description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates an apparatus for changing motor oil in an automobile or motor vehicle. More particularly, the present invention relates to an oil change apparatus that enables vehicle users to safely and conveniently drain the oil from an engine oil sump at the periphery of the vehicle, and to eliminate any chance for spillage.
[0006] 2. General Background of the Invention
[0007] Many individuals prefer to change the oil themselves for a number of reasons. Motor oil can be purchased more cheaply at retail outlets when compared to the cost quoted by automobile dealers and/or quick oil change franchises. Vehicle users can save a round trip to service facilities and the waiting time to have the oil changed. Doing this task at home, users experience the often messy oil collection, the hard work in crawling position and the possible accident of being crushed under a vehicle. The present invention enables users to change the oil cleaner, faster and easier than professional services to smartly save money, labor and time.
[0008] Several systems have been patented that are directed to an apparatus for changing oil. The U.S. Pat. No. 4,977,978 and U.S. Pat. No. 5,074,379 disclose an oil change system that employs a flow line connected to the oil sump and a valve placed at the periphery of the vehicle sill; this apparatus suffers because the flow line is always filled with oil, hoses on automobiles can crack over time causing leakage, a bad leakage leads to an engine overheat; in addition, a swinging padlock is not a sophisticated image for mechanic design and general look of the vehicle. The U.S. Pat. No. 5,630,451 discloses an oil change system with a valve attached to the oil sump and a detachable hose; this apparatus offers an extremely difficult task because the distance between the ground and the vehicle door sill might be as low as five inches, not enough to easily take a look at where the sump outlet is; furthermore, users have to lie down on one side of the body and struggle to work on coupling and detaching the hose, this poor condition of work could accidentally cause a big mess.
BRIEF SUMMARY OF THE INVENTION
[0009] This invention presents an oil change apparatus that provides a mechanic valve and/or an electronic valve which is screwed to the conventionally available sump outlet of the vehicle. A drain bracket with a built-in spigot is mounted to the underneath of the vehicle chassis at a peripheral seam or at a location that is easily and safely accessible to the user. A flow line fluidly connects the valve outlet to the drain bracket.
[0010] The mechanic valve has a spring-loaded valve plug which normally stays at the closed position. One end of a flexible metal cable is attached to the valve plug and the other end to the drain bracket. A manual cable actuator holds the valve in open position only to drain the oil when necessary; an alternative means to the metal cable and the manual cable actuator is the electromagnetic actuator. Compared to other inventions, the flow line in this invention always remains empty except when draining, thereby the vehicle does not have the risk of overheat because of a damaged flow line.
[0011] The electronic valve has a main valve member which rotates to the open position when draining and then rotates in the same direction to the normally closed position; this movement is electronically triggered by a push button. This is a highly convenience advantage over other inventions; there is no need of expensive electric pump to make the oil change slower and more complicated. Furthermore, different vehicles have different sump outlet thread and orientation, a provided adapter offers means to solve this problem. The present invention offers more advantage over others by providing methods to collect all the used oil into a reusable container or two kinds of disposable vessel.
[0012] 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 devices illustrated and in their operation may be made without departing in any way from the spirit of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
[0014] For a further understanding of the nature, objects, and advantages of the present invention, reference should be read in conjunction with the following detailed descriptions and drawings, wherein like reference numerals denote like elements and wherein:
[0015] FIG. 1 is a panoramic bottom view of the oil change apparatus without a valve;
[0016] FIG. 2 is a side view of the first location choice for the drain bracket;
[0017] FIG. 3 is a perspective view of the second location choice for the drain bracket;
[0018] FIG. 4 is a side view of the fitting;
[0019] FIG. 5 is a side view of the drain bracket with single vise bolt;
[0020] FIG. 6 is a perspective view of the hollow spigot-plug;
[0021] FIG. 7 is a panoramic perspective view of the drainage in operation;
[0022] FIGS. 8 , 9 and 10 are respectively side views of the straight, angle and square adapters;
[0023] FIG. 11 is a panoramic bottom view of the oil change apparatus using the mechanic valve;
[0024] FIG. 12A is a sectional view of the mechanic valve shown in normally closed position, horizontally cut along the center line of the valve;
[0025] FIG. 12B is a vertical side view of the mechanic valve cap;
[0026] FIG. 13 is a sectional view of the mechanic valve shown in open position;
[0027] FIG. 14 is a top view of the drain bracket with double vise bolt, and the manual cable actuator in the ready position;
[0028] FIG. 15 shows the manual cable actuator in the draining position;
[0029] FIG. 16 is a panoramic bottom view of the oil change apparatus using the electronic valve;
[0030] FIG. 17 is an exploded perspective view of the electronic valve with the main valve member in open position;
[0031] FIG. 18 is the combination of a side view of the assembled electronic valve in open position and a pictorial diagram of the electronic valve;
[0032] FIG. 19A is a schematic diagram of the control board of the electronic valve;
[0033] FIG. 19B is a schematic diagram of the circuit board of the electromagnetic actuator;
[0034] FIGS. 20 and 21 are sectional bottom views of the electronic valve, cut along the line A-B of FIG. 18 , respectively shown in the normally closed and open positions;
[0035] FIG. 22 is the combination of a sectional view of the mechanic valve shown in normally closed position, a partially cutaway side view of the electromagnetic actuator and its pictorial diagram;
[0036] FIG. 23A is a cross section view of a fastening section if the hose or cable is somewhat parallel to an existing part of the vehicle;
[0037] FIG. 23B is a perspective view of a fastening section if the hose or cable crosses an existing part of the vehicle;
[0038] FIGS. 24A and 24B are respectively perspective views of a reusable oil collection kit and a disposable container;
[0039] FIGS. 25A and 25B are respectively perspective views of an oil collection means and a full disposable liner.
