ditch in which these joints rest before the pull.
FIG. 5 is a is a perspective view of the apparatus on the pulled joints shown in FIG. 4 with the pulled section being installed around joints to be pulled.
FIG. 6 is a perspective view of a user setting up the apparatus to make a pull.
FIG. 7 is a schematic diagram of gas flow through the lines of the pulling section which will cause an extension of the pulling rods, and showing the rods in a fully extended condition.
FIG. 8 is a schematic diagram of gas flow through the lines of the pulling section which will cause a retraction of the pulling rods, and at the beginning of a pull.
FIG. 9 is a schematic diagram of gas flow through the lines of the pulling section which will cause a retraction of the pulling rods, and at the end of a pull showing complete retraction.
FIG. 10 is a perspective view of the apparatus now set up to make a pull between two joints of pipe.
FIG. 11 is a perspective view of the apparatus in the middle of a a pull between two joints of pipe.
FIG. 12 is a perspective view of the apparatus finishing a pull between two joints of pipe.
FIG. 13 is a is a perspective view of the apparatus on the pulled joints shown in FIG. 12 with the pulled section being removed from around the pulled joint so that it can be attached to a second joint of pipe to be pulled.
FIG. 14 is a perspective view of the apparatus now set up to make a second pull of a new joint of pipe onto the two joints of pipe connected in FIGS. 10 through 12 .
FIG. 15A is a sectional view of the system shown in FIG. 14 taken along the lines 15 A- 15 A in FIG. 14 .
FIG. 15B is a sectional view of the system shown in FIG. 14 taken along the lines 15 B- 15 B in FIG. 14 .
FIG. 15C is a sectional view of the system shown in FIG. 14 taken along the lines 15 C- 15 C in FIG. 14 .
FIG. 15D is a sectional view of the system shown in FIG. 14 taken along the lines 15 A- 15 A in FIG. 14 , but showing first and second cylinders laterally adjusted with respect to the centerline of the joints of pipe.
FIG. 16 is a perspective view of the system 10 .
DETAILED DESCRIPTION
Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
FIG. 1 is a side view of first 50 and second 60 joints of pipe to be attached using the method and apparatus 10 . Second joint 50 includes enlarged female end 68 at second end 64 within which will be pulled male end 52 of a first joint of pipe 50 . In various embodiments the pulling can occur while first 50 and second 60 joints are primarily below grade 40 level, such as inside a ditch 42 . FIG. 4 is a side perspective view of first 50 and second 60 joints of pipe to be attached, but now showing more clearly the ditch 42 in which these joints rest before the pull.
FIG. 2 is a top perspective view of the pulling 200 and pulled 100 section of the method and apparatus 10 . FIG. 3 is a perspective view of the control system 600 for the pulling section 200 . In one embodiment, pulling apparatus 10 includes pulling section 200 and pulled section 100 .
Pulled section 100 can include clamping belt 110 along with first 130 and second 140 laterally adjustable connectors. First connector 130 can include strap 131 and loop 132 , and have an extent of lateral adjustability 134 . Second connector 140 can include strap 141 and loop 142 , and have an extent of lateral adjustability 144 . Detachable connection can be achieved by the use of at least one clamping belt 110 , with first end 112 , second end 114 , and sliding lock 120 .
Pulling section 200 can include two pistons 300 , 400 which can be detachably connected to a pipe joint (e.g., joint 50 ). Detachable connection can be achieved by the use of at least one clamping belt 370 , but preferably a second clamping belt 470 is also used.
First piston 300 can have rod 320 slidably connected to its piston chamber. First piston 300 can include inlets 310 and 312 for controlling extension and retraction of rod 320 . Compressed gas entering inlet 310 causes retraction of rod 320 and compressed gas entering inlet 312 causes extension of rod 320 . Rod 320 can be connected to pulling member 350 which can be a conventionally available chain or cable. First piston 300 can include a frictional increasing member 306 , such as a rubber lining or like material.
Similar to first piston 300 , second piston 400 can have rod 420 slidably connected to its piston chamber. Second piston 400 can include inlets 410 and 12 for controlling extension and retraction of rod 420 . Compressed gas entering inlet 410 causes retraction of rod 420 and compressed gas entering inlet 412 causes extension of rod 420 . Rod 420 can be connected to pulling member 450 which can be a conventionally available chain or cable. Second piston 400 can include a frictional increasing member 406 , such as a rubber lining or like material.
First piston 300 can slidably connected to first clamping belt 370 through slot 308 , and slidably connect to second clamping belt 470 through slot 308 . First clamping belt 370 can include first end 372 , second end 374 , and sliding lock 376 . Second piston 400 can slidably connected to first clamping belt 370 through slot 408 , and slidably connect to second clamping belt 470 through slot 408 . Second clamping belt 470 can include first end 472 , second end 474 , and sliding lock 476 . First piston 300 can have an extent of lateral adjustability 360 relative to first 370 and second 470 belts. Second piston 400 can have an extent of lateral adjustability 460 relative to first 370 and second 470 belts.
FIG. 3 shows a perspective view of the control system 600 for apparatus 10 . Control system 600 generally includes switching unit 610 and portable supply of compressed gas 500 . Switching unit 610 can be controlled by handle 620 . Supply of compressed gas 500 can be connected to switching unit 610 by inlet line 650 . Switching unit 610 has two outlets which are connected to lines 710 and 810 . Handle 620 controls three states: (a) state 1 where no gas is allowed to exist to either line 710 or line 810 ; (b) state 2 where gas is allowed to exit to line 710 but not line 810 ; and (c) state 3 where gas is allowed to exit to line 810 but not line 710 . Line 710 is split into lines 720 and 730 (with lines 710 , 720 , and 730 generally being referred together as first set of lines 700 ). Line 810 is split into lines 820 and 830 (with lines 810 , 820 , and 830 generally being referred together as second set of lines 800 ).
FIGS. 5 and 6 are perspective views of apparatus 10 being connected to joints 50 and 60 with pulled section 100 being installed on joint 60 and pulling section being attached to joint 50 . For purposes of clarity in FIG. 6 ditch 42 and ground 40 are not shown with all items being in empty space.
First 300 and second 400 cylinders can be positioned on the opposite sides of joint 50 . Before joint 50 is placed in ditch 42 it is preferred that straps 370 and 470 be placed in ditch 42 under where joint 50 will be lowered. Also preferably before lowering of joint 50 into ditch 42 , second cylinder 400 can be attached to straps 370 and 470 using slot 408 . Alternatively, after joint 50 has been lowered into ditch 42 and on top of straps 370 , 470 ; second ends 374 , 474 of straps 370 , 470 can be threaded through slot 408 of second cylinder 400 and attaching sliding locks 376 , 476 so said second ends 374 , 474 .
Positioning of Cylinders for Pulling Section
After joint 50 has been lowered into ditch 42 and on top of straps 370 , 470 , cylinders 300 , 400 can be positioned about joint 50 . Cylinder 300 can be slid over straps 370 , 470 (schematically indicated by arrow 301 ) to its ultimate pulling position when attached to joint 50 . Cylinder 400 can be slid with respect to straps 370 , 470 (schematically indicated by arrow 401 ) to its ultimate pulling position when attached to joint 50 . After cylinders 300 and 400 are positioned, sliding locks 376 and 476 can be used to lock in place cylinders 300 and 400 .
Preferably, as indicated in FIG. 14A , cylinders 300 , 400 are symmetrically spaced about joint 50 to provide a balanced force on each side joints 50 and 60 which balanced force is parallel to central axis 30 to avoid any tendency to skew or cock joints 50 and 60 during a pull. However, as schematically indicted in FIG. 14A , both cylinders 300 and 400 have an extend of lateral adjustment, respectively angular ranges 360 and 460 , such that cylinder 300 and/or 400 can be angularly spaced above or below the central axis 30 .
In various embodiments both cylinder 300 and 400 are angularly spaced above central axis 30 although symmetrically spaced about joint 50 .
In various embodiments both cylinder 300 and 400 are angularly spaced below central axis 30 although symmetrically spaced about joint 50 .
In various embodiments both cylinder 300 is angularly spaced above central axis 30 while cylinder 400 is angularly spaced below central axis, although both cylinders 300 and 400 are symmetrically spaced about joint 50 .
In various embodiments cylinder 300 can be non-symmetrically spaced about a joint compared to cylinder 400 .
Positioning of Connectors for Pulled Section
After joint 60 has been lowered into ditch 42 and on top of strap 110 , connectors 130 and 140 can be positioned about joint 60 . Connector 130 can be slid over strap 110 (schematically indicated by arrow 135 ) to its ultimate position for being pulled when attached to joint 60 . Connector 140 can be slid with respect to strap 110 (schematically indicated by arrow 145 ) to its ultimate position for being pulled when attached to joint 60 . After connectors 130 and 140 are positioned, sliding lock 120 can be used to lock in place connectors 130 and 140 .
Preferably, as indicated in FIG. 14C , connectors 130 , 140 are symmetrically spaced about joint 60 to provide a balanced pulled force on each side joints 50 and 60 which balanced force is parallel to central axis 30 to avoid any tendency to skew or cock joints 50 and 60 during a pull. However, as schematically indicted in FIG. 14C , both connectors 130 and 140 have an extent of lateral adjustment, respectively angular ranges 134 and 144 , such that connector 130 and/or 140 can be angularly spaced above or below the central axis 30 .
In various embodiments both connectors 130 and 140 are angularly spaced above central axis 30 although symmetrically spaced about joint 60 .
In various embodiments both connectors 130 and 140 are angularly spaced below central axis 30 although symmetrically spaced about joint 60 .
In various embodiments connector 130 is angularly spaced above central axis 30 while connector 140 is angularly spaced below central axis, although both connectors 130 and 140 are symmetrically spaced about joint 60 .
In various embodiments connectors 130 and 140 can be non-symmetrically spaced about a joint.
Operatively Connecting Cylinders to Connectors
Preferably, when positioned on joints 50 and 60 , cylinder 300 will line up with connector 130 ; and cylinder 400 will line up with connector 140 so that chains 350 and 450 will be substantially parallel with central axis 30 along with each other.
Over joint 50 , chains 350 and 450 are respectively connected to rods 320 and 420 . Over joint 60 chains 350 and 450 are respectively connected to connectors 130 and 140 . Preferably, chains 350 and 450 will have some excess length (excess 353 and 453 respectively).
As shown in FIGS. 10-14 , preferably, the length of chains 350 and 450 extend long enough to span the length of at least two normal sized joints 50 , 60 so that multiple pulls can be made without having to move pulling apparatus 200 from its attachment to joint 50 .
Making a Pull for a First Set of Pipe Joints when Below Grade
Initially, rods 320 and 420 can be placed in the initial completely extended positions. FIG. 7 is a schematic diagram of gas flow through the lines 700 of the pulling section 200 which will cause an extension of the pulling rods 320 , 420 , and showing the rods 320 , 420 in a fully extended condition (fully extended positions schematically indicated by dimensional lines 380 , 480 ). Handle 620 is moved (schematically indicated by arrow 1002 ) to allow flow from pressurized gas source 500 to flow lines 700 . This flow proceeds through line 710 (schematically indicated by arrow 1010 ), flow being split into lines 720 (schematically indicated by arrow 1014 ) and 730 (schematically indicated by arrow 1012 ), and ultimately into ports 312 and 412 of cylinders 300 and 400 . Flow into ports 312 and 412 respectively cause rods 320 and 420 to extend (schematically indicated by arrows 1030 and 1032 ). Cylinders 300 and 400 are now in a position to make a pull.
FIG. 8 is a schematic diagram of gas flow through the line set 800 of the pulling section 200 causing retraction of the pulling rods 320 , 420 at the beginning of a pull. FIG. 10 is a perspective view of apparatus 10 now set up to make a pull between two joints of pipe 50 and 60 . Handle 620 is moved (schematically indicated by arrow 1005 ) to flow from pressurized gas source 500 to flow lines 800 . This flow proceeds through line 810 (schematically indicated by arrow 1020 ), flow being split into lines 820 (schematically indicated by arrow 1022 ) and 830 (schematically indicated by arrow 1024 ), and ultimately into ports 310 and 410 of cylinders 300 and 400 . Flow into ports 310 and 410 respectively cause rods 320 and 420 to retract (schematically indicated by arrows 1040 and 1042 ). Cylinders 300 and 400 are now starting to make a pull respectively on chains 350 and 450 which are respectively connected to connectors 130 and 140 which are connected to joint 60 .
FIG. 9 is a schematic diagram of gas flow through the line set 800 of the pulling section 200 causing continued retraction of the pulling rods 320 , 420 , and in the middle of a pull. FIG. 11 is a perspective view of apparatus 10 in the middle of a pull between two joints of pipe 50 and 60 . As shown in FIGS. 9 and 11 , handle 620 is continued to be pushed in the direction of arrow 1005 allowing continued flow from source 500 to flow lines 800 . This continued flow continues to proceed through line 810 (schematically indicated by arrow 1020 ), flow being split into lines 820 (schematically indicated by arrow 1022 ) and 830 (schematically indicated by arrow 1024 ), and ultimately into ports 310 and 410 of cylinders 300 and 400 . Flow into ports 310 and 410 respectively continues to cause rods 320 and 420 to continue retract (schematically indicated by arrows 1040 ′ and 1042 ′). Assuming that the chains 350 , 450 had little to no slack in the position indicated by FIG. 9 , rods 320 and 420 have respectively pulled chains 350 and 450 an equal distance (schematically indicated by dimensional lines 384 and 484 ), which pulled distance has also moved joint 60 through connectors 130 and 140 being clamped onto belt 110 . It is noted that shoulder 67 of joint 60 will restrict relative longitudinal movement of joint 60 and belt 110 (with attached connectors 130 and 140 ). As handle 620 is continued to be place in the position indicated by arrow 1005 continued flow in the directions of arrows indicated above will cause rods 320 and 420 to continue to retract in the directions of arrows 1040 ′ and 1042 until either rods 320 and 420 bottom out in cylinders 300 and 400 or joints 50 and 60 full nest with each other.
In the situation of rods 320 and 420 bottoming out before joints 50 and 60 become fully nested a second, third, or more pulls can be made without relocated either pulling section 200 and pulled section 100 . In this situation of bottoming out, handle 620 is moved in the direction of arrow 620 to fully extend rods 320 and 420 (as described with reference to FIG. 7 ). After full extension chains 350 and 450 are detached from connectors 130 and 140 and then reattached to connectors 130 and 140 to minimize any slack in chains 350 and 450 . After reattaching chains 350 and 450 , second, third, etc. pulls can be made using the procedure described above with respect to FIGS. 8 and 9 until additional retraction of rods 320 and 420 are prevented by the full nesting/attachment/connection of joints 50 and 60 .
FIG. 12 is a perspective view of apparatus 10 finishing a pull between two joints of pipe 50 and 60 . In FIG. 12 , using the above described steps, joints 50 and 60 have full nested with each other wherein rods 320 and 420 have stopped retraction before bottoming out in cylinders 300 and 400 . Dimensional line 384 ′ schematically indicates the extent of retraction for the last pull to fully nest joints 50 and 60 .
Making a Pull for a Second Set of Pipe Joints without Relocating Pulling Section
FIG. 14 is a perspective view of apparatus 10 now set up to make a second pull of a new joint of pipe 70 onto the two joints of pipe connected together with the pull(s) described regarding FIGS. 10 through 12 .
Pulled section 100 is removed from joint 60 , which removal is schematically shown in FIG. 14 . FIG. 14 is a is a perspective view of apparatus 10 located on the pulled joints 50 and 60 with the pulled section 100 being removed from around the pulled joint 60 so that it 100 can be attached to a second joint of pipe 70 to be pulled. Sliding connector 120 is released and strap 110 removed from said connector. Belt 110 (with attached connector 140 ) can be removed from joint 60 by pulling in the direction of arrow 1100 . Preferably, before pulling out belt 110 , connector 130 is removed from belt 110 by sliding connector in the direction of arrow 1120 . At this point pulled section can be laid in ditch 42 under the location of where new joint 70 will be placed in ditch 42 and then attached to said joint 70 in a similar manner as that described with respect to attaching pulled section to joint 60 .
After attaching pulled section to joint 70 , chains 350 and 450 can be attached to connectors 130 and 140 minimizing any slack in said chains. Because pulling section 200 has not been moved, chains 350 and 450 need to have an overall length which can span the length 61 of joint 60 to allow attachment to relocated connectors 130 and 140 (now relocated on joint 70 ). Now the pulling of joint 70 to nest with joint 60 follows a similar procedure as describe above with the pulling of joint 60 to nest with joint 50 and will not be described in detail again. However, it should be noted that pulling on joint 70 when the pulling section 200 is attached to joint 50 has the added advantage of ensuring that joint 60 completely nests with joint 50 because when joint 70 nests with joint 60 , continued pulling forces on joint 70 will be transmitted through joint 60 causing it to want to further nest with joint 50 .
Relocating Pulling Section to New Joint of Pipe
Chains 350 and 450 will not be long enough to make an infinite numbers of pulls without the need to relocate pulling section 200 from joint 50 . Below is described a procedure for removing pulling section 200 .
Pulling section 200 can be removed from joint 50 , which removal is schematically shown in FIG. 14 . FIG. 14 is a is a perspective view of apparatus 10 located on the pulled joints 50 and 60 with the pulling section 100 being removed from around joint 50 so that it 200 can be attached to another joint in the pipe line in connection with another set of pulls. Sliding connectors 376 and 476 are released and straps 370 and 470 removed from said connectors. Belts 370 and 470 (with attached cylinder 400 ) can be removed from joint 50 by pulling in the direction of arrow 1200 . Preferably, before pulling out belts 370 and 470 , cylinder 300 is removed from belts 370 and 470 by sliding cylinder in the direction of arrow 1220 . At this point pulling section 200 can be laid in ditch 42 under the location of where new joint of pipe will be placed in ditch 42 and then attached to said joint of pipe in a similar manner as that described with respect to attaching pulling section to joint 50 .
In one embodiment the end of an already pulled pipe (e.g., first end 72 of joint 70 ) must be slightly lifted in ditch 42 to allow placement of belts 370 and 470 under such joint 70 and attachment of pulling section 200 for the next set of joints of pipe to be pulled.
In one embodiment a second set of straps 370 ′ and 470 ′ can be laid in the ditch under the same joint of pipe (e.g., joint 70 ) on which the pulled section 100 is to be attached for a pull. This is schematically shown in FIG. 14 . In this manner, belts 370 ′ and 470 ′ can be located under joint 70 for the next round of joint pulling.
Independent Ajustability of Pulling and Pulled Sections
FIG. 15A is a sectional view of the pulling apparatus 10 taken along the lines 15 A- 15 A in FIG. 14 . It is noted that pulling can be made at a time when the joints to be pulled are below grade 40 in ditch 42 . Angular indicators 360 and 460 schematically indicate lateral adjustment of cylinders 300 and 400 relative to the joints in the set of joints.
FIG. 15D is a sectional view of the pulling apparatus 10 taken along the lines 15 A- 15 A in FIG. 14 , but now showing first 300 and second 400 cylinders laterally adjusted with respect to the centerline 30 of the joint 50 . The lateral adjustment is schematically indicated by arrow 360 ′ and 460 ′. With such lateral adjustment (arrows 360 ′ and 460 ′) first 300 and second 400 cylinders are located above the height of centerline 30 of joint 50 . Arrow 31 schematically indicates the raised position of first 300 and second 400 cylinders with respect to centerline 30 —to line 32 which is show as being horizontal as first 300 and second 400 cylinders in this figure remain symmetrically spaced about centerline 30 . In various embodiments line 32 spanning between first 300 and second cylinders will not be horizontal when first 300 and second 400 cylinders are not symmetrically spaced about centerline 30 . For example arrow 360 ′ may indicate that first cylinder 300 is laterally adjusted above centerline 30 by about 30 degrees while arrow 460 ′ may indicate that second cylinder 400 is laterally adjusted above centerline by about 15 degrees. In various embodiments one of the cylinders can be laterally adjusted above centerline 30 while the other is laterally adjusted below centerline 30 .
FIG. 15B is a sectional view of the pulling apparatus 10 taken along the lines 15 B- 15 B in FIG. 14 . Angular indicators 360 and 460 schematically indicate lateral adjustment of chains 350 and 450 relative to the joints in the set of joints.
FIG. 15C is a sectional view of the pulling apparatus 10 taken along the lines 15 C- 15 C in FIG. 14 . Angular indicators 360 and 460 schematically indicate lateral adjustment of connectors 130 and 140 relative to the joints in the set of joints. FIG. 16 is a perspective view of pulling system 10 showing lateral adjustment of first 300 and second 400 cylinders along with lateral adjustment of first 130 and second 140 connectors.
In various embodiments connectors 130 and 140 can be laterally adjusted about centerline 30 to about the same extent as their respective first 300 and second 400 cylinders. In various embodiments the extent of lateral adjustment of one or both of first 130 and second 140 connectors can differ from the extent of lateral adjustment of one or both of first 300 and second 400 cylinders.
FIG. 16 is a perspective view of the system 10 shown in FIG. 15D and showing lateral adjustment (arrows 360 ′ and 460 ′) of first 300 and second 400 cylinders along with lateral adjustment (arrows 360 ″ and 460 ″) of first 130 and second 140 connectors.
In FIG. 16 it can be noted that belt 110 of pulled section 100 is held in place by shoulder 67 of joint 60 . In this manner of connection of pulled section 100 , friction is not as important as for pulling section 200 which depends on frictional resistance between the particular joint pulling section is connected to and pulling section members (e.g., first 300 and second 400 cylinders along with belts 370 and 470 ).
The following is a list of reference numerals:
LIST FOR REFERENCE NUMERALS
(Reference No.)
(Description)
5
user
10
attachment system
30
centerline
31
arrow
32
line between first and second cylinders
40
ground
42
ditch
44
interior
45
floor or bottom
48
arrow
50
pipe joint
52
first end
54
second end
58
enlarged female end
60
pipe joint
61
overall length of joint of pipe
62
first end
64
second end
67
tapered shoulder
68
enlarged female end
70
pipe joint
72
first end
74
second end
78
enlarged female end
100
clamping section
110
clamping belt
112
first end
114
second end
120
sliding lock
130
first connector
131
strap for first connector
132
loop for first connector
134
extent of lateral adjustability of first
connector relative to clamping belt
135
arrow
140
second connector
141
strap for second connector
142
loop for second connector
144
extent of lateral adjustability of second
connector relative to clamping belt
145
arrow
200
powered section
210
first clamping belt
212
first end
214
second end
218
sliding lock
230
second clamping belt
232
first end
234
second end
238
sliding lock
300
first powered cylinder
301
arrow
302
first end
304
second end
306
frictional increasing base
308
adjustment slot
310
first inlet
312
second inlet
320
rod
322
first end
350
pull line
352
intermediate point of pull line
353
excess for pull line
354
end of pull line
360
extent of lateral adjustability of first
cylinder relative to clamping belts
370
clamping belt
372
first end
374
second end
376
sliding lock
380
extended position of rod
382
amount of extension of rod
384
amount of retraction of rod
385
retracted position of rod
400
second powered cylinder
401
arrow
402
first end
404
second end
406
frictional increasing base
408
adjustment slot
410
first inlet
412
second inlet
420
rod
422
first end
450
pull line
452
intermediate point of pull line
453
excess for pull line
454
end of pull line
460
extent of lateral adjustability of second
cylinder relative to clamping belts
470
clamping belt
472
first end
474
second end
476
sliding lock
480
extended position of rod
482
amount of extension of rod
484
amount of retraction of rod
485
retracted position of rod
500
portable supply of compressed gas
600
portable compressed gas power unit
610
switching unit
620
handle
650
inlet line
700
first set of lines
800
second set of lines
1000
arrow
1002
arrow
1005
arrow
1010
arrow
1012
arrow
1014
arrow
1020
arrow
1022
arrow
1024
arrow
1030
arrow
1030
arrow
1040
arrow
1042
arrow
1050
arrow
1060
arrow
1100
arrow
1110
arrow
1120
arrow
1130
arrow
1200
arrow
1210
arrow
1220
arrow
1230
arrow
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method and apparatus for pulling multiple joints of pie which comprises a pulling section and a pulled section, the method and apparatus working while the joints of pipe are below grade and capable of pulling multiple joints of pipe without relocating the pulling section. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to communications jacks and the wiring of such jack and more particularly to the termination of individual conductors in associated insulation displacing contacts ("IDC") of a communications jack and the severing of the excess insulated conductor beyond the lead frame support of such jack.
2. Description of the Prior Art
At present individual insulated conductors are terminated in insulation displacing contacts and the portion of the insulated conductor beyond the lead frame support is severed by a cut-off blade on available impact tools. These tools engage the insulated conductor on either side of the IDC slot and force the insulated conductor downwardly into the slot slicing through the insulation, parting it and making electrical and mechanical contact with the metallic conductor therein.
The tool cutting edge scrubs along the outer surface of the lead frame support and if the edge is sharp and the impact high, the insulated conductor may be cleanly severed. However, if the blade cutting edge is not sharp, the impact is low, the insulation soft and pliable and the metallic conductor soft and ductile, the cut will be anything but sharp. The distortion of the insulated conductor outside of the lead frame support could also cause problems in the IDC slot. The conductor could be cut or thinned making for a poor or little contact. There can be exposed bare conductor ends which could short out other conductors and the like.
SUMMARY OF THE INVENTION
The invention disclosed herein overcomes the difficulties noted above with respect to the described prior art devices by providing a cutting ledge to support the insulated conductor to be severed, adjacent the lead frame support and back-up the cutting blade so that a smooth, clean cut can be made, adjacent the lead frame support, to permit the excess insulated conductor to be removed without affecting the quality of the conductor joint at the IDC slot. It is an object of the invention to provide an improved connector which facilitates the removal of any excess portion of a conductor beyond the connector.
It is another object of the invention to provide an improved connector which provides a support for any excess conductor beyond the connector to facilitate the removal of such excess conductor.
It is yet another object of the invention to provide an improved connector which provides a support for any excess conductor beyond the connector and provides an anvil for a cutting blade employed to sever such excess conductor.
Other objects and features of the invention will be pointed out in the following description and claims and illustrated in the accompanying drawings, which disclose, by way of example, the principles of the invention, and the best mode presently contemplated for carrying them out.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings in which similar elements are given similar reference characters:
FIG. 1 is an isometric view taken from below and to the left of a communications jack assembly according to the prior art.
FIG. 2 is an isometric view of the lead frame contacts of FIG. 1.
FIG. 3 is an isometric view of the lead frame carrier of the device of FIG. 1.
FIG. 4 is an isometric view of the lead frame contacts of FIG. 2 installed on the lead frame carrier of FIG. 3.
FIG. 5 is an isometric view of the lead frame support of the device of FIG. 1.
FIG. 6 is an isometric view of the lead frame support of FIG. 5 assembled to the lead frame contacts and lead frame carrier assembly of FIG. 4.
FIG. 7 is an isometric view of the body of the device of FIG. 1.
FIG. 8 is an isometric view of stuffer caps for use with the device of FIG. 1.
FIG. 9 is a side elevational view of an impact tool to install electrical conductors to the contacts of the device of FIG. 1.
FIG. 10 is a fragment and front elevational view, partly in section, of the device of FIG. 1 with a conductor being installed to a contact with the tool of FIG. 9.
FIG. 11 is an isometric view of a lead frame support constructed in accordance with the concepts of the invention which can be used with the remaining components of the device of FIG. 1.
FIG. 12 is an isometric view of the lead frame support of FIG. 11 assembled to the lead frame contacts and lead frame carrier assembly of FIG. 4.
FIG. 13 is an isometric view of the assembly of the components of FIG. 12 with a modified body of the type shown in FIG. 7.
FIG. 14 is a fragmentary front elevational view, partly in section, of the device of FIG. 13 with a conductor being installed to a contact with the tool of FIG. 9.
FIG. 15 is a rear elevational view of the body of FIG. 7.
FIG. 16 is a front elevational view of the body of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIGS. 1 to 10, 15, and 16, there is shown a communications jack assembly 20 constructed in accordance with the prior art and an impact tool 140 often used to install insulated conductors thereto. Jack assembly 20 comprises a body 22, a lead frame carrier 24 and a lead frame support 26, shown in FIG. 1 and other components not visible in FIG. 1. Body 22 has a deflectable latch 28 which is used to lock jack assembly 20 into a corresponding aperture in a support frame (not shown) as is well known in the art. The latch 28 deflects towards body 22 as the body 22 is in advanced into a support frame aperture from the rear and expands away from body 22 after assembly 20 is properly positioned. Assembly 20 can be removed from the rear of the support frame by deflecting the latch 28 and pulling assembly 20 free of the support frame.
The contacts 30 (see FIG. 2) are of the insulation displacement type which do not require that the insulation be removed from an insulated conductor before it can be assembled to a contact. Instead each of the contacts 30 is formed with a slot 32 whose walls are sharp. When an insulated conductor (not shown) is forced down the slot 32, the insulation is severed and displaced in the area of the slot 32 so that the contact arms defining the slot 32 make a good mechanical and electrical contact with the metallic conductor of the insulated conductor. Each of the contacts 30 has a lead 34 formed when the contact 30 is stamped out. The contacts 30 and leads 34 may be connected to runners at one or both ends during manufacture to hold the positions of the contacts 30 until installation upon the lead frame carrier 24 at which time they are removed.
The lead frame carrier 24 is shown in FIGS. 3 and 4. A number of grooves 40 are formed along the longitudinal axis of carrier 24. Each of the grooves 40 will receive one of the leads 34 therein. At a first end 42, the frame is rounded and the free ends of the leads 34 are bent around end 42 to form the contacts 36 of the completed jack assembly 20. Rails 44 permit the lead frame carrier 24 to be assembled to the body 22 and stops 46 limit insertion of the lead carrier 24 into body 22. The contacts 30 are bent perpendicularly to leads 34 and are positioned adjacent supports 48. Each of the supports 48 has a slot 50 which is aligned with contact slot 32 so that access to the contacts is provided.
Turning now to FIGS. 5 and 6 the lead frame support 26 and its assembly to the lead frame carrier 24 with contacts 30 assembled thereto are described. Lead frame support 26, which is mounted over carrier 24 has a base 62 the underside of which contains a support foot 64 which may engage a support surface (not shown). Projecting upwardly from base 62 are two, parallel, spaced apart side walls 66 which have a series of slots 74 positioned along their length. A series of ribs 70, having enlargements 72 adjacent base 62 fit into the channels 52 between the supports 48 of the lead frame carrier 24. The ribs 70 guide the lead frame carrier 24 along channels 52, and the enlargements 72 lock the support 26 to the carrier 24 by engaging the side walls of the channels 52. The slots 74, in both side walls, are aligned with the positions of the contact slots 32 to permit access to the contact slots 32. Thus the slots 50 in supports 48 of lead frame carrier 24, slots 32 in contacts 30 and slots 74 in side walls 66 of the lead frame support 26 are all aligned and an electrical conductor can be supported therein. The insulation can be received in slots 50 and 74 and the central conductor received in the slot 32 of contact 30. At the ends of some of the fingers 76 formed by slots 74 in side walls 66 are locking tabs 78 and further locking tabs 80 appear on both side walls 66. The functions of these tabs will be described below.
FIGS. 7, 15 and 16 show body 22 which is assembled to the sub assembly of FIG. 6, as shown in FIG. 1. An aperture 90 is generally rectangular to accept the lead frame carrier 24 adjacent end 42. Side slots 92 communicating with aperture 90 are shaped to receive rails 44 of carrier 24. Slots 94 receive the contacts 36 adjacent the plug aperture 96 in the front face of body 22 as shown in FIG. 16. Slots 98 on flexible arms 100 provide shoulders 102 to engage the flat back surfaces 83 of locking tabs 80 (see FIG. 5). The arms 100 are deflected outwardly as inclined front face 81 of tabs 80 engage such arms 100 as the lead frame support 26 is advanced within body 22. Once the tabs 80 enter slots 98, the arms 100 return to the position as shown in FIG. 1 to retain the body 22 and lead frame support 26 in assembly.
The individual conductors of a cable to be terminated can be placed in the slots of the jack assembly 20 and terminated by means of a stuffer cap 110 shown in FIG. 8. Stuffer cap 110 has a base 112 and two depending, parallel, spaced apart, side walls 114. Along the interior surface of base 112 and walls 114 are a front wall 116 and a rear wall 118 (mostly hidden in FIG. 8). Front wall 116 has a central rectangular recess 120 and two slots 122 so as to describe two narrow fingers 124 and 126 adjacent the side walls 114. The rear wall 118 is similar to front wall 116.
When the stuffer cap 110 is positioned on lead frame support 26, the outer fingers 124 enter slots 74 in side walls 66 of support 26, the inner fingers 126 enter slots 50 in supports 48 of lead frame carrier 24 and the slots 122 are positioned over the ends of the contacts 30. If an insulated electrical conductor (not shown) is positioned across contact 30 and in slots 74 and 50 and stuffer cap 110 is pushed downwardly towards the base 62 of lead frame support 26, then the conductor insulation will be severed and displaced and contact will be established between contact 30 and the central metallic conductor.
Although not shown a small cross member is placed between front wall 116 and rear wall 118 on the interior surface of each of the side walls 114 to act as a catch for the locking tabs 78 of fingers 76 of lead frame support 26. This locking action insures that the insulated conductor is fully inserted into slots 32 of contacts 30. This is done by expanding side walls 114 away from the lead frame support 26 and pulling stuffer cap 110 upwardly away from lead frame support 26. The stuffer cap 110 can also be applied to lead frame support 26 after all of the conductors are properly seated in slots 32 of contacts 30. This provides strain relief to the conductor on both sides of contact 30, prevents unintentional access and acts as an environmental seal against dirt and other contaminants.
Because the insulated conductors have small external diameters, and the space to work in is small and because it is difficult to align the conductors with the slots 32, 50 and 74 especially while aligning the stuffer cap 110 with these same slots resort is had to various hand tools to install the insulated conductors in the slots 32 of contacts 30 and cut-off the excess insulated conductor beyond the side wall 66 of support 26. It should be noted that the use of a tool is not absolutely necessary to install wires to the contacts but the use of a tool permits the job to be done quickly and insures the best electrical contact possible. One such tool is shown in FIG. 9. The tool 140 is an impact tool having a compression spring (not shown) in its handle 142. The spring is connected to a plunger 144 which is forced into handle 142 by the punch-down bit or punch-down implement, to be described, until a settable predetermined value is reached. The implement is forced against the work piece with a force corresponding to the predetermined value.
The implement 146 has a first pushing portion 148 which engages the conductors between the supports 48, a second pushing portion 150 which engages the portion of the conductor in slot 50 in support 48 of lead frame carrier 24 and a recess 152 which can accommodate the upper portion of the contact 30 to permit the pushing portions maximum conductor contact. A further pushing portion 154 engages the conductor in slot 74 in side wall 66 of lead frame support 26. The final portion of implement 146 is cut-off blade 156 which extends from a cutting edge 158 below the level of the remaining portions of implement 146 and along an inclined face 160.
The operation of tool 140 to install a conductor 170 to jack assembly 20 is shown in FIG. 10. A maximum of eight insulated conductors 170 are positioned between supports 48 of carrier 24 and fanned out, one adjacent each of the eight contacts as shown by insulated conductor 170a. The conductor 170a is manually pushed part way into slot 32 of contact 30 with a tail 174 extending beyond wall 66. The tool 140 is aligned with the contact such that pushing portion 150 enters slot 50, pushing portion 154 enters slot 74, the upper portion of contact 30 enters recess 152 and the cutting edge 158 of blade 156 engages conductor 170a. As the implement 146 moves downwardly in FIG. 10, pushing portion 148 engages insulated conductor 170a to provide strain relief for the conductor 170a as installation is forced into slot 32 of contact 30. The cut-off blade 156 severs tail 174 from insulated conductor 170a and the tail 174 falls free of the jack assembly 20. After all of the insulated conductors 170 are installed stuffer cap 110 is added and the installation is complete. The concept is that if a sharp cutting blade is operated at a high rate of speed, the insulated conductor tail 174 can be cleanly severed from the remainder of the insulated conductor 170a which will be stiff enough to allow cut-off without any further support for the insulated conductor 170a.
The foregoing sequence may well apply to situations where the blade 156 cutting edge 158 is sharp, the blade 156 is precisely positioned with respect to wall 66 and a high impact force employed. However, if cutting edge 158 is not sharp, or if blade 156 is not closely positioned to wall 66, if the conductor insulation has a low modulus of elasticity or the metallic conductor is very ductile the blade may not sever the tail 174 from the remainder of insulated conductor 170a. The insulated conductor 170a could be bent along wall 66 in which state it would inhibit installation of the stuffer cap 110 or positioning of jack assemblies close together. The insulation of the conductor could be removed leaving a bare metallic conductor which could cause shorts to other conductors.
Turning now to FIGS. 11 to 14 there is shown a snap-in jack assembly 200 constructed in accordance with the invention. FIG. 11 shows a lead frame support 226 employed with assembly 200. The outer walls 266 have been modified to add a series of anvils. Anvil 228 is adjacent the base of slot 74a, anvil 230 is adjacent the bases of slots 74b and 74c while anvil 232 is adjacent the base of slot 74d. The opposite side wall 266, not visible in FIG. 11 has a similar arrangement to that described so that there is an anvil at the base of each of the eight contacts of jack assembly 200.
The latch between the lead frame support 226 and the body 222 is altered because the flexible arms can not extend about the entire locking latch 80 as is done with flexible arms 100 of jack assembly 20 of FIG. 1. Instead, locking arm 238 is made up of a first portion 240 which extends along the longitudinal axis and a second portion 242 perpendicular thereto. Inner surface 244 of second portion 242 engages the rear surface 83 of locking tab 80 to hold in assembly the components of jack assembly 226. The leading edge 81 of locking tab 80 forces locking arm 238 away from the body 222, but once the rear surface 83 is adjacent inner surface 244, the locking arm 238 returns to its initial position with inner surface 244 now engaging rear surface 83.
Turning now to FIG. 14 the manner of installing insulated conductors 170 to the improved jack assembly 226 is shown. The lead frame carrier 24, the contacts 30 and the tool 140 remain the same. The significant change made is the addition of the anvils 228, 230 and 232 to the lead frame support 226. In FIG. 14, it is assumed that insulated conductor 170a has been routed between the supports 48 and into a slot 50 in a support 48 of lead frame carrier 24. The insulated conductor 170a is then guided into slot 32 of contact 30 and through slot 74c of lead frame support 226, over anvil 230 and extending beyond side wall 266 of support 226. As above described, the insulated conductor 170a is first manually pushed into slot 32 of contact 30. The tool 140 is pushed downwardly in FIG. 14 so that pushing portion 150 enters slot 50, pushing portion 154 enters slot 74, the upper portion of contact 30 enters recess 152 and the cutting edge 158 of blade 156 engages conductor 170a. Because of the presence of anvil 230 to support and back-up the insulated conductor 170a, a clean cut can be achieved and tail 174 is severed as the blade 156 advances to anvil 230 through insulated conductor 170a.
While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiment, it will be understood that various omissions and substitutions and changes of the form and details of the device illustrated and in its operation may be made by those skilled in the art, without departing from the spirit of the invention. | A multi-conductor communications jack where the individual insulated conductors are forced into associated insulation displacing contacts to make a mechanical and electrical joint with the metallic conductor therein by means of an impact tool which also has thereon a cutting edge for severing the portion of the insulated conductor that extends beyond the jack lead frame. The improvement comprising a series of anvils adjacent the frame and insulation displacing contacts to support the insulated conductor and insure a clean cut without injury to the conductor or insulation and without having to employ two separate tools in two separate operations. The first tool to force the conductor into the contact slot and the second tool, in a separate operation, to sever the excess conductor. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates in general to infant care devices, and more particularly, to a portable diaper changing station and method of using same.
[0002] Changing an infant or young child's diaper can be a somewhat difficult task, even when the changing location is within a home where abundant water and waste facilities are present to accomplish the task. Generally, diaper changing stations and tables designed as furniture items and are kept in the nursery or other bedroom and are not easily moved from one location to another. Changing an infant in the home typically requires the caretaker to carry the baby to the location in the house where the changing table and related changing accessories, such as diaper wipes, diapers and baby lotions, are kept. This involves multiple trips to the changing location every day until the need for diapers no longer exists. In homes with multiple levels, climbing up and down the stairs can be quite exhausting for the caretaker.
[0003] In today's mobile society, infants travel quite frequently with their parents and caretakers. Many families with infants and small children tend to consume a greater number of meals at restaurants and other public venues, instead of dining at home most of the time. Infants spend more time travelling in cars, trains, airplanes and other forms of transport with their parents and caretakers. Although some public places such as airports and restaurants may have a changing station located in a restroom or other accommodation to visitors, they may become unsanitary due to repeated use without regular cleaning. Likewise they may be positioned in such an area as to make changing a diaper inconvenient and embarrassing. Lugging around a heavy changing station to provide a secure and clean changing surface for the infant, in addition to carrying a diaper bag to store the other accoutrements of child care and diaper changes, makes changing a diaper in a public venue all the more difficult and taxing. Moreover, locating a safe, flat and clean surface on which to change an infant's diaper are relatively few in public venues.
[0004] Thus, there is a need for a device which provides a portable, safe, comfortable and secure surface on which a diaper change can be accomplished. There is also a need for a device which is lightweight and can be easily transported and put away for storage when not in use. There is also a need for a portable changing station which can also provide storage and interchangeable tubs for infant care related accessories such as diapers, wipes and other infant related goods.
[0005] Therefore, in view of the above it is one object of the present invention to provide a lightweight, portable diaper changing station which can be easily cleaned and sanitized.
[0006] A further object of the present invention is to provide a diaper changing station that will provide a soft, clean and comfortable surface on which to place the infant or young child, and which will substantially secure the infant or young child during the diaper change process.
[0007] A further object of the present invention is to provide a portable diaper changing station that includes storage capacity for related cleaning items, such as tubs, wipes, lotions and clean diapers which can be stored, exchanged and carried in the changing station.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, an apparatus and method for a portable diaper changing station is disclosed herein. The diaper changing station of the present invention includes a composite, shaped and contoured one piece body member including an integrated handle with a grip. One or multiple, storage compartments with lids may be formed into the body member for storing changing supplies such as tubs, diapers, wipes and powders. In one embodiment, the changing station is generally rectangular in shape, semi-rigid and comprises a nonporous contoured changing surface. A shaped, contoured nonporous head rest may also be formed into the body member.
[0009] Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, descriptions and claims. While specific advantages and embodiments have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is a perspective view of the portable changing station apparatus in accordance with the present invention;
[0012] FIG. 2 is top view of the portable changing station apparatus in accordance with the present invention;
[0013] FIG. 3 is a bottom view of the portable changing station apparatus in accordance with the present invention;
[0014] FIG. 4 is a left side view of the portable changing station apparatus in accordance with the present invention;
[0015] FIG. 5 is a right side view of the portable changing station apparatus in accordance with the present invention;
[0016] FIG. 6 is a front view of the portable changing station apparatus in accordance with the present invention; and,
[0017] FIG. 7 is a back view of the portable changing station apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] For purposes of teaching and discussion, it is useful to provide some overview as to the way in which the invention disclosed herein operates. The following information may be viewed as a basis from which the present invention may by properly explained. Such information is offered for purposes of explanation only and, accordingly, should not be construed to limit the broad scope of the present invention and its potential applications.
[0019] Turning to FIG. 1 , changing station 10 is shown in a perspective view. In the depicted embodiment, changing station 10 is a one piece, formed body which is generally shaped in a rectangular fashion as shown. In one embodiment, changing station 10 is manufactured by a plastic mold injection process which produces a station body 12 that is nonporous, rigid or semi-rigid as preferred by the user. In one embodiment, station body 12 is constructed of a one piece, non-porous, semi-rigid polyurethane foam with a density of 55 and a durometer hardness of 35. A plastic “skin” is created on the surface of the molded foam station body 12 and changing surface 14 during the manufacturing process of station 10 to resist absorption and staining and which is easily cleaned and sanitized after use. Such material may be easily manufactured with a wide degree of color, texture, shapes and designs integrated therewith.
[0020] In alternative embodiments, changing station 10 may be constructed from various plastics, foams, metal, metal alloys, wood or other suitable materials as known in the art. Station body 12 , changing surface 14 and headrest 16 may also include antimicrobial additives in the polyurethane resin to resist and deter microbial growth and odor. In other contemplated embodiments, changing station 10 may consist of two or more members comprising components of the station body 12 , changing surface 14 or headrest 16 . Changing surface 14 is contoured in shape to provide a secure and easily sanitized surface on which to lay and secure the infant or child being changed. Head support 16 is contoured and shaped accordingly to provide a secure and comfortable depression in which to place the child's head while changing the child's diaper.
[0021] Handle 18 is formed into the station body 12 for purposes of easily carrying and manipulating the changing station 10 . Handle 18 includes a formed grip which provides a safe and secure grip for the user to easily transport and manipulated the changing station 10 . The grip may consist of the same material as that of station body 12 or may be other materials such as rubber, notched rubber, metal, or other gripping material as known in the art. In one embodiment, handle is substantially formed and located in proximity to the center of gravity of changing station 10 to provide substantial balance while station 10 is being carried.
[0022] Various configurable and removable dispenser and storage tubs or compartments may be formed into the changing station 10 for a variety of purposes. In the depicted embodiment, dispenser 20 is a compartment designed to accept sanitary wipes and includes a snap closure lid that includes a slot for the dispensation of wipes, tissues or other dispensable items. In one embodiment, the dispensing tub includes a cap with a lanyard attachment point to secure the dispensing tub cap to the tub cover. Storage compartment 22 is shown with a snap closure lid which provides a secure compartment in which to store associated items such as lotions, gels, pacifiers, toys and/or additional diapers. In alternative embodiments, dispenser 20 and storage compartment 22 may be switched, moved or removed in relative location on or about the station body 12 or away completely detached from the station 10 for purposes of cleaning or restocking wipes and other related supplies. In other embodiments, dispenser 20 and storage compartment 22 include lids with various known means of detachably securing the lid including snaps, buttons, hook and loop fasteners among others. In one embodiment, dispenser 20 or storage compartment 22 are sized dimensionally to accept common tubs which hold wipes or other items to allow a user to remove the tub from the dispenser 20 or compartment 22 , discard the spent tub (e.g. after all the wipes have been used) and replace into dispenser 20 or compartment 22 a new tub of wipes or other supplies as needed.
[0023] In the depicted embodiment, safety belt attachment points 24 are preformed slots in station body 12 of sufficient dimension to accept a safety belt which may be draped across the body of a child who has been placed on changing surface 14 for purposes of substantially securing the child to the changing station. In other embodiments, safety belt attachment points 24 may comprise loops, rings, hook and loop fasteners, or snaps or other commonly know means for securing a belt or harness to changing station 10 . Additional safety device retention systems or attachment points may be integrated on station boyd 12 as desired.
[0024] FIG. 2 is a top view of one embodiment of the invention disclosed herein. Station body 12 is shown with safety belt attachment point 24 . Storage lid 30 and dispenser lid 34 are shown detachably secured to station body 12 with hinges 32 , 36 . In one embodiment, lids 30 , 34 are molded with a “living” hinge feature or other known safety hinge design to eliminate potential pinch points. Lids 30 , 34 may also be detachably secured to station body 12 via spring hinges, torque hinges, snaps, hook and loop fasteners or attachment means as known in the art. In the depicted embodiment, dispenser lid 34 includes a slot for dispensing wipes or any other material or object designed to be easily withdrawn without the need for opening the entire lid.
[0025] With reference to FIG. 3 , lids 30 , 34 are shown with tabs 40 integrated therewith. Tabs 40 allow the user to easily lift and open lids 30 , 34 with their fingers or hands. Instead of tabs 40 , other pulls or knobs may be utilized according to the preference of the user.
[0026] Turning to FIG. 4 and FIG. 5 , left and right side views of the changing station 10 are shown. The substantial contour of changing surface 14 is shown and, as previously described, acts to substantially secure a child placed thereon to keep the child from “rolling” out of the changing station 10 . The contour of changing surface 14 also acts to contain any spills or other materials and substantially prevent the spills or other materials from leaking on to other surfaces in proximity of the changing station 10 . Lids 30 , 34 are shown in a “closed” position. Tabs 40 are shown as configured in the closed position of lids 30 , 34 .
[0027] FIG. 6 is a front view of the changing station 10 in one embodiment disclosed herein. Station body 12 is shown with contoured changing surface 14 and headrest 16 . Headrest 16 is preformed into station body 12 and is of sufficient size and dimension to provide a comfortable and secure head rest for a child placed on to the changing surface 14 . In the depicted embodiment, headrest 16 is a contoured, generally oval depression which is formed into the station body 12 and changing surface 14 . In other embodiments, headrest 16 may consist of various geometric shapes and forms, as well as be raised above the horizontal plane of changing surface 14 . Indeed, it is contemplated, that various dimensional configurations for station body 12 , changing surface 14 and headrest 16 may be designed and utilized for infants and children of various ages, sizes and needs.
[0028] Compartments 20 and 22 are shown in a closed position. It is also recognized that compartments 20 and 22 may be designed and utilized for various specific requirements. In the embodiment shown, compartment 20 is a wipe dispenser and compartment 22 is designed to contain various items such as baby lotion, medications or other objects. Other embodiments of the invention disclosed herein may not incorporate one or any storage compartment. In still other possible embodiments, multiple compartments may be integrated into station body 12 at any location and as desired. Likewise, safety belt attachment points 24 may or may not be formed into station body 12 as desired by the user. Handle 18 or another suitable transport attachment may or may not be formed as required or desired by the user. It is contemplated that end users could design and customize the size, shape, color, and storage features to the changing station 10 to suit their individual preferences and needs. In alternative embodiments, various lugs, pulls, straps or other handling means may be incorporated or formed into station body 12 and utilized for transport of the changing station as desired by the user. Likewise, various storage solutions may or may not be incorporated as desired.
[0029] FIG. 7 is a back view of the changing station 10 apparatus disclosed herein. In one embodiment, station rests 50 and cleats 52 are formed as convex and protruding up and away from the horizontal plane of station body 12 . In the depicted embodiment, station rests 50 are substantially larger in diameter than cleats 52 . Station rests 50 act to provide a stable support for the changing station when the changing station is placed on a surface. In an alternative embodiment, rests 50 are formed or cut into station body 12 to prevent station body from creating suction with, sticking to or substantially clinging to any surface upon which the changing station 10 is placed for use in changing a diaper or during storage. Cleats 52 act to provide a friction and/or restriction mechanism when cleats 52 come into contact with any surface or objects resting on a surface on which the changing station 10 is placed. Cleats 52 also act to reduce the surface area of station body 12 which comes into contact with the support surface, thereby making it easier to lift the changing station 10 off and away from the supporting surface. If changing station 10 is placed on an uneven or substantially contoured surface, station rests 50 and cleats 52 will act to provide stability to the changing station. Station rests 50 and cleats 52 may consist of or be covered with non-slip or rubberized materials to reduce slipping of the station and to prevent the marring of the surface on which the station rests. In one embodiment, station rests 50 and cleats 52 are formed as concave dimples into the station body 12 and may act as suction cups to secure the changing station 10 to a flat surface or may be fashioned and constructed to reduce the suction between the station and the surface upon which the station is placed. In still other embodiments, rests 50 and cleats 52 may be formed in mixed concave and convex shapes as desired to provide support, suction, anti-suction or other function as desired to assist in supporting the station 10 and detachably securing it to a variety support surfaces with various topographic environments.
[0030] A method of changing a child's diaper using the portable changing station 10 is as follows. The changing station 10 is placed on a surface which can properly support the station 10 and the child placed thereon. The child is then placed on the station body 12 resting substantially on changing surface 14 which provides a soft and secure area for the child while the child's diaper is being changed. A belt or other retention device may be looped over the child's torso to further releasably secure or restrict the child from gross movement during the changing process. The soiled diaper is removed and discarded into an appropriate receptacle. Wipes may be dispensed from the wipe dispenser 20 to clean the child and any portion of the station 10 which may have become soiled during the changing process. Topical medication or lotions may be withdrawn from storage compartment 22 and replaced after use. In one embodiment, the user may withdraw a tub of wipes from the dispenser 20 and place them in a more convenient area while changing the diaper. After the change is complete, the user may replace the tub into dispenser 20 for transport and later use.
[0031] The advantages of the portable changing station 10 are readily apparent. Station 10 is a lightweight and can be easily transported. Station 10 provides a secure and sanitary surface on which to safely and quickly change a diaper. Station 10 is easily cleaned and sanitized after each use or as necessitated and provides a storage capability for items which are required or facilitate the changing of a diaper. Due to the contoured shape of the changing surface 14 and headrest 16 , changing a diaper can be carried out relatively safely because the potential for the child to fall or roll off the station 10 is minimized. Station 10 is easily customized to suit the preferences of the user including functionality (right handed vs. left handed users) and personal taste (e.g. color or artwork imprints).
[0032] While the invention has been particularly shown and described with reference to a various embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | The portable diaper changing station of the present invention comprises a composite, nonporous shaped body member which is contoured to provide a secure changing surface. A carry handle may be integrated into the body member along with at least one storage compartment for the storage of changing supplies such as diapers, wipes and powders. In one embodiment, the changing station is generally rectangular in shape, rigid and includes a nonporous contoured changing surface with a shaped contoured pad running a substantial length of the contoured changing surface. A shaped nonporous head rest is contoured and formed therein. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 12/692,618 filed on Jan. 24, 2010, the entirety of which is incorporated by reference herein. The U.S. patent application Ser. No. 12/692,618 claims the benefit of U.S. Provisional Application No. 61/222,465, filed on Jul. 1, 2009.
The U.S. patent application Ser. No. 12/692,618 claims priority of Taiwan Patent Application No. 98126689, filed on Aug. 10, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to memories, and more particularly to data access of memories.
2. Description of the Prior Art
Before data is written to a memory, a controller of the memory usually scrambles the data with a scrambler, thus making bits 0 and 1 to have a random distribution in the data. The scrambled data is then stored in the memory, thus preventing bits 0 and 1 from massing in a specific segment of the data. For example, a flash memory is classified into a single-level-cell (SLC) flash memory or a multi-level-cell (MLC) flash memory. When data is written to a MLC flash memory, if the data comprises segments comprising massed bits 0 or massed bits 1 , an error bit rate of the data is increased. A controller of the MLC flash memory therefore has to scramble the data before the data is written to the MLC flash memory.
The data scrambled by a scrambler, however, has deficiency. A controller usually transmits data to a flash memory via a data bus. When the controller sends a data bit 1 to the flash memory, a voltage level of the data bus is increased to a logic high level. When the controller sends a data bit 0 to the flash memory, the voltage level of the data bus is decreased to a logic low level. Because bits 0 and 1 in scrambled data have randomized distributions, when the controller sends the scrambled data to the memory for storage via the data bus, the voltage level on the data bus frequently oscillates between the logic high level and the logic low level. The data bus therefore requires high power due to the frequent oscillation of voltage levels thereon, thus increasing power consumption of a system. When the system comprising the controller and the memory is a portable device with a battery power supply, the time span in which the system operates under a normal voltage supply is shorten, thus degrading the performance of the system. Thus, a controller which can scramble data with low power consumption is desired.
SUMMARY OF THE INVENTION
According to at least one preferred embodiment of the present invention, a flash memory device is disclosed. The flash memory device comprises: a flash memory; and a controller, coupled to the flash memory, receiving first source data from a host, generating a plurality of first scrambled signals according to a plurality of pseudo random sequences and the first source data, obtaining a plurality of transmission powers of the first scrambled signals, and selecting a target scrambled signal from the first scrambled signals according to the transmission powers for storing to the flash memory.
According to at least one preferred embodiment of the present invention, a flash memory controller for controlling access operations of a flash memory is disclosed. The flash memory controller receives first source data from a host and comprises: a plurality of scramblers, for generating a plurality of first scrambled signals according to a plurality of pseudo random sequences and the first source data; a transmission power calculation module, for obtaining a plurality of transmission powers of the first scrambled signals; and a selector, for selecting a target scrambled signal from the first scrambled signals according to the transmission powers for storing to the flash memory.
According to at least one preferred embodiment of the present invention, a method for controlling access operations of a flash memory is disclosed. The method comprises: receiving first source data from a host; generating a plurality of first scrambled signals according to a plurality of pseudo random sequences and the first source data; obtaining a plurality of transmission powers of the first scrambled signals; and selecting a target scrambled signal from the first scrambled signals according to the transmission powers for storing to the flash memory.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a data storage device according to the invention;
FIG. 2 is a block diagram of a write-data processing circuit of a controller according to the invention;
FIG. 3 is a flowchart of a method for processing data to be written to a memory according to the invention;
FIG. 4 is a circuit diagram of a transmission power calculation module according to the invention;
FIG. 5 is a block diagram of a read-data processing circuit of a controller according to the invention;
FIG. 6 is a flowchart of a method for processing data read out from a memory according to the invention; and
FIG. 7 is a schematic diagram of an embodiment of a data access method according to the invention.
DETAILED DESCRIPTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
Referring to FIG. 1 , a data storage device 104 according to the invention is shown. The data storage device 100 is coupled to a host 102 and accesses data according to instructions from the host 102 . In one embodiment, the data storage device 104 comprises a controller 112 and a memory 114 . The memory 114 is for data storage. The controller 112 accesses data stored in the memory 114 according to instructions sent by the host 102 . In one embodiment, a data bus is coupled between the controller 112 and the memory 114 for data transmission. For example, when the host 102 wants to store data D 1 to the data storage device 104 , the controller 112 first receives data D 1 from the host 102 , then encodes the data D 1 to obtain an error correction code C 1 , and then sends the error correction code C 1 to the memory 114 for storage. When the host 102 wants to read data from the data storage device 104 , the controller 112 directs the memory 114 to read an error correction code C 2 stored therein, then decodes the error correction code C 2 to obtain data D 2 , and then sends the data D 2 to the host 102 .
Before the controller 112 stores the data D 1 to the memory 114 , the controller 112 scrambles the bits 0 and 1 of the data D 1 , thus making the bits 0 and 1 of the scrambled data have randomized distributions, and making the scrambled data have a characteristic that is consuming lower power during being transmitted. The scrambled data is then encoded to obtain the error correction code C 1 . Thus, when the data bus transmits the error correction code C 1 from the controller 112 to the memory 114 , the transmission power required by the data bus is reduced. Similarly, because the error correction code C 2 is stored in a format with a low transmission power in the memory 114 , when the data bus transmits the error correction code C 2 from the memory 114 to the controller 112 , the data bus requires less power to transmit the error correction code C 2 . The data storage device 104 therefore consumes a less power than that of a conventional data storage device. The data storage device 104 therefore has improved performance in comparison with a conventional data storage device.
Referring to FIG. 2 , a block diagram of a write-data processing circuit of a controller 200 according to the invention is shown. The other circuit components irrelevant to processing of write data are omitted in FIG. 2 . In one embodiment, the controller 200 comprises a plurality of scramblers 201 ˜ 20 N, a transmission power calculation module 212 , a selector 214 , an index appending module 216 , and an error correction code (ECC) encoder 218 . Referring to FIG. 3 , a flowchart of a method 300 for processing data to be written to a memory 114 according to the invention is shown. The controller 200 processes data received from the host 102 according to the method 300 shown in FIG. 3 . First, the controller 200 receives source data D 1 to be written to the memory 114 from the host 102 (step 302 ). The scramblers 201 , 202 , . . . , 20 N then respectively scramble the data D 1 according to a plurality of pseudo random sequences M 1 , M 2 , . . . , M N to obtain a plurality of scrambled signals S 1 , S 2 , . . . , S N (step 304 ). In one embodiment, the scramblers 201 ˜ 20 N respectively performs XOR operations on the data D 1 and the plurality of pseudo random sequences M 1 , M 2 , . . . , M N to obtain the scrambled signals S 1 , S 2 , . . . , S N . Because the bits 0 and 1 in the scrambled signals S 1 , S 2 , . . . , S N have random distributions, the scrambled signals S 1 , S 2 , . . . , S N have low error bit rates when the scrambled signals S 1 , S 2 , . . . , S N are stored in the memory 114 .
The transmission power calculation module 212 then calculates a plurality of transmission powers of the scrambled signals S 1 , S 2 , . . . , S N to be transmitted on the data bus (step 306 ). The transmission power calculation module 212 then selects a target scrambled signal with the lowest transmission power from the scrambled signals S 1 , S 2 , . . . , S N (step 308 ), and then outputs an index I 1 of a target pseudo random sequence corresponding to (for generating) the target scrambled signal. In one embodiment, the number of the pseudo random sequences M 1 , M 2 , . . . , M N is N, and the bit number of the index I 1 of the target pseudo random sequence is less than Log 2 N. The selector 214 then selects the target scrambled signal J 1 with the lowest transmission power from the scrambled signals S 1 , S 2 , . . . , S N according to the index I 1 . The index appending module 216 then appends the index I 1 to the end of the target scrambled signal J 1 to obtain an output data K 1 (step 310 ). The error correction code encoder 218 then encodes the output data K 1 to obtain an error correction code C 1 to be stored in the memory 114 (step 312 ). Because the error correction code C 1 has the same bit content with that of the target scrambled signal except for a parity and the index I 1 , the data bus transmits the error correction code C 1 to the memory 114 with a low transmission power.
Referring to FIG. 4 , a circuit diagram of a transmission power calculation module 400 according to the invention is shown. The transmission power calculation module 400 comprises a delay unit 402 , an XOR gate 404 , and a counter 406 . Assume that the transmission power calculation module 400 receives a scrambled signal S k from a scrambler, wherein the index k may be selected from the numbers 1˜N. The delay unit 402 delays the scrambled signal S k by a clock period to obtain a delayed signal S k ′. The XOR gate 404 then performs an XOR operation on the delayed signal S k ′ and the scrambled signal S k to obtain a transition signal T. When the bit of the scrambled signal S k changes from the value 0 to the value 1 or from the value 1 to the value 0, the transition signal has a corresponding value of 1. The counter 406 then accumulates the transition signal to count the number CN of times of value changes of the scrambled signal S k . Thus, when the number CN of times of value changes of the scrambled signal S k is high, the data bus requires a high power to transmit the scrambled signal S k .
Referring to FIG. 5 , a block diagram of a read-data processing circuit of a controller 500 according to the invention is shown. In one embodiment, the controller 500 comprises an error correction code (ECC) decoder 502 , an index separation module 504 , a selector 506 , and a descrambler 508 . Referring to FIG. 6 , a flowchart of a method 600 for processing data read out from the memory 114 according to the invention is shown. The controller 500 processes data read out from the memory 114 according to the method 600 and then delivers the processed data to the host 102 . First, when the controller 500 receives a read command from the host 102 , the controller 500 directs the memory 114 to read an error correction code C 2 . After the controller 500 receives the error correction code C 2 from the memory 114 , the ECC decoder 502 then decodes the error correction code C 2 to obtain output data K 2 (step 602 ).
Because the output data K 2 comprises a scrambled signal and an index of a target pseudo random sequence, the index separation module 504 retrieves the scrambled signal J 2 and the index I 2 of the target pseudo random sequence from the output data K 2 (step 604 ). The selector 506 then selects the target pseudo random sequence M* from a plurality of pseudo random sequences M 1 , M 2 , . . . , M N according to the index I 2 (step 606 ). The descrambler 508 then descrambles the scrambled signal J 2 according to the target pseudo random sequence M* to obtain source data D 2 (step 608 ). In one embodiment, the descrambler 508 performs an XOR operation on the bits of the scrambled signal J 2 and the target pseudo random sequence M* to obtain the source data D 2 . Finally, the controller 500 sends the source data D 2 to the host 102 to complete the read operation.
Referring to FIG. 7 , a schematic diagram of an embodiment of a data access method according to the invention is shown. Assume that the controller 112 receives source data D 1 to be written to the memory 114 from the host 102 , as shown in (a) of FIG. 7 . The controller 112 then converts the source data D 1 to scrambled signal J 1 shown in (b) of FIG. 7 , wherein the scrambled signal J 1 has the lowest transmission power. The controller 112 then appends an index K 1N of a pseudo random sequence and a parity to the end of the scrambled signal J 1 to obtain an error correction code C 1 , as shown in (b) of FIG. 7 . The plurality of pseudo random sequences M 1 , M 2 , . . . , M N shown in FIG. 2 have the same data length as the source data D 1 , and the controller 112 must comprise buffers to store the pseudo random sequences M 1 , M 2 , . . . , M N . To shorten the buffer length of the controller 112 , the data lengths of the source data D 1 and the pseudo random sequences M 1 , M 2 , . . . , M N are reduced, thus reducing hardware costs of the controller 112 .
In another embodiment, the controller 112 divides the source data D 1 (e.g. data length of the source data D 1 is a page) into a plurality of segments D 11 , D 12 , . . . , D 1N , as shown in (c) of FIG. 7 . Each segment D 11 , D 12 , . . . , D 1N has a data length equal to 1/N of that of the source data D 1 . The controller 112 then sequentially scrambles the segments D 11 , D 12 , . . . , D 1N to obtain scrambled signals J 11 , J 12 , . . . , J 1N , as shown in (d) of FIG. 7 . The controller 112 then combines the indexes K 11 , K 12 , . . . , K 1N of the pseudo random sequences with the scrambled signals J 11 , J 12 , . . . , and J 1N , to obtain the error correction code C 1 ′, as shown in (e) of FIG. 7 . Because each of the segments D 11 , D 12 , . . . , D 1N has a data length equal to 1/N of the source data D 1 , the data lengths of the buffers of the controller 112 are also equal to 1/N of the source data D 1 to hold the pseudo random sequences M 1 , M 2 , . . . , M N , thus reducing hardware costs of the controller 112 .
In another embodiment, encoding of an error correction code and scrambling of data are simultaneously performed. After the index appending module 216 appends the index K 11 to the end of the scrambled signal J 11 , the error correction code encoder 218 simultaneously encodes the scrambled signal J 11 and the index K 11 to obtain an error correction code C 11 comprising a parity P 11 . When the error correction code encoder 218 generates the error correction code C 11 , the scrambler 201 ˜ 20 N scrambles the segment D 12 , and the transmission power calculation module 212 and the selector 214 selects a scrambled signal J 12 with the lowest transmission power. Similarly, when the error correction code encoder 218 generates the error correction code C 12 , the scrambler 201 ˜ 20 N scramble the segment D 13 , and the transmission power calculation module 212 and the selector 214 selects a scrambled signal J 13 with the lowest transmission power. Thus, encoding of an error correction code and scrambling of data are simultaneously performed to improve performance of the controller 200 .
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A method for controlling access operations of a flash memory includes: receiving first source data from a host; generating a plurality of first scrambled signals according to a plurality of pseudo random sequences and the first source data; obtaining a plurality of transmission powers of the first scrambled signals; and selecting a target scrambled signal from the first scrambled signals according to the transmission powers for storing to the flash memory. An associated flash memory device and an associated flash memory controller are also provided. | 6 |
BACKGROUND OF THE INVENTION
Camping and many similar outdoor activities inevitably involve the task of cooking over an open fire. Unless a grate is provided over the fire pit, this task can become tricky and often reduces the menu to items which can be speared with a stick and held over the fire.
Solutions presently available in stores comprise little more than a rectangular, stainless steel cage with a handle. The items to be cooked are placed in the cage, and the cage is closed and held by hand over the fire. This not only creates extreme fatigue, as the chef must perform lengthy isometric exercises in order to keep the food in proper position over the fire, it requires the chef remain in close proximity to the fire.
There have been attempted solutions to this problem which have been patented but have never enjoyed success in the marketplace for various reasons. For instance, U.S. Pat. No. 2,935,982, which issued to Otis on May 10, 1960, discloses two vertical support members and a horizontal support member, all of which are made from a heavy metal wire material. The device described therein is impractical in that it does not provide the necessary flexibility required by proper cooking techniques. For example, once set up, the device does not allow the chef to relocate the food over a different portion of the campfire. Nor does it allow the chef to back away from the campfire in order to avoid the heat from a growing fire or a change in winds. Also, the flimsy wire material would have a propensity to bend and wobble if used for cooking a heavy food item such as a large steak. Finally, the device does not allow the chef to flip the food over without getting close to the fire.
It would be advantageous to provide an open fire cooking apparatus which is solid, strong, and has the functional flexibility to allow the chef to reposition the food, and him or herself, while the food is being prepared.
SUMMARY OF THE INVENTION
The present invention relates to an open fire cooking apparatus comprising a handle having a first end and a second end which are separated by a distance defined as the length of the handle. The handle is constructed and arranged to removably accept a variety of cooking platforms proximate its first end. Preferably, the handle is telescopically arranged with a first and second handle member, said members arranged substantially concentric with each other such that one member is partially slidably housed within the other, allowing the length of the handle to be adjustable. It is envisioned that the handle have more than two members to allow a greater length range along with relatively compact storage when the members are housed within each other. Preferably the handle has a substantially circular cross section.
The handle and cooking platform are elevated above the ground and fire, respectively, by a first support and a second support. It is preferable that the first support comprise at least one, preferably two legs, having pointed lower ends for insertion into the ground. It is even more preferable that these legs be separated and connected by a substantially horizontal cross member. The cross member is advantageous, not only because it adds stability and rigidity to the first support, but because it provides a place for a user to place his or her foot in order to push the support legs into the ground. The legs are joined at their upper ends, preferably by a second cross member, which carries a handle holding mechanism. The first handle holding mechanism cradles the handle and provides vertical, upward support, as well as lateral support. Preferable, the first handle holding mechanism comprises a upwardly opening, U-shaped bracket. More preferably, the first handle holding mechanism comprises a resiliently biased clip which forcibly holds the handle in place.
The second support may be constructed and arranged like the first support, but preferably comprises a telescoping support member, partially and concentrically housed in a hollow center body having a tightening mechanism for fixing the variable support member at a predetermined height. A plurality of legs, preferably three, radiate from the center body and are angularly separated by interior angles α, β, and y . Angles α, β, and γ are preferably at least 60° each, more preferably on the order of 120° each. A second handle holding mechanism is attached to the top of the telescoping support member. The second handle holding mechanism is preferably a resiliently biased mechanism, similar to that of the first support. Alternatively, because the second handle holding mechanism will be required to exert a downward force on the handle, especially when the cooking platform is weighted down with food, thereby causing the handle to become a lever and the first support to act as a fulcrum, second handle holding mechanism could comprise a downwardly opening bracket, attached at one end of the opening to the telescoping support member.
These and other objectives and advantages of the invention will appear more fully from the following description, made in conjunction with the accompanying drawings wherein like reference characters refer to the same or similar parts throughout the several views. And, although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention in operation over an open fire; and,
FIG. 2 is a cross section taken generally along lines 2 — 2 of FIG. 1 .
DETAILED DESCRIPTION
Referring now to the drawings, and first to FIG. 1, there is shown an apparatus 10 for cooking over an open fire. Apparatus 10 generally comprises a handle 12 , a first support 30 , and a second support 40 .
Handle 12 comprises a first end 14 and a second end 16 , separated from first end 14 by a distance defined as handle length 18 . It is preferable that handle length 18 be variable and, in order to facilitate this, handle 12 preferably comprises a first handle member 20 and a second handle member 22 . First handle member 20 and second handle member 22 are telescopically constructed and arranged such that first handle member 20 fits concentrically within second handle member 22 in such a manner as to allow member 20 to be slid back and forth within member 22 , thereby varying the length 18 of handle 12 . It is envisioned that adding additional, telescopically disposed members would provide a potentially greater maximum handle length, or allow for a potentially shorter minimum handle length, or both.
Preferably, in order to maintain handle 12 at a certain length 18 , second member 22 further comprises a plurality of holes 24 , spaced apart at a predetermined interval, and aligned substantially parallel to the axis of handle 12 . First member 20 preferably comprises an outwardly biased, inwardly displaceable protuberance 26 , sized to fit within holes 24 , such that when protuberance 26 is aligned beneath a hole 24 , protuberance 26 pops into hole 24 , thereby preventing first member 20 to slide relative to second member 22 until protuberance 26 is downwardly pressed by an operator.
First end 14 is constructed and arranged to accept a cooking platform 28 , for placement of food thereon. Preferably, cooking platform 28 is removable from handle 12 such that a variety of different platforms 28 may be used. Examples of such platforms may include a cage, such as the one shown in FIG. 1, a skillet, a skewer, and the like.
Handle 12 is supported by a first support 30 and a second support 40 . First support 30 comprises at least one, preferably two, legs 32 . It is envisioned that legs 32 have pointed lower ends 34 to ease insertion into the ground. It is also envisioned that support 30 define an opening 35 defined on its lower end by a substantially horizontal cross member 36 . Member 36 is preferably wide enough, and opening 35 large enough, to allow a user to press pointed ends 34 into the ground using his or her foot.
Support 30 has a top 37 to which a first handle holding mechanism 38 is attached. Mechanism 38 provides vertical support to handle 12 as it acts as a fulcrum when the apparatus 10 is fully assembled and in use. Therefore, mechanism 38 may simply comprise an upwardly opening, U-shaped bracket, sized to accept handle 12 . However, as can be seen in the Figures, mechanism 38 preferably comprises a commercially available, resiliently biased clip spring. A clip spring provides more support and allows handle 12 to be snapped into place easily and removed by simply lifting handle 12 out of mechanism 38 .
Second support 40 may be constructed and arranged like first support 30 , but preferably comprises a telescoping support member 42 , partially and concentrically housed in a hollow center body 44 , and having a height adjustment mechanism 46 for fixing the variable support member at a predetermined height.
Height adjustment mechanism 46 preferably comprises a threaded bolt extending through center body 44 in such a manner that, when rotated, mechanism 46 presses against telescoping support member 42 , holding it in place. Alternatively, a hole could extend through hollow center body 44 and a second set of holes, spaced apart at a predetermined interval, could extend through telescoping support member 42 , so that a particular height could be selected by lining up the center body hole with one of the support member holes and passing a rod through both. It is also envisioned that a quick-release attachment, like those found commercially on bicycles for raising and lower a bicycle seat, be used to adjust the height of the telescoping support member. Other mechanisms for allowing an adjustable height are known to those skilled in the art and would be acceptable substitutions for those described herein without departing from the spirit of the invention.
The embodiment of second support 40 , which is shown in the Figures, includes a plurality of legs 48 , preferably three, radiating from center body 44 . Legs 48 are angularly separated by interior angles α, β, and y . Angles α, β, and y are preferably at least 60° each, more preferably on the order of 120° each.
A second handle holding mechanism 50 is attached to the top of telescoping support member 42 . Second handle holding mechanism 50 is preferably a resiliently biased mechanism, similar to mechanism 38 of the first support 30 . Alternatively, because the second handle holding mechanism 38 will be required to exert a downward force on the handle, especially when cooking platform 28 is weighted down with food, thereby causing handle 12 to become a lever and first support 30 to act as a fulcrum, second handle holding mechanism 50 could comprise a downwardly opening bracket, attached at upper end 52 of member 42 .
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, 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. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. | An apparatus for cooking food items over an open fire which allows a cook to turn the food and adjust the position of the food over the fire while maintaining a safe distance from the fire. The apparatus is constructed and arranged to allow hands-free operation or, if desired, allow a cook to continually control the position of the food over the fire using one hand. This is accomplished using a telescopic handle and two supports. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to fuel cells, and more particularly to a device to reduce fuel cell stack start-up time and maintain fuel cell stack temperature above 0° C.
BACKGROUND OF THE INVENTION
[0002] Fuel cell systems are increasingly being used as a power source in a wide variety of applications. Fuel cell propulsion systems have also been proposed for use in vehicles as a replacement for internal combustion engines. The fuel cells generate electricity that is used to charge batteries and/or to power an electric motor. A solid-polymer-electrolyte fuel cell includes a membrane that is sandwiched between an anode and a cathode. To produce electricity through an electrochemical reaction, a fuel, commonly hydrogen (H 2 ), is supplied to the anode and an oxidant, such as oxygen (O 2 ) is supplied to the cathode. The source of the oxygen is commonly air.
[0003] In a first half-cell reaction, dissociation of the hydrogen (H 2 ) at the anode generates hydrogen protons (H + ) and electrons (e − ). The membrane is proton conductive and dielectric. As a result, the protons are transported through the membrane. The electrons flow through an electrical load (such as the batteries or the electric motor) that is connected across the membrane. In a second half-cell reaction, oxygen (O 2 ) at the cathode reacts with protons (H + ), and electrons (e − ) are taken up to form water (H 2 O).
[0004] For optimum operation, defined as high power output and quick power delivery, fuel cells need a certain operating temperature. Heat generated through the electrochemical reaction increases the operating temperature of the fuel cell. Excess heat is dissipated through a cooling system.
[0005] At sub-freezing temperatures (e.g. below 0° C. or 273 K), however, starting the fuel cell quickly is more difficult due to frozen water in the fuel cell and the fact that the electrochemical reaction rate in the fuel cell is significantly reduced. This limits current flow and further heating of the fuel cell to the optimum operating temperature.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention provides a system for modulating a temperature of one or more fuel cells in a fuel cell stack. The system includes a catalytic combustor in heat exchange relationship with the fuel cell stack. The catalytic combustor promotes an exothermic reaction. A hydrogen source selectively supplies hydrogen (H 2 ) to the catalytic combustor. The H 2 reacts with oxygen (O 2 ) in the exothermic reaction.
[0007] In one feature, the hydrogen source supplies the H 2 based on a temperature of the fuel cell stack.
[0008] In another feature, the system further includes a flow regulator selectively supplying the H 2 from the hydrogen source to the catalytic combustor. The flow regulator is modulated based on a pressure of the hydrogen source. A heater heats the hydrogen source to increase the pressure thereby increasing flow of the H 2 through the flow regulator.
[0009] In another feature, the catalytic combustor lies adjacent to the fuel cell stack and includes a series of catalyst coated flow channels through which the H 2 and the O 2 flow.
[0010] In still another feature, the catalytic combustor includes a plate having a catalyst layer and that is offset from the fuel cell stack. The H 2 and the O 2 flow over the catalyst layer to induce the exothermic reaction causing heat to radiate from the catalytic combustor to the fuel cell stack.
[0011] In yet another feature, a jacket encloses the fuel cell stack to form a gap between the jacket and the fuel cell stack. Hot exhaust from the catalytic combustor circulates through the gap to heat the fuel cell stack.
[0012] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0014] [0014]FIG. 1 is a schematic illustration of a fuel cell system including a fuel cell stack according to the principles of the present invention;
[0015] [0015]FIG. 2 is a schematic illustration of the fuel cell stack having an adjacent catalytic combustor according to the principles of the present invention;
[0016] [0016]FIG. 3 is a schematic illustration of the fuel cell stack having a diffused radiant catalytic combustor according to the principles of the present invention; and
[0017] [0017]FIG. 4 is a schematic illustration of the fuel cell stack in an enclosure heated by a catalytic combustor according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0019] Referring now to FIG. 1, a fuel cell system 10 is shown. The fuel cell system includes a fuel cell stack 12 that is supplied with hydrogen (H 2 ) from a hydrogen source 14 . An injector 16 facilitates supply of H 2 from the hydrogen source 14 to the fuel cell stack 12 . A compressor 18 facilitates supply of oxygen (O 2 ) containing air to the fuel cell stack 12 . H 2 is dissociated at an anode side of the fuel cell stack 12 to generate hydrogen protons (H + ) and electrons (e − ). The protons are transported through to a cathode side of the fuel cell stack 12 and the electrons flow through an electrical load (not shown). O 2 at the cathode side reacts with protons (H + ) and electrons (e − ) are taken up to form water (H 2 O). H 2 O is exhausted from the fuel cell stack 12 .
[0020] The reaction at the cathode side is exothermic. The heat generated by the exothermic reaction warms the fuel cell stack 12 to a desired operating temperature. The operating temperature is preferably 80° C. However, at 20° C sufficient current is immediately available from the fuel cell stack 12 to power the load.
[0021] Coolant is circulated through the fuel cell stack 12 to maintain the operating temperature of the fuel cell stack 12 . Initially, in the start-up mode during which the fuel cell stack 12 is warming up to a desired operating temperature, the coolant circulates the heat to uniformly warm the fuel cell stack 12 . Once the fuel cell stack 12 achieves the desired operating temperature, the coolant maintains the temperature. A pump 20 pumps coolant through the fuel cell stack 12 from a coolant source 22 . The coolant is in heat exchange relationship with the various components of the fuel cell stack 12 . The coolant exiting the fuel cell stack 12 flows through a heat exchanger 24 where heat from the fuel cell stack 12 is discharged to a heat sink, such as atmosphere.
[0022] A catalytic combustor 26 is associated with the fuel cell stack 12 . As explained in further detail below, exothermic reactions within the catalytic combustor 26 generate heat to warm the fuel cell stack 12 . The heat generated by the catalytic combustor 26 is used during a park mode to maintain the temperature of the fuel cell stack 12 above freezing (0° C.). The catalytic combustor 26 can also be used during the start-up mode to assist in raising the fuel cell stack temperature to the desired operating temperature.
[0023] The fuel cell system 10 further includes an exemplary flow regulator 28 associated with the hydrogen source 14 . The flow regulator 28 can be a pressure relief valve. As pressure within the hydrogen source 14 exceeds a threshold pressure, H 2 is exhausted through the flow regulator 28 to reduce the pressure within the hydrogen source 14 . A heater 30 is associated with the hydrogen source 14 and is operable to heat the hydrogen source 14 . Heating of the hydrogen source 14 induces an increased pressure condition therein. The exhausted H 2 is fed into the fuel cell stack 12 through a flow control device 32 . In one example, the flow control device 32 includes a venturi nozzle that concurrently draws in O 2 containing air from atmosphere. The O 2 containing air mixes with the gaseous H 2 and is fed into the fuel cell stack 12 . As discussed in further detail below, an exothermic oxidization reaction occurs within the catalytic combustor 26 to heat the fuel cell stack.
[0024] A controller 34 is in electrical communication with various components and sensors of the fuel cell system 10 . The controller 34 controls operation of the compressors 16 , 18 and the pump 20 to regulate operation of the fuel cell stack 12 . A temperature sensor 36 generates a temperature signal indicating the temperature of the fuel cell stack 12 . A pressure sensor 38 generates a pressure signal indicating a pressure within the hydrogen source 14 . The controller 34 communicates with the flow regulator 28 to exhaust H 2 when the pressure within the hydrogen source 14 exceeds the threshold pressure. The controller 34 regulates operation of the heater 30 to selectively induce an increased pressure condition within the hydrogen source 14 , as discussed in further detail below.
[0025] Referring now to FIG. 2, a first configuration of the catalytic combustor 26 is shown and is indicated as 26 ′. The catalytic combustor 26 ′ includes a series of flow channels 40 that are covered by a catalyst layer (not shown) and lies adjacent to the fuel cell stack 12 . The H 2 and O 2 mix from the flow control device 32 flows into the flow channels 40 where the catalyst induces the exothermic oxidization reaction. Because the catalytic combustor 26 ′ is in heat exchange relationship with the fuel cell stack 12 , heat transfer (Q) occurs, warming the fuel cell stack 12 .
[0026] Referring now to FIG. 3, a second configuration of the catalytic combustor 26 is shown and is indicated as 26 ″. The catalytic combustor 26 ″ functions as a diffused radiant heater and includes a substrate 42 that is offset by a gap 44 from the fuel cell stack 12 . A housing 46 seals the gap 44 between the substrate 42 and the fuel cell stack 12 . A face of the substrate 42 is coated with a catalyst layer 48 . Gaseous H 2 and O 2 are fed into the gap 44 through an inlet 50 and contact the catalyst layer 48 . The catalyst layer 48 induces the exothermic oxidization reaction. Heat transfer (Q) occurs across the gap 44 to warm the fuel cell stack 12 . Cooled exhaust gas is exhausted from the gap through an outlet 52 .