DETAILED DESCRIPTION OF THE INVENTION
[0040] 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 as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
[0041] The bottom views of FIGS. 1 , 11 and 16 show the panorama of three similar oil change apparatuses: a non-valve, a mechanic valve and an electronic valve. The oil change apparatus is provided for changing oil of all kinds of engine with internal combustion, the non-valve is the cheapest and more suitable for landscaping and farming equipment, the mechanic or electronic valve apparatus is for motor vehicle 70 such as an automobile.
[0042] FIG. 1 shows the bottom view of an automobile which has a plurality of wheels 15 and a chassis 14 . The chassis seam 19 is typically a metal strip under the door(s) sill 20 ; it is the lower end portion of the chassis 14 horizontally extending between the front wheel well 30 and the rear one.
[0043] The non-valve oil change apparatus comprises three parts:—a fitting 18 taking place of the conventionally available outlet plug 253 of the oil sump 10 ,
a drain bracket 13 mounted to chassis seam 19 , and a hose 12 connects the fitting 18 to the drain bracket 13 .
[0046] FIG. 2 shows the lower driver's side of a vehicle where the drain bracket 13 can be mounted anywhere along the chassis seam 19 .
[0047] FIG. 3 shows another location to mount the drain bracket 13 ; it is the lower end of the front wheel well. FIGS. 2 and 3 show the easiest places for mounting the drain bracket 13 , a little farther in the vehicle underneath, along the side and in the rear area of the vehicle, there are more places to install the drain bracket.
[0048] Referring to FIG. 4 , at the sump outlet 40 of the automobile, taking place of the conventionally available plug, the fitting 18 is a straight metal tube, one end is externally threaded to fit the existing sump outlet 40 , the other end fits the inner diameter of the hose 12 . This fitting 18 is intended to be used without a valve 80 , an adapter 90 takes its place if using a valve. A clamp 41 tightens the hose 12 to the fitting outlet. The other end of the hose 12 is tightened to the inlet of the drain bracket 13 shown in FIG. 5 . The drain bracket 13 consists of two metal plates, the outer plate 53 and the inner plate 54 where the spigot 21 is molded to. On top of the metal plates, the grip ridges 55 are intended to strengthen the vise. The vise-bolt 51 mounts the two plates 53 and 54 to the chassis seam 19 , the multi-layer shim 52 should have the same thickness as the chassis ridge 19 to parallel-balance the vise.
[0049] FIG. 6 illustrates a hollow spigot-plug 60 which can take place of the spigot-plug 50 to maximize the distance between the spigot 21 and the road surface. The hexagon wrench 61 is used to loosen and/or tighten the plug 60 .
[0050] FIG. 7 shows the user 71 who safely and easily drains the oil into a collection container 247 without any messy spillage; it's not a good option to work hardly and unsafely in a small space under a jacked or ramp-elevated vehicle just to drain the oil.
[0051] Turning to FIGS. 8 , 9 and 10 , conventionally available sump outlets have various kinds of thread and angle so one of the three adapters is used to horizontally orient the oil change apparatus; adapters 90 are metal tubes, one end is externally threaded to fit the sump outlet 40 and the other end is internally and universally threaded to fit the valve 80 (mechanic or electronic). Consequently, the distance between the apparatus and the road surface is maximized, and different vehicles can use the same universal valve.
[0052] FIG. 11 shows the panorama of the oil change apparatus using the mechanic valve 111 . In FIGS. 11-15 , a metal cable 112 , composed of the inner cable 130 and the outer cable 131 (like the conventionally available bike brake cable), is provided for opening and closing the valve 111 ; one end of the inner cable 130 is connected to the drain bracket 13 and the other end is attached to the valve plug 135 biased towards the valve seat 136 by the spring 122 .
[0053] In the normally closed position of FIG. 12A , the valve plug 135 engages the valve seat 136 thereby no oil can exit from the adapter 90 . The hose 12 , fastened by clamp 41 , fluidly connects the valve outlet to the drain bracket 13 .
[0054] FIGS. 14 and 15 show the manual cable actuator 143 respectively in ready and draining positions. The manual cable actuator 143 is a detachable tool composed of:
[0000] 1) A flat bar with a V-shaped prying tip 140 on one end and a handle 142 on the other end.
2) A movable stick with a V-shaped metal jam plate 141 on one end and a little hinge on the other end which is welded to the flat bar.
[0055] After the prying tip is used to pull the cable tip-lock 150 , the jam plate 141 is snapped in to keep the valve plug 135 in open position ( FIG. 13 ).
[0056] The single-bolt drain bracket ( FIG. 5 ) and the double-bolt bracket ( FIG. 14 ) are interchangeable for three embodiments of oil change apparatus.
[0057] In the open position of FIG. 13 for draining with the manual cable actuator 143 in place ( FIG. 15 ), the pulled inner cable 130 compresses the spring 122 towards the valve cap 132 a , and this action pulls the valve plug 135 away from the valve seat 136 to open the valve 111 . The oil flow direction 11 is from the oil sump 10 , through the adapter 90 and the open valve towards the spigot 21 via the hose 12 .