[0027] Although the illustration of FIG. 3 includes the catalyst layer 48 on the fuel cell stack side of the substrate 42 , it is anticipated that other configurations are conceivable. For example, the catalyst layer 48 could be on the face of the substrate 42 facing away from the fuel cell stack 12 . Heat transfer to the stack would then occur through the substrate 42 and across the gap 44 to the fuel cell stack 12 . Although the heat transfer performance of such a configuration is not optimal, such a configuration is possible. Further, the illustration of FIG. 3 includes the catalytic combustor 26 ″ positioned adjacent to one face of the fuel cell stack 12 . It is anticipated, however, that the catalytic combustor 26 ″ could be configured so as to include a substrate 42 with a catalyst layer 48 opposed to one ore more faces of the fuel cell stack 12 or even encompassing the entire fuel cell stack 12 .
[0028] Referring now to FIG. 4, a third configuration of the catalytic combustor 26 is shown and is indicated as 26 ′″. The fuel cell stack 12 is covered by an insulated covering or enclosure 56 . The insulated covering 56 is formed of a synthetic cover or wrapping. There is a gap 58 between the insulated covering 56 and the fuel cell stack 12 . It is anticipated however, that the insulated covering 56 could be defined by walls of a fuel cell stack compartment within which the fuel cell stack 12 is retained.
[0029] An exhaust end of the catalytic combustor 26 ′″ extends into the gap 58 through the insulated covering. An H 2 and O 2 gaseous mixture are fed into the catalytic combustor 26 ′″ through the flow control device 32 . An exothermic oxidization reaction occurs generating hot exhaust gas including residual O 2 , N 2 and H 2 O. The exhaust gas flows about the fuel cell stack 12 in the gap 58 between the fuel cell stack 12 and the insulated covering 56 , warming the fuel cell stack 12 .
[0030] As the exhaust gas flows through the gap 58 and heat transfer to the fuel cell stack 12 occurs, the exhaust gas is cooled and the H 2 O vapor condenses. The gap 58 is configured to enable sufficient dwell time of the exhaust gas within the gap 58 so adequate heat transfer occurs. The cooled exhaust gas and the condensed H 2 O are exhausted from the gap 58 by a vent 60 disposed through the bottom of the insulated covering 56 .
[0031] The catalytic combustor 26 is constantly supplied with H 2 and O 2 . In this manner, costly regulation and monitoring components and algorithms are avoided. The catalytic combustor 26 provides a steady stream of hot exhaust gases and thus heat transfer. The exhaust gas temperature, however, is limited to 100° C. (373 K). This can be controlled using increased air flow provided by a fan blower (not shown). The fan blower, operates cyclically to lower its energy consumption. Local over-heating resulting from temperature spikes are avoided by sufficient gas distribution within the gap 58 . High temperature spikes are balanced as a result of the rapid and sufficient heat distribution within the gap 58 and through the high heat capacity of the fuel cell stack 12 .
[0032] The fuel cell system 10 is operable in three main modes: park, start-up and normal operation. Operation of the fuel cell system 10 during each of these modes will be discussed in turn. Park mode is a cool-down period generally occurring after normal operation of the fuel cell system 10 . As the fuel cell system 10 initially enters the park mode, boil off H 2 is exhausted through the flow regulator 28 and through the flow control device 32 where it is mixed with O 2 . The H 2 /O 2 mixture flows into the catalytic combustor 26 and exothermically reacts to generate heat. The heat initially maintains the temperature of the fuel cell stack 12 as the temperature of fuel cell system 10 drops to ambient.
[0033] As discussed above, the fuel cell stack 12 is maintained at a temperature above 0° C. (273 K) to avoid freezing of residual H 2 O. As the effectiveness of the original heat wears off and the temperature of the fuel cell stack 12 drops toward 0° C., the controller 34 switches on the heater 30 to heat the hydrogen source 14 . As the hydrogen source 14 is heated, an increased pressure condition results and is detected by the pressure sensor 38 . The flow regulator 28 again exhausts H 2 to the fuel cell stack 12 to induce a subsequent exothermic reaction. In this manner, as the temperature of the fuel cell stack 12 periodically dips toward 0° C. the fuel cell system 10 initiates the exothermic reaction in the catalytic combustor 26 to avoid sub-freezing temperatures. Although the freezing temperature of water at nominal conditions is 0° C., liquid water in the stack will typically have solids dissolved therein or be subject to pressure variation, resulting in the freezing temperature of water in the stack varying from the nominal value. Thus, the invention is exemplified based on the 0° C. reference for convenience, but a range around same is contemplated. Further, the method of the invention contemplates corrective measures as the temperature of the stack declines toward 0° C., and initiation of corrective measures near and slightly above the freezing temperature of water.
[0034] During the start-up mode, the initial temperature of the fuel cell stack 12 is presumably lower than the desired operating temperature. Although operation of the fuel cell stack 12 increases the temperature to the desired operating temperature, the fuel cell system 10 assists the temperature increase by feeding H 2 and O 2 into the catalytic combustor 26 . As similarly described above, an exothermic reaction occurs within the catalytic combustor 26 resulting in a more rapid temperature increase. Because the catalytic combustor 26 is also in heat exchange relation with the coolant flow of the fuel cell stack 12 , the heat generated by the reaction warms the coolant. The warmed coolant evenly distributes the heat through the fuel cell stack 12 to warm the fuel cell stack 12 to the desired operating temperature.
[0035] Once the fuel cell stack 12 is warmed to the desired operating temperature, as sensed by the temperature sensor 36 , normal operation of the fuel cell system 10 ensues. That is to say, the flow regulator 28 is closed to inhibit H 2 flow into the catalytic combustor 26 through the flow control device 32 . The controller 34 regulates operation of the compressors 16 , 18 and pump 20 to generate current from the fuel cell stack 12 and to maintain the fuel cell stack 12 at the desired operating temperature.
[0036] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A system for modulating a temperature of one or more fuel cells in a fuel cell stack includes a catalytic combustor in heat exchange relationship with the fuel cell stack. The catalytic combustor promotes an exothermic reaction. A hydrogen source selectively supplies hydrogen (H 2 ) to the catalytic combustor. The H 2 reacts with oxygen (O 2 ) in the exothermic reaction. In one feature, the catalytic combustor lies adjacent to the fuel cell stack and includes a series of catalyst coated flow channels. In another feature, the catalytic combustor includes a plate having a catalyst layer and that is offset from the fuel cell stack. Heat to radiates from the catalytic combustor to the fuel cell stack. In still another feature, a jacket encloses the fuel cell stack to form a gap between the jacket and the fuel cell stack through which hot exhaust from the catalytic combustor circulates. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. Ser. No. 09/372,701 now U.S. Pat. No. 6,395,401B1, filed Aug. 11, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to composite membranes and their use as flashing around window frames, door frames, structural joints and other highly exposed surfaces of building frames or like structures prior to the application of exterior finishing materials, and their use as intermediate layers in the application of exterior finishing materials to building structures.
2. Discussion of Related Art
Composite membranes are commonly used in the construction industry for protecting and waterproofing the frame structure of building frames and roofs. The exposure of a building frame or roofs to environmental factors such as water and moisture can result in devastating damage to the structure. Therefore, it is important for the composite membrane to bond tightly with the structure so environmental factors, such as water and moisture, are not allowed to contact and ultimately harm the structure. Composite membranes are applied to substrates such as a roof, wood framing, steel framing and plywood sheathing, gypsum sheathing and cement board sheathing before any exterior finishing materials are mounted on the substrates. The membranes are formed of materials such as polyethylene and rubberized bitumen or asphalt. Although they adhere well to substrates, these membranes have slick surfaces that are not compatible with conventional bonding materials such as adhesives and base coats normally used to adhere exterior finishing materials such as weather barriers and insulation, to the substrate. As a result, the exterior finishing materials must be mounted onto the composite membrane with mechanical devices such as screws and nails. Although the mechanical devices may effectively secure the exterior finishing materials to the composite membrane as well as the substrate, the mechanical devices must penetrate and perforate the composite membrane creating potential weak points in the membrane where damaging water and moisture may enter. The lack of tight adhesion between the composite membrane and the exterior finishing materials reduces the stability and wind load capacity of the structure.
OBJECTS AND SUMMARY OF THE INVENTION
In light of the problems with conventional composite membranes commonly used in waterproofing systems, it is an object of the present invention to provide a composite membrane that has a rough surface that will bond with materials such as adhesives and base coats.
It is another object of the present invention to provide a method of adhering exterior finishing materials to highly exposed exterior portions of a building structure by utilizing a composite membrane as an intermediate layer between the structure and exterior finishing materials without the use of mechanical devices such as nails and screws.
It is another object of the invention to provide a composite membrane capable of forming a bond with a tensile strength sufficient to withstand design wind loads required of a specific project which may be in excess of 70 PSF.
In accordance with these objectives, the present invention provides a composite membrane having a rough surface that is compatible with bonding materials. This bond-compatible composite membrane comprises a bituminous material layer and a polyester fabric layer. The bond-compatible composite membrane is utilized in a method of waterproofing wood framing, metal framing, plywood, sheathing gypsum, cement board and other highly exposed exterior portions of a structure by adhering the bituminous material layer to the structure and bonding exterior finishing materials such as weather barrier, insulation, exterior cladding and exterior insulation and finishing systems (EIFS) to the polyester fabric layer. The adhesive strength of the bond formed between the polyester fabric layer and the exterior finishing materials is sufficient to hold the exterior finishing materials on the substrate without mechanical devices that will perforate the composite membrane.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a partial cross sectional view of a bond-compatible composite membrane adhered to release paper;
FIG. 2 is a cross sectional diagram of a bond-compatible composite membrane positioned between a substrate and a weather barrier;
FIG. 3 is an illustration of the bond-compatible composite membrane mounted on highly exposed portions of a framed structure such as the door frame, window frame and exterior joints, prior to the application of a weather barrier or other exterior surfacing materials;
FIG. 4 is a partial cross sectional diagram of a finished exterior wall depicting the bond-compatible composite membrane adhered to a substrate, insulation material adhered to the bond-compatible composite membrane and exterior cladding mounted over the insulation.
DETAILED DESCRIPTION OF THE INVENTION
1. Overview of the Invention
Referring now to FIGS. 1 and 2, the invention relates to a bond-compatible composite membrane 12 comprising a bituminous material layer 14 and a polyester fabric layer 16 . The bituminous material layer 14 of the bond-compatible composite membrane 12 protects substrate 20 from damaging environmental factors such as moisture. Substrate 20 may be wood framing, metal framing, plywood sheathing, gypsum board, cement or other structural materials. The polyester fabric layer 16 of the composite membrane 12 has a rough surface that is compatible with, i.e. forms a bond with, bonding materials 24 . The bonding materials are used to secure exterior finishing materials 26 to the composite membrane 12 . The dual function of the single bond-compatible composite membrane 12 allows it to act as both an effective protective layer and an excellent bonding surface for adhesives, base coats and other bonding materials 24 , thereby eliminating the need to secure the exterior finishing materials 26 to the substrate 20 with mechanical devices that weaken the protective properties of the bituminous material.
2. The Bond-Compatible Composite Membrane
Referring again to FIG. 1, the bond-compatible composite membrane 12 is manufactured as a membrane sheet 10 . The membrane sheet 10 comprises a bond-compatible composite membrane 12 and release paper 18 . The bond-compatible composite membrane 12 is formed of two layers, a bituminous material layer 14 and a polyester fabric layer 16 . Preferably, the bituminous layer 14 comprises between approximately 90%-99% by total weight of the composite membrane 12 . The polyester fabric layer 16 comprises between approximately 1%-10% by weight of the composite membrane 12 , but preferably 8% by total weight of the composite membrane 12 . In addition, the polyester fabric layer 16 is preferably a non-woven, mesh fabric.
The bituminous material layer 14 comprises rubberized asphalt or bitumen and optionally, a polymer such as styrene-butadiene, and calcium carbonate. Preferably, the bituminous material layer 14 comprises, between approximately 67%-74% bitumen, between approximately 0%-15% styrene-butadiene, and between approximately 0%-15% calcium carbonate, by total weight of the composite membrane 12 .
The membrane sheet 10 is manufactured by a reverse roll coating process (not pictured). Bituminous material is heated to a temperature of approximately 260° F. The hot liquid bituminous material is then poured onto release paper 18 forming the bituminous material layer 14 of the composite membrane 12 . Non-woven polyester fabric is placed on the bituminous material layer 14 . The non-woven polyester fabric forms the polyester fabric layer 16 of the composite membrane 12 . The release paper 18 , bituminous material, and polyester fabric are rolled through rollers filled with cold water to press to the polyester fabric into the bituminous material and solidify the resulting composite membrane 12 .
The bond-compatible composite membrane 12 is between approximately 35 and 45 mils (1/1000″) thick, and preferably approximately 40 mils thick. The membrane sheet 10 is wound into rolls and distributed for use in conjunction with the application of exterior finishing materials and systems.
3. Method of Adhering Exterior Finishing Materials to a Bond-Compatible Composite Membrane
Referring now to FIGS. 2, 3 and 4 , the composite membrane 12 serves as an intermediate layer in the application of exterior finishing materials 26 to substrates 20 . Exterior finishing materials 26 are securely adhered to the exterior of a structure through the following procedure. Substrate 20 is primed with a primer 22 that is compatible with bituminous materials. However, if the substrate 20 is steel framing or other non-porous materials, the primer 22 is not necessary. A membrane sheet 10 is then provided and the release paper 18 is removed to expose the bituminous material layer 14 of the composite membrane 12 . The bituminous material layer 14 is then adhered to the primer coated substrate 20 to form a tight protective bond.
As depicted in FIG. 3, the composite membrane 12 is preferably applied around highly exposed exterior surfaces of building such as door frames, window frames and construction joints that are particularly susceptible to environmental damage.
Following the application of the bituminous material layer 14 to the primer 22 (if used) that was applied to the substrate 20 , bonding material 24 is applied to the polyester fabric layer 16 of the composite membrane 12 . Acceptable bonding materials 24 are adhesives, base coats such as cementitious compositions and acrylic compositions, and other materials that form a bond.
Exterior finishing materials 26 such as weather barriers, insulation, exterior cladding and exterior insulation and finishing systems (EIFS) are mounted on the polyester fabric layer 16 of the composite layer 12 with the bonding material 24 applied to the polyester fabric layer 16 . The quality of the bond is determined by the tensile strength of the bond. Higher tensile strengths indicate stronger bonds. Bonding materials 24 preferred for use in conjunction with the composite membrane 12 have tensile strengths of at least 7.5 psi at room temperature, 7.0 psi at 120° F., and 3.7 psi at 0° F.
The preferred bonding materials 24 for use with the composite membrane 12 are NC II Base Coat, Standard Basecoat, Senerquick Adhesive and Alpha Dry Basecoat. The tensile strength of bonds formed between the composite membrane 12 and these preferred bonding materials 24 were measured. The results of these measurements are set forth in Table 1 below.
TABLE 1
Average Tensile
NCII Base
Standard
Senerquick
Alpha Dry
Strength in psi
Coat
Basecoat
Adhesive
Basecoat
@ Room Temperature
18.0-22.0
19.0-25.0
7.5-9.1
19.3-20.9
(approximately 70° F.)
(20.0 +/− 2.0)
(22.0 +/− 3.0)
(8.3 +/− 0.8)
(20.1 +/− 0.8)
@ 120° F.
18.0-22.0
17.0-21.0
7.0-11.0
15.0-21.0
(20.0 +/− 2.0)
(19.0 +/− 2.0)
(9.0 +/− 2.0)
(18.0 +/− 3.0)
@ 0° F.
17.0-19.0
17.0-23.0
3.7-4.9
18.0-22.0
(18.0 +/− 1.0)
(20.0 +/− 3.0)
(4.3 +/− 0.6)
(20.0 +/− 2.0)
The composition of the preferred bonding materials is set forth in Table II below.
TABLE II
Bonding Material
Weight % of Components
NCII Base Coat
Kaolin
1.0-2.0%
Water
1.5-20.0%
Acrylic Polymer
10.0-15.0%
Crystalline silica
55.0-65.0%
Feldspar
1.0-5.0%
Mica
1.0-5.0%
Standard Basecoat
Crystalline silica
45.0-70.0%
Acrylic Polymer
5.0-30.0%
Talc
0.0-15.0%
Water
Balance
Senerquick Adhesive
Acrylic Polymer
15.0-20.0%
Water
35.0-40.0%
Calcium Carbonate
40.0-45.0%
Alpha Dry Basecoat
Silica, crystalline quartz
40.0-55.0%
Portland Cement
35.0-45.0%
Calcium Carbonate
2.0-5.0%
Fly Ash
1.0-3.0%
Polymer
Balance
The tensile strength of the bond is also indicative of the wind load strength of the bond. Consequentially, the high tensile strength of the bonds between the polyester fabric layer 16 and the bonding material 24 translates into higher wind resistance.
The tensile strength of adhesive bonds formed with the preferred bonding materials 24 listed above are sufficient to support several layers of exterior finishing materials 26 , or exterior finishing systems formed of multiple layers of materials such as insulation 28 and exterior cladding 30 as depicted in FIG. 4 .
Many changes and modifications may also be made to the invention without departing from the spirit thereof. The scope of the changes will become apparent from the appended claims. | The invention is directed to a bond-compatible composite membrane comprising a first self-adhesive material layer and a second rough fabric layer, and its use as an intermediate layer between a building structure substrate and exterior finishing materials. Unlike conventional composite membranes, the bond-compatible composite membrane has a rough surface that allows bonding materials to adhere to it. Therefore, mechanical devices are not needed to attach the exterior finishing materials to the building structure. | 1 |
TECHNICAL FIELD
This invention relates to training agents in a call center for performing additional types of work.
BACKGROUND OF THE INVENTION
Within the art, a number of different types of customer resource management systems (also referred to as call centers, contact centers, or automatic call distribution systems) are known. One of the problems in customer resource management systems is to retrain agents who are good at performing one type of work in a customer resource management system but need to be trained to perform an additional type of work. This retraining is commonly referred to as upskilling. Within the prior art, this retraining process is a manual process controlled by the agent's supervisor who must constantly monitor and set goals for the agent.
SUMMARY OF THE INVENTION
A method and apparatus trains agents in a call center by directing a plurality of telecommunication calls to an agent by a controller wherein a percentage of the telecommunication calls are unskilled telecommunication calls that the agent is unskilled at processing; determining by the controller success of the agent in handling each of the unskilled telecommunication calls; determining by the controller stress of the agent in handling each of the unskilled telecommunication calls; calculating by the controller average success of the agent in handling all of the unskilled telecommunication calls; calculating by the controller average stress of the agent in handling all of the unskilled telecommunication calls; increasing the percentage of unskilled telecommunication calls by the controller upon average success being greater than a predefined level of success and the average stress being less than a predefined level of stress; and stopping after the percentage equals a predefined percentage.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates an embodiment of a system;
FIG. 2 illustrates an embodiment of a customer resource management system;
FIG. 3 illustrates, in flowchart form, operations performed by stress processing; and
FIG. 4 illustrates, in flowchart form, operations performed by upskilled processing.
DETAILED DESCRIPTION
FIG. 1 illustrates an embodiment. Call center 104 is providing service via switching system 101 for telephone sets 102 - 103 . Agents utilizing agent positions 106 - 107 interact with the customers utilizing telephones sets 102 - 103 and customer terminal 105 . In a first embodiment, call center 104 is directed by the agent's supervisor to provide the agent who is being upskilled with a percentage of a new type of work which the agent is not skilled at providing in addition to types of work that the agent is skilled in providing. As the agent's skill in providing the new type of work improves, call center 104 increases the percentage of the new type of work until a predetermined goal is reached. The agent's supervisor predetermines the percentage increments of the new type of work that will be added. In a second embodiment, the agent's supervisor may change the percentage increments at a later time. Call center 104 determines that the agent is improving with respect to the new type of work by monitoring the agent's stress level and success level in providing the new type of work from the point of view of results achieved. In a third embodiment, if the workload of the call center exceeds a predefined threshold, the agent's percentage of the new type of work is temporarily decreased until the workload of the call center drops below the predefined threshold.
The stress level of the agent may be measured by voice analysis of the agent, textual analysis of the agent, visual analysis of the agent, or by measuring physiological parameters of the agent such as blood pressure, skin resistance, pulse rate, etc. such parameters could be measured by a stress detector attached to the agent position such as stress detector 110 .
The success level can be measured by the number of customer purchases achieved by the agent in interactions with customers. The success level could also be measured for non-purchase type work by measuring the emotions of customers during calls. For example, if a customer is happy or satisfied at the end of the call, the agent can be considered to have been successful.
FIG. 2 illustrates, in block diagram form, one embodiment of call center 104 . Processor 202 provides the overall control for the functions of call center 104 by executing programs and storing and retrieving data from memory 201 . Processor 202 connects to switching network, 101 via interface 203 . Processor 202 interfaces to user interface 218 via interface 207 . Processor 202 interfaces to switching network 101 via interface 203 . Processor 202 interfaces to agent positions 106 - 107 via interface 219 . Processor 202 interfaces to server 108 via interface 221 . Processor 202 performs the operations of call center 104 by executing the routines illustrated in memory 201 .
Operating system 212 provides the overall control and the necessary protocol operations. The communication and control of the various interfaces illustrated in FIG. 2 is provided by interfaces routine 217 . Call center processing 208 provides overall control of call center 104 .
Stress processing 216 provides stress detection operations with data being stored in upskill database 211 . Stress processing 216 may use voice analysis to determine stress. The use of voice analysis to determine stress is well known in the art and is detailed in U.S. Pat. No. 7,283,962 or U.S. Patent Application No. 2003/0033145. If the emotions of customers are being detected, stress processing 216 would use voice analysis to perform this detection. If the physiological parameters are being utilized to detect stress in an agent, stress processing 216 would obtain this data from a stress detector such as stress detector 110 via an agent computer such as computer 111 as illustrated in FIG. 1 . If the visual analysis is being utilized to detect stress in an agent or customer, stress processing 216 would obtain visual data from a camera such as camera 121 via an agent computer such as computer 111 or camera 123 via a customer computer 122 as illustrated in FIG. 1 . The use of visual analysis to determine stress is well known in the art and is detailed in U.S. Patent Application publication 2005/0069852 A1. Visual analysis could include but is not limited to analysis of the eyes of the customers and agents. If textual analysis is being used, the text would be obtained via the agent or customer's keyboard input via the agent or customer keyboard. These U.S. Patent Application publications and U.S. Patent are hereby incorporated by reference.
Upskill processing 215 provides control over the upskill training of the agents using information from stress processing 216 and by determining success levels for agents. Upskill processing 215 stores and retrieves data in/from upskill database 211 . Stress processing 216 stores stress information for the agents in upskill database 211 for use by upskill processing 215 .
In another embodiment, server 108 of FIG. 1 executes upskill processing and stress processing as well as storage for upskill data by communication with customer resource management system 104 .
FIG. 3 illustrates, in flowchart form, operations performed by stress processing 216 of FIG. 2 . These operations are performed for each agent who is being retrained to handle a new type of call (also referred to as upskilling). The operations are performed each time an agent is given a call by customer resource management system 104 . After being started in block 301 , decision block 302 determines if the call is a type of call that the agent is skilled at handling. If the answer is yes, block 303 calculates the stress level for this call, and block 304 averages the calculated stress level into an average stress level for all skilled calls handled by the agent and stores the result in upskill database 211 before returning control to decision block 302 .
Returning to decision block 302 , if the answer is no, control is transferred to decision block 306 . The latter decision block determines if the call is a type of call for which the agent is unskilled at handling. If the answer is yes, control is transferred to block 307 which calculates the stress level of the agent during the call. Then, block 308 averages the calculated stress level into the average stress level for unskilled calls stored in upskill database 211 and stores this information in upskill database 211 before transferring control to decision block 309 . If the answer in decision block 306 is no, control is transferred back to decision block 302 .
After receiving control from block 308 , decision block 309 determines if the emotions of the customer are to be calculated during this call. These calculated emotions may be utilized to determine customer satisfaction. The calculated customer emotions are periodically stored over the duration of the call by block 311 in upskill database 211 . After execution, block 311 returns control back to decision block 302 .
FIG. 4 illustrates, in flowchart form, operations performed by upskill processing 215 . After being started in block 401 , decision block 402 determines if the call presently being handled by the agent is an unskilled call. If the answer is yes, block 403 calculates the agent's success level on the call. This success level may be determined by whether or not the agent made a sale or the level of satisfaction or other emotions of the customer during the call. After receiving control from block 403 , block 404 averages the calculated success level into an average success level stored in upskill database 211 for unskilled calls with the result being stored in upskill database 211 before transferring control to decision block 405 . If the answer in decision block 402 was no, control is transferred to decision block 405 .
Decision block 405 determines if the overall workload of the call center has exceeded a predefined value/threshold. If the answer is yes, the training of the agent to handle unskilled calls will be modified, and the percentage of unskilled calls handled by the agent will be reduced by execution of block 414 . Block 414 saves the current percentage of unskilled calls being handled by the agent for future restoration by block 416 and reduces the percentage of unskilled calls that the agent will handle by a predefined percentage before transferring control back to decision block 402 . Note, that this predefined percentage can reduce the number of unskilled calls handled by the agent to zero. If the answer in decision block 405 is no, control is transferred to block 416 . The latter block restores the save percentage of unskilled calls if this is the first time that block 416 has been executed after the overall workload has dropped below the predefined value before transferring control to decision block 406 . Decision block 406 determines if the period of time has elapsed for the evaluation of the agent since the agent's progress is only periodically evaluated. If the answer is no in decision block 406 , control is transferred back to decision block 402 . If the answer is yes in decision block 406 , control is transferred to decision block 407 .
Decision block 407 accesses the average stress level information for the agent from upskill database 211 . This information had been stored there by stress processor 216 . In one embodiment, decision block 407 compares the stress level for unskilled calls against the stress level for skilled calls and would only allow the stress level for unskilled calls to be a predefined percentage higher than the stress level for skilled calls. In another embodiment, decision block 407 would not allow the stress level for unskilled to be larger than predefined level.
If the answer is no in decision block 407 , control is transferred to block 413 . The latter block decreases the percentage of unskilled calls that the agent will handle before returning control to decision block 402 . If the answer is yes in decision block 407 , control is transferred to decision block 408 .
Decision block 408 accesses the agent's average success level from upskill database 211 and determines if this level is acceptable. If the answer is no, control is transferred to block 413 whose operations have already been described. If the answer in decision block 408 is yes, control is transferred to block 409 .
Block 409 increases the percentage of unskilled calls that will be handled by the agent before transferring control to decision block 411 . The latter decision block tests to see whether the agent is now receiving a percentage of unskilled calls that meets the goal set for the agent. If the answer is yes, the process is done and control is transferred to block 412 . If the answer in decision block 411 is no, control is transferred back to decision block 402 .
When the operations of a computer, processor or server are implemented in software, it should be noted that the software can be stored on any computer-readable medium for use by or in connection with any computer related system or method. In the context of this document, a computer-readable medium is an electronic, magnetic, optical, or other physical device or means that can contain or store a computer program for use by or in connection with a computer related system or method. The computer, processor or server can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In the context of this document, a “computer-readable medium” can be any means that can store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. For example, the computer-readable medium can be, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (electronic), a read-only memory (ROM) (electronic), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical).
In an alternative embodiment, where the computer, processor or server is implemented in hardware, the telephone set, control computer or server can be implemented with any or a combination of the following technologies, which are each well known in the art: a discrete logic circuit(s) having logic gates for implementing logic functions upon data signals, an application specific integrated circuit (ASIC) having appropriate combinational logic gates, a programmable gate array(s) (PGA), a field programmable gate array (FPGA), etc.
Of course, various changes and modifications to the illustrated embodiments described above will be apparent to those skilled in the art. These changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intending advantages. It is therefore intended that such changes and modifications be covered by the following claims except insofar as limited by the prior art. | A method and apparatus trains agents in a call center by directing a plurality of telecommunication calls to an agent by a controller wherein a percentage of the telecommunication calls are unskilled telecommunication calls that the agent is unskilled at processing; calculating by the controller average success of the agent in handling all of the unskilled telecommunication calls; calculating by the controller average stress of the agent in handling all of the unskilled telecommunication calls; increasing the percentage of unskilled telecommunication calls by the controller upon average success being greater than a predefined level of success and the average stress being less than a predefined level of stress; and stopping after the percentage equals a predefined percentage. | 6 |
CROSS REFERENCE TO COPENDING APPLICATION
This is a continuation-in-part of application Ser. No. 07/498,445, filed Mar. 22, 1990 now abandoned, which was a continuation of application Ser. No. 06/851,221 filed Apr. 14, 1986 now abandoned.
Technical Field
The present invention relates generally to a window dressing system and more particularly to a window dressing system for creating and thence carrying a pleated drape and a top window treatment.
BACKGROUND OF THE INVENTION
Window dressing systems are typically used for decorative purposes around a window as well as for blocking light entering a room from it. These systems usually include a drape having hooks or carriers which can be movably engaged with a track mounted over a window along a wall. The draperies can be slid back and forth along the track to a position that allows a desirable amount of light to enter a room through the window. Numerous devices, such as wands or cords and pulley arrangements, can be used to slide the carriers back and forth along the track when adjusting the position of the draperies to a desired location.
Often, it is desirable to provide draperies with pleats to give them a more decorative and appealing look. Pleating, however, usually requires a more complicated system of carrier tracks and carriers. Additionally, pleats formed in the draperies can make cleaning more difficult. This problem is compounded since pleated draperies are also more difficult and time consuming to mount once they have been cleaned due to the added complexity of the carriers and track system.
Carriers have at times been made with separable fasteners to simplify removal of the draperies. Fasteners, such as snap fasteners, have been used to connect draperies to the carrier elements so the draperies may simply be separated from the carrier elements and the track by unsnapping the fasteners. However this method has presented additional problems in the form of inadvertent loosening of the draperies from the carriers. For instance, moving the draperies too rapidly, brushing up against the draperies, or simply the weight of the draperies themselves often caused such snap fasteners to become unfastened at unwanted times.
With window dressing systems, it is often desirable to use a top window treatment, such as a valance or cornice. Such a window treatment decoratively covers the top region of the draperies as well as any mechanisms such as tracks or carriers. Using a top window treatment, however, also adds to the complexity of the window dressing system since additional brackets are necessary to hold the treatment over the top region of the draperies without obstructing their longitudinal movement. In the past, various brackets and fasteners have been used to mount these additional top window treatments, but those brackets and fasteners have presented problems due to the added complexity as well as the added difficulty and expense involved in assembling the components on site and mounting the window dressing system along a wall. Additionally, removal and cleaning of those window treatments have been difficult and time consuming.
The present invention addresses the foregoing drawbacks of known drapery systems.
SUMMARY OF THE INVENTION
The present invention provides a window dressing system for creating and thence carrying a pleated drapery or the like and a separate top window treatment in spaced relationship from a wall, or other supporting structure, proximate a window to be covered or framed by the drapery. The window dressing system, according to one aspect of the invention, includes a bracket having an inner face for disposition toward the wall, an outer face for disposition away from the wall, and a longitudinal axis for disposition generally parallel to and spaced from the wall. The bracket also includes a set of preferably two track members located on opposite sides of the longitudinal axis from each other. The first track member extends interiorly of the bracket, adjacent the inner face, and is configured to receive window drapery hardware in sliding engagement therewith for supporting the top region of the drapery. The second of the track members extends exteriorly of the bracket, adjacent to the outer face, and is configured to receive top window treatment hardware to support the top window treatment which conceals the window dressing system from view. The bracket also includes an anchoring element for receiving mounting hardware which secures the bracket to a wall.
A standard is disposed in operative engagement with the bracket at the anchoring element and secures the bracket to the wall. The standard also functions to space the bracket from the wall and to create a longitudinal pleat zone between the bracket and the wall within which the drapery may move between its opened and closed positions.
Positioned at each end of the bracket and disposed generally normal to the longitudinal axis are first and second return members which extend inwardly of the bracket into proximity with the wall. These first and second return members close the opposing ends of the pleat zone. Each of the return members includes at least one retaining clip for receiving and restraining the terminus of the top window treatment and preferably a second such clip for the drapery as well.
According to a further aspect of the invention, glide tape is attached to the drape proximate its upper end. The glide tape includes a flexible linear web which is secured to the drapery generally congruent with the longitudinal axis. A plurality of glide elements are preferably permanently affixed to the flexible web and are disposed along it in a linear spaced array so that each of the glide elements projects outwardly of its plane. Each glide element is formed with a geometry generally complementary to the geometry of the first track member so that the glide tape may be slidingly engaged therewith for reciprocable travel in the direction of the longitudinal axis. This glide tape is most preferably combined with pleating tape, which has a spaced array of apertures wherein the interaperture spacing is less than the interelement spacing of the glide elements. This pleating tape, when disposed over the glide tape, creates and maintains pleats in the drape even when the drape is fully extended. The combination of components makes this window dressing system easy to assemble, disassemble or mount on a wall.
BRIEF DESCRIPTION OF THE DRAWING
The invention will hereafter be described with reference to the accompanying drawing, wherein like numerals denote like elements, and:
FIG. 1 is a perspective view of a window dressing system according to the invention;
FIG. 2 is a schematic top view, showing the pleated drape top window treatment mounted on the drapery bracket;
FIG. 3 is a cross-sectional view taken generally along the line 3--3 in FIG. 2;
FIG. 4 is an exploded view showing the glide tape and the pleating tape;
FIG. 5 is a perspective view of an end of the window dressing system bracket;
FIG. 6 is a cross-sectional view taken generally along line 6--6 in FIG. 5; and
FIG. 7 is an exploded view showing an end of the bracket and a return member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the figures of the drawing, a window dressing system designated generally as 10 is shown to include a bracket 12, a pair of standards 14 for affixing it to a wall 16, a drapery hardware assembly 17 for supporting a pleated drapery 18 between the bracket and the wall, and top window treatment hardware assembly 19 for supporting a top window treatment 20. The window dressing system 10 is designed to create a pleated pattern in the drapery material and permit the drapes to open and close in front of a window (not shown) while maintaining the desired pleated configuration.
The window dressing system 10 is typically mounted along a wall in a position which will allow pleated drapery 18 to be selectively extended to cover a window in varying degrees, thus allowing the desired amount of light to pass through the window and into a room. Bracket 12 is usually disposed above the window to support the drapes and is generally long and narrow, having a longitudinal axis 22 which preferably runs parallel to wall 16.
Bracket 12, best viewed in FIG. 6, is shown to include an inner face 24 disposed toward wall 16 and an outer face 25 disposed away from the wall. An inner track member 26 and an outer track member 28 are located on opposite sides of a central web 30 of the bracket. Inner track member 26 extends interiorly of bracket 12 and inner face 24 and is configured to receive window drapery hardware 17 in sliding engagement therewith for supporting drapery 18. Outer track member 28 extends exteriorly of bracket 12 adjacent outer face 25 and is configured to receive top window treatment hardware 19 to support top window treatment 20 for concealing window dressing system 10 from view.
In the preferred embodiment, illustrated in FIG. 6, central web 30 extends in the direction of longitudinal axis 22 and is generally rectilinear in overall cross-section with the longer sides oriented in the vertical direction. Central web 30 extends between an upper flange member 32 and track members 26 and 28, both disposed at a first or lower end 34 of web 30, to define an intermediate longitudinal slot 36. Slot 36 extends all the way along bracket 12 congruent with longitudinal axis 22, terminating at a pair of openings 37 disposed at the longitudinal ends of central web 30, as best viewed in FIG. 5.
Preferably, first end 34 is on the lower side of bracket 12 when bracket 12 is mounted to wall 16. The set of track members, 26 and 28, extend interiorly and exteriorly from central web 30, respectively, at first end 34. Inner track member 26 includes a generally vertical flange 38 spaced from web 30 by a base track 40, preferably comprised of an upper track 42 and a lower track 44 separated by a channel 46. Flange 38 is disposed at the distal end of base track 40 and extends perpendicular to base track 40 and away from channel 46 on both sides. Similarly, outer track member 28 includes a generally vertical flange 48 spaced from web 30 by an arm 49 extending outwardly and merging into a base track 50. The base track 50 preferably includes an upper track 52 and a lower track 54 separated by a channel 56. Flange 48 is disposed at the distal end of base track 50, extending perpendicular to base track 50 and away from gap 56 on both sides.
In an alternative embodiment, track members 26 and 28 each may have a general T-shape configuration which includes a single base track member from which extend an upper and lower flange, wherein the base of the inner track member T is attached to central web 30 and the base of the outer track member T is attached to extended portion 49. In such an embodiment, there is no channel corresponding to 46 or 56.
In the illustrated embodiment, bracket 12 also includes an anchoring element 60 for receiving a mounting hardware assembly 61. Anchoring element 60 is preferably disposed at a second or upper end 62 on an opposite side of central web 30 from the inner and outer track members described above. In a preferred embodiment, best viewed in FIG. 6, anchoring element 60 includes an arm 64 extending beyond central web 30 and disposed generally perpendicular to the wall on which window dressing system 10 is to be mounted. Anchoring element 60 includes an inner edge 66 which lies generally parallel with longitudinal axis 22 on the interior side of central web 30. Anchoring element 60 also includes an outer edge 68 which lies generally parallel with longitudinal axis 22 and is disposed to the exterior of central web 30. A generally flat upper surface 70 extends between inner edge 66 and outer edge 68. Extending beneath plate 70 are a pair of shoulders 72, one of each lying adjacent inner edge 64 and outer edge 66, respectively. Shoulders 72 extend generally parallel to longitudinal axis 22 and facilitate the mounting of bracket 12 to standards 14.
Mounting bracket 12 is preferably secured to a wall at a spaced distance to form a longitudinal pleat zone 74 disposed between the wall and the bracket. Longitudinal pleat zone 74 provides a space so that pleated drapery 18 may be suspended from bracket 12 and hang between the wall and bracket 12.
Standard 14 is disposed in operative engagement with bracket 12 at anchoring element 60. In the preferred embodiment, best viewed in FIGS. 1 and 3, there are a pair of standards 14. Each standard is comprised of a narrow, flat body member 76 and a wall attachment end 78 connected to the body member for affixing standard 14 to a wall. Standard 14 further comprises a bracket connection end 80 to which bracket 12 may be mounted. Wall attachment end 78 preferably includes a wall mount flange 82 which extends at approximately 90° from body member 76 and preferably includes a plurality of holes 84. Standards 14 may be affixed to a wall by any convenient means such as fasteners which are known in the art, like screws 86.
Bracket connection end 80 is formed to receive mounting hardware assembly 61 which slidably engages a surface, preferably the bottom surface, of bracket connection end 80 and body member 76. Body member 76 preferably includes a pair of slots 90 to which mounting hardware assembly 61 can be attached and selectively positioned by a fastener 92, preferably a simple bolt-and-nut. The fastener 92 extends through mounting hardware 61 and slot 90 to hold mounting hardware assembly 61 against body member 76. Preferably, the fastener is one which can be loosened and tightened so that the distance between bracket 12 and wall 16 (and thus the lateral dimension of pleat zone 74) can be adjusted by sliding fastener 92 along slot 90.
In a preferred embodiment, mounting hardware assembly 61 includes a flat bar 94 having a fastener end 96 through which fastener 92 extends and a mounting end 98 which engages anchoring element 60. Preferably, mounting end 98 terminates in a hook 100 which extends across upper surface 70 of anchoring element 60 and around outer edge 68 and the outer shoulder 72. A cam 102 is rotatably connected to bar 94 between the hook 100 and fastener end 96. Cam 102 is disposed so that when hook 100 curls around outer edge 68 and shoulder 72, cam 102 may be rotated under inner edge 64 and inner shoulder 72 to frictionally engage central web 30, thus securely fixing bracket 12 between hook 100 and cam 102. Once bracket 12 is securely fastened to the mounting hardware assembly 61, the width of longitudinal pleat zone 74 can be adjusted simply by moving fastener 92 to a different location along slot 90.
Pleated drapery 18 hangs from bracket 12 in longitudinal pleat zone 74. It is ordinarily comprised of a web of material 104 having a top region 106 attached to bracket 12 and a bottom region 108 disposed away from bracket 12. Web 104 also preferably includes a front face 110 and a rear face 112. Web 104 may be comprised of a single sheet of material, such as a fabric web, or a plurality of sheets, each suspended from bracket 12.
Window drapery hardware assembly 17 is mounted along top region 108, as best viewed in FIGS. 3 and 4. It connects drapery 18 to inner track member 26 and allows the drapery to move in a longitudinal direction along bracket 12. Preferably, the window drapery hardware 17 comprises a glide tape 116, which is attached to drapery 18 proximate the upper edge thereof along substantially its entire length. Glide tape 116 is formed from a flexible linear web 118 carrying a plurality of glide elements 120 projecting outwardly of the plane of flexible web 118 in a spaced linear array. In the preferred embodiment, glide tape 116 is secured to the drapery material by sewing it or by adhesively bonding it thereto. Glide elements 120 are formed with a reentrant geometry generally complementary to the geometry of inner track member 26 so that glide tape 116 may be slidingly engaged therewith for reciprocable travel in the direction of longitudinal axis 22.
Glide elements 120 can be affixed to flexible linear web 118 in numerous ways known in the art, although the use of rivets is preferred. In a preferred embodiment, best viewed in FIG. 3, glide elements 120 are each generally C-shaped in cross-section and include a pair of retainer elements 122 which extend towards each other at the open end of the "C". The general C-shape of glide elements 120, including retainer elements 122, allows glide elements 120 to be snapped over inner track flanges 38 of inner track member 26 by spreading the open end of the "C" and snapping the glide elements over the flanges 38, thus facilitating longitudinal movement along track member 26. Once glide elements 120 are connected to inner track member 26, either by sliding them over an end of inner track member 26 or by snapping them over the track flanges 38, transverse movement away from inner track member 26 is prevented by the interference between flanges 38 and retainer elements 122.
Pleating tape 124 is preferably used in cooperation with glide tape 116 to preserve a pleated appearance in drapery 18, even when drapery 18 is spread out along longitudinal axis 22 to its maximum extent. Pleating tape 124, shown in FIG. 4, is a flexible web having a spaced array of apertures 126 wherein the interaperture spacing is less than the intermember spacing between glide elements 120 on flexible linear web 118. Pleating tape 124 is disposed over glide tape 116 with at least some (and preferably all) sequential glide elements 120 projecting through at least some (and once again preferably all) sequential apertures 126 of pleating tape 124.