[0058] FIG. 16 shows the oil drain apparatus using an electronic valve 160 . One end of the electric cable 161 , composed of three to four wires (the chassis can be used as a ground wire), is connected to the electronic valve 160 . The other end is connected to the control board 162 which can be installed somewhere in the vehicle, neither necessarily close to hot engine parts nor exposed to rain water or street water.
[0059] In FIGS. 17 and 18 , the valve body 188 has an externally threaded inlet to be connected to the adapter 90 ; it also has a tubular outlet 179 with grip rings 144 intended to strengthen the hose attachment. The main valve member 173 is built with:
[0000] 1) The upper part: a cylindrical section 175 which rotates stably in the cylindrical cavity 178 .
2) The lower part: a concave section 176 which normally closes the valve and opens it when draining
3) The top center part: a valve stem 174 to be connected to the shaft of the electronic motor 170 together with the ring switch 172 .
[0060] Two fasteners 125 are provided to assemble the valve cap 132 b and the gasket 124 c with two internally threaded fasteners 200 while securing the main valve member 173 inside the cylindrical cavity 178 . Two mounting slots 171 are used to mount the motor 170 to the motor mounting bars 177 .
[0061] In FIG. 18 , the LED 184 , the beeper 185 , the push button 183 and the fuse 181 can be placed apart from the control board 162 (dual circuit) at suitable location and with proper wiring (see diagrams), the electronic regulator 182 should be on the control board.
[0062] The power from the conventionally available vehicle battery 180 supplies a nominal 12 volt direct current; the details of electronic experiment performed accordingly to the schematic diagram of FIG. 19A are hereafter:
time width: t=1.1×R 1 ×C 1 =1.1×0.233MΩ×3.3 μF=0.77 second, t is the time that the motor takes to rotate 180°; experimented values (R 1 and R 2 are two potentiometers):
R 1 =0.233 MΩ R 2 =390 kΩ R 3 =220 kΩ R 4 =82Ω
C 1 =3.3 μF C 2 =10 μF
[0066] the value of R 4 and optional R 5 depends respectively on the kind of motor and beeper.
[0067] The control circuit on the left of FIG. 19A is programmed by the resistor R 1 and the capacitor C 1 to energize the motor 170 to start and stop rotating at pre-determined positions, this circuit is based on the accurate timing of the left timer 190 and its electronic network to power the motor; the start is triggered by pressing the push button 183 and the stop automatically occurs when the RC timing is out. The alert circuit on the right of FIG. 19A is a self-triggered circuit which is performed by the right timer 190 , the resistors R 2 & R 3 , and the capacitor C 2 .
[0068] When the main valve member 173 reaches and stays at the open position ( FIG. 21 ), the ring switch 172 closes the alert circuit to turn on the blinking LED 184 and the intermittent beeper 185 . When the main valve member 173 leaves the open position to reach and stay at the normally closed position ( FIG. 20 ), the ring switch disconnects the alert circuit. There is no manual control for the alert circuit, it's totally automatic.
[0069] The control circuit rotates the concave section 176 a half round (180°) by the first button push which changes the position from normally closed to open, the second button push rotates the concave section 176 , in the same direction, which moves exactly the other half round to the normally closed position. The concave section always spins in the counter-clockwise direction, it moves twice to form a closed circle (360°) for one-time draining, it does not spin in one direction and then spin in the opposite direction to get back to the normally closed position.
[0070] The bottom view of FIG. 20 describes the concave section 176 blocking the communication of adapter 90 and hose 12 ; after being energized to open the valve, the concave section 176 on FIG. 21 allows the waste oil to flow from oil sump 10 to hose 12 via adapter 90 .
[0071] Turning to FIG. 22 , instead of the manual cable actuator, the mechanic valve 111 can be operated by the electromagnetic actuator which comprises a relay 192 and an actuating lever 223 . The relay is an electric coil 222 reeled around an iron core 224 . When the on/off switch 220 is closed, the vehicle battery energizes the relay, creates a magnetic field to pull the actuating lever 223 , consequently the valve opens for draining; simultaneously, the alert circuit 221 (timing circuit related to the schematic diagram of FIG. 19B ) turns on the blinking LED 184 and the intermittent beeper 185 . Both of the alert circuit and the relay should be turned off by the switch 220 as soon as the oil is all drained out, the spring always urges the valve to normally closed position.
[0072] In FIGS. 23A and 23B , the hose or cable 232 must be secured to existing parts 231 a or 231 b of the vehicle underneath by clamp 41 . Sandwiched between the hose and the vehicle part, the insulation 233 a or 233 b is meant to prevent possibly burnt hose. The anti-kink tube 230 protects the hose or cable 232 from being choked or damaged when clamped.
[0073] In FIG. 24A , the reusable container 247 has an opening 244 with cap 241 a , an air inlet and outlet 245 with cap 241 b , and a handle 246 . The waste oil flows from the spigot 21 , through a threaded coupler 240 , a flexible and transparent tube 242 (held inside the opening 244 by the holding clip 243 ) and into the reusable container 247 . Discharged oil from the spigot is highly visible through the transparent tube and at the peripheral location of the vehicle so users can close the valve as soon as the waste oil is all drained out. The oil is collected in a proper workmanlike manner, ready to be brought to a recycling facility.