Apertures 126 are designed to fit over glide elements 120 to prevent top region 106 and thus drapery 18 from being extended to a completely flat or planar configuration. To maintain cooperation between the pleating tape and the glide elements, pleating tape 124 is placed over glide elements 120 before they are connected to inner track member 26. Pleating tape 124 is captured between flexible linear web 118 and inner track member 26 and engagement with glide elements 120 is maintained. This establishes and maintains the pleated configuration of the finished drapery product.
First and second return members 128, one of each located at each longitudinal end of bracket 12, are disposed generally normal to longitudinal axis 22. Return members 128, shown in detail in FIG. 7, extend inwardly of bracket 12, toward wall 16, and into proximity with the wall to close the opposing ends of pleat zone 74. Each return member has a retaining clip 130 for receiving and restraining the terminus of top window treatment 20 as best viewed in FIG. 1. In the preferred embodiment, a similar clip 131 is provided on the interior side to restrain the drapery.
The return members 128 are preferably made from a generally flat, stiff plastic material which extends between the longitudinal ends of bracket 12, proximate openings 37, and wall 16. Each return member 128 has a lip 132 configured to engage slot 37 of bracket 12. Preferably, lip 132 is lightly press fit into slot 36 so that the resistance will maintain the engagement between them. So positioned, return members 128 prevent glide elements 120 from sliding off the longitudinal ends of inner track 26, ensuring that drapery 18 remains completely suspended from inner track 26 and, by securing the ends of the drape and top window treatment, provide a finished look. However, if drapery 18 needs to be removed from inner track 26, possibly for cleaning, one of the return members 128 can simply be pulled loose from opening 37 so that glide elements 120 and drapery 18 can be moved longitudinally past the end of inner track 26.
Top window treatment 20 is supported on outer track member 28, preferably to conceal bracket 12 and window drapery hardware assembly 17 from view. Top window treatment 20 is usually a decorative facade which may take many forms including that of a valance or cornice, so it may be soft or rigid. As best viewed in FIG. 3, a decorative surface 136 is exposed to view and a backing surface 138 is disposed towards bracket 12. Hardware assembly 19 is affixed to backing surface 138 to attach top window treatment 20 to bracket 12. Preferably, window treatment hardware assembly 19 includes a mounting tape 140 having a flexible base layer 142 and a plurality of glide members 144 geometrically configured for engagement with outer track member 28. Glide members 144 are preferably similar to glide elements 120 used to suspend the drapery 18 from inner track member 26. Glide members 144 thus facilitate removal of the top window treatment 20 from outer track member 28 for servicing such as cleaning.
Mounting tape 140 is of sufficient stiffness to provide support for the window treatment 20 particularly when window treatment 20 is made from a cloth material. Glide members 144 are preferably affixed to base layer 142 by rivets and extend from base layer 142 in a direction away from backing surface 138. In an alternative embodiment, base layer 142 may be interchanged or supplemented with shirring tape which allows a cloth window treatment to be permanently and tightly pleated in an appealing configuration. Regardless, it is preferred to stiffen the top window treatment if it is not made from a rigid material so it will retain its shape, projecting suitably above and below the bracket 12 to hide it and the associated hardware from view.
Unless removed, top window treatment 20 remains stationary when mounted on outer track member 28. Drapery 18, however, is configured for longitudinal movement along longitudinal axis 22. Drapery 18 may be moved along inner track member 26 by a variety of ways which are known in the art including simply sliding it by hand. However, a wand 146 can be attached to drapery 18 as shown in FIG. 1. Simply by moving the wand, the drapery can be moved back and forth along bracket 12. Other systems, such as a traverse system using pulleys and an associated cord are well known in the art and can also be used to move drapery 18.
Window dressing systems are commonly known and come in many different shapes and combinations. However, the present invention provides a novel advancement in its unique combination of elements which provide a dependable system which is easy to use and install.
Drapery 18 is equipped with glide elements which are securely fastened to the drapery so that the drapery will not come loose from bracket 12. There is no risk that separable fasteners will be lost or broken when drapery 18 is removed for cleaning. The glide elements allow drapery 18 to be simply slid from inner track 26 when removed. Since the pleats formed result from pleating tape, there are no permanent or semi-permanent pleats in drapery 18 to interfere with the removal or cleaning of the drapery. Reinstalling the drapery is just as simple since the glide elements are merely slid over track 26 and a return member 128 is pressed in place to hold drapery 18 in pleating zone 74.
Top window treatment 20 is just as easily installed or removed from bracket 12. Glide members 144 are preferably permanently attached to top window treatment 20 so that the top window treatment can easily be slid onto or removed from outer track 28.
The unique combination of components and their secure interconnection also facilitates shipping and mounting of the window dressing system along a wall. The completed or partially completed system can be shipped intact. Thus, the installer can simply fasten standards 14 of the ready-made window dressing system to a wall.
It will be understood that the foregoing description is of preferred exemplary embodiments of this invention, and that the invention is not limited to the specific forms shown. For example, the inner and outer track members as well as the cooperating glide elements and glide members can use different configurations which will allow longitudinal movement while preventing transverse movement of the drapery. Additionally, various systems for imparting motion to the drapery may be used and different configurations or return members may be used. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims. | The present invention provides a window dressing system which, according to one aspect of the invention, has a bracket for supporting a drapery on one side and a window treatment on the other side. The bracket is configured with tracks which cooperate with movable hardware assemblies attached to the top window treatment and the drapery in a manner that provides simple and efficient removal of the window treatment and the drapery for servicing. The drapery hardware assembly is also designed to facilitate pleating of the drapery in an easy to assemble and disassemble arrangement. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/DE03/02328 filed Jul. 15, 2003 which designates the United States, and claims priority to German application no. 102 33 907.4 filed Jul. 25, 2002.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a device for transmitting a displacement of an actuator using an elastomer ring.
DESCRIPTION OF RELATED ART AND BACKGROUND OF THE INVENTION
The use of devices for transmitting a displacement of an actuator is known in the field of injection valves. The device thereby sets the required clearance for example between the actuator and a setting element to be controlled. Depending on the embodiment of the device, it is also possible to achieve a translation of the displacement of the actuator. For example, with piezoelectric actuators, it is advantageous to increase the relatively slim displacement lift of the piezoelectric actuator, in order to control for example a closing element of a valve or an injection needle.
To transmit the displacement, transmission chambers are provided that are delimited by a first and a second piston and a housing. The transmission chambers are filled with a transmission medium, such as hydraulic oil. For the device to function correctly, it is necessary for there to be minimum pressure in the transmission chambers. To this end, the transmission chambers are hydraulically connected to a compensation chamber. The compensation chamber is used to compensate any change in volume of the transmission chambers and to provide the transmission chambers with a transmission medium at a defined pressure. For the volume of the compensation chamber to be flexible, it is known for the compensation chamber to be sealed using a metal membrane, enabling the volume of the compensation chamber to change. However, sealing the chamber using a metal membrane is relatively complicated and the metal membrane itself is relatively expensive.
SUMMARY OF THE INVENTION
The object of the invention is to provide a device to transmit a displacement of an actuator, which does not require a metal membrane.
A considerable advantage of the device according to the invention is that the compensation chamber is delimited by an elastomer ring. The use of elastomer makes it possible on the one hand to vary the volume in the compensation chamber and on the other to subject the fluid in the compensation chamber to the action of pressure. By using a ring made out of elastomer, it is possible to seal relatively high pressures via the elastomer.
In a simple embodiment, the elastomer ring is connected in a circumferentially sealed manner to an inner wall of a housing on the outside and to a piston rod on the inside.
Depending on the manufacturing method used, it is advantageous to provide a first and/or a second sleeve on the outside and/or inside of the elastomer ring. The first outer sleeve is connected in a circumferentially sealed manner to the inner wall of the housing and to the elastomer ring. The second inner sleeve is connected in a circumferentially sealed manner to the first piston or the piston rod and to the elastomer ring. By using the outer sleeve, it is possible to configure the inner wall of the housing so that it is shorter. Furthermore, the surface of the inner wall of the housing does not have to be suitable for use in a vulcanization process, the elastomer being connected in a sealed manner to the inner wall. Greater flexibility is therefore provided in manufacturing the inner wall. It is also possible, for example, for the outer sleeve to be connected in a circumferentially sealed manner to a face end of the housing. Increased flexibility is therefore provided with respect to the region of the connection between housing and elastomer ring.
The use of the second, inner sleeve also makes it possible to manufacture the piston and/or the piston rod independently of the hydraulically sealed connection to the elastomer ring. Increased flexibility is therefore also provided in manufacturing the piston rod.
Furthermore, it is possible to carry out the vulcanization process, in which the elastomer is connected in a circumferentially sealed manner to the inner and outer sleeves, independently of the housing and first piston. It is not until after the process of connecting the elastomer ring to the outer and inner sleeves that the outer and inner sleeves are welded in a circumferentially sealed manner to the housing and/or to the piston or piston rod. The first and second sleeves are preferably made of steel.
The elastomer used has an elasticity that can however diminish when subjected to high pressures in the compensation chamber or for longer periods. To stabilize the elastomer ring, a tension device is preferably provided, which subjects the outside of the elastomer ring to the action of pretension. In this way, the elastic function of the elastomer ring is supported by the tension device.
A preferred embodiment of the tension device is the configuration of a spiral spring, which is clamped between the elastomer and a lay-on surface firmly connected to the piston rod. This creates a means of pretensioning which is independent of the position of the first piston.
To introduce the pretension effectively, it is advantageous to provide a pressure transmission device, which transmits the pretension evenly onto the elastomer ring. By transmitting the pretension evenly, it is possible to avoid local overloading of the elastomer ring.
The pressure transmission device is preferably in the form of a ring.
The ring preferably has a graduated guide, the ring being guided on the piston rod and furthermore the part of the ring with the larger diameter being supported on the elastomer ring. By guiding the ring parallel to the piston rod, the pretensioning force is evenly transmitted to the elastomer ring over the entire ring surface. By guiding the ring along the piston rod, it is possible to avoid tilting the ring and thus only partially loading the elastomer ring.
It is furthermore advantageous to protect the surface of the elastomer ring on which the tension device is acting by means of a protective film. The function of the protective film is to reduce the amount of wear and tear on the surface of the elastomer ring. The protective film is preferably configured in the form of a rubber film, which is affixed to the ring.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be shown in more detail with reference to the figures, in which;
FIG. 1 shows a schematic representation of an injection valve,
FIG. 2 shows a transmission device,
FIG. 3 shows a perspective representation of an elastomer ring,
FIG. 4 shows a plan view of a pressure ring and
FIG. 5 shows a further transmission device.
DETAILED DESCRIPTION OF EMBODIMENTS
The invention is shown below using the example of an injection valve 1 . However, the use of the transmission device according to the invention is not restricted to injection valves, as the transmission device according to the invention can be used in diverse technical fields to transmit a displacement of an actuator.
FIG. 1 shows an injection valve 1 with an actuator 2 mechanically linked to an injection valve needle 4 via a transmission device 3 . The actuator 2 is for example configured as a piezoelectric actuator and the transmission device 3 preferably has a translation function, so that a displacement of the actuator 2 is transmitted in the direction of the injection needle 4 by the transmission device 3 in order to effect a larger displacement of the injection needle 4 . The injection needle 4 is assigned to injection holes of the injection valve. As a function of the displacement of the actuator 2 , the injection needle 4 releases the injection holes, so that fuel is injected into an internal combustion engine via the injection holes.
Depending on the embodiment, the transmission device 3 can also have an inverse function, so that the setting element that is mechanically linked to the injection needle 4 is withdrawn from the injection needle 4 when the actuator 2 is displaced in the direction of the injection needle 4 .
Instead of the translation function, the transmission device 3 can also have a pure transmission function, the displacement of an actuator being transmitted in order to effect a corresponding displacement of the injection needle.
FIG. 5 shows a more precise representation of the transmission device 3 .
A first piston 6 is provided in the form of a sleeve that is open on one side. The sleeve-shaped part of the piston delimits a first transmission chamber 10 , into which a second piston 7 is guided. The first and second pistons 6 , 7 delimit the first transmission chamber 10 . The first piston 6 is in turn guided in a cylinder-shaped chamber of a housing, which has an end surface 15 on the face end to the first piston 1 . An aperture 16 is placed in the end surface 15 , through which a piston rod of the second piston 7 is guided. The piston rod has a smaller diameter than the second piston 7 . The piston rod passes via a ring-shaped recess in the wider diameter of the second piston 7 . A second transmission chamber 11 is configured between the end surface 5 , the recess and a ring-shaped face surface 17 of the first piston 6 . The second transmission chamber 11 is hydraulically connected to the first transmission chamber 10 via a first sealing gap 18 , which is configured between a side wall of the second piston 7 and inner wall of the first piston 6 . The first transmission chamber 10 is delimited by a second end surface 19 of the first piston 6 and a second face surface 20 of the second piston 7 . The first sealing gap 18 is designed in a narrow manner so that transient pressure differences are not compensated. Furthermore, the second transmission chamber 11 is connected to a compensation chamber 22 via a second sealing gap 21 , which is configured between the outer wall of the first piston 6 and the inner wall of the housing 4 . The first transmission chamber 10 is hydraulically connected to the compensation chamber 22 via a bore 60 , which is placed in the first piston 6 . The first piston 6 passes into the piston rod 51 via a second recess. The piston rod 51 is essentially in the form of a cylinder and has a smaller diameter than the first piston 6 .
In a first embodiment according to FIG. 5 , an elastomer ring is placed between the housing and the second piston 7 and/or the piston rod 51 of the first piston 6 . The elastomer ring 50 is thereby connected in a circumferentially sealed manner to the housing 5 on the outside and to the piston rod 51 on the inside. A vulcanization method is used to effect the connection. The housing 5 and the first piston 6 having piston rod 51 are made of steel.
The geometry of the elastomer ring is such that the elastomer ring has sufficient elasticity and at the same time the necessary stability to delimit the pressure of the compensation chamber 22 . Due to its elastic properties, the elastomer ring should enable the volume in the compensation chamber to grow and also prevent too high an increase in pressure.
The first and second transmission chambers 10 , 11 and the compensation chamber are filled with a transmission fluid. In this way, it is possible to achieve a motive link between the first and second pistons 6 , 7 . If the first piston 6 is moved deeper into the housing 5 by the actuator, the second piston 7 is in turn moved deeper into the housing 5 . Inverse motion is thus achieved between the first and second pistons 6 , 7 . The compensation chamber 22 is connected to the second transmission chamber 11 via the second sealing gap 21 , the second sealing gap 21 being designed in such a narrow manner that transient pressure differences between the transmission chamber 11 and the compensation chamber 22 are not compensated. The term transient is understood to mean activating times of the actuator that the actuator requires in order to activate a setting element, in the example shown to activate the injection needle.
Pressure differences lasting for a longer period of time are compensated via the second sealing gap 21 between the second transmission chamber and the compensation chamber 22 . In this way, it is possible to automatically achieve a compensation of clearance. The first and second pistons 6 , 7 can therefore always be laid onto an actuator and/or a setting element. The transmission element is preferably under pressure. The pressure can for example be transmitted to the transmission fluid via the elastomer ring 50 using a tension device. Instead of the embodiment shown in FIG. 2 , it is also possible to select other arrangements of the transmission chambers, so that a movement of the first piston 6 is transmitted in order to effect a movement of the second piston 7 in the same direction.
In a preferred embodiment according to FIG. 2 , the elastomer ring 50 is connected to a first outer sleeve 52 on the outside and to a second inner sleeve 53 on the inside. The first sleeve 52 is connected in a circumferentially sealed manner to the housing 5 , preferably welded. The connection surface can be arranged on the inside or on a face end of the housing. On the inside surface, the second sleeve 53 is connected in a circumferentially sealed manner to the piston rod 51 , preferably welded. Using an outer and inner sleeve 52 , 53 has the advantage of making it possible to carry out the connection process between the elastomer ring 50 and the outer and inner sleeve 52 , 53 independently of the connection process between the outer and inner sleeve 52 , 53 and the housing 5 and/or piston rod 51 .
In a preferred embodiment, a tension device is provided, which is used to pretension the elastomer ring 50 in the direction of the compensation chamber 22 . In a simple embodiment, a spiral spring 54 is provided for this purpose, which is clamped between a stop ring 55 and the elastomer ring 50 . The stop ring 55 is connected firmly to the piston rod 51 . In a preferred embodiment, a pressure transmission device is provided between the tension device and the elastomer ring 50 , said pressure transmission device transmitting the pretension force of the spiral spring 54 having a larger surface to the surface of the elastomer ring 50 . The pressure transmission device is preferably configured in the form of a pressure ring 56 . The pressure ring 56 preferably has a support surface essentially corresponding to the surface of the elastomer ring 50 . In a further preferred embodiment, the pressure ring 56 has a graduated guide, the pressure ring 56 being guided by the piston rod 51 in the area of the guide with the smaller diameter. In this way, the pressure ring 56 is guided axially, so that the pressure ring 56 is not able to tilt. In this way it is possible to ensure that the pressure ring 56 evenly transmits the pretension force preset by the spiral spring 54 onto the elastomer ring 50 via the lay-on surface of the pressure ring 56 .
FIG. 3 shows a schematic representation of the elastomer ring 50 .
FIG. 4 presents a view of the pressure ring 56 from below, clearly showing a contact surface 58 , which is used to support the pressure ring 56 on the elastomer ring 50 . The guide aperture 59 is also shown, through which the piston rod 51 is guided in a finally constructed state and via which the pressure ring 56 is guided in such a manner that it can move axially in the axial direction of the piston rod 51 . In this way it is possible to avoid tilting the support surface of the pressure ring 56 .
In a preferred embodiment, a protective film 57 is affixed to the surface of the pressure ring 56 , which is assigned to that of the elastomer ring 50 . The protective film 57 is comprised for example of rubber and serves to protect the elastomer ring 50 from abrasion due to the pressure ring 56 . The protective film 57 preferably has a greater hardness than the elastomer ring 50 . | A device for transmitting a displacement of an actuator to a setting element comprises two pistons that delimit two transmission chambers and a compensation chamber with a housing. The compensation chamber is hydraulically connected to the two transmission chambers. The transmission chambers transmit a displacement of the first piston in order to effect a displacement of the second piston. The compensation chamber serves as a reservoir for the transmission medium with which the transmission chambers are filled. The compensation chamber is delimited by an elastomer ring. The elastomer ring depicts a simple and economical realization with which it is possible to subject the compensation chamber to the action of pressure and to change the volume of the compensation chamber at the same time. In a preferred embodiment, the elastomer ring is externally subjected to the action of a tension force via a pressure ring. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a reinforcing cord made of at least one strand of metal wires for reinforcing elastomeric products.
Conventional reinforcing cords are assembled of metal wires having circular cross-section. Known also are reinforcing cords assembled of flattened metal wires having approximately rectangular cross-section. For instance, in the British Patent specification No. 225,477 reinforcing having flattened strands of wires is described in which the flatness of the strands and hence of the entire cord is amplified due to the fact that metal wires are employed in the flat strands which engage one another along their flat sides.
SUMMARY OF THE INVENTION
A general object of the present invention is to provide an improved reinforcing cord of the aforedescribed kind which has a more compact construction without through-going capillaries.
Another object of this invention is to provide such an improved reinforcing cord in which the force (stress)-elongation behavior can be adjusted to a desired value in a particuarly simple manner.
A further object of the invention is to provide such an improved reinforcing cord in which variations of diameter along its length are substantially reduced.
An additional object of this invention is to provide a reinforcing cord whose stiffness can be varied. The overall cross-section of the reinforcing cord corresponds substantially to a circle.
In keeping with these objects and others which will become apparent hereafter one feature of the invention results, in a reinforcing cord for use in elastomeric products, in a combination which comprises at least one strand of metal wires, the wires having substantially rectangular cross-section defining opposite broad sides and short narrow sides, and having rounded corners, the metal wires in the strand contacting one another along their broad sides and the strand being twisted about its longitudinal axis.
In the preferred embodiment, the contour of the cross-section of the strand is approximately rectangular and the ratio of its sides is between 2:1 and 1:1.
The contour of the strand is formed by the outer flat surfaces of the metal wires constituting the strand.
Due to the contact of long or broad sides of metal wires in the strand, the reinforcing cord of this invention has a particularly high strength. When the reinforcing cord of this invention is used in an elastomeric product, for example in cord tires of a motor vehicle, then it occupies less space than prior art cords of the same strength. Due to the twist of the reinforcing cord about its center or longitudinal axis the stress-elongation behavior of the cord is rendered more advantageous. At the same time, a uniform, compact cross-section is created over the entire length of the reinforcing cord which reduces the risk of frictional contact with adjoining cords when embodied in an elastomeric product.
In order to facilitate the penetration of the elastomeric material between the embedded cords, it is of advantage when the broad or long sides of the rectangular metal wires have a slightly bulging configuration whereas the narrow sides have a more bulging configuration.
In the case when the reinforcing cord is made of a single metal wire, then the latter has a substantially square cross-section. Preferably, the square cross-section is produced by shaping a round metal wire of a corresponding thickness by drawing through a correspondingly square open die.
When the reinforcing cord is made of a strand of several metal wires then all metal wires have approximately rectangular cross-section with opposite broad sides of the same length. The rectangular cross-section of the metal wires is achieved preferably by flatrolling or by drawing through a drawing die having a correspondingly rectangular cross-section. In the flatrolling process or in drawing round metal wires through the drawing die it is of advantage when no shaping is made in the direction transverse to feeding direction of the wire so that the material is free to flow in this transverse direction. In this manner, the desired strong bulging of the metal sides of the rectangular cross-section is obtained. The rectangular metal wires having the same length of their broad flat sides may, in the same cord, be of different thickness. Nevertheless from the standpoint of manufacturing economy it is of advantage when all wires have approximately the same thickness.
Preferably the ratio of the broad side to the short side of the rectangular cross-section is approximately between 4 and 1.5. For example, if the reinforcing cord of this invention includes a flat metal wire having a ratio of its broad side to its short side of about 1.5 then an additional thin metal wire with a ratio of its width to thickness of about 3 must be added in order to obtain a substantially square cross-section of the cord.
The reinforcing cords of this invention can be manufactured in a simple manner by flatrolling or drawing through a die round wires and simultaneously uniting the flattened metal wires along their broad sides and twisting the united strand about its longitudinal axis. The number of twists per meter, as mentioned before, affects the breaking elongation of the cord.
The twisting of the strand of contacting flat wires or of a single wire of a square cross-section is made preferably by a twisting device arranged between the rolls or drawing die and spool.
A particularly cost saving and simple manufacturing of reinforcing cords of this invention uses alternating twisting in a S and Z direction instead of a continuous twisting in the S or Z direction. The alternating twisting takes place along the entire length of the reinforcing cord. In the preferred embodiments of this invention the reinforcing cord has between 40 and 200 twists per meter.
It has been found that in practice a particular advantageous embodiment of the reinforcing cord of this invention includes two flat metal wires each having a substantially rectangular cross-section of the same size whereby the broad sides of the two wires are in contact with one another and the ratio of the broad side to the short side of individual metal wires is about 2.
As mentioned before, it is also possible to make reinforcing cord according to this invention containing a single metal wire of a square cross-section only or including a strand assembled of 3, 4 or even more metal wires whereby the upper limit of the number of metal wires is determined by the desired stiffness of the cord. The more metal wires are used in the reinforcing cord, the lower is the stiffness of the latter.
For reinforcing cords intended for use in heavy duty truck cord tires for example two or more reinforcing cords of this invention can be united into a reinforcing rope. The before-described reinforcing cords can be classified as a group of simple stranded reinforcing cords. These simple stranded cords can be employed as strands for more complex reinforcing cords whereby the advantages of simply stranded cords are preserved. The complex reinforcing cords made of intertwisting simpler reinforcing cords will be designated in the following description as reinforcing ropes.
A reinforcing rope can be assembled either entirely of reinforcing cords of this invention or the latter can constitute only the core of the rope. In the latter case one or more reinforcing cords are employed as cord strands around which several single wires are layed.
It is of a particular advantage when the number of single wires layed around the cord strand or strands is larger than the number of metal wires in the cord strand having approximately rectangular cross-section.
In a preferred embodiment, reinforcing rope is devised which includes reinforcing cord made of two metal wires of a substantially rectangular cross-section (at a width/length ratio of 2) employed as a cord strand, and 8 single wires of circular cross-section layed around the cord strand. The length of lay of the single wires is preferably 10 to 20 millimeters.
The reinforcing rope is preferably wrapped around with one or more wrapping wires forming a helix around the rope. The helically wound wrapping wires are preferably of a flat cross-section with the broad side contacting the rope wires so that the diameter of the reinforcing rope is reduced. Simultaneously the risk of fretting corrosion between the wrapping wire and the supporting metal wires in a completed elastomeric product is also reduced.
The risk of fretting corrosion is always present when two metallic surfaces are in contact with one another and are loaded so that the contacting surfaces are subject to a minute shifting movement in opposite directions. Such a condition occurs between the metal wires of the reinforcing cord which take up the load of the elastomeric product, and the wrapping wires.
The reinforcing cords and reinforcing ropes of this invention find a useful application particularly in manufacturing pneumatic tires of motor vehicles, heavy duty hoses, conveyor belts or diving belts. They are suitable particularly as cord belts in tires of heavy trucks, load construction machines or tractors.
As known, metal wires employed in reinforcing cords of this invention are made of carbon alloyed steel. Preferably metal wires having 0.6-0.9 percent by weight of carbon are suitable. Tensile strength of such wires produced by drawing and having a circular cross-section, is about 2,500 to 3,500 N/square millimeter. The steel wires must exhibit an excellent bind with the elastomeric material of the product in which they are embedded. For this reason the metal wires are coated with another material such as a plastic material. It is also of advantage when the steel wires are coated with a brass layer.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself however both as to its construction and its method of operation together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a sectional plan view of four cross-sections of three different reinforcing cords A, B and C, of which cords A and B are prior art reinforcing cords and cord C is the cord according to this invention;
FIG. 2 shows a sectional plan view of another embodiment of the reinforcing cord of this invention;
FIG. 3 shows a diagram of force versus elongation of three different reinforcing cords of this invention;
FIG. 4 shows the diagram of force versus elongation of three prior art reinforcing cords;
FIG. 5 is a schematic side view of a device for measuring air permeability of a reinforcing cord of this invention embodied in an elastomeric material;
FIG. 6 is a sectional side view of a testing sample for measuring the air permeability of the reinforcing cord; and
FIG. 7 is a sectional top view of a reinforcing rope according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates three different reinforcing cords A, B and C, of which cords A and B are prior art cords and C is the reinforcing cord according to this invention. Each of the cords A, B and C are shown in cross-sections perpendicular to their longitudinal axis and at different characteristic twisting angles of 0° , 90° , 180° and 270° whereby the selected direction of twisting is indicated by arrow.
Cord A consists of four wires 1, 2, 3 and 4 each having a circular cross-section and being twisted around the longitudinal axis as indicated. Cord B also consists of four wires 5, 6, 7 and 8 of a circular cross-section whereby wires 7 and 8 are parallel wires contacting one another along a straight line and being surrounded by helically wound wrapping wires 5 and 6 which also extend parallel one to another. The reinforcing cord C according to this invention in this embodiment consists of two metal wires 9 and 10 of a substantially rectangular cross-section each having a ratio of 2:1 of its long side to its short side and contacting one another along their long sides and the entire cord being twisted about its longitudinal axis.
It will be seen from FIG. 1 that the prior art cord A can be circumscribed by a peripheral circle 11 of a constant diameter which is larger than that of the corresponding circumscribed circle 14 in the reinforcing cord C according to this invention. It will be also seen that the prior art cord A exhibits a through-going capillary 15 extending along the longitudinal axis of the cord A between the four wires 1, 2, 3 and 4. This central capillary 15 cannot be penetrated by rubber when the cord is embedded in the elastomeric material and consequently in the case of a mechanical damage of the elastomeric material in which the reinforcing cord is embodied, corrosive media are permitted to enter the capillary 15 and propogate to such a extent that a separation of layers may occur.
In contrast, in the reinforcing cord C according to this invention the formation of any capillary between the wires is made impossible and therefore the aforedescribed corrosive affects cannot occur.
In the prior art reinforcing cord B the wrapping wires 5 and 6 continuously change their position relative to the core wires 7 and 8 so that in this known embodiment a through-going capillary passage cannot result and the propagation of corrosive media in embodied cords is also excluded. The disadvantage of this prior art cord however is relatively large diameter of circumscribed circles 12 and 13 which independently from the position of wires 5, 6, 7 and 8 even in the most favorable position is always larger than the corresponding circle 14 in the cord C of this invention. Moreover, in the embedded condition the risk of frictional contact between adjoining layers is considerably larger in the cord B than in the cord C of this invention. By virtue of the particular structure of the cord C the spacing between individual cords embodied in the elastomeric product can be reduced and consequently a higher strength per unitary cross-sectional area of the elastomeric product is obtained.
In embedding reinforcing wires in the elastomeric material it is of importance that all wires in the cord be approximately of the same length in order to achieve planar webs of the binding body. It will be seen that in prior art cords A and B this condition is strongly dependent on stresses acting on the individual wires during twisting. In comparison, in reinforcing cord C of this invention the length of the wires remains substantially the same.
FIG. 2 shows a cross-section of a cord according to this invention consisting of three superposed flat wires 16 each having a rectangular cross-section whereby the ratio of the broad side to the thickness or to the short side of each wire is about 3. The contour 17 of the cord corresponds substantially to a square with rounded corners.
EXAMPLE 1
In FIG. 3 there is illustrated a plot diagram of a force-elongation behavior of cords 18, 19 and 20 according to this invention, each consisting of two superposed flat wires of a rectangular cross-section and of equal thickness. The cords differ one from the other by a number of twists per unit length. The results are tabulated in the following Table I.
FIG. 4 shows a similar force-elongation diagram of a prior art reinforcing cord 21-23 each consisting of two steel wires of circular cross-section and each having a different number of twists per meter. The results are also tabulated in the following Table I. The effective cross-section area of cords 18, 19 and 20 according to this invention corresponds to that of prior art cords 21, 22 and 23.
TABLE I______________________________________Cord Wire Twists per Elongation K.sub.maxNr Cross-section meter at K.sub.max %______________________________________18 B: H = 2 0 2.4 10019 B: H = 2 70 3.6 9720 B: H = 2 100 4.4 9621 Circular 0 2.0 10022 Circular 70 2.5 9723 Circular 100 2.7 96______________________________________
It is apparent from the plot diagrams of FIGS. 3 and 4 that the elongation of the reinforcing cords according to this invention in response to the applied force can be substantially increased in comparison to prior art cords assembled of round wires whereby the maximum permissible tensile load in both types of cords is comparable and slightly decreases with increasing widths.
EXAMPLE 2
In this example, two prior art commerically available reinforcing cords are compared with a reinforcing cord according to this invention. In the following Table II, cords 24, and 25 correspond to prior art cords A and B in FIG. 2. Reinforcing cord 26 of this invention consists of two superposed flat wires each having an approximately rectangular cross-section with rounded corners. Each of these wires has been produced by flatrolling from a round wire having 0.36 millimeters diameter and being flattened to a thickness of about 0.25 millimeters. The cross-sectional area both of the starting round wires and of the flatrolled finished wires is approximately the same. The specific parameters and properties of the known cords 24 and 25 and of the cord 26 of this invention are tabulated in Table II.
TABLE II______________________________________ Reinforcing Comparison Comparison cord of This Cord 24 Cord 25 Invention 26______________________________________Designation of 4 × 0.25 2 + 2 × 0.25 2 × 0.36constructionLength of lay mm 12.5 14 16Tensile strength N 520 520 523m-weight ktex 1.59 1.59 1.59Breaking 1.87 1.79 2.55elongation %Average cord 0.6 0.66 0.57diameter mmBending 23 23 36stiffness SUPermeability to 43 0 0air in vulcanizedcondition ml/min______________________________________
The bending strength has been determined according to BISFA "Internationally agreed methods for testing steel wire cords 1981, Chapter II, Determination of Stiffness."
The air permeability in vulcanized condition provides information about the quality of embedding of a reinforcing cord in rubber. The air permeability has been determined by means of a testing device illustrated in FIG. 5, whereby a testing body according to FIG. 6 has been used.
In order to measure the air permeability, a 7.5 centimeter long piece a reinforcing wire 29 is embedded in rubber 28 whereby the reinforcing cord 29 is visible at both end faces of the testing body 27. Simultaneously a sealing ring 30 and a tubular connection piece 31 are embedded in rubber 28 around opposite ends of the cord.
By a union nut 33 the testing body 27 is hermetically connected to a connection piece 34 which is connected via tube 35, a pressure-reducing valve 36 and a pressure-air conduit 37 to a non-illustrated source of pressure air. The opposite tubular connection-piece 31 is connected to a U-shaped tube 32 whose upwardly directed front is immersed in a container 38 filled with water 39. The front of the tube 32 opens into a measuring cylinder 40 provided with graduations.
The cylinder 40 at the beginning of the test is filled with water up to the zero mark and is also immersed into the body of water 39. Valve 41 at the top of the measuring cylinder 40 serves for adjusting the height of the water column in the cylinder.
At the beginning of the measurement of the air permeability a pressure of about 1 bar is adjusted by means of the pressure-reducing valve 36. In the case when air penetrates through test body 27 due to faulty or incomplete embedding of the reinforcing cord 29 in the rubber mass 28, then the resulting air bubbles are assembled in the measuring cylinder 40 and the rate or the amount of air accumulated in the measuring cylinder 40 per time unit, is being measured.
It will be seen from Table II that the reinforcing cord 26 of this invention is substantially more compact in comparison with prior art cords 24 and 25. The average diameter of the cords indicated in Table II serves a measure for compactness. The prior art cords exhibit substantially larger diameter than the cord of this invention (see diameter 13 of Cord B, FIG. 1).
The embedding of the reinforcing cords of this invention in an elastomeric (rubber) product is superior to that of prior art cords as it will be seen from the values of the air permeability in vulcanized condition. The corresponding values can be achieved with prior art cord 25 only by substantially increasing the outer diameter.
The bending stiffness of the reinforcing cord 26 is larger than that of the cords 24 and 25 and consequently the cord of this invention is suited better for the application in cord tires of motor vehicles than conventional cords. In order to facilitate the comparison of the cords in Table II, the tensile strength of all three cords has been set to about 520 N.
It will be also recognized from the Table II that the reinforcing cord 26 of this invention of the same tensile strength has substantially increased breaking elongation in comparison with prior art cords 24 and 25.
EXAMPLE 3
In Example 3 a reinforcing rope 42 includes a core consisting of two superposed flat wires 44 each having a substantially rectangular cross-section with rounded corners, and being twisted around their central or longitudinal axis, is surrounded by eight wires 45 of a circular cross-section, as illustrated in FIG. 7. In the following Table III, the reinforcing rope of this invention is compared with a rope 43 having a core made of three round wires which are surrounded by six round wires wound around the cord. The construction and the properties of the reinforcing rope 42 of this invention and of the prior art rope 43 are shown in Table III.
TABLE III______________________________________ Reinforcing rope 42 Comparative of the invention prior art rope______________________________________Designation of 2 × 0.38 F + 8 × 0.30 3 × 0.20 + 6 × 0.38constructionLength of lay 16/16 10/18mmTensile 1762 1700strength Nm-weight ktex 6.13 6.14Breaking 2.31 2.00elongation %Average cord 1.16 1.18diameter mmBending 161 170stiffness SUPermeability to 0 25air invulcanizedconditionml/min______________________________________
Constructive designation "0.38 F" means that a round steel wire at a diameter of 0.38 millimeters has been flattened by rolling to a thickness of 0.255 millimeters whereby the cross-sectional area of the flattened wire has remained substantially the same.
It will be seen from Table III that in comparison with prior art reinforcing rope 43, the reinforcing rope 42 of this invention has a slightly smaller diameter and a higher tensile strength. In this example a measure of compactness of the rope is tensile strength related to an average diameter of the rope, corresponding in the rope 42 of this invention to the value 1519 N/mm (1762 N:1.16 mm) while in prior art rope 43 the value is 1441 N/mm (1700 N:1.18 mm). It is evident that a reinforcing cord of this invention is substantially more compact than the prior art rope.
The bending strength and the air permeability in vulcanized condition has been determined in the same manner as described in connection with Example 2. The bending strength of the reinforcing cable 42 of this invention is slightly higher than that of the comparison rope 43 whereas the former is superior when embodied in the elastomeric (rubber) material as evident from the test of the permeability to air.
It will be understood that each of the elements described above or two or more together may also find a useful application in other types of construction differing from the types described above.
While the invention has been illustrated and described as embodied in specific examples of the reinforcing cords, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapted for various applications without omitting features that from the standpoint of prior art fairly constitute essential characteristics of the generic or specific aspects of this invention. | A reinforcing cord for use in radial tires, conveyor belts, hoses or driving belts, includes at least one strand of metal wires twisted along the longitudinal axis of the strand. Each metal wire has a substantially rectangular cross-section defining two opposite broad sides. The wires in the strand engage one another along their broad sides and preferably are wrapped around by a wrapping wire. | 3 |
PRIORITY CLAIM
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/754,234, filed Jan. 18, 2013, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The subject matter disclosed herein relates generally to active vibration control systems and methods. More particularly, the subject matter disclosed herein relates to implementation and control schemes for an active vibration control system, such as is used to control vibration in a helicopter.
BACKGROUND
[0003] It is sometimes desired to place multiple actuators, such as linear actuators or circular force generators (CFGs), close together at particular locations to increase controllability of certain modes of vibration. When this is done, however, adaptive algorithms that are commonly used to control such modes of vibration (e.g., filtered least mean squares) can have difficulty finding the optimal solution. These difficulties can generally arise either because the algorithm takes a significantly longer path to find the minimal solution (i.e., slow convergence) or because it can have a difficult time finding a unique solution, and it will thus oscillate back and forth looking for the minimum (i.e., poor performance).
[0004] As a result, it would be advantageous for systems and methods for controlling multiple actuators to quickly and accurately identify an optimal solution to generate the desired force output from the combined operation of the multiple actuators.
SUMMARY
[0005] In accordance with this disclosure, systems, methods, and computer program products for directional force weighting of an active vibration control system are provided. In one aspect, an active vibration control system includes a plurality of force generators arranged in an array, with each of the plurality of force generators being configured to generate individual component force outputs. An even number of the plurality of force generators are arranged in pairs that are placed in close proximity to one another for multi-directional force generation. A controller is configured to individually control each of the plurality of force generators to achieve a combination of the individual component force outputs that produces a desired total force vector.
[0006] In another aspect, a method for directional force weighting of an active vibration control system is provided. The method involves arranging a plurality of force generators in an array, identifying individual component forces corresponding to force outputs of each of the plurality of force generators, determining a combination of the individual component forces that will produce a desired total force vector, and adjusting the outputs of each of the plurality of force generators such that the combination of the individual component forces are at least substantially similar to the desired force vector.
[0007] Although some of the aspects of the subject matter disclosed herein have been stated hereinabove, and which are achieved in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a flow chart representing a method of controlling an active vibration control system according to an embodiment of the presently disclosed subject matter.
[0009] FIG. 2 is a schematic view of an arrangement of multiple force generators according to an embodiment of the presently disclosed subject matter.
[0010] FIG. 3 is an illustration of a mapping matrix used for force mapping according to an embodiment of the presently disclosed subject matter.
[0011] FIG. 4 is a schematic view of an arrangement of multiple force generators according to an embodiment of the presently disclosed subject matter.
[0012] FIGS. 5 through 7 are illustrations of mapping matrices used for force mapping according to embodiments of the presently disclosed subject matter.
[0013] FIG. 8 is a schematic view of an arrangement of multiple force generators according to an embodiment of the presently disclosed subject matter.
[0014] FIG. 9 is a mapping matrix used for linear force mapping according to an embodiment of the presently disclosed subject matter.
DETAILED DESCRIPTION
[0015] Numerous objects and advantages of the subject matter will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings, which illustrate such embodiments.
[0016] Actuator mapping is able to transform redundant and/or poorly conditioned degrees of freedom into simpler primary Degrees of Freedom (DOFs) in a very simple way. As shown in FIG. 1 , for example, achieving a desired force output from a system of independently-controlled force actuators using this kind of actuator mapping involves a selection step S 1 in which the degrees of freedom that are desired for the system to output are selected. A mapping step S 2 then maps the desired degrees of freedom to the degrees of freedom that are realizable by the force actuators in the system. Based on this mapping, a control step S 3 controls each of the force actuators in the system to achieve the desired output. Furthermore, such actuator mapping is generally applicable to any vibration control system, including linear, circular, or mixed actuation systems.
[0017] In one non-limiting example, a system of linear actuators is controllable to achieve an aggregate force output that includes both linear and rotational modes of vibration. As shown in FIG. 2 , for example, a first linear actuator 10 a is configured to generate linear vibrations in a first direction (e.g., along an x-axis), and a second linear actuator 10 b , a third linear actuator 10 c , and a fourth linear actuator 10 d are each configured to generate linear vibrations in a second direction that is substantially perpendicular to the first direction (e.g., along a z-axis), with each of the linear actuators being independently controlled by a controller 30 . In addition, third linear actuator 10 c and fourth linear actuator 10 d are positioned near one another such that they are mapped into one or more independent control degrees of freedom as a single paired linear actuator 20 to improve control performance of the system. Furthermore, if resonant actuators are used, the resonant frequency of the coupled actuators can be tuned close to one another, or a phase offset correction can be added. In this way, the controlled actuation of all of the linear actuators enables modes of vibration to be achieved beyond the first and second directions.
[0018] To achieve these complex modes of vibration, a transformation matrix is applied to the inputs from each of the linear actuators to achieve a desired output. In general, an active vibration control system operating at a single frequency is described as
[0000]
e=Cf+d
[0000] where e is a [n×1] complex vector of vibration signals at the frequency of interest and measured by the vibration sensors, f is a [m×1] complex vector of input force commands at the frequency of interest, C is the [n×m] complex transfer function matrix between f and e, and d is the n×1 complex vector of vibration signals measured when there is no control. The control system is functional to adapt f such that the product of C and f looks as close to −d as possible such that e is minimal (in a least squares sense).
[0019] In this regard, a force transform vector is produced:
[0000] M 1= M 2 M 3
[0000] where an output force vector M 1 represents a complex vector with elements for which control weighting is desired, and a transformation matrix M 2 maps the natural modes of vibration generated by an input force vector M 3 to achieve the desired control weighting.
[0020] Referring again to the actuator configuration shown in FIG. 2 , for example, a control scheme is implemented in one embodiment based on the relationship described above to achieve a complex output force vector M 1 as shown in FIG. 3 that is selected to best neutralize the uncontrolled vibration (e.g., the negative of the complex vector of vibration signals d from the relationship discussed above). In this embodiment, output force vector M 1 includes vibrations in a first x-direction (e.g., aligned with first linear actuator 10 a ), a first z-direction (e.g., aligned with second linear actuator 10 b ), and a second z-direction (e.g., substantially aligned with paired linear actuator 20 ), as well as generating a rotational mode of vibration (e.g., about paired linear actuator 20 ). This output is achieved by multiplying transformation matrix M 2 (e.g., complex transfer function matrix C from the relationship discussed above) by input force vector M 3 (e.g., complex vector of input force commands f from above), where input force vector M 3 represents the natural degrees of freedom of each of the linear actuators in the system. In particular, as shown in FIG. 3 , input force vector M 3 comprises elements representing a first x-direction (e.g., aligned with first linear actuator 10 a ), a first z-direction (e.g., aligned with second linear actuator 10 b ), a second z-direction (e.g., aligned with third linear actuator 10 c ), and a third z-direction (e.g., aligned with fourth linear actuator 10 d ). By particularly configuring transformation matrix M 2 , the particular inputs that are needed for each of first, second, third, and fourth linear actuators 10 a , 10 b , 10 c , and 10 d (i.e., the values of input force matrix M 3 ) to achieve the resultant mode of vibration defined by output force vector M 1 are found.
[0021] Similarly, the pairing of proximal circular force generators (CFGs) enables bidirectional force generation. There may be situations where a systems engineer will want to create a single direction force using two CFGs. For example, multiple circular forces can be mapped to independent linear forces (and vice versa). To this end, the vibration control algorithm implicitly will converge to an elliptical resultant force profile for pairs of CFGs such that a weighted sensor set is minimized. The following provides a manner for doing so by penalizing or applying control weighting to various rectilinear directions while maintaining independent CFG control.
[0022] For example, as shown in FIG. 4 , if a system consists of five CFGs (e.g., a first CFG 11 a , a second CFG 11 b , a third CFG 11 c , a fourth CFG 11 d , and a fifth CFG 11 e ) each being independently controlled by controller 30 , the first four CFGs are grouped as a first CFG pair 21 a and a second CFG pair 21 b , and fifth CFG 10 e is unpaired. A goal to minimize the vibration signals (e.g., vector e from the relationship discussed above) is achieved while constraining first CFG pair 21 a to produce forces in the x-direction only, constraining second CFG pair 21 b to produce forces in the y-direction only, and provide an option to apply a small level of control weighting to fifth CFG 11 e.
[0023] Again, identifying the proper control weighting for each of the five CFGs in this exemplary configuration is achieved by transforming the input forces generated individually into an aggregate output force vector having the desired modes of vibration. In particular, for example, FIG. 5 provides one generalized implementation of transformation matrix M 2 in which a sub-matrix tof converts forces from circular force format to rectilinear force format.
[0024] Using this form of force transform, a cost function is defined as follows:
[0000]
J
=
e
*
Qe
+
F
*
RF
=
e
*
Qe
+
f
*
Γ
*
R
Γ
f
=
e
*
Qe
+
f
*
R
^
f
[0000] where Q is a sensor weighting matrix and R is a control weighting matrix. With respect to the configuration discussed above with respect to the arrangement shown in FIG. 4 , R takes the following form to achieve the control objectives stated above:
[0000] R =diag{0, r ay ,r by ,0, r 5 }
[0000] where r ay , r by , are adjustable to ensure unidirectionality of first CFG pair 21 a and second CFG pair 21 b , respectively, and r 5 provides control weighting on fifth CFG 11 e.
[0025] The adaptation algorithm has the following form:
[0000] f k+1 =( I−{circumflex over (R)} ) f k −μC*Qe k
[0026] FIGS. 6 and 7 provide further non-limiting examples of the above principles being applied generally to achieve a desired force output using collocated CFGs. Specifically, FIG. 6 illustrates a configuration of transformation matrix M 2 that is configured to map independent linear forces to four circular forces. In this non-limiting example, output force vector M 1 contains four circular force outputs to be achieved, and transformation matrix M 2 is able to map input force vector M 3 to these linear forces from an array of CFGs. Specifically, input force vector M 3 represents two linear forces acting in a single linear direction. In addition, those having skill in the art will recognize that transformation matrix M 2 is further able to transform four circular forces into two linear forces.
[0027] In addition, in the configuration shown in FIG. 7 , transformation matrix M 2 is designed to transform force inputs from six CFGs (e.g., three clockwise-rotating CFGs and three counter-clockwise-rotating CFGs) into a complex mode of vibration having both circular and linear components. Specifically, the circular force inputs are represented in input force matrix M 3 as a first counter-clockwise rotational force F ccw1 , a first clockwise rotational force F ccw2 , a second counter-clockwise rotational force F ccw3 , a second clockwise rotational force F ccw4 , a third counter-clockwise rotational force F ccw5 , and a third clockwise rotational force F ccw6 , and the complex force outputs are represented in output force matrix M 1 as a first circular force F c1 , a second circular force F 2c , a first linear force F z , and a second linear force F y .
[0028] In yet a further configuration, actuators are mounted near the transmission of a helicopter to suppress the primary DOFs: X, Y, Z, pitch, and roll. Specifically, as shown in FIG. 8 for example, eight circular force generators are operable to independently control the five primary rigid body DOF's, thereby creating the possibility of a zero-vibration application. In this non-limiting example, a first CFG 12 a and a second CFG 12 b are arranged substantially in the center of an array as a first CFG pair 22 a . In addition, a third CFG 12 c and a fourth CFG 12 d are each arranged at positions that are spaced apart from first CFG pair 22 a on opposing sides of first CFG pair 22 a . Similarly, a fifth CFG 12 e and a sixth CFG 12 f are likewise disposed on opposing sides of first CFG pair 22 a , with third CFG 12 c and sixth CFG 12 f functioning as a second CFG pair 22 b and fourth CFG 12 d and fifth CFG 12 e functioning as a third CFG pair 22 c . A seventh CFG 12 g and an eighth CFG 12 h are arranged at positions that are spaced apart from first CFG pair 22 a on opposing sides of first CFG pair 22 a and shifted approximately 90° with respect to second CFG pair 22 b and third CFG pair 22 c.
[0029] An exemplary mapping matrix for such a configuration is designed as shown in FIG. 7 . As discussed above, the eight CFGs are operable to independently control the five primary rigid body DOFs represented in output force vector M 1 : a first linear vibrational force F x , a second linear vibrational force F y , a third linear vibrational force F z , a first moment M γ , and a second moment M η . This control is achieved by applying a configuration of transformation matrix M 2 that maps three counter-clockwise rotational forces (i.e., F ccw1 of first CFG 12 a , F ccw3 of third CFG 12 c , and F ccw5 of fifth CFG 12 e ) and five clockwise rotational forces (i.e., F cw2 of second CFG 12 b , F cw4 of fourth CFG 12 d , F cw6 of sixth CFG 12 f , F cw7 of seventh CFG 12 g , and F cw8 of eighth CFG 12 h ) represented in input force matrix M 1 to the five primary rigid body DOFs.
[0030] In any configuration, if the control authority of a particular DOF is significantly larger or smaller than the others, it can also cause poor transient performance. A simple way to improve this is to normalize the actuator response in the plant model (C-model):
[0031] for n=1: nact
nor(n)=C(:,n)′*C(:,n); Cnor(:,n)=C(:,n)./(nor(n));
[0034] end
[0035] The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter. | Systems, methods, and computer program products for directional force weighting of an active vibration control system involve arranging a plurality of force generators in an array, identifying individual component forces corresponding to force outputs of each of the plurality of force generators, determining a combination of the individual component forces that will produce a desired total force vector, and adjusting the outputs of each of the plurality of force generators such that the combination of the individual component forces are at least substantially similar to the desired force vector. | 1 |
RELATED APPLICATIONS
The present application relates to application U.S. Ser. No. 08/306,794 entitled "Engine Hydraulic Valve Actuator Spool Valve" filed on Sep. 15, 1994 and assigned to the same assignee, Eaton Corporation, as this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hydraulic engine valve actuator. More specifically, the present invention relates to a hydraulic engine valve actuator having a slidingly connected upper body and lower body disposed between two parallel seating surfaces.
2. Description of the Prior Art
A major obstacle to the efficient operation of internal combustion engines has been the timing of the opening and closing of both the intake and the exhaust engine valves. In the ideal situation, both the timing and the lift of the engine valve can be independently regulated by an electronic control unit depending on the operational needs of the engine intake or exhaust. One method to provide for independent operation of the valves is through a hydraulic actuator where a high pressure hydraulic source is used to supply the energy to open and close the valve according to the position of a hydraulic control valve as determined by an electronic control unit. Prior art devices can be seen by reference to U.S. Pat. Nos. 3,926,159; 4,791,895; 4,930,464; 4,821,689; and 5,255,641 the disclosures which are hereby expressly incorporated by reference.
High speed operation of an engine valve requires precise clearances and operational stability to provide for relatively friction free operation thereby allowing for high speed of response and minimal consumption of energy. To date, the main body of the hydraulic valve actuator has been securely fastened to a portion of the engine thereby contributing to the introduction of frictional forces upon the introduction of high pressure hydraulic oil and/or wear due to long term operation which adversely affects the performance of the valve actuator.
SUMMARY OF THE INVENTION
The present invention includes a variable engine valve control system comprising a free moving engine intake or exhaust valve with a piston attached to its top. The piston is subjected to fluid pressure acting on surfaces on both sides of the piston, with the surfaces being of unequal areas. The volume at one end of the piston is connected to a source of high pressure fluid while the volume at the other end can be connected either to a source of high pressure fluid or to a source of low pressure fluid, or disconnected from them both through action of a controlling means such as a combination solenoid and spool valve.
Selective actuation and de-actuation of the controlling means causes an inflow of pressurized fluid into the volume at one end of the piston and outflow of fluid from the volume at the other end of the piston, such action leading to a change in the balance of forces acting on the piston and causing movement of the engine valve from one fixed position to another.
The inflow of pressurized fluid causes expansion between an upper actuator housing and a lower actuator housing where the upper and lower actuator bodies are slidingly connected and sealed with an annular sealing ring to prevent the migration of high pressure oil. The hydraulic actuator is mounted between two parallel surfaces, an upper surface comprised of an oil supply header having a parallel surface and fixed relative to an engine head surface. The upper actuator housing contacts and seals against the supply header and the lower actuator housing contacts the head surface. The actuator is thus relatively free to move and self-adjust to maintain relatively precise alignment with the engine valve which is piloted on the lower actuator housing. Also, as the upper actuator housing moves upward away from the lower actuator housing, the seal between the upper actuator housing and the supply header is improved.
One provision of the present invention is to allow for the relative movement of the hydraulic valve actuator relative to the engine valve to provide for minimized friction and wear.
Another provision of the present invention is to provide for an upper actuator housing slidingly joined to a lower actuator housing to provide an increased sealing pressure.
Another provision of the present invention is to provide for an upper actuator housing slidingly joined to a lower actuator housing to provide for the relative movement of the valve actuator to an engine valve thereby minimizing friction and wear.
Another provision of the present invention is to provide for an upper actuator housing slidingly connected to a lower actuator housing and sealed against the migration of high pressure hydraulic oil by a sealing ring therebetween where the upper actuator housing and lower actuator housing are relatively free to self-adjust to the alignment of an engine valve.
Still another provision of the present invention is to provide for the expansion control of a hydraulic valve actuator having an upper actuator housing slidingly joined to a lower actuator housing by providing for two fixed parallel surfaces with the hydraulic valve actuator positioned therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the engine valve hydraulic actuator of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In this disclosure, certain terminology will be used for convenience and reference only and will not be limiting. For example, the terms "rightward" and "leftward" will refer to directions in the drawings in connection with which the terminology is used. The terms "inwardly" and "outwardly" will refer to directions toward and away from, respectively, the geometrical center of the apparatus being described. The terms "upward" and "downward" will refer to directions as taken in the drawings in connection with which the terminology is used. All foregoing terms include the normal derivatives and equivalents thereof.
Now referring to FIG. 1, the cross-sectional view of the hydraulic actuator 2 of the present invention is shown. A source of high pressure hydraulic oil is fed to the area labeled as oil supply 3 which is used to supply the primary actuation energy to the hydraulic actuator 2 of the present invention to cause an engine valve 5 to translate upwardly and downwardly according to signals supplied by an electronic control unit 8. The hydraulic oil can also be an engine oil as used to supply the basic lubrication to the engine mechanicals.
The hydraulic actuator 2 is comprised of an upper actuator housing 4A slidingly connected to a lower actuator housing 4B. The control solenoid 6 is used to control when the hydraulic actuator 2 is energized or de-energized through the axial motion of the spool valve 10. The spool valve 10 moves laterally leftward and rightward within the valve bore 23 formed in the upper actuator housing 4A so as to control the flow of high pressure oil through the upper actuator housing 4A toward the lower actuator housing 4B and also control the flow of hydraulic oil from the upper actuator housing 4A to atmosphere. When the solenoid 6 is energized, the spool valve 10 is moved magnetically to the left and when de-energized, the spool valve 10 is forced to the right by the return spring 7. The solenoid 6 is comprised of a coil 13 which is wound around a magnetically conductive coil ring 11 and contained by solenoid cover 15 which is mounted to the side of the upper actuator housing 4A. The return spring 7 axially forces the spool valve 10 in a rightward direction so as to cause the hydraulic oil contained in the upper actuator housing 4A to be vented to atmosphere thereby allowing the engine valve 5 to assume its closed position due to the forces generated by the high pressure oil present in lower oil passage 19.
A piston 9 is attached to one end of the engine valve 5 and vertically traverses an upper piston cavity 17 formed in the body of the upper actuator housing 4A as the valve 5 moves upward and downward to open and close at the command of the electronic control unit 8 which sends electrical signals to the control solenoid 6. The lower actuator housing 4B sits on and can move relative to the head surface 18 thereby allowing the lower actuator housing 4B to self-position to minimize friction and wear between the lower actuator housing 4B and the engine valves as they move relative one to the other. The lower actuator housing 4B is hydraulically sealed to the upper actuator housing 4A by way of sealing ring 14 which expands to contact in a sealing manner both the upper and lower actuator housing 4A and 4B.
The supply header 12 is stationary with respect to the engine cylinder head 16 and provides for a stable mounting surface for the hydraulic valve actuator 2. The upper actuator housing 4A has a relatively flat actuator surface 22 which contacts the supply surface 24 where the overall effect is to trap the hydraulic valve actuator 2 between the supply surface 24 and the head surface 18. In this manner, the hydraulic valve actuator 2 is free to position itself between the supply header 12 and the engine cylinder head 16 thereby self-aligning with the engine valve 5 to minimize friction and wear. Header seal 25 functions to seal the upper actuator housing 4A to the supply header 12 to prevent oil leakage. The header seal 25 also introduces sufficient friction on the upper actuator housing 4A in an axial direction to hold the upper actuator housing 4A in position against supply header 12 when the high pressure oil is not present. The header seal 25 is shown as an o-ring but other types of sealing devices can be employed to provide a similar function. As the oil pressure is increased in the upper piston cavity 17, the upper actuator housing 4A tends to separate from the lower actuator housing 4B and the header seal 25 is further compressed by this movement thereby improving the sealing function. The hydraulic pressure forces oil into the clearance between the piston 9 and the adjacent wall in the upper actuator housing 4A which acts to center the upper actuator housing 4A relative to the valve piston 9 and valve 5. Since the lower actuator housing 4B pilots into the upper actuator 4A and is free to slide on the head surface 18 of the cylinder head 16, it centers itself on the stem of engine valve 5.
The oil pressure present in the lower cavity 27 tends to separate the lower actuator housing 4B away from the upper actuator housing 4A thereby forcing the actuator surface 22 toward the supply surface 24. This maintains the compression on the header seal 25 which functions to prevent oil leakage from the supply header 12 which is fixed relative to the cylinder head 16 using a prior art method of fixing its position relative to the cylinder head 16 such as by bolting and bracketry.
Upper oil passage 20 is supplied high pressure oil from the header passage 28 and is sealed to the header passage 28 by header seal 25 so that no leakage occurs. The upper oil passage 20 supplies high pressure oil to the valve bore 23 for distribution to the lower oil passage 19 and the supply flow port 21.
An adjustment feature could be incorporated to adjust the separation between the supply header 12 and the upper actuator housing 4A. Shims (not shown) could be used to move the upper actuator housing 4A downward and thereby change the snubbing point of the hydraulic fluid and the closing velocity of the engine valve 5. The open position is shown in FIG. 1 where the closed position would require the spool valve 10 to be moved by the return spring 7 rightward to lower the oil pressure in the upper piston cavity 17 thereby causing the high pressure oil in the lower oil passage 19 to move the piston 9 upward. The valve 5 stops when it contacts the valve seat 26. Thus, lower or raising the upper actuator housing 4A relative to the oil supply header 12 will result in increasing or decreasing the valve closing velocity. The oil sealing capability of the header seal 25 must be maintained for example, by increasing its thickness to accommodate the increase in separation distance between the supply header 12 and the upper actuator housing 4A.
The description above refers to particular embodiments of the present invention and it is understood that many modifications may be made without departing from the spirit thereof. The embodiments of the invention disclosed and described in the above specification and drawings are presented merely as examples of the invention. Other embodiments, materials, forms and modifications thereof are contemplated as falling within the scope of the present invention only limited by the claims as follows. | An engine valve hydraulic actuator having an upper actuator housing slidably attached to a lower actuator housing is disposed between an oil supply header and an engine cylinder head where the supply header and the cylinder head are fixed relative to one another. The upper actuator housing is allowed to position and seal itself relative to the oil supply header and the lower actuator housing is allowed to position itself relative to the engine cylinder head to minimize friction and wear and thereby improve overall performance. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of earlier filed U.S. application Ser. No. 10/185,290 filed Jun. 27, 2002 now abandoned, the contents of which are incorporated herein by reference; which earlier filed application claims the benefit of U.S. Provisional Application Ser. No. 60/301,962, filed on Jun. 29, 2001, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention dates to delivery methods, systems and components thereof for use with hazardous or toxic pharmaceutical substances, and especially to delivery and injection methods, systems and components thereof for use with radiopharmaceutical substances.
2. Prior Art
As used herein, the term “pharmaceutical” refers to any substance to be injected or otherwise delivered, into the body (either human or animal) in a medical procedure and includes, but is not limited to, substances used in imaging procedures (for example, contrast media) and therapeutic substances. A number of such pharmaceutical substances pose a danger to both the patient and the personnel administering the substance if not handled and/or injected properly. Examples of hazardous pharmaceuticals include, but are not limited to, radiopharmaceuticals, biological pharmaceuticals, chemotherapeutic pharmaceuticals and gene therapeutic pharmaceuticals.
Examples of use of a radiopharmaceutical include positron emission tomography (PET) and single-photon emission computerized tomography (SPECT), which are noninvasive, three-dimensional, imaging procedures that provide information regarding physiological and biochemical processes in patients. The first step in producing PET images or SPECT images of, for example, the brain or another organ, is to inject the patient with a dose of the radiopharmaceutical. The radiopharmaceutical is generally a radioactive substance that can be absorbed by certain cells in the brain or other organ, concentrating it there. For example, fluorodeoxyglucose (FDG) is a normal molecule of glucose, the basic energy fuel of cells, attached a radionuclide or radioactive fluor. The radionuclide is produced in a cyclotron equipped with a unit to synthesize the FDG molecule.
Cells (for example, in the brain) which are more active in a given period of time after an injection of FDG, will absorb more FDG because they have a higher metabolism and require more energy. The radionuclide in the FDG molecule suffers a radioactive decay, emitting a positron. When a positron collides with an electron, an annihilation occurs, liberating a burst of energy in the form of two beams of gamma rays in opposite directions. The PET scanner detects the emitted gamma rays to compile a three dimensional image.
In that regard, after injecting the radiopharmaceutical, the patient is typically placed on a moveable bed which slides by remote control into a circular opening of the scanner referred to as the gantry. Positioned around the opening, and inside the gantry, there are several rings of radiation detectors. Each detector emits a brief pulse of light every time it is struck with a gamma ray coming from the radionuclide within the patient's body. The pulse of light is amplified, by a photomultiplier, and the information is sent to the computer which controls the apparatus.
The timing of injection is very important. After the generation of the radiopharmaceutical, a countdown begins. After a certain time, which is a function of the half-life of the radionuclide, the radiation level of the radiopharmaceutical dose falls exactly to a level required for the measurement by the scanner. In current practice, the radiation level of the radiopharmaceutical volume or dose is typically measured using a dose calibrator. Using the half-life of the radionuclide, the time that the dose should be injected to provide the desired level of radioactivity to the body is calculated. When that time is reached, the radiopharmaceutical dose is injected using a manually operated syringe.
Most PET radionuclides have short half-lives. Under proper injection procedures, these radionuclides can be safely administered to a patient in the form of a labelled substrate, ligand, drug, antibody, neurotransmifter or other compound normally processed or used by the body (for example, glucose) that acts as a tracer of specific physiological and biological processes.
Excessive radiation to technologists and other personnel working in the scanner room can pose a significant risk, however. Although the half-life of the radiopharmaceutical is rather short and the applied dosages are themselves not harmful to the patient, administering personnel are exposed each time they work with the radiopharmaceuticals and other contaminated materials under current procedures. Constant and repeated exposure over an extended period of time can be harmful.
A number of techniques used to reduce exposure include minimizing the time of exposure of personnel, maintaining distance between personnel and the source of radiation and shielding personnel from the source of radiation. In general, the radiopharmaceutical is typically delivered to a nuclear medicine facility from another facility equipped with a cyclotron in, for example, a lead-shielded container. Often, the radiopharmaceutical is manually drawn from such containers into a shielded syringe. See, for example, U.S. Pat. No. 5,927,351 disclosing a drawing station for handling radiopharmaceuticals for use in syringes. Remote injection mechanisms can also be used to maintain distance between the operator and the radiopharmaceutical. See, for example, U.S. Pat. No. 5,514,071, disclosing an apparatus for remotely administering radioactive material from a lead encapsulated syringe.
In one procedure, the radiopharmaceutical is injected into tubing that is coiled within a lead container. Typically, the shielded syringe used to inject the radiopharmaceutical is disconnected and replaced by a larger syringe, filled in most cases with saline, for injection into the body and flush. By emptying the second syringe, the radiopharmaceutical is flushed through the shielded, coiled tubing in the container and injected into the person, to be scanned. An excess volume of saline supplies a flushing function.
Although substantial effort is made to reduce exposure of administering and other personnel to harmful radiation, some exposure is experienced under current procedures. Being in the injection room longer than necessary is thus to be avoided. Moreover, the cumulative radiation exposure resulting from multiple injection procedures must be closely monitored to avoid overexposure. Indeed, personnel that administer radiopharmaceuticals are typically periodically rotated out of such duties to reduce the risk of overexposure.
In addition to the difficulties introduced by the hazardous nature of radiopharmaceuticals, the short half-lives of such radiopharmaceutical further complicate the administration a proper dosage to a patient. As discussed above, initial calibration of radioactivity is often made and the injection is then timed so that a dose of the desired level of radioactivity to the body is delivered (as calculated from the half-life of the radiopharmaceutical). See, for example, U.S. Pat. No. 4,472,403 in which a motor driven syringe is controlled to inject a quantity of a radiopharmaceutical stored in the syringe by calculating the injection quantity based upon the half-life of the radiopharmaceutical and the delay before injection.
Radiation detectors have also been placed upon syringe shields and in line with the radiopharmaceutical delivery system. For example, U.S. Pat. No. 4,401,108 discloses a syringe loading shield for use during drawing, calibration and injection of radiopharmaceuticals. The syringe shield includes a radiation detector for detecting and calibrating the radioactive dosage of the radiopharmaceutical drawn into the syringe. U.S. Pat. Nos. 4,562,829 and 4,585,009 disclose strontium-rubidium infusion systems and a dosimetry system for use therein. The infusion system includes a generator of the strontium-rubidium radiopharmaceutical in fluid connection with syringe for supplying pressurized saline. Saline pumped through the strontium-rubidium generator exits the generator either to the patient or to waste collection. Tubing in line between the generator and the patient passes in front of a dosimetry probe to count the number of disintegrations which occur. As the flow rate through the tubing is known, it is possible to measure the total activity delivered to the patient (for example, in milliCuries). Likewise, radiation measurements have been made upon blood flowing through the patient. For example, U.S. Pat. No. 4,409,966 discloses shunting of blood flow from a patient through a radiation detector.
The danger to administering personnel and other difficulties that arise from the nature of hazardous pharmaceuticals such as radiopharmaceuticals often affect the quality and safety of the injection procedure. For example, given the care that must be taken to prevent radiation overexposure (including limiting the duration of injection procedures), the concern with properly timing an injection and the need to prevent the creation of radioactive wastes, it is often difficult to properly eliminate air from all fluid paths before an injection begins.
It is thus very desirable to develop devices, systems and methods through which toxic or hazardous pharmaceuticals (far example, radiopharmaceuticals) can be administered in controlled manner to enhance their effectiveness and patient safety, while reducing exposure of administering personnel to such hazardous pharmaceuticals.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method of injecting a hazardous pharmaceutical comprising the steps of: connecting a source of flushing fluid to a first port of a fluid delivery set; connecting a pressurizing unit of a powered injector system (including a powered injector and the pressurizing unit) to a second port of the fluid delivery set; purging air from the fluid delivery set; and, after purging air from the fluid delivery set, connecting a third port of the fluid delivery set to a source of the hazardous pharmaceutical. The fluid delivery set can, for example, include a valve system or assembly to control flow of fluid through the fluid delivery set. The ports of the fluid delivery set can, for example, include luer connectors as known in the medical arts to form a removable, secure and generally sealed connection
The method preferably further includes the steps of (i) removably connecting a disposable fluid path that is connectable (via, for example, a catheter) to a patient to the fluid delivery set and (ii) purging air from the disposable fluid path before connecting the fluid delivery set to the source of hazardous pharmaceutical.
By removing air from the fluid delivery set and the patient fluid path before any connection is made to the source of hazardous pharmaceutical, exposure of administering personnel to the hazardous pharmaceutical to that point is eliminated. Connecting the fluid delivery set to the source of pharmaceutical can be automated or otherwise accomplished remotely (for example, with use of an extending or robotic arm as known in the machine and robotic arts) to prevent exposure during that connection.
The pressurizing unit can, for example, be a syringe in operative connection with the powered injector. In the case that the pressurizing unit is a syringe, the method can further include the steps of drawing hazardous pharmaceutical into the syringe and injecting the hazardous pharmaceutical through the fluid delivery set and the disposable fluid path. Using a powered injector having a control unit removed in distance or shielded from the position of the syringe, fluid delivery set and fluid path prevents exposure of operating/administering personnel to the hazardous pharmaceutical. The method preferably further includes the step of flushing the fluid delivery set and the disposable fluid path after injection using the flushing fluid (for example, saline and/or another biologically acceptable flushing agent). A powered injector can also be used with a saline syringe in a similar manner as described above to limit exposure of operating personnel to the hazardous pharmaceutical.
In the case that the hazardous pharmaceutical is a radiopharmaceutical, the method can further include the step of measuring the level or dosage of radioactivity of the radiopharmaceutical injected. Preferably, the level of radioactivity or dosage is measured very near in time or simultaneously with delivery of the radiopharmaceutical to provide an accurate measurement of the dosage delivered. For example, the level of radioactivity can be measured by positioning the syringe within a dose calibrator. The level of radioactivity can also measured by placing a radioactivity detector in operative connection with a line through which the radiopharmaceutical is dispensed or delivered.
In another aspect, the present invention provides a system for delivery of a hazardous pharmaceutical including: a syringe in operative connection with a powered injector and a protective container to enclose the syringe during operation thereof. The protective container is constructed or adapted to protect personnel from detrimental effects of the pharmaceutical. The system preferably also includes at least one source of flushing fluid; a fluid path adapted to connect to a patient; at least one source of the pharmaceutical; and a fluid delivery set. The fluid delivery set preferably includes a valve assembly to which the syringe, the source of flushing fluid, the fluid path and the source of pharmaceutical are removably connectable.
The valve assembly preferably provides flow control through the fluid delivery set such that operator contact with the fluid delivery set is not required after connection of the source of pharmaceutical to the fluid delivery set. The valve assembly also preferably provides flow control through the fluid delivery set such that the entire fluid delivery set can be purged of air with the syringe and the source of flushing fluid in fluid connection with the valve assembly before the source of pharmaceutical is connected to the fluid delivery set. In one embodiment, the valve assembly includes a bypass line in continuous fluid connection between the source of flushing fluid and the fluid path.
In the case that the pharmaceutical is a radiopharmaceutical, the protective container can, for example, be a component of a dose calibrator adapted to measure the level of radioactivity of the pharmaceutical within the syringe. In one embodiment, the syringe is connected to the powered injector via an extending adapter that preferably extends from the powered injector when connected thereto to position the syringe within the protective container.
The adapter can, for example, include an injector attachment member to attach the adapter to a powered injector and a plunger extension fixed in position relative to a powered injector. The plunger extension preferably has a plunger attachment member to attach to a plunger of the syringe. In one embodiment, the adapter also includes a syringe carriage slidably attached to the adapter. The syringe carriage includes a syringe attachment member to removably attach a syringe thereto so that a barrel of a syringe can be moved relative to a plunger thereof to control fluid flow into and out of a syringe.
The above embodiment of an adapter facilitates orientation of the syringe tip or exit of the syringe directed toward the powered injector when the syringe is attached to the syringe attachment member. This orientation can facilitate purging of air from the syringe when the syringe is placed within, for example, a dose calibrator positioned below the injector. In that regard, lead-shielded dose calibrators are often relatively large and heavy and thus often positioned most easily near the floor. Moreover, this relative positioning of the injector and dose calibrator assists in limiting exposure of operating/administering personnel by directing any waves of radiation escaping from the dose calibrator upward to the ceiling of the room. Moving the syringe barrel relative to the syringe plunger in the manner described in the above embodiment facilitates use of commercially available injectors and syringes for use therewith by eliminating the need to change/recalibrate the direction and distance the injector drive member must advance or retract to complete a desired operation.
In another aspect, the present invention provides a method of using a powered injector system to inject a radiopharmaceutical into a body including the steps of: attaching an extending adapter to the front end of the powered injector; the adapter including an injector attachment to place the adapter in operative connection with the powered injector, the adapter also including a syringe attachment to attach a syringe to the adapter to place the syringe in operative connection with the powered injector; and extending the adapter into a radiation shield. As discussed above, the radiation shield can form part of a dose calibrator to measure the radioactivity of radiopharmaceutical within the syringe. In one embodiment, the exit of the syringe is oriented upward relative to the opposite end of the syringe when the syringe is positioned within the dose calibrator to facilitate purging of air from the syringe. As discussed above, the opening through which the syringe passed to enter the dose calibrator is preferably oriented in a direction (for example, upward toward the ceiling) to decrease the likelihood of exposure of personnel to any radiation waves exiting the dose calibrator during use thereof.
In a further aspect, the present invention provides an adapter for use with a powered injector to attach a syringe to the powered injector including: an injector attachment member to attach the adapter to a powered injector and a syringe attachment member spaced from the injector attachment member by a sufficient distance to position a syringe attached to the syringe attachment member within a radiation dose calibrator. Preferably, the adapter facilitates use of commercially available injector systems with commercially available dose calibrators without the requirement of substantial and/or expensive modification thereto.
In another aspect, the present invention provides an adapter for use with a powered injector to attach a syringe to the powered injector including an injector attachment member to attach the adapter to a powered injector and a plunger extension fixed in position relative to a powered injector. The plunger extension bas a plunger attachment member to attach to a plunger of the syringe. The adapter further includes a syringe carriage slidably attached to the adapter and including a syringe attachment member to removably attach a syringe thereto so that a barrel of the syringe can be moved relative to a plunger thereof to control fluid flow into and out of the syringe. As discussed above, the syringe can be oriented with a syringe tip thereof directed toward the powered injector when attached to the syringe attachment member.
In another aspect, an adapter includes an attachment member to removably attach the adapter to a powered injector and a syringe carriage slidably attached to the attachment member. The syringe carriage includes a syringe attachment member to which a syringe can be removably attached. The adapter further includes an end member attached a fixed distance from the attachment member. The end member has a plunger extension attached to the end member and extending toward the injector. The plunger extension includes a plunger attachment member on an end thereof opposite the end attached to the end member. The syringe carriage is adapted to move a barrel of the syringe relative to a plunger of the syringe when a syringe is attached to the syringe attachment member and a plunger thereof is attached to the plunger extension member.
In another aspect, the present invention provides a shield for use with a radiopharmaceutical including a housing that is impenetrable by radioactive energy from the radiopharmaceutical. The shield also includes at least one opening in the housing through which an article containing the radiopharmaceutical which is positioned within the housing can be viewed. The opening is in visual alignment with a reflective surface in which a viewer can view a reflection of the article. The opening is positioned within the housing such that there is no direct line between the viewer and the article that is not shielded by a portion of the housing. Because radiation energy from radiopharmaceuticals travel in straight lines, the viewer is shielded from exposure to radiation.
In a further aspect, the present invention provides a method of injecting a. radiopharmaceutical into a body including the steps of positioning a pressurizing unit or device containing a first volume of the radiopharmaceutical within a dose calibrating unit adapted to measure the level of radioactivity of the radiopharmaceutical; and injecting a second volume of the radiopharmaceutical. The second volume is determined through measurement by the dose calibrating unit to provide a desired level of radioactivity. The second volume can, for example, be less than the first volume. In one embodiment, the pressurizing chamber is a syringe in fluid connection with a powered injector.
In another aspect, the present invention provides a kit for injecting a hazardous pharmaceutical into a body including: a fluid path adapted to connect to a patient; and a fluid delivery set. The fluid delivery set includes a valve assembly to which a pressurizing unit, a source of flushing fluid, the fluid path and a source of the pharmaceutical are removably connectable. The valve assembly provides flow control through the fluid delivery set such that operator contact with the fluid delivery set is not required after connection of the source of pharmaceutical to the fluid delivery set. The valve assembly also preferably provides flow control through the fluid delivery set such that the entire fluid delivery set can be purged of air with the syringe and the source of saline in fluid connection with the valve assembly before the source of pharmaceutical is connected to the fluid delivery set.
In still a further aspect, the present invention provides a method of injecting a radiopharmaceutical into a patient comprising the steps of: connecting a powered pressurizing device that is controlled without intimate or close contact by an operator (far example, remotely controlled, automated or preprogrammed so that the operator is not within a radiation field of a dangerous level) to a valve assembly of a fluid delivery set; connecting at least one source of a flushing fluid to the valve assembly; connecting a patient fluid path to the valve assembly, the patient fluid path terminating in a patient connector; connecting a source of a ready-made (that is, prepared earlier for example, in an offsite cyclotron) radiopharmaceutical to the valve assembly; and controlling the valve assembly at least during injection of the hazardous pharmaceutical such that operator presence in the vicinity of the radiopharmaceutical is not required. In general, a dose to an individual decreases with the square of the distance from the radiation source. Thus, close operator contact with the pressurizing device, fluid delivery set and other components of the fluid delivery system is not required when the radiopharmaceutical is present in the fluid delivery system. Moreover, shielding as described above can also be used to prevent exposure. The valve assembly can also be controlled without intimate contact by an operator (for example, remotely controlled, automated or preprogrammed).
In general, the present invention provides for administration or delivery of a toxic or hazardous pharmaceuticals (for example, radiopharmaceuticals) in a controlled manner to enhance the effectiveness of the pharmaceutical and to enhance patient safety (as compared to current procedures and equipment for delivering such pharmaceuticals), while reducing exposure of administering personnel to the hazardous pharmaceuticals. In general, commercially available injector systems are readily adaptable for use in the present invention without substantial or expensive modification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a schematic representation of an embodiment of a system of the present invention.
FIG. 1B illustrates a top cross-sectional view of an embodiment of a shielded container for a fluid delivery set of the present invention.
FIG. 1C illustrates a side cross-sectional view another embodiment of a shielded container for a fluid delivery set of the present invention.
FIG. 2A illustrates a perspective view an embodiment of an injector and a syringe adapter of the stem of the present invention.
FIG. 2B illustrates a perspective view of injector control units used in connection with the injector of the present invention.
FIG. 3 illustrates a perspective view of the system of the present invention in which the injector head and syringe adapter have been lowered so that the syringe is positioned within the dose calibration unit.
FIG. 4A illustrates a perspective view of the adapter of FIG. 2A detached from the injector with the syringe attached thereto.
FIG. 4B illustrates a perspective view of the adapter of FIG. 2A detached from the injector with the syringe detached therefrom.
FIG. 4C illustrates a side cross-sectional view a portion of the system of FIGS. 1 through 4B .
FIG. 5A illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a pressurizing device and a source of radiopharmaceutical within a shielded dose calibrator.
FIG. 5B illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a source of radiopharmaceutical within a shielded dose calibrator.
FIG. 5C illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a radiation detector in line between a pressurizing device and a source of radiopharmaceutical within a shielded close calibrator.
FIG. 5D illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a radiation detector in line with the exit line of a pressurizing device.
DETAILED DESCRIPTION OF THE INVENTION
As illustrated in FIG. 1A , in one embodiment of the present invention, a system 10 includes a fluid delivery set or system 15 including a valve system 16 that provides a fluid connection for a saline source 20 (for example, a syringe), a source 40 of a pharmaceutical to be injected into a patient, a pressurizing chamber or unit for the pharmaceutical (for example, a syringe 60 in fluid connection with a powered injector 70 in the embodiment of FIG. 1 ) and a fluid path set 80 that is connectable to the patient (via, for example, tubing terminating in a catheter 100 ). In general, the fluid delivery set 16 , valve system 15 and other elements of the present invention enable purging of air from the system, filling of syringe 60 with the pharmaceutical, delivery of the pharmaceutical (for example, injecting the pharmaceutical into the patient) via syringe 60 , and providing a saline flush, while minimizing or eliminating exposure of administering or operating personnel to the detrimental effects of the pharmaceutical and minimizing or eliminating creation of contaminated waste. Moreover, fluid delivery set 15 and other elements of the present invention also facilitate safe delivery of the pharmaceutical to multiple destinations (for example, injection into a series patients).
In the embodiment of FIG. 1 , valve system 16 includes a three-way stopcock 30 including a first port 32 that is in fluid connection with saline syringe 20 . As second port 34 of stopcock 30 is in fluid connection with source 40 of a toxic or hazardous pharmaceutical (for example, a radiopharmaceutical). Source 40 of the pharmaceutical is preferably enclosed within a container 44 that is designed to reduce the risk of contamination of personnel administering the pharmaceutical. For example, in the case of a radiopharmaceutical, the container can fabricated from lead or tungsten to substantially prevent exposure of such personnel to undesirably high levels of radiation.
A third port 36 of stopcock 30 is in fluid connection with, for example, a dual check valve 50 . The flow through stopcock 30 is controlled via control 38 . A first port 52 of dual check valve 50 is in fluid connection with syringe 60 that is preferably in operative connection with powered injector 70 . A second port 54 of dual check valve 50 its preferably in fluid connection with patient fluid path set 80 that includes, for example, flexible tubing 90 connected to catheter 100 . Preferably, patient fluid path set 80 is disposable on a per patient basis to reduce the likelihood of cross-contamination when system 10 is used for injection of fluids into multiple patients. Patient fluid path set 80 is preferably in fluid connection with second port 54 of dual check valve 50 via a one-way check valve 110 to further reduce the likelihood of cross-contamination.
Preferably, saline source 20 is also in fluid connection with fluid path set 80 via bypass tubing or conduit 120 of valve system 16 to provide, for example, flush and KVO (keep vein open) functions on demand without having to adjust control 38 of valve system 15 . In the embodiment of FIG. 1 , a tee 130 is positioned between saline source 20 and dual check valve 30 . A side port 132 of tee 130 is in fluid connection with bypass tubing 120 . Bypass tubing 120 is preferably in fluid connection with check valve 110 (an thereby with fluid path set 80 ) via a one-way check valve 140 .
In injection procedures and other fluid delivery operations in which non-hazardous pharmaceuticals are delivered, purging air from the entire fluid path (including, the fluid path between a source of the pharmaceutical and the delivery point) typically includes the forcing an amount of the pharmaceutical through the fluid path to, for example, a waste receptor before beginning the procedure (for example, before insertion of a catheter into the patient). However, in the case of a hazardous pharmaceutical such as a radiopharmaceutical, it is very desirable to minimize or eliminate the creation of waste pharmaceutical. Moreover, as discussed above, it is also preferably in, the case of a hazardous pharmaceutical to minimize exposure of administering personnel to the pharmaceutical. The present invention, thus preferably enables purging of air from the entirety of fluid delivery set 15 (and preferably, also from patient fluid path set 80 ) before connection of fluid delivery set 16 to pharmaceutical source 40 . In this manner, exposure of administering personnel to hazardous materials during purging is eliminated and no hazardous waste is generated.
After connecting fluid delivery set 16 , which is fluid filled and purged of air, to pharmaceutical source 40 , air can be introduced into fluid delivery system 10 from pharmaceutical source 40 . Thus, precautions are preferably taken as known in the art to reduce the likelihood of introduction of air into system 10 from pharmaceutical source 40 . Moreover, a bubble detector 150 can be placed in communication with line 46 to detect if air is drawn from pharmaceutical source 40 . Examples of a bubble detectors suitable for use in the present invention include the BDF/BDP series ultrasonic air bubble detectors available from Introtek of Edgewood, N.Y.