[0074] In FIG. 24B , with the same threaded coupler 240 , flexible tube 242 and holding clip 243 as shown in FIG. 24A , the carrying strings 251 are portable means for users. The disposable container 248 can be made by cheap material such as paraffin wax paperboard.
[0075] FIG. 25A demonstrates the waste oil gushing out from the sump outlet 40 , the oil jet gradually changes its course; this fact always causes a mess. A widely opened cardboard box 250 , lined with a liner 252 such as a garbage bag, offers a better solution than any conventionally available containers in stores.
[0076] FIG. 25B shows the liner 252 filled with used oil, the top portion of the liner can be tightly self-knotted, cheap carrying strings 251 made the combination of liner and box easily movable to be disposed at an oil collection facility. This method can be performed whether or not the vehicle is equipped with the oil drain apparatus.
[0077] The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.
REFERENCE NUMERALS
[0078]
[0000]
Part number
Description
10
sump/oil sump
11
oil flow direction
12
flow line/hose
13
drain bracket
14
chassis
15
wheel/tire
16
front of vehicle
17
rear of vehicle
18
fitting
19
chassis seam
20
sill/door sill
21
spigot/built-in spigot
30
wheel well
40
sump outlet
41
clamp (having various styles and tightening
diameters)
42
anti-leak washer
50
spigot plug
51
vise bolt
52
multi-layer shim
53
outer plate
54
inner plate
55
grip ridge
60
hollow hexagon spigot-plug
61
wrench (hexagon tip style)
70
vehicle
71
user
80
valve (mechanic or electronic)
90
adapter
100
threaded connection
111
mechanic valve/spring-loaded mechanic valve
112
flexible metal cable
120
opening for fastener
121
opening for inner cable 130
122
spring
123
tubular tip
124a, 124b and 124c
gasket/rubber O ring
125
fastener
130
inner cable
131
outer cable
132a and 132b
valve cap
133
gasket holder/washer
134
cable tip
135
valve plug
136
valve seat
140
prying tip
141
jam plate
142
handle
143
manual cable actuator
144
grip ring
150
cable tip lock
160
electronic valve
161
electric cable
162
electronic control board (dual timing circuit)
170
motor (DCM-702 motor)
171
mounting slot
172
ring switch
173
main valve member
174
valve stem
175
cylindrical section
176
concave section
177
motor mounting bar
178
cylindrical cavity
179
outlet/valve outlet
180
vehicle battery (conventionally available)
181
fuse
182
electronic regulator
183
push button/trigger
184
LED (light emitting diode)/blinking LED
185
beeper/intermittent beeper
186
wire/print circuit line
187
wire holder
188
valve body
190
LM 555 timer
191
2N3904 transistor
192
relay
200
internally threaded fastener
220
on/off switch
221
alert circuit of FIG. 19B
222
electric coil
223
actuating lever
224
iron core
230
anti-kink tube
231a and 231b
existing part of vehicle
232
hose or cable
233a and 233b
insulation
240
threaded coupler
241a and 241b
cap
242
flexible and transparent tube
243
plastic holding clip
244
container opening
245
air inlet and outlet (optional)
246
handle/container handle
247
container/reusable container
248
disposable container
250
receptacle/cardboard box
251
carrying string
252
liner/plastic bag
253
conventionally available outlet plug
[0079] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All used materials are biocompatible.
[0080] 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 present invention provides several embodiments of an oil change apparatus that basically have a valve/fitting connected to the conventionally available oil sump, a drain bracket installed on a low portion of equipment or vehicle periphery, and a flow line that fluidly connects the valve/fitting and the drain bracket. The oil change apparatus enables vehicle users to quickly and easily drain oil at a safe and convenient location. The present invention also provides several reusable and disposable means to properly collect waste oil. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a gas burner, particularly an atmospheric gas burner with premixing of primary air, with a burner ring having gas outlet ducts, and with a burner cover which may be constructed so as to form one piece with the latter.
2. Description of the Prior Art
Various constructions of gas burners for hearths are known. The known burners have flame outlet openings which are formed as slots, grooves or bore holes which are generally directed outwardly in a radial direction proceeding from an imaginary center point of the burner.
In the course of attempts to improve the efficiency of such burners and in particular also their environmental acceptability, i.e. to reduce emissions of noxious substances, burner constructions have been developed which diverge from the conventional types. Such burner designs are shown, for example, in DE-37 09 445-A1.
The object of the invention is to provide a solution by which, in particular, the NO x content as well as the CO content in the exhaust gas in atmospheric burners is significantly reduced, specifically over a large regulating range between low and high settings of the burner.
SUMMARY OF THE INVENTION
This object is met, according to the invention, in that the center axis of the gas outlet ducts lies at an angle diverging from 0° relative to a radius associated with the respective outlet opening.
The oblique position of the gas outlet ducts relative to an imaginary associated radius results in a significant whirling effect. After exiting the outlet ducts designed according to the invention, the gas/air mixture is whirled in a helical or spiraling manner resulting in optimal burn-up. The CO and NO x are accordingly reduced.
An additional advantage consists in that the flames cannot proceed along the shortest path from the flame outlet opening to the edge of the pot when the latter is put in place, but rather are compelled to remain for a longer period of time beneath the base of the pot, resulting in a kind of spiral stream beneath the pot base. Consequently, the flame energy can be exploited in a distinctly improved manner, i.e. in order to achieve uniform cooking output, the burner can either operate for a shorter period of time on the whole or can be operated at a lower setting so that the amount of noxious substances loading the environment is necessarily reduced in its entirety.