In, the case that it is desirable to purge system 10 (for example, in the case that air is found in one of the fluid path lines) a waste container 160 (which is preferably shielded) is preferably provided. In the embodiment of FIG. 1A waste container 160 is in fluid connection with a control valve 170 (similar in operation to control valve 30 ) which is in line just before check valve 110 . Control valve 170 can be controlled remotely or automated to reduce likelihood of exposure of operating personnel to the toxic pharmaceutical. It is also possible, for example, to provide valve 50 with control in a manner known to those skilled in art such that fluid can be purged back to source 40 . In general, system 10 is purged using syringe 60 and/or saline source 10 as described below.
During operation of system 10 , saline syringe 20 (which can be a hand syringe or a syringe powered by an injector 24 ) is first filled with saline. Saline syringe 20 is then connected to valve system 16 of fluid delivery set 15 via first port 32 on three-way stopcock 30 . Saline syringe 20 is preferably used to purge air from system 10 . Saline syringe 20 also provides a flush to patient fluid path set 80 after injection of pharmaceutical(s) to ensure that substantially all the pharmaceutical is injected into the patient and to ensure that very little if any of the toxic or hazardous pharmaceutical remains, for example, within fluid path set 80 .
Syringe 60 is attached to injector 70 . In the case of injection of a radiopharmaceutical, at least syringe 60 of injector 70 is preferably enclosed within a shielded container during an injection procedure. In one embodiment, the shielded container is a radiation dose calibration unit 200 as discussed in further detail below. Air is first preferably expelled from syringe 60 by advancing plunger 62 of syringe 60 toward syringe tip 64 . Syringe 60 is then connected to dual check valve 50 of valve system 16 via first port 42 . Patient fluid path set 80 is connected to valve system 16 via one-way check valve 110 .
Control 38 is adjusted to place saline syringe 20 in fluid connection with tubing 46 . Tubing 46 can, for example, terminate in a spike 48 or other connection member to cooperate with a septum 45 on source 40 (for example, a bottle) as known in the art. A small volume of saline is injected or expelled from saline syringe 20 to purge air from tubing 46 and spike 48 . Control 38 is then adjusted to place saline syringe 40 in fluid connection with dual check valve 50 . A small volume of saline is expelled to purge flush bypass line 120 of air. Dual check valve 50 provides sufficient resistance to flow such that saline expelled from saline syringe 20 passes through bypass line 120 rather than through dual check valve 50 .
Injector 70 is use to retract plunger 62 to draw saline from saline syringe 20 . injector 70 is then used to expel air in line between syringe 60 and catheter 100 by expelling (via advancement of plunger 62 ) the saline therefrom. At this point, all lines of system 14 are free of air and filled with saline. Syringe 60 is substantially empty except for a small amount of saline not expelled.
At this point, injector syringe 60 is preferably positioned within dose calibrating unit 200 or other radiation containment device in the case of injection of a radiopharmaceutical. Container 44 is opened and pharmaceutical source 40 is spiked to place source 40 in fluid connection with valve system 16 . Spiking of pharmaceutical source 40 can be done automatically, remotely or robotically to reduce or prevent exposure of operating personnel. The patient is then connected to patient fluid path set 80 via catheter 100 . System 10 is now ready for an injection. The pharmaceutical is drawn into syringe 60 by retraction of plunger 62 relative to syringe tip 64 and then injected into the patient by advancement of plunger 62 relative to syringe tip 64 . Saline is then expelled from saline syringe 20 , passing through bypass line 120 , to flush the pharmaceutical from patient fluid path set 80 . All of these functions are accomplished with little on no exposure of the operator or administering personnel to radiation.
In that regard, all adjustment of control 38 were made before the radiopharrnaceutical was drawn into fluid delivery set 15 . Control 38 can also be adjusted remotely or automatically (for example, via electronic/computer control) in, for example, cases when some pharmaceutical is within fluid delivery set 15 (for example, in a second or subsequent procedure in a case in which fluid delivery set 15 is used for multiple deliveries/injections) to prevent exposure of administering personnel. Other types of valve systems or assemblies, for example, a manifold system, can be used to effect the control of valve assembly 16 .
Fluid delivery set 15 is preferably disposable after one or more uses to, for example, reduce the risk of cross-contamination between patients. Fluid delivery set 15 , including valve system 16 , and/or other components of system 10 can be placed within a protective containment unit 18 during use thereof to further shield personnel from radiation that may emanate from, for example, valve system 15 . FIG. 1 B illustrates one embodiment of protective containment unit or shielded container 18 for fluid delivery set 15 of the present invention. In general, radioactive rays emanate in straight lines from a radiation source. Containment unit 18 provides a view of fluid delivery set 15 without providing a straight line of sight between the viewer and fluid delivery set 15 . In that regard, it is often desirable for administering personnel to have a view of tubing in a fluid path to, for example, provide visual assurance of the absence of air bubbles. Containment unit 18 includes a shielded housing 160 having a view port 162 . Radioactive frays cannot escape through view port 162 as there is no line of sight (that is, unobstructed line) between view port 162 and fluid delivery set 15 . Containment unit 18 includes a mirrored surface 164 to provide a view of fluid delivery set 15 . FIG. 1C illustrates another embodiment of a containment unit 18 a in which a view of fluid delivery set 15 is provided by mirrored surface 174 which is in alignment with fluid delivery set 15 via view port 172 . One or more additional mirrored surfaces 176 can be provided to give further views of fluid delivery set 15 .
In each of containment units 18 , one or more mirrored surfaces are used to provide a view of fluid delivery set 15 without creating an unshielded direct line between the viewer and the fluid delivery set 15 (or other radioactive source). There is no need to provide a transparent shield (for example, lead shielded glass) over view ports 162 or 172 because the lack of an unshielded direct line of sight between the viewer and fluid delivery set 15 prevents exposure to radiation. Elimination of leaded glass can be advantageous as such glass is often expensive and heavy and can sometimes diminish or degrade a view.
In the case of injection of a radiopharmaceutical, positioning a pressurizing unit or chamber such as syringe 60 within dose calibrating unit 200 such as the Capintec CRC-15PET dose calibrator available from Capintec, Inc. of Ramsey, N.J., which measures the total radiation of the volume of radiopharmaceutical enclosed within the pressurizing chamber, shields administering personnel from radiation and enables delivery of a known volume of the radiopharmaceutical having a known radiation level (as measured directly by dose calibrating unit 200 ). The accurate control of injection volume and flow rate provided by powered injector 70 enables automatic injection of a calculated volume of fluid (using for example processing unit 71 of injector 70 ) that will provide the level of radiation necessary, for example, for a PET or SPECT image given the measured radiation of the total volume of radiopharmaceutical contained within syringe 60 provided by dose calibration unit 200 . Thus, it is no longer necessary to calculate and wait for the precise moment in time when radioactive decay has brought the level of radiation of a volume of radiopharmaceutical to the desired level, thereby saving time, and reducing the complexity of the injection procedure.
FIGS. 2-4C illustrate one embodiment of a setup for system 10 as described above. In this embodiment, a PULSAR injector available from Medrad, Inc. of Indianola, Pa. was used. Injection head 72 was separated from control unit 74 as described in U.S. Provisional Patent Application Ser. No. 60/167,309, filed Nov. 24, 1999, U.S. patent application Ser. No. 09/721,427 filed Nov. 22, 2000 and U.S. patent application Ser. No. 09/826,430 filed Apr. 3, 2001, all assigned to Medrad, Inc. Injection head 72 is slidably positioned in general alignment with an opening 204 in dose calibration unit 200 on a generally vertical slide bar or stand 220 via a clamping extension 224 . Injector 70 also includes a first remote control unit 76 for communicating data/instructions such as injection volume and flow rate into control unit 74 remotely (via, far example, communication line 75 ). Further, injector 70 includes a second remote control unit 78 for remote manual control of drive member 79 of injector 70 . The function of first remote control unit 76 and second control unit 78 can be combined. On currently available PULSAR injectors, manual controls for drive member 79 are positioned upon injector head 72 . However, to prevent undesirable exposure to radiation in system 10 of the present invention, such controls are preferably also positioned remotely from injector head 72 . Saline source/syringe 40 can also be controlled via injector 70 through a second injector head (not shown) as described, for example, in U.S. Provisional Patent Application Ser. No. 60/167,309, filed Nov. 24, 1999, U.S. patent application Ser. No. 09/721,427 filed Nov. 22, 2000 and U.S. patent application Ser. No. 09/826,430 filed Apr. 3, 2001.
In the embodiment of FIGS. 2A through 4C , system 10 is positioned upon a cabinet stand 300 . Slide bar 220 extends generally vertically from cabinet stand 300 . Cabinet stand 300 includes a passage 310 farmed therein through which syringe 60 can pass to enter dose calibration unit 200 . Cabinet stand 300 also preferably includes a second passage 320 through which pharmaceutical source 40 can pass to be deposited with container 44 . A cap 330 can be provided to seal container 44 . In the embodiment of FIGS. 2A through 4C , first passage 310 is preferably oriented such that radiation emanating therefrom is directed generally vertically toward the ceiling (or in another suitable direction) to reduce the likelihood that personnel within the room of the injection procedure will be exposed to such radiation.
Injector head 72 is oriented in a generally vertical, downward direction on slide bar 220 to position syringe 60 within dose calibrating unit 200 . To ensure that air is purged from a syringe, however, injector heads are typically positioned such that the exit or syringe tip of the syringe if oriented upward during purging. As air is less dense than other injection media and saline flushes, the air rises to the syringe tip or exit and is readily purged by, for example, forcing a small amount of fluid from the syringe. To enable a generally vertical orientation of syringe 60 with syringe tip 64 oriented upward in the present invention, a syringe adapter 400 was used.
Syringe adapter 400 attaches to injector 70 in preferably the same manner as syringes are attached thereto. Attachment adapters can be used as known in the art to facilitate such attachment. Adapter 400 can, for example, be removably attached to injector 70 via flanges 412 on an attachment member 410 that cooperate with retaining slots in injector 70 (not shown) as described in U.S. Pat. No. 5,383,858, assigned to the assignee of the present invention, the disclosure of which is incorporated herein by reference.
Adapter 400 includes a drive extension 420 that removably connects to drive member 79 of injector 70 via an attachment member 430 that can, for example, include capture members that cooperate with a drive member flange 79 . Drive extension 420 attaches to a syringe carriage 440 at an upper plate member 442 of syringe carriage 440 . Syringe carriage 440 is slidable disposed upon adapter 400 via slide bars 450 a and 450 b that extend from the rear surface of attachment member 410 to a fixed, lower base 460 . Syringe carriage 440 includes a syringe attachment member 444 attached to a lower plate member 446 of syringe carriage 440 . Upper plate member 442 and lower plate member 446 are connected via connecting members 448 (for example, metal or plastic bars), Syringe attachment member 444 can include slots (not shown) that cooperate with flanges 66 on a rear portion of syringe 60 to removably attach syringe 60 to syringe carriage 444 as illustrated in FIGS. 4A , and 4 C (as described, far example, in U.S. Pat. No. 5,383,858). Via syringe carriage 440 , the barrel of syringe 60 is slidable in an upward and downward direction on adapter 400 .
Adapter 400 further includes a plunger extension 470 that includes a plunger attachment including, for example, a flange 474 that cooperates with capture members 63 on the rear of plunger 62 to removably connect plunger extension 470 to plunger 62 . Adapters as known in the art can facilitate connection of plunger extension 470 to various plungers. Plunger extension 470 maintains plunger 62 in a fixed position relative to base 460 and injector head 72 . By upward and downward movement of syringe carriage 440 (via injector drive member 79 and drive extension 420 ), the position of plunger 62 within syringe 60 is changed. For example, advancing drive member 79 causes the barrel of syringe 60 to move downward and causes a corresponding or relative advancement of plunger 62 toward syringe tip 64 , thereby causing fluid to be expelled from syringe 60 . Upward movement (or retraction) of drive member 79 causes the barrel of syringe 60 to move upward and corresponds to retraction of plunger 62 relative to syringe tip 64 , thereby drawing fluid into syringe 60 .
An extending syringe adapter such as adapter 400 , enables use of commercially available injector systems and commercially available dose calibrators in the system of the present invention without substantial modification. The use of adapter 400 is transparent to the injector control software/hardware as no change and/or recalibration of the controlled movement of drive member 79 of injector 70 is required.
FIGS. 5A Through 5D illustrate several other embodiments of the present invention for providing dose calibration generally in real time. In FIG. 5A , a pressurizing device 520 (for example, a syringe in communication with a powered injector) and a radiopharmaceutical source 540 are positioned within a dose calibrator 550 . In FIG. 5B , radiopharmaceutical source 540 is placed in a dose calibrator 550 ′, while pressurizing device 520 is placed in a shielded enclosure 560 . In the embodiment of FIGS. 5C and 5D , radiation level detectors are placed in operative connection with flow lines (for example, tubing). In FIG. 5C , a radiation detector 570 is placed in line between radiopharmaceutical source 540 (enclosed within a shielded container 580 ) and pressurizing device 520 (enclosed within a shielded container 590 ). In FIG. 5D , a radiation detector 570 ′ is placed in line with the exit of pressurizing device 540 . In general, the flow rate through the line in operative connection with radiation detector 570 or 570 ′ is known. The radiation level of a particular dose is thus easily measured using radiation detectors 570 and/or 570 ′.
Although the present invention has been described in detail in connection with the above examples, it is to be understood that such detail is solely for that purpose and that variations can be made by those skilled in the art without departing from the spirit of the invention except as it may be limited by the following claims. | A method and apparatus of dispensing a radiopharmaceutical wherein a source of flushing fluid is connected to a first port of a fluid delivery set; a pressurizing unit of a powered injector system (including a powered injector and the pressurizing unit) is connected to a second port of the fluid delivery set; air is purged from the fluid delivery set; and, after purging air from the fluid delivery set, a third port of the fluid delivery set is connected to a source of the radiopharmaceutical. A valve system is included to control flow of fluid. A syringe is operatively connected with a powered injector. A radioactive shield encloses the syringe during operation to protect personnel from detrimental effects. A dose calibrator measure the radioactivity in the syringe. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority of Korean Patent Application Number 10-2013-0102437 filed Aug. 28, 2013, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a head light module which improves driving convenience of a driver by selectively irradiating a low beam and a high beam in accordance with a mode and reduces noise that occurs when the mode is converted.
[0004] 2. Description of Related Art
[0005] A head light module, also called a headlamp, is a device that serves to illuminate a forward path on which a vehicle runs, and requires brightness to enable a driver to verify obstacles on a road, which are 100 m from the front of the vehicle, at night.
[0006] A headlamp assembly of the related art (Japanese Patent Laid-Open Publication No. 2001-110213) includes a bulb (lamp), a reflector which supports the bulb and reflects forward light irradiated from the bulb, and a lens connected to a front side of the reflector by a holder.
[0007] The head light module is configured so that light irradiated from the bulb is converted into a low beam or a high beam by an operation of a shield unit provided in the head light module.
[0008] The shield unit includes a rotating pin, and a plate-shaped shield that is rotated about the rotating pin, and in this case, light irradiated from the bulb may be converted into a low beam or a high beam in accordance with a degree of rotation of the shield according to a linear movement of a solenoid.
[0009] Accordingly, a low beam state is made in an initial state in which the solenoid is not operated, and a high beam state is made when the shield is rotated forward about the rotating pin as the solenoid is linearly moved forward.
[0010] Meanwhile, the rotational operation of the shield of the shield unit is stopped by a damper (stopper), and in this case, noise and vibration occur due to a collision between the shield and the damper, and the noise and the vibration may be displeasing to the driver. Therefore, researches are continuously conducted to reduce noise and vibration occurring in the shield unit.
[0011] The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY
[0012] Various aspects of the present invention provide for a head light module which prevents dissatisfaction a driver by reducing noise and vibration that occur due to a collision between a shield and a damper when a rotational operation of the shield of a shield unit is stopped by the damper (stopper).
[0013] Various aspects of the present invention provide for a head light module including: a lamp which is disposed to irradiate light; a shield which is disposed to be rotatable about a rotating pin so as to selectively block a movement path or light path of a portion of the light irradiated from the lamp; a plunger which is disposed to be moved in a longitudinal direction thereof in order to push or pull one side of the shield; a compressive roll pad which is disposed so that an outer circumferential surface thereof is in contact with the plunger, rotated in accordance with a forward and rearward movement of the plunger, and compressed by the plunger or returns back to an original shape thereof when the plunger is moved forward or rearward; and an actuator which moves the plunger forward or rearward so that the shield selectively blocks the movement path of a portion of the light irradiated from the lamp.
[0014] The head light module may further include a plunger pin which is formed to protrude on one side surface of the plunger; a pad pin which is disposed on a rotation center portion of the compressive roll pad; a connecting arm which connects the plunger pin and the pad pin; a forward and rearward guide which guides the movement of the plunger pin; and an inclined guide which guides a movement of the pad pin.
[0015] The head light module may further include a drive arm having one end portion hinge-coupled to a front end portion of the plunger, and the other end portion hinge-coupled to the shield, such that the plunger rotates the shield.
[0016] The head light module may further include a shield mounting bracket on which the shield is installed so as to be rotatable through the shield rotating pin.
[0017] The head light module may further include a damper which is disposed between the shield mounting bracket and the shield so as to attenuate an impact occurring between the shield mounting bracket and the shield.
[0018] While the plunger is moved rearward and the shield is rotated about the shield rotating pin, the compressive roll pad may be compressed by the plunger, a movement speed of the plunger may be reduced by the compression force, and an impact occurring at the damper may be reduced.
[0019] The damper may be fixed to the shield mounting bracket, and a rotational operation of the shield may be stopped by the damper in accordance with a forward or rearward movement of the plunger.
[0020] The compressive roll pad may be an elastic member capable of being compressed by being pressed by the plunger, and expanded to return back to an original shape thereof.
[0021] According to the head light module of the present invention, when the plunger is moved rearward, a rotational operation of the shield is interrupted by the damper, whereas a rearward speed of the plunger is reduced by energy by which the plunger compresses the compressive roll pad, and noise and vibration occurring between the shield and the damper are effectively reduced.
[0022] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view of a shield unit of a head light module of the related art.
[0024] FIG. 2 is a side view illustrating a low beam state of an exemplary head light module according to the present invention.
[0025] FIG. 3 is a side view illustrating a high beam state of the exemplary head light module according to the present invention.
[0026] FIG. 4 is a top plan view illustrating a low beam state of a shield unit of the exemplary head light module according to the present invention.
[0027] FIG. 5 is a top plan view illustrating a high beam state of the shield unit of the exemplary head light module according to the present invention.
[0028] FIG. 6 is a partial detailed view illustrating the low beam state of the shield unit of the exemplary head light module according to the present invention.
[0029] FIG. 7 is a partial detailed view illustrating the high beam state of the shield unit of the head light exemplary module according to the present invention.
[0030] FIG. 8 is a graph illustrating an operation state of the exemplary head light module according to present invention.
DETAILED DESCRIPTION
[0031] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0032] FIG. 1 is a perspective view of a shield unit of a head light module of the related art.
[0033] Referring to FIG. 1 , a shield unit includes an actuator 100 , a forward and rearward guide 150 having a guide slot 155 formed therein, a plunger pin 166 , a connecting arm 168 , a pad pin 170 , an inclined guide 160 , a shield mounting bracket 130 , a damper 120 , a shield 110 , a rotating pin 140 , a drive arm 180 , a compressive roll pad 162 , a power source socket 102 , an actuator plunger 163 , and a plunger 164 .
[0034] The shield 110 is mounted to the shield mounting bracket 130 so as to be rotatable about the rotating pin 140 . The damper 120 serves to absorb an impact between the mounting bracket 130 and the shield 110 .
[0035] One side of the shield 110 is connected to the drive arm 180 , and the drive arm 180 is connected to the plunger 164 . The actuator plunger 163 is formed to protrude at a center of a front end portion of the actuator 100 , and a front end portion of the actuator plunger 163 is fixed to a rear end portion of the plunger 164 by a pin or the like.
[0036] The actuator plunger 163 and the plunger 164 are disposed to be moved as a single body forward and rearward by the actuator 100 .
[0037] The plunger pin 166 is formed to protrude on one side surface of the plunger 164 , and the plunger pin 166 is inserted into the guide slot 155 of the forward and rearward guide 150 . Therefore, the plunger 164 is disposed to reciprocate forward and rearward along the guide slot 155 .
[0038] A front end portion of the plunger 164 is connected to the drive arm 180 by a hinge, and the rear end portion of the plunger 164 is connected to the actuator 100 .
[0039] The actuator 100 may include a solenoid (not illustrated), and the power source socket 102 supplies external power to the actuator 100 through an electric wire.
[0040] In various embodiments of the present invention, the plunger pin 166 and the pad pin 170 are connected to each other through the connecting arm 168 , and the compressive roll pad 162 may be moved forward and rearward by movements of the plunger 164 and the plunger pin 166 .
[0041] An outer circumferential surface of the compressive roll pad 162 is in close contact with the plunger 164 , the pad pin 170 is disposed on a rotation center portion of the compressive roll pad 162 , and the pad pin 170 is moved along a slot of the inclined guide 160 .
[0042] In addition, even though the forward and rearward guide 150 and the inclined guide 160 are connected to each other, because the slot of the inclined guide 160 is disposed to be inclined with respect to a direction of the guide slot 155 of the forward and rearward guide 150 , the pad pin 170 may be moved close to or away from the plunger 164 when the plunger 164 is moved forward and backward.
[0043] When the plunger 164 is moved forward, a distance between one surface of the plunger 164 and the pad pin 170 is increased such that the compressive roll pad 162 is not compressed, or is slightly compressed by the plunger 164 .
[0044] Further, when the plunger 164 is moved rearward, the distance between the one surface of the plunger 164 and the pad pin 170 is decreased such that the compressive roll pad 162 is compressed by the plunger 164 .
[0045] In addition, when the plunger 164 is moved rearward, a rotational operation of the shield 110 is interrupted by the damper 120 , and a rearward speed of the plunger 164 is reduced due to energy by which the plunger 164 compresses the compressive roll pad 162 , such that noise and vibration, which occur between the shield 110 and the damper 120 , are reduced.
[0046] FIG. 2 is a side view illustrating a low beam state of a head light module according to various embodiments of the present invention.
[0047] Referring to FIG. 2 , a lamp (bulb) 205 is disposed to be fixed in a reflector 200 , a lens 210 is disposed in front of the lamp 205 , and light irradiated from the lamp 205 is reflected by the reflector 200 and then irradiated forward through the lens 210 .
[0048] As illustrated, the light irradiated through the lens 210 includes a high beam that is irradiated toward a higher portion, and a low beam that is irradiated toward a lower portion.
[0049] Further, when the plunger 164 is moved rearward by the actuator 100 , the shield 110 is rotated counterclockwise so as to be vertically disposed, the high beam irradiated through the reflector 200 is blocked, and only the low beam is irradiated forward through the lens 210 .
[0050] FIG. 3 is a side view illustrating a high beam state of the head light module according to various embodiments of the present invention.
[0051] Referring to FIG. 3 , the light irradiated through the lens 210 includes the high beam that is irradiated toward a higher portion, and the low beam that is irradiated toward a lower portion.
[0052] Further, when the plunger 164 is moved forward by the actuator 100 , the shield 110 is rotated clockwise, and the high beam and the low beam irradiated through the reflector 200 are irradiated forward through the lens 210 .
[0053] FIG. 4 is a top plan view illustrating a low beam state of a shield unit of the head light module according to various embodiments of the present invention, and FIG. 5 is a top plan view illustrating a high beam state of the shield unit of the head light module according to various embodiments of the present invention.
[0054] Referring to FIG. 4 , the plunger 164 is moved rearward by the actuator 100 such that the shield 110 blocks the high beam. Further, a first distance difference dl is formed between a movement line 400 of the plunger 164 and a position 410 of the pad pin 170 .
[0055] Referring to FIG. 5 , the plunger 164 is moved forward by the actuator 100 such that the shield 110 does not block the high beam. Further, a second distance difference d 2 is formed between the movement line 400 of the plunger 164 and the position 410 of the pad pin 170 , and the first distance difference dl is smaller than the second distance difference d 2 .
[0056] Referring to FIGS. 4 and 5 , a front end portion of the forward and rearward guide 150 and the inclined guide 160 may be joined with each other, and the guide slot 155 of the forward and rearward guide 150 may be connected to the slot of the inclined guide 160 .
[0057] FIG. 6 is a partial detailed view illustrating the low beam state of the shield unit of the head light module according to various embodiments of the present invention, and FIG. 7 is a partial detailed view illustrating the high beam state of the shield unit of the head light module according to various embodiments of the present invention.
[0058] Therefore, referring to FIG. 6 , when the plunger 164 is moved rearward by the actuator 100 , an amount of compression by which the compressive roll pad 162 is compressed by one surface of the plunger 164 is large.
[0059] Referring to FIG. 7 , when the plunger 164 is moved forward by the actuator 100 , an amount of compression by which the compressive roll pad 162 is compressed by the one surface of the plunger 164 is small, or the compressive roll pad 162 is not compressed.
[0060] FIG. 8 is a graph illustrating an operation state of the head light module according to various embodiments of the present invention.
[0061] Referring to FIG. 8 , a horizontal axis refers to a rotation angle of the shield 110 , and a vertical axis refers to a distance between the pad pin 170 and the plunger 164 .
[0062] Further, in accordance with the rotation angle of the shield 110 , a region of the graph is divided into a section (left side) where the shield 110 is opened, and a section (right side) where the shield 110 is closed.
[0063] As illustrated, the distance between the pad pin 170 and the plunger 164 is gradually increased in the section where the shield 110 is opened, and the distance between the pad pin 170 and the plunger 164 is gradually decreased in a section where the shield 110 is closed.
[0064] For convenience in explanation and accurate definition in the appended claims, the terms lower, front or rear, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0065] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A head light module includes: a lamp disposed to irradiate light; a shield disposed to be rotatable about a rotating pin so as to selectively block a light path of a portion of the light irradiated from the lamp; a plunger disposed to be moved in a longitudinal direction thereof in order to push or pull one side of the shield; a compressive roll pad disposed so that an outer circumferential surface thereof is in contact with the plunger, rotated in accordance with a forward and rearward movement of the plunger, and compressed by the plunger or returns back to an original shape thereof when the plunger is moved forward or rearward; and an actuator which moves the plunger forward or rearward so that the shield selectively blocks the light path of a portion of the light irradiated from the lamp. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of co-pending application Ser. No. 776, filed Jan. 3, 1979, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a multi-twist spindle for processing endless fibers and yarn by twisting, and for combining material from at least two countershafts with the simultaneous creation of a left and a right twist, or of a single direction combined twist.
Ring spindles and flyer spindles on which the fibers are wound for twisting of endless fibers, and yarn single twist spindles with a rotating countershaft, are known in the art. Double twist spindles, three twist spindles and multitwist spindles can be provided with two or more stable countershafts from which the combined fibers are taken up. These spindles are single purpose spindles. The fibers taken up from countershafts obtain the same direction and same height of the twist. These characteristics are severe limitation to the use of the equipment.
SUMMARY OF THE INVENTION
These drawbacks are eliminated by the multitwist spindle according to the present invention. The main feature of the instant multitwist spindle is the provision of a main support for the countershafts. A main shaft is rotatably mounted in the main support and a main carrier is fixed to the main shaft. In a second embodiment, first and second main carriers are provided. In another embodiment, additional carriers are located between the main support and posts. These additional carriers are designated the left and right carriers, respectively for purposes of description only. A differential gear mechanism is provided between the main carrier and the left carrier. The main support is provided with a stabilizer and a brake.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following description of the preferred embodiments, reference is had to the annexed drawings in which:
FIG. 1 is a sectional elevational view of a multitwist spindle with two countershafts on an upper and lower shaft according to a first embodiment of the invention;
FIG. 2 is a sectional elevational view of a mutlitwist spindle with four countershafts according to another embodiment of the invention;
FIG. 3 is a sectional elevational view of a multitwist spindle with a main carrier and left and right additional carriers according to a third embodiment of the invention; and
FIG. 4 is a sectional elevational view of a multitwist spindle with first and second main carriers according to a fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is provided a multitwist spindle having a main shaft 4 to which is fixed main carrier 30. Main shaft 4 is rotatably supported in bearing 2 which is mounted in bearing housing 3 on post 1. Main pulley 5 is fixed to the outer end of main shaft 4 and is rotatably coupled to driving pulley 7 by means of main transmission 6.
Main shaft 4 has rotatably mounted thereon main bearing 9 which is fixed in main bearing housing 10 on main support 8. Supported on main support 8 are upper bearing 60 and lower bearing 59. Rotatably mounted on upper and lower bearings 60 and 59 are shafts 64 and 63, respectively. Pulleys 17 and 18 are fixed to shafts 64 and 63, rspectively. Pulleys 17 and 18 are connected, by means of transmissions 24 and 27, respectively, to upper and lower lateral pulleys 22 and 23, respectively. Pulleys 22 and 23 are fixed to upper and lower wheels 20 and 21 which are, in turn, pressure coupled to wheel 19. Wheel 19 is fixed to main shaft 4. Stabilizer 28 and light brake 29 are provided on main support 8. A tube 46 with a main brake 54 is inserted into main shaft 4.
Turning now to FIG. 2, it will be seen that the basic relationship of the main shaft 4 to the supporting and driving means represented by the numerals 1 through 3 and 5 through 7 is the same as in the embodiment of FIG. 1. Similarly, main support 8 is mounted on main shaft 4 through main bearing 9 as in the embodiment of FIG. 1. Main support 8, in addition to supporting upper and lower bearing 60 and 59, and upper and lower shafts 63 and 64, supports a second upper bearing 58 and shaft 62 and a second lower bearing 57 and shaft 61. For ease in description, the upper and lower bearings 60 and 59 and the upper and lower shafts 64 and 63 will sometimes be referred to as the "outer" bearings and shafts while the second upper and lower bearings 58 and 57 and shafts 62 and 61 will sometimes be referred to as the "inner" bearings and shafts.
As in the embodiment of FIG. 1, the outer shafts 64 and 63 have fixed to them pulleys 17 and 18, respectively. Affixed to inner shaft 62 are pulleys 13 and 14, while affixed to inner shaft 61 are pulleys 15 and 16. Pulley 17 is connected to pulley 13 by means of transmission 24 and pulley 18 is connected to pulley 16 by means of transmission 27. Pulleys 14 and 15 are connected, respectively, to pulleys 12 and 11 which are mounted on main shaft 4.
Attention is now drawn to FIG. 3 which shows still another embodiment of the invention wherein a left shaft 41 is rotatably supported by left post 33 and is driven by means of pulley 43 which is connected through transmission 36 to pulley 34. Left shaft 41 has fixed to it left carrier 44 and is inserted into 40. Pulley 34 is fixed to the left end of drive shaft 31 which has fixed to the right end thereof, pulley 35.
Right post 32 rotatably carries right shaft 39 which is driven by pulley 38 connected by transmission 37 to pulley 35. Right shaft 39 has fixed thereto right carrier 42. Main shaft 4 is driven through differential gear mechanism 40 and carries pulley 48. Pulleys 17 and 18 are connected to pulley 48 through transmission 47.
In the embodiment of FIG. 4, left shaft 41 is rotatably supported on left post 33 and driven by means of pulley 43 which is connected, through transmission 36, to pulley 34. Similarly, right shaft 39 is rotatably mounted on right post 32 and is driven by means of pulley 38 which is connected, through transmission 37, to pulley 35. Pulleys 34 and 35 are mounted on either end of drive shaft 31. Left carrier 44 is fixed to left shaft 41 and right carrier 42 is fixed to right shaft 39. Left and right shafts 41 and 39 are carried by main support 8. In addition, left inner post 67 and right inner post 68 are carried on main support 8. Left inner shaft 64 is rotatably mounted on left inner post 67 and right inner shaft 63 is rotatably mounted on right inner post 68. Pulley 69, fixed to shaft 41, is connected, through transmission 75, to pulley 70 which is fixed to a second drive shaft, 66. Pulley 72 on drive shaft 66 is connected through transmission 76 to pulley 71 mounted on shaft 64. In a like manner, pulley 74 on drive shaft 66 is connected through transmission 77 to pulley 73 mounted on shaft 63. The other end of drive shaft 66 from pulley 70 is journalled for rotation in main support 8.
In operation, an external driving source (not shown) turns driving pulley 7 (FIGS. 1 and 2) or 34 (FIG. 3) which, in turn, drives transmission 6 and pulley 5 (FIGS. 1 and 2) or transmission 36 and pulley 43 (FIG. 3) to, thereby, turn main shaft 4 (FIGS. 1 and 2) or left shaft 41 and main shaft 4 (FIG. 3). Main carrier 30 turns with main shaft 4 and left carrier turns with left shaft 41 (FIG. 3). Also, middle wheel 19 (FIG. 1), pulleys 11 and 12 (FIG. 2), or pulley 48 (FIG. 3) are rotated as main shaft 4 turns. This rotation causes turning of pulleys 17 and 18 through pulleys 22 and 23 and wheels 20 and 21 in the embodiment of FIG. 1; turning of pulleys 13 and 15 as well as pulleys 14 and 16 which, in turn, drive pulley 17 and 18, in the embodiment of FIG. 2; or turning of pulleys 17 and 18 which are directly connected to pulley 48 through transmission 47, in the embodiment of FIG. 3. This rotation of pulleys 17 and 18, and pulleys 13-14 and 17-18 in the embodiment of FIG. 2, causes shafts 64 and 63, and 62 and 61 in the embodiment of FIG. 2 to rotate.
In the embodiment of FIG. 3, when the external source of power drives pulley 34, drive shaft 31 and pulley 35 are also driven. This, in turn, drives pulley 38 through transmission 37, and right shaft 39 to which right carrier 42 is affixed, causing right carrier 42 to turn.
The embodiment of FIG. 4 operates in much the same way as that of FIG. 3. An external source of power drives pulley 34 and drive shaft 31. The turning of pulley 34 drives pulley 43 through transmission 36. Pulley 43, in turn, drives shaft 41 which, through pulley 69, transmission 75, and pulley 70, drives drive shaft 66. When drive shaft 66 turns, it transmits the motion to shaft 64 through pulley 72, transmission 76, and pulley 71, and to shaft 63 in a similar manner.
With each revolution of the multitwist spindle of the invention, regardless of which embodiment is used, the fibers 49 and 50 (FIGS. 1, 3 and 4) or 49-52 (FIG. 2) pass over the main brake 54 (FIGS. 1, 2 and 3) or over the roller 78 (FIG. 4) to obtain two twists. Passage of the twisted fibers 53 over the main carrier 30 and eyelet 56 (FIGS. 1 and 2), the main carrier 30 and the right and left carriers 42 and 44 (FIG. 3), or over the right and left carriers alone (FIG. 4) to a takeup mechanism (not shown), produces two combined twists of the same or opposite direction.
Referring to FIG. 3, it will be seen that right shaft 39 and left shaft 41 have the same direction of rotation. The use of differential gear mechanism 40 makes it possible to rotate pulley 48 in the opposite direction. | A multitwist spindle for processing of fibers and yarn by twisting and combining materials from at least two countershafts with equal or different heights of twist while simultaneously forming a left and right twist or a single direction combined twist. The spindle has at least one rotating shaft with a yarn carrier fixed to it and at least two rotating countershafts on which the yarn is mounted. | 3 |
FIELD OF THE INVENTION
This invention relates to a process for controlling the temperature in the combustion zone of a furnace, such as a multiple hearth furnace or a fluidized bed furnace, without forcing additional air through the furnace for cooling purposes.
DESCRIPTION OF RELATED ART
Numerous methods have been reported to control the temperature in the combustion zone of a furnace. Controlling the air supplied to the furnace is one option, while adding cooler gases or vapors can be employed. Water sprayers have also been used for cooling purposes.
In U.S. Pat. No. 4,046,085 Barry et al. show a multiple hearth furnace operated by separately supplying air to the respective hearths to add an oxidant, including water vapor or steam, to the fixed carbon zone to accelerate combustion.
U.S. Pat. No. 3,958,920 of Anderson shows a multiple hearth furnace in which relatively low temperature gases from the drying zone are recycled to the combustion zone to absorb excess heat. The method of this patent is known as the "Anderson Recycle" and functions by recycling 800° F. moisture-laden gases from the drying hearth back to the combustion hearth to control temperature. The fan used to recirculate such gases, however, has to handle 800° F. gases with entrained particulate material which is a very severe service.
Lewis, in U.S. Pat. Nos. 4,391,208, 4,453,474 and 4,481,890 discloses various temperature control methods for a furnace including supplying high velocity mixing jets as well as combustion air supply jets to the combustion hearths of a multiple hearth furnace.
In U.S. Pat. No. 4,557,203, Mainord discloses using multiple water sprayers within a reclamation furnace to control temperature.
Hafeli in U.S. Pat. No. 4,056,068 describes using a multiplicity of secondary air and water nozzles to add air and cooling water to a refuse incinerator to cool and condition flue gas to about 10% water vapor for efficient flue gas treatment.
In U.S. Pat. No. 4,630,555 Guillaume et al. disclose a water nozzle which uses oxygen to spray water into a batch operated incinerator. The liquid/gas mixture is aimed a specific distance above the material to be burned to assist incineration.
Sowards in U.S. Pat. No. 4,060,041 describes a fluidized bed incinerator system for solid wastes where downwardly flowing air impinges upon the upwardly fluidized bed medium.
SUMMARY OF THE INVENTION
An objective of the invention is to control combustion zone temperature in a furnace independent of flue gas oxygen content. That is, controlling furnace temperature without forcing additional air through the furnace for cooling purposes.
A further objective of the invention is to use the heat of vaporization of a fine mist of liquid water droplets within the combustion zone to control temperature therein.
A further objective of the invention is to position the liquid water mist generating means external to the combustion zone to prevent clogging of the mist generating means, and to introduce the fine water mist into the combustion zone of the furnace so as to prevent damage to the furnace refractory lining.
The invention is a method for controlling temperature in a combustion zone in a furnace, independent of flue gas oxygen content, comprising the steps:
(a) supplying combustion air to said furnace for combustion of a fuel therein;
(b) providing a plurality of low volume gas flow entry ports to said combustion zone in said furnace with carrier gas continuously flowing through said ports into said combustion zone;
(c) selecting a set point value for said combustion zone temperature which, upon said temperature exceeding said set point value, commences generation of a fine water mist external said combustion zone by mist generating means within said carrier gas, said mist flowing into said combustion zone with said carrier gas and reducing temperature within said combustion zone by vaporization therein; and
(d) adding a proportionately greater amount of water mist to said carrier gas as the temperature of said combustion zone deviates above said set point value, said amount of water mist added limited by the capacity of said mist generating means, and ceasing said water mist generation upon said combustion zone temperature falling to or below said set point value.
The carrier gas is preferably air while the liquid water mist generating means may be a two-fluid atomizer or similar device.
In one embodiment the carrier gas and water mist are introduced into the combustion zone hearths of a multiple hearth furnace.
In another embodiment the carrier gas and water mist are introduced into the freeboard space of a fluidized bed furnace.
Other aspects, advantages and objects of the invention will become apparent to those skilled in the art upon reviewing the following detailed description, the drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a multiple hearth furnace employing the invention.
FIG. 2 is a detailed drawing of the low volume gas flow entry port and mist generating means of the invention.
FIG. 3 is a schematic representation of a fluidized bed furnace employing the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a multiple hearth furnace 10 has a tubular outer shell 12 which is a steel shell lined with fire brick or other similar heat resistant material. The interior of the furnace 10 is divided by means of hearth floors 14 and 16 into a plurality of vertically aligned hearths, the number of hearths being preselected depending upon the particular waste material being incinerated. Each of the hearth floors is made of a refractory material and is slightly arched so as to be self supporting within the furnace. Outer peripheral drop holes 18 are provided near the outer shell at the outer periphery of the floors 16 and central drop holes 20 are provided near the center of hearth floors 14. A rotatable vertical center shaft 22 extends axially through the furnace 10 and is supported in appropriate bearing means at the top and bottom of the furnace. This center drive shaft 22 is rotatably driven by an electric motor and gear drive assembly generally indicated at 24. A plurality of spaced rabble arms 26 are mounted on the center shaft 22, and extend outwardly in each hearth over the hearth floor. The rabble arms have rabble teeth 28 formed thereon which extend downwardly nearly to the hearth floor. As the rabble arms 26 are carried around by the rotation of the center shaft 22, the rabble teeth 28 continuously rake through the material being processed on the respective hearth floors, and gradually urge the materials toward the respective drop holes 18 and 20.
The incineration of sewage sludge will be used to describe the invention. For purposes of discussion, the hearths are designated as 1 through 8 starting from the top of the furnace. The waste feed material to be processed enters the top of the furnace through inlet 30 onto the 1 hearth. In other situations the waste feed material may be fed to both the 1 and 2 hearths, or introduced through multiple feed inlets. Combustion air is supplied to each hearth through air inlets 32 and flue gas exits the furnace through an exhaust gas outlet 34. The flue gas exiting the furnace from sewage sludge incineration normally contains about 20 to 40% water vapor. The combustion air alternatively may be supplied to only a portion of the heaths or may be supplied totally to the bottom hearth, hearth 8, of the furnace. In this example sufficient air is supplied to the furnace for the stoichiometric oxidation or combustion of all the waste material within the furnace by the air inlets 32. In other situations it may be advantageous to use less than stoichiometric amounts of air for combustion. In those instances the furnace would be operating in a "starved air" or pyrolysis mode.
In the combustion of a wet material such as sewage sludge, the hearths 1 and 2 are termed the drying zone where the majority of the water is removed from the solids. As the sludge is passed downwardly through the furnace in a general serpentine fashion, i.e., alternately inward and outward across the hearths, the combustion gases from the various hearths flow upwardly, countercurrent to the downward flow of solid material. As oxidation of the solids commences, the temperature in hearths 3, 4 and 5 are the hottest, and these hearths are designated as the combustion zone of the multiple hearth furnace. The noncombustibles solids which remain are termed ash and the ash material continues down through hearths 6, 7 and 8 where cooling occurs. These last hearths are termed the ash cooling zone. The cooled ash exits the bottom of the furnace through an exit 36.
In the operation of a multiple hearth furnace for incinerating waste material, it is important to control the maximum temperature of operation to prevent damage to the rabble arms and teeth and the furnace refractory including the hearths. The center shaft 22 and rabble arms 26 are generally hollow which allows cooling air to pass through them, affording some degree of protection from high temperatures. Control of maximum temperature is particularly important in the incineration of thermally conditioned and dewatered sludge which is characterized by low moisture content, high volatile content, and high heating or calorific value. The maximum temperatures will thus occur in the combustion zone of the furnace. It may be possible to maintain a maximum temperature in the combustion zone by forcing additional air, much above stoichiometric requirements, through the furnace. This however requires additional energy and larger, more costly equipment and results in higher operating costs.
Applicants have found that temperature control can be achieved by providing a plurality of low volume gas flow entry ports 38 to the combustion zone with a carrier gas, air, continuously flowing into the combustion chamber. The carrier gas contains a fine water mist, from a mist generating means external the combustion zone, which absorbs heat upon entering the combustion zone by evaporation. The carrier air comprises only a small fraction of the total volume of combustion air supplied to the furnace. Details of the entry port, mist generating means and temperature control technique are described in FIG. 2.
Referring to FIG. 2, a low volume gas flow entry port 38 passes through the furnace outer shell 12 and the refractory/insulating lining 40. A low volume flow of air from an outside source (not shown) flows through the entry port 38 into the combustion zone 42, carrying with it a fine mist of liquid water droplets to absorb heat from the furnace. The carrier air volume is small compared to that of the combustion air. The water mist generating means 44 is a two-fluid atomizer, although other mist generating means, such as an ultrasonic vaporizer, may be used as long as a fine water mist is generated.
The atomizer is made up of an outer pressurized air delivery line 46 and an inner water supply line 48 with a control valve 50. The atomizer is designed to provide a very fine water droplet mist directed axially within the entry port 38.
The water supply valve 50 is operated by a controller 52 which is also connected to a temperature sensing probe 54 which monitors temperature in the combustion zone 42. As the temperature in the combustion zone rises above a preselected set point value, the controller 52 opens the water supply line valve 50 and commences generation of a fine water mist to reduce combustion zone temperature. Should the temperature in the combustion zone 42 increases further, controller 52 opens the valve 50 to a greater extent to provide additional water mist to reduce combustion zone temperature to the set point value. Design of the atomizer limits the amount of water mist capable of being applied to the combustion zone 42. The weight ratio of water mist to carrier air is a maximum of about 50:1, and preferably less than about 40:1. Typically the water mist to carrier air weight ratio is in the range of about 25:1 to 1:1 during normal furnace operation.
If for some reason the maximum water mist flow into the combustion zone 42 is insufficient to bring the temperature down to the set point value, other control means, such a ceasing addition of fuel to the furnace, come into effect. The method of the present invention provides a fine degree of temperature control (as opposed to a coarse degree) with respect to combustion zone temperature.
Further, the fine water mist droplet size prevents damage to the refractory which may be caused by a coarser water spray alone. Further, the placement of the mist generating means external the combustion zone coupled with the cooling flow of carrier air within entry port 38 prevents clogging of the atomizer by precipitated salts or particulate material.
Several entry ports are provided for temperature control of the combustion zone in a multiple hearth furnace. For the furnace of FIG. 1, each hearth, 3, 4 and 5, of the combustion zone has 2 to 4 cooling mist entry ports for precise temperature control. Each hearth has one temperature sensing probe 54 while a single controller 52 operates the water supply to all cooling mist entry ports for each hearth.
Referring to FIG. 3, a fluidized bed furnace 100 has a tubular outer shell 102 which is a steel shell lined with fire brick or other similar heat resistant material. The interior of the furnace is divided by a support 104 which supports the tuyeres 106 and the bed medium 108. The support 104 divides the interior of the furnace into a lower wind box 110 and an upper combustion zone composed of the fluidized bed 108 and the freeboard zone 112. Combustion air is supplied by a blower 114 which forces air into the wind box 110, upward through the tuyeres 106, fluidizing the bed 108 and combusting the waste material within the bed 108 and the freeboard zone 112. The fluidized bed 108 and the freeboard zone 112 thus constitute the combustion zone for the furnace. The waste material enters the furnace through an inlet 116 at the furnace top or alternatively through an inlet 118 below the surface of the fluidized bed medium 108. Exhaust gases exit the furnace through an exhaust gas outlet 120.
Low volume gas flow entry ports 122 continuously provide carrier gas to the freeboard zone 112. The carrier gas contains a fine water mist, from mist generating means 124 external the freeboard zone 112, which absorbs heat upon entering the freeboard zone by evaporation. Carrier gas is supplied through a conduit 126 from a source not shown. The entry ports 122, the mist generating means 124 and temperature control techniques are as described for FIG. 2. | An improved method for controlling combustion zone temperature in a furnace independent of flue gas oxygen content is disclosed. The method comprises supplying a carrier gas containing a fine mist of liquid water droplets to the furnace combustion zone to control the maximum temperature within the combustion zone. The invention is applicable to both multiple hearth furnaces and fluidized bed furnaces, protecting the refractory furnace lining from damage. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an image forming apparatus, and more particularly relates to an electrostatic color copier by which a color image of a document can be formed on a recording paper.
In a conventional color image forming apparatus of the kind described above, the following principle is applied: toner is attracted to an electrostatic latent image which has been formed on the circumferential surface of a photoreceptor drum so that a toner image is formed; and the formed toner image is transferred onto a recording paper.
In this kind of image forming apparatus, the following transfer systems by which a toner image on a photoreceptor drum surface is transferred onto a recording paper, have been widely known.
(1) The conveyance transfer system which is characterized in that: an image is transferred onto a horizontally conveyed recording paper while the recording paper is squeezed by a photoreceptor drum and an idle roller. This system is mainly applied to monocolor copiers.
(2) The paper drum transfer system which is characterized in that: a paper drum is provided opposed to a photoreceptor drum; and a recording paper is tightly wound around the paper drum so that an image can be transferred onto the recording paper. This system is mainly applied to color copiers.
The above-described transfer systems have a disadvantage as follows.
(1)' In the case of the conveyance transfer system, an image can be formed on various sizes of paper. However, when the drum size is increased, there is a possibility that a recording paper can become stuck around the photoreceptor drum.
(2)' In the case of the paper drum system, it is suitable for forming a color image since multiple transfer can be conducted. However, this system can not be applied to various sizes of paper, or when thick paper is used as a recording paper.
As large and precise images are required recently, the transfer belt system has become a center of attention, wherein the transfer belt system is characterized in that a recording paper is electrostatically attracted onto the surface of a transfer belt. In the transfer belt system, there is no possibility that a recording paper becomes adhered onto the surface of a photoreceptor drum, so that the transfer belt system is effective when it is applied to a color copier which is provided with a large photoreceptor drum. Consequently, this system has been applied to many copiers.
In the case of a conventional image forming apparatus, the apparatus is composed in such a manner that: a transfer belt unit consisting of a transfer belt stretched around a paper entry side roller (an idle roller) and a delivery side roller (a drive roller) is provided; the transfer belt is pressed against the photoreceptor drum surface with pressure when transfer is conducted; and when transfer is not conducted, the transfer belt is separated from the photoreceptor drum by a cam mechanism provided on a support frame, wherein the transfer belt is rotated around the delivery roller. Then, the transfer belt comes into contact with the photoreceptor drum only when transfer is performed, and the wear of both the transfer belt and photoreceptor drum can be reduced.
Since the transfer belt unit is a heavy structure consisting of at least two rollers, one belt and a frame, a heavy load is given to the cam which moves the transfer unit up and down, so that it is difficult to move the transfer unit in quick response, and further there is a possibility that the cam becomes worn out and problems are caused in the cam drive mechanism.
Due to the above-described situation, it is a primary object of the present invention to provide an image forming apparatus in which the transfer belt can be contacted with and moved from the photoreceptor drum surface without giving too heavy a load to the cam mechanism.
In the case of the above-described conventional image forming apparatus, it is necessary to provide a toner recovery box to the transfer unit, which scrapes the residual toner adhered to the surface of the transfer belt and recovers the scraped toner.
This toner recovery box is fixed to the apparatus body through a delivery tube. On the other hand, the transfer belt unit needs to be attachably provided to the apparatus body so that it can be easily removed from the body when the transfer belt is exchanged during maintenance. Further, the transfer belt unit and the toner recovery box must form one body when copy operations are performed, so that toner can not be scattered from the gap between the transfer belt unit and the toner recovery box.
With a view to solving the problems described above, the second object of the present invention is to provide an image forming apparatus having a means to couple a transfer belt and a toner recovery box is provided, by which the toner recovery box can be easily separated from the transfer belt. Furthermore the means is simply composed and of low cost.
SUMMARY OF THE INVENTION
It is the first object of the present invention to provide an image forming apparatus which is provided with a transfer belt unit comprising a transfer belt stretched around an entry side roller and a delivery side roller and provided with a cam mechanism on a support frame side, said cam mechanism rotated around the delivery side roller so that the transfer belt can be contacted with a photoreceptor drum with pressure when transfer is performed and the transfer belt can be separated from the photoreceptor drum when transfer is not performed; said image forming apparatus characterized in that: a spring means is provided between said belt unit and support frame so that the weight of said transfer belt can be reduced and the load given to the cam can be approximately zero.
It is the second object of the present invention to provide an image forming apparatus which is provided with a transfer belt unit comprising a transfer belt stretched around an entry side roller and a delivery side roller, and provided with a cam mechanism on a support frame side, said cam mechanism rotated around the delivery side roller so that the transfer belt can be contacted with a photoreceptor drum with pressure when transfer is performed and the transfer belt can be separated from the photoreceptor drum when transfer is not performed, said image forming apparatus characterized in that: a toner scraping means to scrape residual toner from the belt is provided to the belt surface at a position close to one of the rollers; a toner recovery box holding means which holds a toner recovery box at an appropriate position to said transfer belt is provided, wherein the transfer belt unit and toner recovery box are coupled by the holding means when copy operations are conducted and can be separated by releasing the holding means when maintenance is conducted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the image forming apparatus of the present invention when transfer is conducted;
FIG. 2 is a sectional view of the image forming apparatus of the present invention when transfer is not conducted;
FIG. 3 is a perspective view of a transfer belt unit;
FIG. 4 is a perspective view of a toner recovery unit; and
FIG. 5 is a sectional view of the toner recovery unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following are the explanations of an example of the image forming apparatus of the present invention, wherein the image forming apparatus is a color image copier.
In the drawings, the numeral 1 is a photoreceptor drum which is provided inside the image forming apparatus body. The image of a document (not shown in the drawing) placed on a platen glass is transformed into a toner image on the photoreceptor drum 1, the external circumferential surface 1a of which is made from a photosensitive material. A toner image is formed on the photoreceptor drum surface 1a in such a manner that: the light reflected by the document is irradiated on the external circumferential surface 1a so that an electrostatic latent image can be formed; and the latent image is developed by the toner in the development unit 20 so that a toner image can be formed. In the image forming apparatus of the present invention, this operation is repeatedly conducted for each primary color (Y, M, C and Bk) and a toner image in full color can be obtained.
The numeral 2 is a transfer belt unit which is composed of a delivery side roller (a drive roller) 3, an entry roller (an idle roller) 4, an endless transfer belt 5 stretched around the rollers 3 and 4, and upper frame F 1 holding the above-described movable members.
The transfer belt 5 electrostatically attracts recording paper K which has been supplied from an automatic paper feed unit or a hand feeding tray. Charger C 2 used for transferring the toner image on the above-described photoreceptor drum 1, is provided in a position below transfer part T in which the drum 1 and the transfer belt 5 are contacted.
Recording paper K is conveyed as follows: recording paper K which has been sent from a paper feed unit or a hand feeding tray, is previously exposed to the electric charge of the same polarity as the toner by the action of charger C 1 so that the toner can not be attracted by recording paper K; recording paper K is conveyed onto the transfer belt 5; and in transfer portion T, recording paper K is strongly attracted by the transfer belt 5 which is charged by charger C 2 to the reverse polarity, so that recording paper K is maintained flat and the toner can be strongly and tightly adhered to recording paper K.
Even when supporting frame F 2 is fixed to the apparatus body, the above-described upper frame F 1 can be rotated around the delivery side roller 3 so that upper frame F 1 can be relatively moved with regard to the photoreceptor drum 1. When upper frame F 1 is moved a little in the vertical direction by the cam 6 provided on supporting frame F 2 , the above-described transfer belt 5 can be contacted with the photoreceptor drum 1 (as illustrated in FIG. 1) when image transfer is performed, and the transfer belt 5 can be separated from the photoreceptor drum 1 (as illustrated in FIG. 2) when image transfer is not performed.
The cam 6 is rotated by the drive shaft 7, wherein the drive shaft 7 is controlled by timing control unit P consisting of a sensor to detect the leading edge of recording paper K and a solenoid (not shown in the drawing), so that the transfer belt 5 can be contacted with and separated from the photoreceptor drum 1 according to the conveyance position of recording paper P.
At a position in upper frame F 1 close to the entry side roller 4 is provided the ratchet (the holding means) 15 which holds the handle 14 of the toner recovery box 11.
The above-described supporting frame F 2 is placed below the above-described transfer belt unit 2 in order to support it, and provided with the above-described cam 6, the cam drive shaft 7 and the spring means 8 so that supporting frame F 2 can be rotated around fulcrum S 1 which is provided on the delivery side (which is the left side in FIGS. 1 and 2). Namely, when supporting frame F 2 is rotated around fulcrum S 1 , the above-described transfer unit 2 is contacted with the photoreceptor drum 1 when the apparatus of the present invention is operated (when a series of image forming operation is conducted), and the transfer belt unit 2 is separated from the photoreceptor drum 1 when maintenance work is conducted (when the transfer belt is exchanged or the apparatus is adjusted). However, in order to realize the working action described above, the toner recovery box 11 placed on the entry roller 3 side, must be supported in the form of a cantilever. Accordingly, a relatively heavy load is given to the cam 6. The character r is a bumping roller which is used in order to determine the gap between supporting frame F 2 and the photoreceptor drum 1 when supporting frame F 2 is set close to the photoreceptor drum 1. The character G is a guide roller which adjust and stabilize the tension of the transfer belt 5 when transfer is performed.
The above-described spring means 8 facilitates the rotation of the above-described transfer belt unit 2, and is provided between the above-described upper frame F 1 and the supporting frame F 2 , wherein the spring means 8 bears almost all the weight of the transfer belt unit 2 so that the load of the above-described cam 6 can be reduced.
Namely, the load which is given to the above-described cam 6 can be expressed as follows: "the spring force of the spring means" is subtracted from "the weight of the belt unit 2". Consequently, a very small load is given to the cam 6, so that the frequency of mechanical breakdown is low and further it is possible to realize a transfer belt drive system which can be moved in quick response.
The numeral 9 is an arm which supports the bottom of supporting frame F 2 . When the arm 9 is rotated around fulcrum S 2 , the rotative position of supporting frame F 2 can be controlled and the above-described transfer belt unit 2 can be contacted with or separated from the photoreceptor drum 1. The character D is a buffer to reduce the shock given the supporting frame F 2 by the arm 9.
The numeral 10 is a blade which is placed at a position close to the above-described entry side roller 4 and comes into contact with the surface of the above-described transfer belt 5 in order to scrape the residual toner on the transfer belt 5. The numeral 11 is a toner recovery box, which is located at a position close to an optional roller that comes into contact with the inside of the transfer belt 5, in this example the toner recovery box 11 is located below the above-described entry side roller 4, and which collects the scraped toner by the action of the blade 10. The numeral 12 is a screw which is provided inside the toner recovery box 11, and which conveys the collected toner to a toner tube 13 located on the side of the toner recovery box 11 so that the collected toner can be discharged into a toner accumulating portion (not illustrated in the drawing) which is connected with the toner tube 13. The character B is a brush to prevent toner scattering. Brush B is made of feathers and seals the gap between the above-described transfer belt 5 and the toner recovery box 11 in order to prevent the collected toner from scattering.
The numeral 14 is a handle which is made of a cylindrical member and provided on both sides of the toner recovery box 11. When the handle 14 is held by the ratchet (the holding means) 15, the transfer belt unit 2 and the toner collecting box 11 can be unified. To be specific, the ratchet 15 is made of a plastic member and provided with a C-shaped portion 15a so that the handle 14 can be held and released due to the resilient deformation of the plastic member. The apparatus of the present invention is operated as follows: the handle 14 is held by the ratchet 15; even though the transfer belt unit 2 is vertically moved by the cam 6, the transfer belt unit 2 and the toner recovery box 11 are unified so that the collected toner can be prevented from scattering; and when maintenance work is conducted, the handle 14 is released from the ratchet 15 and the transfer belt unit 2 can be removed from the apparatus body.
In the above-described example, recording paper K conveyed from the paper feed part, is conveyed onto the transfer belt 5 of the transfer belt unit 2, which transfer belt 5 is previously exposed to the electric charge of the same polarity as that of the toner by the action of charger C 1 . Then a toner image formed on the photoreceptor drum 1 in the development part 20, is transferred onto a recording paper in transfer part T. At this moment, the arm 9 pushes up supporting frame F 2 and further the cam 6 pushes up upper frame F 1 , so that the transfer belt 5 is contacted with the photoreceptor drum 1 with pressure. In transfer part T, the electric charge of which polarity is reverse to that of the toner, is sharply supplied by charger C 2 , so that recording paper K closely comes into contact with the upper surface 5a of the transfer belt 5 and attracts the toner on its surface. Recording paper K is conveyed by the transfer belt 5 while its shape is flat. At this moment, the spring means 8 supports almost all of the weight of the transfer unit 2 and the weight is transmitted to to the arm 9 through supporting frame F 2 . Accordingly, the load given to the cam 6 is very low. Since the handle 14 of the toner recovery box 11 is held by the ratchet 15, the toner recovery box 11 is never separated from the transfer belt 5. Further, brush B seals the gap between the transfer belt 5 and the toner recovery box 11, so that there is no fear of toner scattering. When maintenance work is conducted, the handle 14 can be easily released from the ratchet 15 and the transfer belt unit can be easily removed.
The position of supporting frame F 2 is determined by bumping roller r and its bumping force is appropriately reduced by the action of buffer D. After images have been transferred onto recording paper K, the transfer belt unit 2 is rotated around the delivery side roller 3 and separated from the photoreceptor drum 1. A small amount of toner which has been left on the surface of the transfer belt 5, is scraped off by brush B and the blade 10, collected into the toner recovery box 11 and discharged into the tube 13 by the screw 12. Recording paper K is also conveyed to the delivery side by delivery belt H.
As explained above, the present invention is to provide an image forming apparatus which is provided with a transfer belt unit consisting of a transfer belt stretched between an entry side roller and a delivery side roller and provided with a cam mechanism on a support frame side, which cam mechanism is rotated around the delivery side roller so that the transfer belt can be contacted with a photoreceptor drum with pressure when transfer is performed and the transfer belt can be separated from the photoreceptor drum when transfer is not performed, and which image forming apparatus is characterized in that: a spring means is provided between said belt unit and support frame so that the weight of said transfer belt can be reduced. Consequently, the load given to the cam can be greatly reduced and the apparatus can be prevented from wearing out, so that the occurrence of mechanical breakdown can be prevented.
As a result, the present invention contributes to improvements in maintainability and reliability of an image forming apparatus.
Further, the present invention is to provide an image forming apparatus which is provided with a transfer belt unit consisting of a transfer belt stretched between an entry side roller and a delivery side roller and provided with a cam mechanism on a support frame side, which cam mechanism is rotated around the delivery side roller so that the transfer belt can be contacted with a photoreceptor drum with pressure when transfer is performed and the transfer belt can be separated from the photoreceptor drum when transfer is not performed, and which image forming apparatus which is characterized in that: a toner scrape means to scrape the residual toner on the belt, is provided close to one of the rollers which comes into contact with the inside surface of said transfer belt; a toner recovery box holding means which holds a toner recovery box at an appropriate position on said transfer belt, is provided. Consequently, the transfer belt unit and the toner recovery box can be unified while the apparatus is in operation in order to prevent toner scattering, and the toner recovery box can be easily separated from the transfer belt unit when maintenance work is conducted.
As a result, the present invention contributes to improvements in the stability of operation and the maintainability. | The invention provides an image forming apparatus having a transfer device. The transfer device includes a plurality of rollers, a belt and a cam. The belt is rotatable around the plurality of rollers so as to convey a recording sheet thereon. The transfer device is adapted to be pivotable around a pivot axis thereof. The cam pivots the transfer device so as to bring the belt in contact with and out of an imaging surface of a photoreceptor. In the device there is further provided a spring for supporting the transfer device to reduce the weight loaded onto said cam member. | 6 |
FIELD OF THE INVENTION
The present invention generally related to computer security and more specifically to systems and methods for secure data disposal.
DESCRIPTION OF THE RELATED ART
In certain storage applications, data stored on magnetic disk drives must be retained for a certain time period and then, after the specified expiration date, securely disposed of. Once the expiration date has passed, the physical disks or other devices which contained the data may be re-used by other users or applications for other purposes or may be entirely disposed of. Because even after the erasure by conventional techniques, the magnetic storage media may leave traces of information, which used to be written thereon, there is a need for secure data erasure technique in order to avoid security breaches associated with sensitive information being accessed by unauthorized persons.
There exist conventional techniques for securely erasing data from magnetic media such as magnetic disks by means of overwriting such data multiple times with new or random data. For example, DoD (Department of Defense) Directive 5220, incorporated herein by reference calls for multiple data block overwrites to erase magnetic data. Another method for securely erasing data from magnetic media is described in “Secure Deletion of Data from Magnetic and Solid-State Memory” by Peter Gutmann, Department of Computer Science, University of Auckland, New Zeland (http://www.cs.auckland.ac.nz/˜pgut001/pubs/secure_del.html), incorporated herein by reference. Unfortunately, all the conventional methods for sanitizing magnetic media are very time consuming and are not suitable for use when the disks need to be disposed of or reused immediately after the data expiration date or end of the usage of the data.
Another way to ensure secure disposal of data is to have the data securely encrypted with a key. It is known in the art that disposal of a key which encrypts such data has a similar effect to data disposal. For example, CRYPTOSHRED™ key deletion technology, available in products provided by Decru, Inc., involves secure deletion of encryption keys, resulting in all copies of associated encrypted data being instantly destroyed. As would be appreciated by those of skill in the art, this method, which involves disposing of encryption keys on a condition that the data has been encrypted and stored on magnetic disks, has a similar effect to secure data deletion described above. The primary advantage of the data deletion by cryptographic key disposal is in the speed of the data disposal process. Specifically, the key erasure takes a very short time compared with conventional techniques, wherein all data must be over-written multiple times. On the other hand, the cryptographic data disposal technique entails burdens associated with management and updating of encryption keys securely for extended periods of time.
Therefore, the conventional techniques fail to provide a methodology for fast and secure disposal of data written on various magnetic media upon the expiration thereof.
SUMMARY OF THE INVENTION
The inventive methodology is directed to methods and systems that substantially obviate one or more of the above and other problems associated with conventional techniques for secure data disposal.
One aspect of the invention is a computerized system, method and computer programming product for secure data disposal. The inventive system includes multiple storage volumes which store data having an expiration date and a storage controller operatively coupled with the logical storage volume, the storage controller comprising a central processing unit (CPU) and a memory unit, the memory unit storing information on the expiration date of the data stored in the storage volume and an encryption key. The aforesaid storage controller initiates the encryption of the data stored in one of the storage volumes using the stored encryption key to obtain encrypted data. The encryption is being initiated by the storage controller prior to the data expiration date. Additionally, the storage controller write the encrypted data to the one of the storage volumes, rewrite the encrypted data; and disposes of the encryption key.
Another aspect of the invention is a computerized system, method and computer programming product for securely disposing of data stored in multiple storage volumes. The data on each volume is associated with an expiration date. According to the inventive concept, an encryption method associated with a respective logical storage volume is being loaded and the stored data is encrypted with the loaded encryption method and an encryption key. The inventive technique also involves loading a data rewrite method associated with the respective storage volume and rewriting the encrypted data using the loaded rewrite method. Finally, the encryption key is disposed of in a secure manner.
Additional aspects related to the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Aspects of the invention may be realized and attained by means of the elements and combinations of various elements and aspects particularly pointed out in the following detailed description and the appended claims.
It is to be understood that both the foregoing and the following descriptions are exemplary and explanatory only and are not intended to limit the claimed invention or application thereof in any manner whatsoever.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification exemplify the embodiments of the present invention and, together with the description, serve to explain and illustrate principles of the inventive technique. Specifically:
FIG. 1 shows an exemplary system configuration of an embodiment of the invention.
FIG. 2 shows an exemplary embodiment of an algorithm table.
FIG. 3 shows an exemplary embodiment of a table that contains the estimated length of time required to process data rewriting for specific storage devices within the storage system.
FIG. 4 shows an exemplary embodiment of a table stored in the memory of the controller which contains the expiration date information for each data set designated by the corresponding logical unit number (LUN)
FIG. 5 illustrates the operation of the inventive algorithm for conversion of data volumes.
FIG. 6 illustrates an exemplary algorithm for data processing.
FIG. 7 illustrates the method used by the processor to handle read requests while the processor performs the data encryption process described in FIG. 6 .
FIG. 8 illustrates an exemplary embodiment of a method used by the processor 103 to handle write requests while the process described in FIG. 6 is performed.
FIG. 9 illustrates the steps of the “Read and Write” process in mode detail.
FIG. 10 shows an example of a scheduling table which specifies when the data conversion process described by FIG. 5 should start for each LU and when the key for each LU is discarded.
FIG. 11 shows a table generated by the processor when logical storage units are allocated.
FIG. 12 shows a time chart which indicates when the inventive conversion processes for each LU must start executing, so that each process completes on the respective data expiration time as specified in the table of FIG. 4 .
FIG. 13 illustrates an exemplary embodiment of a computer platform upon which the inventive system may be implemented.
DETAILED DESCRIPTION
In the following detailed description, reference will be made to the accompanying drawing(s), in which identical functional elements are designated with like numerals. The aforementioned accompanying drawings show by way of illustration, and not by way of limitation, specific embodiments and implementations consistent with principles of the present invention. These implementations are described in sufficient detail to enable those skilled in the art to practice the invention and it is to be understood that other implementations may be utilized and that structural changes and/or substitutions of various elements may be made without departing from the scope and spirit of present invention. The following detailed description is, therefore, not to be construed in a limited sense. Additionally, the various embodiments of the invention as described may be implemented in the form of a software running on a general purpose computer, in the form of a specialized hardware, or combination of software and hardware.
1. Exemplary System Configuration
FIG. 1 shows an exemplary system configuration of an embodiment of the invention. The specific elements of the shown embodiment are described in detail below. Specifically, element 101 designates the storage system which has the functionality in accordance with the inventive technology. The storage system 101 includes a storage controller 102 , which further includes a central processing unit (CPU) 103 and a schedule table 104 , which stores information specifying when the data conversion process must starts for each logical storage unit (LU) and when the encryption key for each LU is discarded.
Numeral 105 designates an algorithm table, which is stored in the memory of the controller 102 . The algorithm table 105 stores information on the algorithms that are user in encrypting the stored data. An exemplary embodiment of the table 105 is shown in FIG. 2 and designated with numeral 201 . As shown in FIG. 2 , the exemplary algorithm table stores information on encryption methods, rewrite methods, and the corresponding current encryption key. The information on the encryption method stored in table 105 ( 201 ) includes a designation of the encryption algorithm, the key length, if the algorithm can take several key lengths, and the mode of the rewrite operation.
The controller 102 further manages a table 106 , which is stored in the memory in the controller 102 . This table contains estimated length of time required to process data rewriting for specific storage devices within the storage system. An exemplary embodiment of this table 106 is shown in FIG. 3 and is designated in this figure with the numeral 301 .
The storage controller 102 further includes a clock 107 and a table 108 . The table 108 is stored in the memory of the controller 102 and contains expiration date information for each data set, designated by the corresponding logical unit number (LUN). An exemplary embodiment of table 108 is shown in FIG. 4 and designated with numeral 401 in that figure.
Finally, numerals 109 through 113 in FIG. 1 designate Logical Volumes, each of which is assigned a unique LUN (logical unit number). Specifically, the LUN of the volume 109 is 0001, the LUN of the volume 110 is 0002, and so on.
2. Exemplary System Operation
FIG. 5 illustrates the operation of the inventive algorithm for conversion of data volumes. The below description corresponds to the conversion of the data on volume 109 , which has the LUN of 0001. As would be appreciated by those of skill in the art, the same algorithm may be applied to converting data stored in other logical volumes of the inventive storage system as well as data stored in various types of physical and logical storage units.
With reference to FIG. 5 , at step 501 , the processor 103 loads an encryption method into the memory in order to encrypt the data on the volume 109 . The encryption algorithm is loaded from the aforesaid algorithm table 105 or 201 . It should be noted that if the processor 103 supports only one algorithm, such as the algorithm described in the record 202 of the table 201 shown in FIG. 2 , the algorithm information may not have to be stored in the form of a table as is shown as 105 or 201 . In such a case, the encryption algorithm may be hard-coded either within the hardware of the processor 103 or within the corresponding software, which is executed by the processor 103 .
After the encryption method is loaded, at step 502 , the processor 103 proceeds to encrypt the data stored in the volume 109 with the loaded encryption method 202 . The processor 103 may be configured to work in conjunction with an encryption chip or an encryption software module. During this conversion, the processor 103 may accept input-output (I/O) operations from the host 115 , which may involve the data stored in the volume 109 . In other words, the processor 103 may continue conversion of the data on the volume 109 , while properly handling I/O requests from the host 115 , which may involve the data being encrypted. The encryption key for this step is stored in the column 211 of the table 201 .
At step 503 , the processor 103 loads the data rewrite method, the description of which is also stored in the record 202 of table 201 of FIG. 2 . The column 210 of the table 201 , for example, stores values specifying how many times the data on a storage volume must be re-written. As would be appreciated by those of skill in the art, the multiple re-writing is necessary to erase physical traces of the data on the storage media, which, at least theoretically, may be used to restore the recently over-written data. For the example, according to the record 202 in the table 201 , the data stored in the volume 109 with LUN 0001 will be read and re-written again 3 times.
The aforesaid data rewrite method could be, for example, one of the data encryption methods, such as the method used at step 502 of the inventive algorithm. Another suitable data rewrite method involves mere reading of the data from the corresponding storage volume and writing the read data at the same address, where the data was stored. On the physical level, such simple re-write operation accomplishes the purpose of eliminating physical traces of the previously written data.
In the case of the latter re-write algorithm, the processor 103 reads each block of data from the storage volume and writes it back to the same volume. During the aforesaid re-write operation, the physical address of the written data slightly varies with each write operation because the disk head, writing the data may use a slightly different orbit every time when the data is written. This achieves the aforesaid goal to replace the former plaintext data with encrypted data created at the step of 502 of the algorithm shown in FIG. 5 , without leaving any physical traces of the old information on the storage media.
In an embodiment of the inventive system, during the re-write operation performed in accordance with any of the described algorithms, the processor 103 is configured to allow the host's I/O requests.
The contents of the table 201 will now be described with reference to FIG. 2 . Table 201 stores information on the specific encryption method which is used for encrypt information on each logical storage unit (LU). Specifically, the column 208 identifies the encryption method, while the column 209 identifies the data rewrite method for each LU listed in column 207 . The decision at steps 501 and 505 of the inventive algorithm shown in FIG. 5 are made based on the contents of the table 201 . If there is only one data encryption/re-writing algorithm available for each of the steps 501 or 505 , the methods which are normally chosen at those steps can be hard coded and may not appear explicitly.
At step 504 , the processor 103 initializes a re-write counter ‘n’ to zero. At step 505 , the processor 103 compares the number of the already performed re-writes n with the predetermined number of rewrites m, obtained from the table 201 . The number of re-writes m is a predefined number, which indicates how many times the data rewrite process is repeated. If it is determined that n is larger than or equal to m, then the conversion process has been completed. On the other hand, if n is smaller than m, the processor 103 performs data rewrite process at step 506 and increments the counter n by one at step 507 . Subsequently, the process proceeds back to the aforesaid step 505 , whereupon another counter check is performed.
When one of the encryption methods is used for performing the data rewrites, a different encryption key may be used for each data re-writing step 506 . If a different key is used for each data rewriting step 506 , during each subsequent rewrite, the data in the LU is first decrypted using the previous version of the key and then again re-encrypted using the new key. As it would be appreciated by those of skill in the art, upon the completion of the last re-write, only the encryption key for the final rewrite needs to be stored in the column 211 of the table 201 until the expiration date and other encryption keys used at the step 502 or the previous step(s) 506 may be discarded. However, during each encrypting or re-writing process, the old key (not required for the encryption step 502 ), the new key and the address where the rewriting process has been completed using the new key have to be stored somewhere in the persistent memory so that the encrypted data can be recovered in the case of the controller 102 failure etc. In an embodiment of the invention, the encryption keys used for one logical storage unit (LU) are different from those for other LUs.
After the data has been completely or partially encrypted, and until the data expiration date, the processor 103 may still receive the data access operation requests from the host 115 , which may involve the encrypted data. Upon the receipt of a data write request from the host, the processor 103 encrypts the received data with the encryption key stored in table 201 and writes the data so encrypted to the storage volume. Upon the receipt of the data read request, the processor, likewise, decrypts the requested data read from the storage volume using the encryption key store in table 201 and furnishes the decrypted data to the requesting host 115 . In the algorithm table 201 , the encryption key that is being currently used is stored in the column 211 . When the conversion process completes, the encryption key for the final round or re-write operations is stored in column 211 of the table 201 .
When read and write method are used as the data rewrite method 506 , the processor 103 always encrypts data in the write requests and write it on the volume when it receives write requests, and decrypt data on the volume when it receives read requests with the encryption key used at step 502 , which is stored in 211 . During the read and write process, the processor 103 does not have to decrypt/encrypt data as long as the data is no read or written by host.
FIG. 6 provides additional details on the execution of the aforesaid step 502 . Specifically, at step 601 , the processor 103 initializes variables P 0 and P 1 to have zero value, and loads the encryption method chosen at step 501 . At step 602 , the processor 103 reads the first block of data from the volume 109 , then increments variable P 0 by one. The P 0 variable identifies the storage block within the logical storage unit that is being processed.
At step 603 , the processor 103 creates a copy of the data from the target logical storage unit and encrypts it with the prescribed encryption method. In the exemplary algorithm illustrated in FIG. 6 , the encryption method is a triple DES encryption algorithm with the mode of operation CBC, applied to each 64 byte long data segment in the block.
At step 604 , the processor 103 writes the encrypted data at the same address within the logical storage unit, from which the original data was read. At step 605 , the processor 103 increments the variable P 1 by one. The variable P 1 represents the number of blocks which have been processed by the processor 103 .
At step 606 , the processor 103 discards the copy of the data which has not been encrypted. This data copy is preserved during the encryption process so that the processor 103 can allow host 115 to read the affected data while the data is being processed.
Finally, at step 607 , the processor 103 checks for an unprocessed block within the volume 109 . If such a block is found, the processor 103 reads the next block of the data and increments the counter P 0 by one at step 608 . If all the data has been processed, this process ends.
FIG. 7 illustrates the method used by the processor 103 to handle read requests while the processor performs the data encryption process described in FIG. 6 . With reference to FIG. 7 , when the processor 103 receives a read request from the host 115 , it checks whether the requested data has already been processed (encrypted). This is accomplished by comparing the address of the requested data with the value of the variable P 1 . If the address of the requested data is before the P 1 , this means the data has already been encrypted. In this case, the data is read back from the disk at step 703 . The read data is then decrypted with the appropriate encryption method and then returned to the requesting host at step 704 .
If the address of the requested data is after both the P 1 and P 0 , it indicates that the data has not yet been encrypted. In this case, the processor 103 simply reads the data from the disk and returns the data to the requesting host 115 . This is accomplished at step 706 . If the requested data is located at P 0 -th block, the corresponding plaintext data is held by the processor 103 . Therefore, the processor 103 returns the unencrypted data to the host 115 at step 707 .
FIG. 8 illustrates an exemplary embodiment of a method used by the processor 103 to handle write requests while the process described in FIG. 6 is performed. Specifically, when the processor 103 receives a write request from the host 115 , it checks whether the data is to be written before or after the P 1 address. If the data is to be written before the P 1 address, the processor 103 encrypts the data received from the host with the encryption method and writes the encrypted data tp the address specified in the write command.
On the other hand, if the data is to be written after the P 1 address and after the P 0 address, the processor 103 simply writes the data to the disk without encryption. If the data is to be written at the P 0 -th block, which is being processed in accordance with the process of FIG. 6 , the processor 103 waits until the process shown in FIG. 6 completes processing of the block (step 806 ), and then encrypts the data received from the host with the appropriate encryption method and writes the encrypted data to the disk at step 807 . As would be appreciated by those of skill in the art, the foregoing description provides just one exemplary embodiment of the algorithm for accessing the data while the data processing operation is under way.
Other suitable processes may be utilized for this purpose as well. Specifically, if the data encryption process of FIG. 6 is just before the step 603 , and if the data read from the disk at the step 602 / 608 can be replaced with the data provided by the host together with the write command, the data from the write request may be encrypted according with the process of FIG. 6 , and the steps 806 and 807 do not take place.
As it has been described in detail above, the rewrite process described with reference to the step 506 can be an encryption process, such as the process shown in FIG. 6 , or it can involve simple read and write operations. The column 208 in the table 201 of FIG. 2 lists exemplary rewrite methods. Specifically, the table 201 indicates that the “Read and Write” method is used as the data rewrite method for the storage device with LUN 0001, see column 202 .
FIG. 9 illustrates the steps of the “Read and Write” process in more detail. Initially, at step 901 , the processor 103 chooses the first block of the data volume. At step 902 , the processor 103 determines whether the chosen block is being written by host 115 . If the block is being so written, the processor 103 chooses the next block at step 908 . If it is not, the processor 103 reads the block at step 903 .
At step 904 , the processor 103 may pause for a specified time of period, such as, for example, 10 seconds or 1 minute. This pause is not a mandatory step. Depending on the characteristics of the magnetic disk, it may be appropriate to wait for some time for the purpose of more completely filling the magnetic surface of the storage media with the data. At step 905 , the processor 103 determines whether the data block has been written by host 115 since the completion of the step 903 . If so, the data is discarded at step 909 and the process proceeds to the step 908 .
If the block has not been so written, the processor 103 writes the data block back at the same address, from which the data was read at step 903 .
At step 907 , the processor 103 determines whether there is still an unprocessed block on the storage volume. If all of the data blocks have been processed, the process terminates. If unprocessed blocks are found, the process proceeds to step 908 .
As it has been described herein, a rewrite process for a data block can be skipped when other process has already rewritten the block, because the rewriting of those skipped blocks may be handled in the previous or subsequent rewriting processes sufficient number of times to conceal the trace of the plain data. However, if the rewriting processes need to be performed the exact number of times specified in the column 210 , the skip shall not happen. In such a case, the algorithms described in FIGS. 6 , 7 and 8 are used in order to accept input and output requests from the host during the rewriting process. However, in this case, the data encryption or decryption is not performed in the respective process steps such as steps 603 , 704 , 803 and 807 of the inventive process flows shown in FIGS. 6 , 7 and 8 . It is assumed that encryption and decryption according to host input and output requests are performed in parallel with this process.
Table 1001 shown in FIG. 10 is an example of scheduling table 104 which specifies when the data conversion process described by FIG. 5 should start for each LU and when the key for each LU is discarded. The processor 103 generates this information using the information contained within the tables 201 , 301 , 401 , and 1101 .
Table 1101 shown in FIG. 11 is generated by the processor 103 when the LUs are allocated. Depending on the characteristics of the data stored in each LU, the entry of the algorithm table 201 which describes the algorithms used to convert data and the expiration date/time in the column 407 in the table 401 are read by the processor 103 for each LU. In certain situations, the actual data disposal time may be later than the corresponding data expiration date. In such a case, the cell 409 of the table 401 , which specifies the time to disposal after the data expiration, has a non-zero value. The column 311 of the table 301 shown in FIG. 3 describes how long each algorithm listed in column 310 takes to process a specific data volume having the storage capacity listed in column 309 . The data in the table 301 is provided for a specific storage configuration, which is specified in columns 307 and 308 of that table. Using the aforesaid tables, information in the table 1001 is populated by the processor 103 .
The conversion start time in column 1008 of table 1001 is the time when the processor 103 must start the conversion in order to complete the conversion process just in time for the data expiration date. For example, because it takes 300 minutes for the volume LUN 0001 to be converted, the conversion start time is “3/20/2010 07:00:00”, which is 300 minutes prior to the expiration time. The encryption key disposal time in column 1009 of table 1001 is the time when the key used for converting each LU can be disposed of. This time indicates when the data is erased.
The processor 103 periodically checks the table 1001 and the clock 107 to determine if there are any processes that need to be stated. If such processes exist, the processor 103 starts the conversion process illustrated in FIG. 5 , or disposes of the key for the corresponding LU.
3. Exemplary Applications of the Inventive Technique
A. Use Case 1
After the conversion process has been completed, and after the expiration date of the volume data, the processor 103 may discard the encryption key stored in the column 211 of table 201 . As would be appreciated by those of skill in the art, the loss of the key has the same effect as a secure erasure of the stored data. Table 401 contains the information indicating when the key is scheduled to be discarded for each logical storage unit.
B. Use Case 2.
Using the information in the tables of 201 , 301 and 1101 , it is possible to calculate how long it takes to perform the data conversion process described in FIG. 5 . Specifically, the information in the aforesaid tables shown that 100 minutes, 420 minutes, 2120 minutes and 840 minutes are required to complete the conversion process for the storage volumes with LUN values of 0001, 0002, 0003 and 0004, respectively.