Further advisable constructions of the invention follow from the subclaims.
It is advisable, for example, that the gas outlet angle relative to the associated radii be adjusted between 15° and 90°, where a 90-degree angle results in a practically tangential outflow. The slots can be constructed as bore holes and can be straight or curved in their axial direction as well as in their cross-sectional shape. V-shaped cross sections can be provided as well as ducts of different dimensions which are arranged parallel next to one another, which leads to an optimal regulation between partial and full load. Additional outlet openings can also be provided for forming auxiliary flames in a manner known per se.
To facilitate adaptation of the flow conditions within the burner to specific applications, it may be advantageous to provide the burner cover with a flow guiding cone and/or with whirling/cooling ribs.
It has been shown that special adaptation between the outer contour of the burner cover and the outer contour of the burner ring relative to the outlet edges of the gas outlets also results in different burning behavior, for which the invention provides special designs, depending on the intended use, as indicated in the subclaims.
The flow ducts in the interior of the burner can also be designed in different ways according to the invention, either with or without flow cones.
Finally, it may be advantageous to provide for additional outlet openings in the adaptor mount through which secondary air can be sucked in from the trough space below the burner for flame cooling, as is likewise provided in a further construction of the invention. This step in which the flames are cooled also serves to maximize the use of fuel while reducing harmful emissions.
In the following, the invention is explained in more detail by way of example with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view in partial section through a burner according to the invention with a partial top view of a construction of the gas outlet ducts in FIG. 1a;
FIGS. 2 to 4 show sections through variants of burners according to the invention;
FIGS. 5a and 5b show partial sections through burner cover constructions;
FIG. 6 shows a top view of a burner ring, according to the invention, with straight gas outlet ducts and flames shown in an implied manner;
FIG. 7 shows a partial view of a modified example of a burner ring with curved gas outlet ducts;
FIGS. 8a and 8b show constructions of the flow cone;
FIG. 9 shows cross-sectional designs of gas outlet ducts;
FIG. 10 shows a partial section in the region of the flow cone;
FIGS. 11 to 15 show different edge constructions of burner covers and burner rings in the region of the gas outlet openings;
FIGS. 16 to 19 show different partial cross sections through burners with different gas flow control in the interior of the burner with auxiliary flame formation with full burning;
FIG. 20 shows a side view in partial section through another embodiment example of a burner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The gas burner shown in partial section in FIGS. 1, 1a and designated in general by 1 is constructed as follows: a burner support 2 with an injector 20 penetrates a gas trough 3 from below, the latter being implied in the drawing. An adaptor mount 4 on which a burner ring 5 is supported encloses the region of the burner support projecting out over the gas trough 3. The burner ring 5 is shown in a partial view from the top in FIG. 1. The burner is closed at the top by a burner cover 6 which is outfitted in the center with an inwardly directed flow cone 7 in the example shown in FIG. 1.
It can be seen that the burner ring 5 is outfitted with a plurality of gas outlet ducts 8 whose center axis, indicated in FIG. 1a by an arrow 9, is arranged at an angle to the corresponding radius, designated by 10, which angle diverges from 0° and is designated by α in FIG. 1a. The free outlet end of the gas outlet ducts 8 is designated by 8a.
Similarly to FIG. 1a, FIG. 6 shows a top view of the burner ring 5 with implied flames 11 which, as can be seen, are not directed radially outward, but rather form an angle to the radial flow so as to result in a whirling formation. The ducts 8 shown in FIGS. 6 and 1a are constructed in a straight line as seen from the top. FIG. 7 shows a possibility for a curved design of these ducts. The ducts shown in FIG. 7 are designated by 8' and the formed flames by 11'.
Just as the ducts 8 and 8' can be constructed so as to be straight or curved as seen from the top, they can also have different cross-sectional shapes. A selection of these cross-sectional shapes is indicated in FIG. 9. In addition to ducts having U-shaped, V-shaped or I-shaped cross sections, ducts with a circular cross section can also be provided as indicated in FIG. 9 by 8" or adjacent ducts may have different cross-sectional dimensions as indicated in FIG. 9 by 8".
As is known, per se, additional gas outlet slots or bore holes, designated by 11 in FIG. 2, can be provided below the gas outlet ducts so as to form auxiliary flames at full load, for example, as indicated in FIG. 2 by an arrow 12. The configuration of the gas flow through the gas outlet ducts 8 is designated by 13.
In addition, FIG. 3 shows that additional openings 14 can be provided to suck in secondary air from below the trough 3. This secondary air, whose flow path is designated by 15 in FIG. 3, serves to cool the flames.
As far as possible, structural component parts having the same function are designated by identical reference numbers in the various drawings. For example, the burner cover is consistently designated by 6, even though its cross-sectional shape or the construction of its edge may vary from one view to another.
The flow cone 7, which also has the same reference number in all of the Figures, can have a curved or straight shape with respect to its cross section, as shown in FIGS. 8 and 8b, respectively. For the sake of simplicity, the curved flow cone is designated by 7 (FIG. 8a) and the straight flow cone in the example of FIG. 8b is designated by 7'. In addition to the flow cone, cooling ribs 16 may also be provided, e.g. in the cover 6. These cooling ribs 16 may have a helical or spiral shape for creating a pre-whirling or can also enclose the flow cone concentrically. Different cross-sectional shapes are shown in FIGS. 5a and 5b.
Flow configurations at various load ranges are indicated by arrows in FIG. 10.
FIGS. 11 to 15 show different designs of the configuration of the gas outlet ducts 8 relative to the free front edge 6a of the burner cover and the free front edge 5a of the burner ring, respectively, relative to the outlet opening 8a.
FIG. 11 shows a design in which these three elements, i.e. the free outer edge 6a of the burner cover 6, the outlet opening 8a of the flow ducts 8, and the outer edge 5a of the burner ring 5, are exactly flush with one another.
FIG. 12 shows a design in which the free outer edge 6a of the burner cover 6 projects over both the gas outlet opening 8a and the free outer edge 5a of the burner ring 5. In FIG. 13, the free edges 6a and 5a project over the gas outlet openings 8a. FIG. 14 shows a design similar to that in FIG. 13, but in which the transitional areas passing into the free outer edges 6a and 5a are different. FIG. 15 shows a converging configuration.
All of the constructions of the gas outlet ducts 8 and the geometrical configurations of the gas outlet openings 8a result in different burning behavior and accordingly in different emissions of noxious substances. The type of gas, gas pressure, ambient temperature and the like are also included as parameters. Correspondingly different geometrical designs are provided depending on the type of gas.
Variations of the inner gas flow paths are shown in FIGS. 16 to 19. FIG. 16 shows a flow space for the gas which bulges out prior to entering the gas outlet ducts 8 and is designated by 17. FIG. 17 shows a substantially parallel guidance of the gas flow path 17'. FIG. 18 shows a region 17" which widens from the inside toward the outside as a result of a gas guiding or deflecting body 18 in the interior of the burner. Finally, FIG. 19 shows another baffle insert 18' which optimizes the secondary flame formation in particular.
FIG. 20 shows another embodiment example of the invention in which parts which are otherwise identical to those in FIG. 1 have the same reference numbers with an added "c". The injector 20c is fastened at the support 2c by means of a clamping ring 21. The adapter mount 4c can also be fixed at the plate of the cooking trough 3c by the clamping ring 21 simultaneously.
In contrast to the preceding examples, the burner in this example is constructed in three parts from the burner ring elements 5c and the burner cover elements 6c, since an intermediate disk 19 which also provides the flow edge for the gas flame is provided in the front edge region of the burner cover 6c.
Naturally, the described embodiment examples of the invention can be further modified in many respects without departing from the fundamental idea. Thus, the cross-sectional shapes of the baffle body and guiding body mentioned above represent examples, as do the designs of e.g. the flow guiding cone 7, the cooling ribs 16 or the special cross-sectional shapes and configurations of the ducts 8. | An atmospheric gas burner includes a burner ring having a plurality of gas outlet ducts defining a respective plurality of gas outlet openings and each having a center axis extending at an angle greater than 0° relative to a radius of the respective outlet opening, and a burner cover overlying the burner ring with the burner ring having a portion projecting beyond outer edges of lower regions of the gas outlet openings, and the burner cover having a portion which overhangs about the outer edges of upper regions of the gas outlet openings. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/315,906, filed Dec. 22, 2005, entitled Motion-Compensating Light-Emitting Apparatus, which in turn is a continuation-in-part of U.S. patent application Ser. No. 11/022,215, now U.S. Pat. No. 7,312,863, filed Dec. 23, 2004, entitled Motion-Compensating Light-Emitting Apparatus, all of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a system for maintaining a beam of electromagnetic radiation, such as visible light, pointed in a particular direction, despite unwanted movement of the device emitting the beam with respect to an inertial frame of reference.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to light-emitting devices and particularly to those devices intended to produce a beam in a selected direction such as toward a target of interest. The invention provides motion-compensation technology suitable for use with such light-emitting devices, which may dampen and/or substantially eliminate the effect of unintentional motion, vibration, or movements, such as angular and/or translational movements, caused by mechanical vibrations, hand tremors, and so forth.
[0004] Light-emitting devices, such as laser diode devices, are used in a variety of consumer, computer, business, medical, scientific, military, outdoor, telecommunication and industrial products, including but not limited to compact disk (CD) players and computer CD-ROM drives, digital video disk (DVD) players and DVD-ROM drives, laser printers, laser pointers, barcode scanners, measurement devices, rangefinders, scopes, industrial material processing devices, marking and cutting systems, medical equipment, fiber optic transmission systems, satellite communications, and digital printing presses. Many of these applications require precision accuracy for successful implementation. However, conventional light-emitting devices may be affected by unintentional angular and/or translational movements (e.g., fine vibrations from the machine in which a laser is encased, fine tremors from a shaking hand holding a laser, etc.) and, as a result, generate an unsteady column of light—producing an effect that may cause inferior performance.