Numeral 1201 in FIG. 12 designates a time chart indicating when the inventive conversion processes for each LU must start executing, so that each process completes on the respective data expiration time as specified in the table 401 of FIG. 4 . For example, if the processor 103 starts the conversion process 300 minutes prior to the expiration time of the data on LUN 0001, the conversion process completes just in time, see the element 1202 of the aforesaid figure.
However, because the execution of each conversion process may impose a heavy workload upon the available storage system resources, it is preferable to schedule the conversion processes in such a way as to avoid an impact of one such process on other processes within the storage system or on other conversion processes.
Specifically, element 1206 of FIG. 12 designates an exemplary conversion process execution schedule, which seeks to minimize the impact of multiple data conversion processes on one another. For example, the conversion process 1207 , corresponding to the data stored in the volume with LUN 0001, starts 420 minutes earlier than process 1202 , with the processor 103 scheduled to process only one volume at a time until 3/20/2010 12:00.
Also, the conversion process 1209 for the storage device with LUN 0003 starts just after the process for LUN 0002 ends and the conversion process 1210 for the LUN 0004 starts just after the process 1209 for LUN 0003 ends. In the shown example, the process 1210 for LUN 0004 still continues for a certain period of time after the expiration time reaches. However, the processor 103 is scheduled to process only one volume at a time, which may be more preferable for some applications, than completing the process always before the expiration date/time.
The described schedule may be changed when new LU is added to the storage system. When the schedule is changed, the schedule table 401 is updated by the processor 103 .
FIG. 13 is a block diagram that illustrates an embodiment of a computer/server system 1300 upon which an embodiment of the inventive methodology may be implemented. The system 1300 includes a computer/server platform 1301 , peripheral devices 1302 and network resources 1303 .
The computer platform 1301 may include a data bus 1304 or other communication mechanism for communicating information across and among various parts of the computer platform 1301 , and a processor 1305 coupled with bus 1301 for processing information and performing other computational and control tasks. Computer platform 1301 also includes a volatile storage 1306 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 1304 for storing various information as well as instructions to be executed by processor 1305 . The volatile storage 1306 also may be used for storing temporary variables or other intermediate information during execution of instructions by processor 1305 . Computer platform 1301 may further include a read only memory (ROM or EPROM) 1307 or other static storage device coupled to bus 1304 for storing static information and instructions for processor 1305 , such as basic input-output system (BIOS), as well as various system configuration parameters. A persistent storage device 1308 , such as a magnetic disk, optical disk, or solid-state flash memory device is provided and coupled to bus 1301 for storing information and instructions.
Computer platform 1301 may be coupled via bus 1304 to a display 1309 , such as a cathode ray tube (CRT), plasma display, or a liquid crystal display (LCD), for displaying information to a system administrator or user of the computer platform 1301 . An input device 1310 , including alphanumeric and other keys, is coupled to bus 1301 for communicating information and command selections to processor 1305 . Another type of user input device is cursor control device 1311 , such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor 1304 and for controlling cursor movement on display 1309 . This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.
An external storage device 1312 may be connected to the computer platform 1301 via bus 1304 to provide an extra or removable storage capacity for the computer platform 1301 . In an embodiment of the computer system 1300 , the external removable storage device 1312 may be used to facilitate exchange of data with other computer systems.
The invention is related to the use of computer system 1300 for implementing the techniques described herein. In an embodiment, the inventive system may reside on a machine such as computer platform 1301 . According to one embodiment of the invention, the techniques described herein are performed by computer system 1300 in response to processor 1305 executing one or more sequences of one or more instructions contained in the volatile memory 1306 . Such instructions may be read into volatile memory 1306 from another computer-readable medium, such as persistent storage device 1308 . Execution of the sequences of instructions contained in the volatile memory 1306 causes processor 1305 to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.
The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor 1305 for execution. The computer-readable medium is just one example of a machine-readable medium, which may carry instructions for implementing any of the methods and/or techniques described herein. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device 1308 . Volatile media includes dynamic memory, such as volatile storage 1306 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise data bus 1304 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, punchcards, papertape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EPROM, a flash drive, a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to processor 1305 for execution. For example, the instructions may initially be carried on a magnetic disk from a remote computer. Alternatively, a remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer system 1300 can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on the data bus 1304 . The bus 1304 carries the data to the volatile storage 1306 , from which processor 1305 retrieves and executes the instructions. The instructions received by the volatile memory 1306 may optionally be stored on persistent storage device 1308 either before or after execution by processor 1305 . The instructions may also be downloaded into the computer platform 1301 via Internet using a variety of network data communication protocols well known in the art.
The computer platform 1301 also includes a communication interface, such as network interface card 1313 coupled to the data bus 1304 . Communication interface 1313 provides a two-way data communication coupling to a network link 1314 that is connected to a local network 1315 . For example, communication interface 1313 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 1313 may be a local area network interface card (LAN NIC) to provide a data communication connection to a compatible LAN. Wireless links, such as well-known 802.11a, 802.11b, 802.11g and Bluetooth may also used for network implementation. In any such implementation, communication interface 1313 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
Network link 1313 typically provides data communication through one or more networks to other network resources. For example, network link 1314 may provide a connection through local network 1315 to a host computer 1316 , or a network storage/server 1317 . Additionally or alternatively, the network link 1313 may connect through gateway/firewall 1317 to the wide-area or global network 1318 , such as an Internet. Thus, the computer platform 1301 can access network resources located anywhere on the Internet 1318 , such as a remote network storage/server 1319 . On the other hand, the computer platform 1301 may also be accessed by clients located anywhere on the local area network 1315 and/or the Internet 1318 . The network clients 1320 and 1321 may themselves be implemented based on the computer platform similar to the platform 1301 .
Local network 1315 and the Internet 1318 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 1314 and through communication interface 1313 , which carry the digital data to and from computer platform 1301 , are exemplary forms of carrier waves transporting the information.
Computer platform 1301 can send messages and receive data, including program code, through the variety of network(s) including Internet 1318 and LAN 1315 , network link 1314 and communication interface 1313 . In the Internet example, when the system 1301 acts as a network server, it might transmit a requested code or data for an application program running on client(s) 1320 and/or 1321 through Internet 1318 , gateway/firewall 1317 , local area network 1315 and communication interface 1313 . Similarly, it may receive code from other network resources.
The received code may be executed by processor 1305 as it is received, and/or stored in persistent or volatile storage devices 1308 and 1306 , respectively, or other non-volatile storage for later execution. In this manner, computer system 1301 may obtain application code in the form of a carrier wave.
Finally, it should be understood that processes and techniques described herein are not inherently related to any particular apparatus and may be implemented by any suitable combination of components. Further, various types of general purpose devices may be used in accordance with the teachings described herein. It may also prove advantageous to construct specialized apparatus to perform the method steps described herein. The present invention has been described in relation to particular examples, which are intended in all respects to be illustrative rather than restrictive. Those skilled in the art will appreciate that many different combinations of hardware, software, and firmware will be suitable for practicing the present invention. For example, the described software may be implemented in a wide variety of programming or scripting languages, such as Assembler, C/C++, perl, shell, PHP, Java, etc.
Moreover, other implementations of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Various aspects and/or components of the described embodiments may be used singly or in any combination in the computerized storage system with data replication functionality. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | When data is stored for a certain retention period, well prior to the expiration date, the storage controller starts encryption of data on a certain volume while ensuring data access from hosts, and repeats read and write of the data predefined number of times while also ensuring data access from hosts. When the expiration date is reached and if the encryption completes, the storage controller dispose of the encryption keys. Using this technique, one can reuse the volume for other purposes as soon as the expiration is reached. Because one can start this process even much earlier than the expiration date, one can balance the workload of the controller by scheduling the process in order to avoid the peak of the workload for the data disposal process. Also, it is possible to minimize the period to manage encryption keys which makes key management easier. | 6 |
The present invention is relative to a watch case including a caseband-bezel provided with a hollow having a substantially arched profile opening out towards the interior of the case, a crystal and a back cover for retaining a movement surmounted by a dial and a casing ring arranged between the movement and the caseband.
BACKGROUND OF THE INVENTION
Watch cases are known formed preferably of precious metal (gold or platinum) the caseband of which is hollowed out on the interior in order to achieve a substantial economy of precious material and thus to allow a lower selling price than could be permitted if such caseband were solid.
Patent document CH-A-664 251 describes a watch case of gold in which the movement is fixed to the caseband-bezel which is hollowed out on the interior. Such fastening is obtained through a fitting piece which is centered by the interior. To this end an axial projection from the fitting piece is loosely fitted around a corresponding projection which is fixed to the case and which is constituted by a portion of a flange another part of which is squeezed between an internal lip of the caseband bezel and the crystal. The axial securing of the fitting piece is assured by a latching bolt which bears against the shoulder of the caseband and maintains the fitting piece supported under the lip.
Patent document EO-A-0 379 974 (=U.S. Pat. No. 4,970,708) also describes a watch case including a hollowed-out caseband in vault form. Such caseband includes first and second cylindrical support surfaces cooperating respectively with a crystal and a back cover. Three studs fixed to the caseband are arranged within the space defined by the vault-formed hollow. Each of the studs bears a projection extending towards the movement and borne by the case, said projection bearing an upper snap on which rests a flange against which the crystal is supported, and a lower snap on which rests a casing ring against which the back cover bears.
The hollowed-out casebands described in the documents cited hereinabove are fragile in the sense that they are sensitive to lateral shocks applied to the watch, the extreme thinness of the wall of the caseband explaining why this latter may be dented by the slightest blow thereagainst.
Resistance to shock has been improved by arranging ribs within the caseband as within the interior of the back cover as such is seen in patent document EP-A-O 378 125 (=U.S. Pat. No. 4,995,023). If improvements have been brought about in respect of the deforming of the caseband due to traction by the bracelet, such improvements are however minimum as to shock resistance, such caseband being easily dented because of its very small thickness (on the order of 0.15 mm).
It is noted in other respects that cases obtained according to the patents cited hereinabove give such an impression of lightness that one can be placed in doubt as to whether they are formed of gold. As it is not authorized to add weight which would be present only with the sole purpose of inducing belief in the presence of solid gold with neither function nor real utility for the constitution or the operation of the watch, the present invention imagines filling almost entirely the hollow of the caseband made of gold by a circle, preferably made of brass, such circle fulfilling two functions: that of a casing ring support for the movement and coupling of this latter with the caseband and that of reinforcement of the caseband for rendering it resistant to shocks, since behind the caseband made of thin gold is found said ring which renders the caseband subject to denting only with difficulty. It will be understood that additionally such ring makes the watch heavier.
SUMMARY OF THE INVENTION
With this purpose the present invention is characterized in that the casing ring is made up from a plurality of segments juxtaposed and partially engaged within the caseband hollow in order to overlay at least 85% of its periphery, the outer contour of said segments being formed so as to be in close contact with said substantially arched profile, means being applied so as to maintain said segments in place within said hollow.
The invention is now to be explained by means of the examples illustrated by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the caseband according to a first embodiment of the invention in which caseband is found housed four segments making up a casing ring retained by an elastic ring;
FIG. 2 is a cross-section along line II--II of FIG. 1;
FIG. 3 is a cross-section of FIG. 1 at the place where is found one of the fastening clamps of the movement onto the casing ring;
FIG. 4 is a cross-section along line IV--IV of FIG 1;
FIG. 5 shows how the segments making up the casing ring are assembled in the caseband-bezel;
FIG. 6 is a plan view of the caseband according to a second embodiment of the invention, in which caseband four segments are housed making up a casing ring, retained following one another by elastic jumper links;
FIG. 7 is a cross-section along line VII--VII of FIG. 6;
FIG. 8 is a plan view of the caseband according to a third embodiment of the invention, in which caseband are housed four segments making up a casing ring retained by two clamps bearing on either side on a reinforcement of the tube traversing the caseband;
FIG. 9 is a cross-section along line IX--IX of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is readily seen on FIGS. 2 to 4, the watch case includes a caseband-bezel 11 provided with a hollow 26 having a substantially arched profile 8 in the form of a vault opening out towards the interior of the case. The case is completed by a crystal 16 and a back cover 12 in order to contain a movement 13 surmounted by a dial 14. A casing ring 10 is arranged between movement 13 and the caseband 11. Hands 15 are located between the dial 14 and crystal 16, this spacing being well defined by a flange 18. Sealing of crystal 16 relative to the caseband 11 is assured by a cylindrical packing 17 which bears on a fall 25 formed in the top part of the bezel forming an integral portion of the caseband 11. The back cover 12 is snap-fastened onto caseband 11, its sealing being assured by a packing 19. It will be noted that such back cover could also be made integrally with the caseband, thus to form a monoshell case. Movement 13 is introduced from above into the caseband and bead 30 with which it is provided comes to bear on shoulder 7 of the casing ring 10. Movement 13 is fixed to the ring 10 by means of securing clamps, a single one 22 of which is visible on FIG. 3. As is seen on FIG. 2, a tube 20 traverses caseband 11 in which tube is placed the time setting stem of the movement (not shown). Since the wall of the caseband is very thin (on the order of 0.2 mm), there has been provided at the place of passage of such tube, a stiffener 21 for the caseband materialized by additional material added on or formed integrally with said caseband. Such stiffener 21 is also visible in the plan views of FIGS. 1, 6 and 8.
The hollowed-out caseband 11 may be formed by turning by means of form milling cutters or by stamping and folding back by means of a rotary press, according to the method described in the patent document EO-A-0 378 125 cited hereinabove, such method being chosen above all for the very large production runs and which, in addition, permits forming of lugs 23. In one case as in the other, it is sought to obtain a very thin wall as a measure of economy of precious material. However, as has been mentioned hereinabove, a caseband this thin withstands very badly shocks which are applied thereto during normal wear and is rapidly dented. Likewise the weight of the watch will cause doubts to arise that its case is made of precious metal since its caseband is hollowed out with the evident purpose of selling the product less dearly.
Solutions are brought for these problems by the essential characteristic of the present invention which consists in using a casing ring which fills up almost entirely the hollow of the caseband by closely fitting its interior profile. The casing ring formed of brass, for example, brings a solution to the weight problem, the problem of shock resistance being resolved by an intimate contact of the casing ring with the caseband in the periphery of this latter. To arrive at this purpose, the casing ring is composed of a plurality of segments, here four segments 1, 2, 3 and 4 as is seen on FIGS. 1, 6 and 8. Such segments are juxtaposed, partially engaged in the hollow 26 of the caseband and cover over at least 85% of its periphery. As is seen particularly well on FIGS. 3, 4, 7 and 9, the outer contour 9 of each segment is formed to be in close contact with the substantially arched profile 8 exhibited by the interior of caseband 11. In order to maintain such segments in place within the hollow, even prior to setting in the movement, recourse may be had to different means according to the chosen embodiment. Three different systems will be explained further on, all of which use a groove 6 having a substantially rectangular profile formed in each segment.
FIG. 5 indicates how the segments are assembled in the caseband. One begins by the introduction of the first segment I in hollow 26 by bringing its end 31 to bear against the stiffener 21 of tube 20. The assembly of segments 2 and 3 is continued in the same manner. The last segment 4 is finally introduced into the caseband according to the direction of arrow A. The segments thus juxtaposed are then slid in a manner such that the empty portions situated to the right and to the left of tube 20 are of almost equal length. The number of segments to be provided will depend from several factors, in particular from the filling factor of the hollow and of the depth of the hollow. In the example shown on the drawing, the depth of the hollow 26 is such that four segments are necessary if one wishes to fill up at least 85% of the internal periphery of such hollow. Once the geometric equilibrium has been attained relative to the tube, the segments will be secured in order to maintain them in place, which facilitates subsequent assembly of the movement.
FIG. 1 shows a first embodiment of the invention, in which the means of maintaining segments 1, 2, 3 and 4 in place consists of an elastic ring 5 which is arranged in groove 6 formed in each segment. In order to facilitate the grasping or the lifting up of the ring, there have been provided two holes 24 which permit seizing it with a special tweezer. It is to be noted that ring 5 is seen in cross-section in FIGS. 2, 3 and 4.
FIGS. 6 and 7 show a second embodiment of the invention in which the means for maintaining segments 1, 2, 3 and 4 in place consist of an elastic jumper link 27. The top 32 of link 27 is arranged in grooves 6 already described, while the legs 33 are introduced into slots 34 formed towards the ends of the segments. FIG. 6 shows that three links 27 permit the coupling and holding in place of the four segments 1, 2, 3 and 4. There may be observed on FIG. 7 the bottom of slot 34.
FIGS. 8 and 9 show finally a third embodiment of the invention in which the means for maintaining segments 1, 2, 3 and 4 in place consist of two clamps 28, each bearing on the stiffener 21 of tube 20 as mentioned hereinabove. FIG. 8 shows that each of the clamps 28 is screwed into groove 6 in respect of segments 1 and 4 by means of screws 29.
All the examples cited hereinabove take account of a case made of two parts, namely the caseband bezel and back cover. It has been suggested that such case could be formed in a single piece. In order to be complete, one may add that such case could be formed of three pieces, the caseband being separated from the bezel and with a separate back cover. It will be understood that the special characteristics of the present invention can be applied as well to one or another of such embodiments. | A watch case is made of gold with a caseband-bezel (11) hollowed-out in order to diminish the weight of gold as much as possible. To avoid dents in the caseband-bezel the hollow (26) is filled with metal, for example brass, which also serves as a casing ring (10) to secure the movement (13) to the case. The installation of such casing ring in the caseband hollow is possible only if the ring is made in at least four segments (1, 2, 3, 4 ) which are placed side-by-side and which are held in place by means guided in a groove (6) formed in the ring. | 6 |
BACKGROUND OF THE INVENTION
The present invention is directed to printing sleeves for offset or flexographic printing, and more particularly to printing sleeves having a sound dampening feature that attenuates noise during mounting and dismounting of the sleeve from a support cylinder.
An offset printing unit has a plurality of rotatable cylinders, including at least one plate cylinder and at least one corresponding blanket cylinder. The plate cylinder carries a printing plate having a surface on which an inked image is defined. The blanket cylinder carries a printing blanket. The plate on the plate cylinder transfers the inked image to the blanket on the blanket cylinder at a nip between the plate cylinder and the blanket cylinder when the cylinders rotate. The blanket on the blanket cylinder subsequently transfers the inked image to the material being printed, such as a web of paper.
Printing blankets have conventionally been formed as flat sheets which are then mounted on a blanket cylinder by wrapping the sheet around the blanket cylinder. More recently, printing blankets in the form of hollow tubular sleeves have become more prevalent. Such sleeves are mounted on a blanket cylinder by sliding the sleeve telescopically over the blanket cylinder. The sleeve and the blanket cylinder are designed so that the sleeve is receivable over the blanket cylinder with an interference fit.
The blanket cylinder is equipped with air flow passages and openings to direct a pressurized flow of air over the blanket cylinder. When the sleeve is located over the air flow openings in the blanket cylinder, the pressurized flow of air expands the sleeve diametrically. The expanded sleeve can be moved axially onto, or off of, the blanket cylinder when in its expanded condition. When the pressure is relieved, the sleeve contracts diametrically against the blanket cylinder and thus establishes an interference fit with the blanket cylinder. Flexographic printing sleeves have also been developed and are mounted onto and dismounted from support cylinders in much the same manner as offset sleeves.
One problem with such sleeves is that the compressed air that is used in mounting and dismounting the sleeves from the cylinders can create a whistle or other loud noise during the procedure. The sleeve ends may also vibrate causing additional noise to emanate during mounting and dismounting. In some instances, press operators may need to don ear protection gear to avoid injury. One solution to the problem has been proposed by Vrotacoe et al, U.S. Pat. No. 5,215,013. Vrotacoe et al describe a blanket sleeve having a damping ring made of a resinous material that is adhered to the interior wall of the sleeve near and end thereof. The ring is designed to reduce vibrations caused by the flow of pressurized air and attenuate noise associated with mounting and dismounting of the sleeves.
Another solution has been proposed by Boucher et al, U.S. Pat. No. 6,347,586 B1. Boucher et al adhere a sound dampening material on the outer surface of the blanket cylinder such that the material engages the interior wall of the printing sleeve during mounting and dismounting thereof. The preferred material for use is a non-woven, fibrous material such as the “hook” portion of a VELCRO® closure.
However, the proposed solutions have not been entirely successful in solving the problem. Accordingly, there remains a need in the art for a printing sleeve having a sound dampening feature that attenuates noise during mounting and dismounting of the sleeve from a support cylinder.
SUMMARY OF THE INVENTION
The present invention meets the need in the art by providing an easy to manufacture and install sound dampening pad for a printing blanket sleeve that effectively attenuates noise emanating from the sleeve during air pressurized mounting and dismounting thereof.
In accordance with one aspect of the present invention, a printing blanket sleeve for mounting onto an underlying cylinder using a pressurized flow of air through at least one flow opening in said cylinder is provided. The sleeve comprises a cylindrical base having first and second ends and at least one additional layer on the base having a printing surface. As is typical in this art, the blanket sleeve may include additional reinforcing, stabilizing, and/or compressible layers. The sleeve base has an inside diameter that is less than the diameter of the underlying cylinder but which is expandable under the influence of pressurized air such that the inside diameter of the sleeve base temporarily has a diameter that is greater than the diameter of the underlying cylinder.
The printing blanket sleeve includes a sound dampening pad mounted on at least one of the ends of the printing blanket sleeve for attenuating noise associated with the mounting and dismounting of the printing blanket sleeve. The sound dampening pad comprises a flexible material extending around substantially the inner circumference of the sleeve base and over an end of the printing blanket sleeve.
In a preferred form, the sound dampening pad has a generally J-shaped configuration, in which the inner radius of the “J” is in contact with the inner circumference of the sleeve base and an outer surface of an end of the sleeve. Generally, the shorter leg of the “J” has a thickness that is less than the overall thickness of the printing blanket. Also, the longer leg of the “J” is not so long as will interfere with the end of the blanket cylinder onto which the blanket sleeve is mounted. A suitable thickness for the legs of the sound dampening pad is from about 0.03 to about 0.05 inches (0.76 to about 1.27 mm), and most preferably about 0.042 inches (1.07 mm).
The sound dampening pad may be comprised of natural or synthetic rubber or a thermoplastic polymer having the requisite flexibility for installation of the pad. In a preferred form, the sound dampening pad includes an adhesive on an inner surface thereof to secure the pad to the printing blanket sleeve. In one embodiment, the adhesive is a pressure sensitive adhesive in the form of a double-sided adhesive tape.
In accordance with another aspect of the invention, a sound dampening pad is provided and comprises a flexible polymeric material having a generally J-shaped configuration and inner and outer surfaces. At least a portion of the inner surface of the J-shape includes a pressure sensitive adhesive thereon. Preferably, the sound dampening pad comprises natural or synthetic rubber or a thermoplastic polymer having the requisite flexibility for mounting it in the sleeve.
In a preferred form, the pressure sensitive adhesive comprises a double-sided adhesive tape in which the exposed surface of the double-sided adhesive tape includes a release liner thereon. In another embodiment, the double-sided adhesive tape includes a foam core.
In accordance with another embodiment of the invention, a method for mounting a sound dampening pad to a printing blanket sleeve is provided. The method comprises providing a sound dampening pad comprising a flexible polymeric material having a generally J-shaped configuration and inner and outer surfaces with at least a portion of the inner surface of the J-shape including a pressure sensitive adhesive thereon, adhering the inner surface of the sound dampening pad to the inner surface of the printing blanket sleeve such that the sound dampening pad extends substantially about the inner circumference of the sleeve and over the end of the sleeve.
In a preferred form, the sound dampening pad is in the form of a length of material and the pad is cut to have a length of substantially the inner diameter of the sleeve prior to installation. Preferably, the inner radius of the J-shaped configuration is placed in contact with the inner circumference of the base and an outer surface of an end of the sleeve and secured thereto. The sound dampening pad provides the additional advantages of aiding in the installation of the blanket sleeve. The edges of the pad overlap the sharp edge of the base of the sleeve and provide protection to an operator's hands as the sleeve is pushed onto and pulled off of the cylinder.
Accordingly, it is a feature of the present invention to provide an easy to manufacture and install sound dampening pad for a printing blanket sleeve that effectively attenuates noise emanating from the sleeve during air pressurized mounting and dismounting thereof. Other features and advantages of the invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like elements are indicated with like reference numerals, and in which:
FIG. 1 is a front elevational view of an embodiment of the sound dampening pad of the present invention;
FIG. 2 is a side view of the sound dampening pad of FIG. 1;
FIG. 3 is a perspective view of a printing blanket sleeve that is adapted to be mounted onto an underlying blanket cylinder, the printing sleeve includes a sound dampening pad on one end thereof;
FIG. 4 is a enlarged sectional view showing a printing blanket sleeve mounted onto a blanket cylinder, and
FIG. 5 is a sectional view showing an end of a printing blanket sleeve with a sound dampening pad installed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the sound dampening pad is shown in FIGS. 1 and 2. The pad 10 comprises an elongated strip of a flexible polymeric material such as natural or synthetic rubber or a thermoplastic polymer. Pad 10 has a “J-shaped” configuration as best seen in FIG. 2 having inner 12 and outer 14 surfaces. It will be apparent that pad 10 may have other cross-sectional shapes including a U-shape. Pad 10 may be formed by any suitable method such as casting, molding, or extrusion. Pad 10 may be supplied in an indeterminate length and cut to size as needed. In this way, the pad can be installed on sleeves having varying diameters.
An adhesive 16 is positioned on inner surface 12 of the pad. In a preferred form, adhesive 16 comprises a double-sided adhesive tape. The tape may include a foam core with pressure sensitive adhesive coated onto both surfaces thereof. The adhesive tape may include a release liner on the exposed surface of the tape that protects the adhesive until the pad is installed. A suitable adhesive tape is a 20 mil thick (0.5 mm), ⅜ inch wide (9.5 mm) transfer tape available from 3M.
As shown in FIGS. 3 and 4, sound dampening pad 10 is adapted to be installed onto at least one of the ends of printing blanket sleeve 20 . As is conventional in the art, sleeve 20 is designed to provide an interference fit with cylinder 22 . Because the outer surface 24 has a diameter that is slightly greater than the inside diameter of sleeve 20 , sleeve 20 must expand as it is moved in the directions of the arrows in FIG. 3 against a chamfered edge surface 26 .
As the inner surface of sleeve 20 is moved over air flow orifices 28 on the end of cylinder 22 , air pressure is supplied from a source 30 through line 32 and into inlet 34 . Internally-located air flow lines (not shown) connect with the orifices 28 as is conventional in this art. The air pressure causes sleeve 20 to expand as it is mounted axially onto cylinder 22 . Once sleeve 20 has been completely mounted, the flow of air is stopped, and sleeve 20 contracts against outer surface 24 to provide a snug interference fit. Pad 10 serves to protect an operator's hands during mounting and dismounting of the blanket sleeve by covering the sharp edges of the sleeve base. This permits the operator to push against the end of the sleeve during installation because the pad provides a soft, flexible surface against which to push or pull the sleeve.
Sleeve 20 can be subsequently removed, such as for replacement or repair, by reversing the process. That is, pressurized air is supplied again to air flow orifices 28 causing the inner diameter of sleeve 20 to expand sufficiently so that is can be slid off of cylinder 22 and dismounted. The base layer of sleeve 20 is selected such that it will provide the requisite expansion under appropriate air pressure (typically about 80-120 psi).
The construction of sleeve 20 is unimportant to the invention. However, for sake of completeness, FIG. 4 illustrates, in an enlarged sectional view, typical layers that may be found on typical printing sleeves in this art. For example, sleeve 20 as shown includes a base 40 , a compressible layer 42 overlying base 40 , a reinforcing layer of a woven fabric 44 , and a print surface layer 46 . Typically, base 40 can comprise a thin layer of nickel. Alternatively, base 40 may comprise a polymer resin reinforced with glass, metal, or aramid fibers.
Compressible layer 42 is typically formed of an elastomer and includes voids 48 so that the sleeve is volume compressible during printing. The voids may be formed by any of a number of processes known in the art including the introduction of hollow microspheres into the elastomer during manufacture of the blanket sleeve. Print surface layer 46 is typically formed of a rubber such as nitrile rubber and is designed to accept an inked image from a print cylinder (not shown).
As shown in FIG. 4, air under pressure is forced through orifices 28 on outer surface 24 of cylinder 22 to cause radial expansion of sleeve 20 . Once the sleeve is mounted and the air flow terminated, sleeve 20 provides a snug interference fit on cylinder 22 .
As sleeve 20 is expanded during mounting and dismounting operations, the pressurized flow of air between outer surface 24 of cylinder 22 and the inner surface of sleeve 20 causes the sleeve to vibrate. These vibrations in turn create noise. Sound dampening pad 10 is provided to attenuate the noise by damping the vibrations that arise when the sleeve is being mounted or dismounted.
As best shown in FIG. 5, pad 10 is mounted onto an end of sleeve 20 such that the longer leg of the J-shaped configuration is applied to the inner surface 21 using adhesive 16 to secure the pad to the sleeve. The shorter leg of the J-shaped configuration extends over the end edge of sleeve base 40 and around to the outer surface thereof. As shown, the shorter leg on the “J” preferably has a total thickness less than the overall thickness of the blanket sleeve.
As also shown in FIG. 5, the longer leg of the “J” that is designed to fit around the inner circumference of the sleeve, preferably has a length such that it will not interfere with the end of cylinder 22 . Typically, the pad has a thickness of from between about 0.030 to about 0.050 inches (0.76 to about 1.27 mm), and most preferably about 0.042 inches (1.07 mm). Pad 10 is designed such that when installed it extends substantially completely around the inner circumference of base 40 .
Sound dampening pad 10 thus substantially reduces the vibrations and accompanying noise associated with the mounting and dismounting of blanket sleeve 20 . Because the pad produces a snuff fit on both surfaces and the end edge of sleeve base 40 , vibrations, and the sound resulting therefrom, are substantially reduced.
The invention having been described with respect to preferred embodiments, it will be apparent that the invention is not limited to just those embodiments shown but may be varied or modified and still be within the scope of the invention. | An easy to manufacture and install sound dampening pad for a printing blanket sleeve is provided. The pad effectively attenuates noise emanating from the sleeve during air pressurized mounting and dismounting of the blanket sleeve to an underlying cylinder. The sound dampening pad is fabricated from a flexible polymeric material and has a generally J-shaped configuration with inner and outer surfaces. At least a portion of the inner surface of the J-shape includes a pressure sensitive adhesive thereon to secure the pad to the inner surface of the sleeve. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus and method. More specifically, the present invention relates to an image forming apparatus and method in which a controller controls a charger such that a current supplied from the charger to a battery changes based on a detected current supplied to the image forming apparatus.
2. Description of the Related Art
A background image forming apparatus such as a copier, a facsimile, or a printer fixes a toner image onto a record medium with heat to make a copied or a recorded medium. The toner image is fixed via a fixing device onto the record medium, because the toner image melts, softens and permeates into the record medium. The record medium is also conveyed while being nipped in the fixing device.
Japanese Published Unexamined Patent Application No. 2002-184554 shows an image forming apparatus including a heater and a battery. In this application, the temperature of the heater can be rapidly increased because the battery supplies power to the heater.
Further, Japanese Published Unexamined Patent Application No. Hei 10-282821 shows an image forming apparatus including a heater, a main power source and a battery. In this application, the battery is charged by the main power source during a standby time, and the battery discharges energy to the heater during a ramp-up period.
Turning now to FIG. 3 , which illustrates a portion of a background image forming apparatus. As shown, the portion 20 of the image forming apparatus includes a controller 3 with a driver (not shown), a fixing device 4 , a heating switch 7 , a charger 8 , a switching member 9 , a battery 10 , a voltage detector 11 for detecting a voltage of the battery 10 , and a power source 21 . The power source 21 is supplied with power from an external power source 2 and supplies power for driving, e.g. 24V, and for controlling (e.g. 5V) to the controller 3 . The fixing device 4 includes a fixing member and a member opposite to the fixing member (not shown), a temperature sensor 22 for detecting a temperature of the fixing member, a first heater 5 and a second heater 6 both configured to heat the fixing member. The fixing member and the member opposite to the fixing member form a nip in which a record medium is passed between. Further, the switching member 9 includes a charging switch for connecting or disconnecting the charger 8 to the battery 10 and a discharging switch for connecting or disconnecting the battery 10 to the second heater 6 .
According to the structure described above, the charger 8 charges the battery 10 via the outside power source 2 when the switching member 9 connects the charger 8 to the battery 10 . In addition, the battery 10 supplies power to the second heater 6 when the switching member 9 connects the battery 10 to the second heater 6 , and meanwhile the outside power source 2 supplies power to the first heater 5 independently of the battery 10 . Further, the controller 3 is supplied with power from the power source 21 , and receives a temperature detecting signal A from the temperature sensor 22 and a voltage detecting signal B from the voltage detector 11 . Based on the signal A and B, the controller 3 outputs a control signal C to switch on-off the heating switch 7 and a control signal D to switch the switching member 9 .
Thus, the first heater 5 and the second heater 6 heat the fixing member, and thereby a toner image is heated by the fixing member and fixed onto the record medium while passing through the nip.
Next, FIG. 4A illustrates a timing diagram showing power supplied from the outside power source 2 to the background image forming apparatus without the second heater 6 as a comparative example, and FIG. 4B is a timing diagram showing power supplied from the outside power source 2 to the background image forming apparatus with the second heater 6 .
In the background image forming apparatus in FIGS. 3 and 4B , the controller 3 controls the switching member 9 such that the battery 10 connects to the heater 6 during a ramp-up period. Thereby, it is possible to rapidly raise the temperature of the fixing member and thus shorten the ramp-up period. Meanwhile, the controller 3 controls the switching member 9 such that the charger 8 is connected to the battery 10 during a standby time. Therefore, the battery 10 is charged until a necessary voltage is achieved to supply power to the heater 6 at the next ramp-up period.
However, the present inventor determined that the background image forming apparatus does not efficiently charge the battery 10 as described below. In more detail, FIG. 5 is a table showing the relation between a copying speed and a standard of energy consuming rate for a copier using an A3 size record medium. The table is based on a target standard in 2006 in the Japanese Rationalization in Energy Use Law. The following expression is a calculated result of the energy consuming rate in FIG. 4A when the copying speed is more than 40 and not more than 50. The electric energy is 800 W*3 min during a ramp-up period, 1100 W*2 min during copying, 180 W*15 min during a standby time, and 80 W*40 min during a low-power mode. That is, (800*3)+(1000*2)+(180*15)+(80*40)/60=171.6<176 Wh/h so the target standard is satisfied.
Further, the following expression is a calculated result of the energy consuming rate in FIG. 4B , when the charging energy is 150 W*15 min during copying, the ramp-up period is 1 min, and thereby the low-power mode is 42 min in addition to the above condition. That is, (800*1)+(1000*2)+(330*15)+(80*40)/60=185.2>176 Wh/h and the target standard is not satisfied.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to solve the above-noted and other problems.
To achieve these and other objects, the present invention provides a novel image forming apparatus including a heater configured to heat and fix a toner image formed on a recording medium, a detector configured to detect a current supplied from an outside power source to the image forming apparatus, and a battery configured to supply power to said heater. Also included is a charger configured to charge the battery with the power supplied from the outside power source, and a controller configured to control the charger such that a current supplied from the charger to the battery changes based on the current detected by the detector.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present 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 is a block diagram of a portion an image forming apparatus according to a first embodiment of the present invention;
FIGS. 2A-2C are timing diagrams showing the timings for the power supplied from an outside power source to the image forming apparatus, the timings for charging and discharging a battery, and the timings for charging or discharging the power in the first embodiment, respectively;
FIG. 3 is a block diagram of a portion of a background image forming apparatus;
FIG. 4A is a timing diagram showing timings for power supplied from an outside power source to the background image forming apparatus without a second heater as a comparative example;
FIG. 4B is a timing diagram showing timings for power supplied from the outside power source to the background image forming apparatus with a second heater such as shown in FIG. 3 ; and
FIG. 5 is a table showing the relation between a copying speed and a standard of energy consuming rate for a copier using an A3 size record medium.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the description will be made of embodiments of the present invention with reference to the drawings, wherein like reference numerals designate identical or corresponding parts through the several views.
Turning first to FIG. 1 , which is a block diagram of a portion 1 of an image forming apparatus according to a first embodiment of the present invention. As shown, the portion 1 of the image forming apparatus includes a detector 12 , and a calculating circuit 13 in addition to the image forming apparatus 20 shown in FIG. 3 . The detector 12 detects a value of a current and voltage supplied from the outside power source 2 to the portion 1 of the image forming apparatus. Further, the calculating circuit 13 calculates a power based on the current and the voltage values detected by the detector 12 , and then outputs a signal E indicative of the calculated power to the controller 3 . The calculating circuit 13 is shown as being separate from the controller 3 , but may also be included in the controller 3 .
Next, FIGS. 2A-2C illustrate timing diagrams showing timings for the power supplied from the outside power source 2 to the portion of the image forming apparatus 1 , the timings for charging and discharging the battery, and the timings for charging or discharging the power in the first embodiment. With reference to FIGS. 1 and 2A , during a ramp-up period, the controller 3 controls the switching member 9 such that the battery 10 connects to the second heater 6 . During an image forming period, the power and the current supplied from the outside power source 2 to the image forming apparatus 1 changes according to how much power is supplied to each component in the image forming apparatus 1 such as an image scanning unit, an image forming unit, etc. Then, the controller 3 controls the switching member 9 such that the charger 8 is connected to the battery 10 based on the current detected by the detector 12 . The controller 3 also controls the charger 8 such that the current supplied from the charger 8 to the battery 10 changes based on the current detected by the detector 12 .
Further, as shown in FIG. 2A , the current supplied to the apparatus is not always constant. Thus, during periods when all of the current from the outside source is not being used (i.e., some of the components are not currently being operated and thus do not require power), the excess current is used to charge the battery by switching to connect the charger 8 to the battery 10 as shown in FIG. 2 B. Note that the shaded area in FIG. 2A illustrates time periods when not all of the current is being used by the image forming apparatus, and FIG. 2B illustrates how the battery is charged during these time periods. FIG. 2C illustrates power charged and discharged by the image forming apparatus.
In more detail, the controller 3 compares the power calculated by the calculating circuit 13 to a threshold value of power, and controls the switching member 9 such that the charger 8 is connected to the battery 10 when the calculated power is less than the threshold value of the power as shown in FIGS. 2A and 2B . The threshold value of the power is not more than a rated apparent power. In addition, the controller 3 controls the charger 8 such that the charger 8 supplies a constant current to the battery 10 and supplies a power that corresponds to a difference between the calculated power and the threshold value of the power as shown in FIG. 2 C.
In this embodiment, the battery 10 includes an electric double-layer capacitor, which can supply a higher-density power that is at least three times that of a lead acid battery and a nickel cadmium battery, and thus can supply a large amount of power in a short time. Further, the electric double-layer capacitor can be rapidly charged in a few seconds using a large current, and thereby the electric double-layer capacitor can be charged even though a time period for charging is short during the image forming period as shown in FIG. 2A , for example.
In addition, the electric double-layer capacitor charges and discharges by physically absorbing ions and not by chemical reaction. Thus, the capacitor's lifetime is less vulnerable to a shortened life span due to the battery being repeatedly charged and discharged. For example, a lifetime of the nickel cadmium battery lasts for about 500 to 1,000 charging and discharging times, which is equivalent to about a month if the battery is charged and discharged 20 times a day. Meanwhile, the capacitor's lifetime lasts for about 100,000 times of charging and discharging. Therefore, it is possible to significantly lengthen the lifetime of the battery 10 when a electric double-layer capacitor is used.
In addition, when the image forming period is long, it is possible to completely charge the battery 10 during this image forming period. However, when the image forming period is short, the battery 10 is also charged during the standby time as shown in FIGS. 2A and 2B . In addition, as shown in FIGS. 2A and 2B , a lot of current from the external power source 2 can be used to charge the battery during the standby time because of the large difference between the calculated power and the threshold value of the power. Thus, the standby time period does not have to be lengthened to charge the battery 10 , which differs from the lengthy standby time period needed to charge the battery shown in FIG. 4 B.
Further, as discussed above, the electric double-layer capacitor can supply a large amount of power in a short time. Therefore, it is possible to be exempt from the Japanese Rationalization Energy Use Law, which requires that the standby time period be not more than 15 min when the ramp-up period is not more than 30 sec.
Turning now to the following expression, which is a calculated result of the energy consuming rate when the copying speed is more than 40 and not more than 50. In this instance, the electric energy is 800 W*30 sec during a ramp-up period, 1500 W*2 min during copying, 1500 W*30 sec during a standby time period while the battery is charged, 180 W*30 sec during a standby time without the battery being charged, and 80 W*56.5 min during a low-power mode. That is, (800*0.5)+(1500*2)+(1500*0.5)+(180* 0.5)+(80*56.5)/60=146<<176 Wh/h and the target standard is satisfied by a greater margin than in the background apparatus.
Further, the battery 10 disclosed in the embodiments above may also supply power to the second heater 6 during the image forming period, and the first heater 5 does not necessarily have to be included in the image forming apparatus 1 .
In a modification of the first embodiment, the controller 3 compares the current detected by the detector 12 with a threshold value of the current. Then, the controller 3 controls the switching member 9 such that the charger 8 is connected to the battery 10 when the detected current is less than the threshold value of the current. Further, the threshold value of the current is determined based on a rated apparent power and voltage. In addition, the controller 3 controls the charger 8 such that the charger 8 supplies a constant current to the battery 10 . The charger 8 preferably supplies the constant current in correspondence with a difference between the detected current and the threshold value of the current.
In another modification of the first embodiment, the image forming apparatus includes a detecting circuit (not shown) for detecting a power consumption of the image forming apparatus except the power used by the detector 12 . In this instance, the detecting circuit detects the power consumption by detecting whether each electric load in the image forming apparatus is in an ON state or an OFF state, or by a sequence program that controls each electric load in the image forming apparatus.
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. | An image forming apparatus including a heater configured to heat and fix a toner image formed on a recording medium a detector configured to detect a current supplied from an external power source to the image forming apparatus and a battery configured to supply power to said heater. Also included is a charger configured to charge the battery with the power supplied from the external power source and a controller configured to control the charger such that a current supplied from the charger to the battery changes based on the current detected by the detector. | 6 |
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