[0005] An example of the above mentioned effect will now be described with reference to a laser pointer. Fine tremors of the human hand, when holding even a lightweight laser pointer (or other pointing device), have been measured at a frequency range of 1 to 5 Hz. These unwanted vibrations are often amplified when the person maneuvering the device is nervous. The resulting deviation of the projected spot from the intended target point to the actual point is proportional to the distance from the pointing device to the target object (e.g., a point on a screen). This deviation may be approximately equal to the product of the sine or the tangent of the angle and the distance to the projected spot. In other words, for small angular movements (such as less than 10 degrees), the movement of the projected spot is approximately equal to the product of the distance to the target and the angle of the movement (in radians). For instance, small angular movements of +/−1 degree of a laser pointing device may result in movements of approximately +/−2 cm of the projected spot on a target 1 meter away; and, these angular movements will result in a 10-fold larger projected spot movement (approximately +/−20 cm) for a target 10 meters away (which may be typical of large lecture halls). In contrast to angular movements, translational movements (sideways movements of the hand) are not amplified by the distance from the light-emitting device to the target object. That is, if the hand holding a laser pointer is moved sideways by 1 cm, the spot on the target is also moved sideways by 1 cm irrespective of how far the target is from the hand.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides a motion-compensated, light-emitting apparatus which enables a steady beam of light to be projected onto a desired target even if subjected to undesired unsteady conditions by automatically redirecting or compensating for unintentional, off-target angular and/or translational movements. The present apparatus may use miniature gyroscopes and/or accelerometers and/or other motion sensing type devices and an optical system including light-refracting elements arranged within the apparatus. In a preferred embodiment of the present invention, a motion-compensating light-emitting device is provided which utilizes a mirror mounted on a cantilever composed of an aluminum and Lead Zirconium Titanate (PZT) metal sandwich. In a preferred embodiment, the mirror, positioned by the cantilever, deflects the light beam to compensate for the unwanted tremor based on the angular rates and/or translational motion measured by two or more motion sensors.
[0007] In an alternate embodiment of the present invention, a motion-compensated, light-emitting device utilizes a micro mirror in a two axis Micro-Electronic Mechanical System (MEMS)-based, gimbal-less scanning mirror device. In a preferred embodiment, a commercially available MEMS, made entirely of monolithic single-crystal silicon in a single miniature package, changes a mirror angle in two deflection axes. When an electric field is applied to the preferred two axis MEMS, the mirror surface tilts an amount that is proportional to the applied voltage to stabilize the direction of the emitted light beam.
[0008] In an alternate embodiment of the present invention a motion compensated, light-emitting device is provided that displays a variety of stabilized-rasterized and stabilized-vector graphics as well as stabilized multi-frame animations at arbitrary refresh rates. The system is highly adaptable to projection onto various surfaces and in a variety of applications, including projection onto specially-coated transparent surfaces. Due to the low power consumption and vibration stabilized output of this device, the system preferably is miniaturized, highly portable and fully mobile when used with a laptop small computer. The computer may project different letters, symbols, or graphics or other static or moving images that can change and evolve over time. The system preferably includes a two axis MEMS micro mirror. The signals providing the desired rasterized or vector graphics are added to the vibration stabilization signals, and unwanted movement is reduced or eliminated in the resulting projection.
[0009] In an alternate embodiment of the present invention, a motion-compensated, light-emitting device displays full color, high-quality images that remain in focus at all distances using holographic laser projection technology. The term “holographic” refers not to the projected image, but to the method of projection. A diffraction pattern of the desired 2D image, calculated using holographic algorithms, is displayed on a phase-modulating Liquid Crystal on Silicon (LCOS) microdisplay attached to a two axis MEMS micro mirror. When illuminated by coherent laser light, the desired image is projected on various surfaces without distortion by the micro-tremors imposed on the projection system.
[0010] Rather than blocking light, a phase-modulating LCOS microdisplay mounted on the MEMS micro mirror steers light to exactly where it is needed, making the system highly efficient. Unlike conventional projection systems, a projection lens is not needed. Instead, a demagnification lens pair expands the diffracted image from the microdisplay, producing an ultra-wide throw angle, greater than 100°. The projected images are in focus at all distances from the projector, eliminating the need for focus control.
[0011] The diffractive method of projection naturally lends itself to miniaturization and low cost implementation, allowing images to be projected onto curved and angled surfaces without distortion. In addition, the system is highly tolerant of microdisplay pixel failure—essential in safety critical applications in markets such as automotive.
[0012] In an alternate embodiment of the present invention a motion-compensated, light-emitting device stores the exact orientation of the laser or projection system for later retrieval, derived from a location determination system, a range to target determination system and information from motion detection devices such as accelerometers under user control. The system automatically maintains a light beam emitted from the device in the exact orientation, as stored. In addition, the system may store several orientations, and the system can reorient the light beam in sequential, round-robin fashion. With sufficient displacement of the compensating mirrors, the system can be moved from its location, and if the targets are far enough away, the system can maintain the orientation of the light beam at the marked targets. In addition, by adding some simple modulation to the laser light beams the beams can be turned off when not actually pointing at memorized locations, thus maintaining illumination only at the desired locations that were previously set in memory.
[0013] In one aspect, the present invention is directed to a light-emitting apparatus comprising: a light beam generator that emits a light beam; a device that produces a first signal indicating motion of the generator; an integrator that integrates the first signal to produce a second signal indicating movement of the light beam generator; and a light diverting device mounted to an electronically adjustable cantilever; wherein the second signal is applied to the cantilever so that the light beam projects substantially in a particular direction.
[0014] In another aspect of the present invention, the cantilever comprises a first layer of ceramic and a second layer of lead zirconium titanate.
[0015] In another aspect of the present invention, the apparatus further comprises first and second angular rate-sensing devices; and first and second cantilevers; wherein the first angular rate-sensing device measures pitch angular velocity and the second angular rate-sensing device measures yaw angular velocity, the integrator integrates signals produced by both first and second signals and the integrated signals are applied to the first and second cantilevers, respectively.
[0016] In another aspect of the present invention, the apparatus further comprises a graphics generator that generates a third signal; and a signal combiner that combines the first and second signals with the third signal; wherein the third signal, applied to the cantilevers, diverts the light beam to project an image.
[0017] In another aspect of the present invention, the apparatus further comprises a user interface that selects a current orientation of the generator; and a memory that stores the current orientation; wherein the apparatus maintains the light beam projected at the current orientation.
[0018] In another aspect of the present invention, the apparatus further comprises a measurement device that generates a third signal representative of a measured orientation and wherein the memory further stores the measured orientation.
[0019] In another aspect of the present invention, the measurement device comprises a digital magnetometer and the measured orientation is azimuth.
[0020] In another aspect of the present invention, the memory stores more than one orientation and the apparatus directs the beam in a sequence of one or more directions from the orientations stored in the memory.
[0021] In another aspect of the present invention, the light diverting device comprises a mirror.
[0022] In another aspect of the present invention, the light diverting device comprises a lens.
[0023] In another aspect of the present invention, the integrator integrates the first signal to produce a second signal that indicates an angular and translational movement of the light beam generator; and; wherein the second signal is applied to the cantilever so that angular and translational movement is substantially eliminated.
[0024] In another aspect, the present invention is directed to a light-emitting apparatus comprising: a light beam generator that emits a light beam; a motion-sensing device that produces a first signal indicating movement of the generator; an integrator that integrates the first signal to produce a second signal indicating a movement of the light beam generator; and a micro electronic mechanical system that positions a light diverting device; wherein the second signal is applied to the micro electronic mechanical system to project the beam substantially in a particular direction.
[0025] In another aspect of the present invention, the light diverting device comprises a mirror.
[0026] In another aspect of the present invention, the light diverting device comprises a lens.
[0027] In another aspect of the present invention, the apparatus further comprises first and second angular rate-sensing devices; wherein the first angular rate-sensing device measures pitch angular velocity and the second angular rate-sensing device measures yaw angular velocity, the integrator integrates signals produced by both first and second signals and the integrated signals are applied to the micro electronic mechanical system.
[0028] In another aspect of the present invention, the apparatus further comprises a graphics generator that generates a third signal; and a signal combiner that combines the first and second signals with the third signal; wherein the third signal, applied to the micro electronic mechanical system, diverts the light beam to project an image.
[0029] In another aspect of the present invention, the integrator integrates the first signal to produce a second signal that indicates an angular and translational movement of the light beam generator; and; wherein the second signal is applied to the micro electronic mechanical system to project the beam so that angular and translational movement is substantially eliminated.
[0030] In another aspect of the present invention, the apparatus further comprises a user interface that selects a current orientation of the generator; and a memory that stores the current orientation; wherein the apparatus maintains the light beam projected at the current orientation.
[0031] In another aspect of the present invention, the apparatus further comprises a measurement device that generates a third signal representative of a measured orientation and wherein the memory further stores the measured orientation.
[0032] In another aspect of the present invention, the measurement device comprises a digital magnetometer and the measured orientation is azimuth.
[0033] In another aspect of the present invention, the memory stores more than one orientation and the apparatus directs the beam in a sequence of one or more directions from the orientations stored in the memory.
[0034] In another aspect of the present invention, the apparatus further comprises a plurality of colored lasers; and a laser collimating device that combines the plurality of colored lasers into a single beam; wherein the light beam generator comprises the plurality of colored lasers; and wherein the light diverting device comprises a micro display that generates an image from the single beam.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a diagram of a motion-compensating light-emitting apparatus according to an embodiment of the present invention;
[0036] FIG. 2 is a diagram of the motion-compensating light-emitting apparatus of FIG. 1 to which reference will be made in explaining the operation thereof;
[0037] FIG. 3 is a diagram of a motion-compensating light-emitting apparatus according to another embodiment of the present invention;
[0038] FIG. 4 is a diagram of the motion-compensating light-emitting apparatus of FIG. 3 to which reference will be made in explaining the operation thereof;
[0039] FIG. 5 is a diagram to which reference will be made in explaining the operation of the present apparatus;
[0040] FIG. 6 is a diagram of a motion-compensating light-emitting apparatus according to another embodiment of the present invention;
[0041] FIG. 7 is a block diagram of a motion-compensated, laser diode pointer utilizing cantilevers;
[0042] FIG. 8 is a block diagram of a motion-compensated light-emitting apparatus according to another embodiment of the present invention comprising a two axis MEMS based micro mirror;
[0043] FIG. 9 is a block diagram illustrating a motion-compensated light-emitting device for displaying a variety of stabilized rasterized and stabilized vector graphics as well as stabilized multi-frame animations at arbitrary refresh rates;
[0044] FIG. 10 is a block diagram of a motion-compensated, holographic laser projector; and
[0045] FIG. 11 is a block diagram of a motion and position compensated laser pointer.
DETAILED DESCRIPTION OF THE INVENTION
[0046] FIG. 1 is a diagram of a laser diode pointer 100 which includes vibration or motion compensation circuitry in accordance with an embodiment of the invention. A visible laser diode 110 may be used as the light source. There are several ways of implementing the vibration compensation scheme. In accordance with an embodiment of the invention, two angular velocity sensors (gyros) 120 and 125 are aligned in orthogonal directions and used to measure the angular movements in the pitch and yaw axis (also referred to as the X and Y axis). In a preferred embodiment, the two miniature gyroscopes comprise, for example, a micro electro mechanical system (“MEMS”), such as model ADXRS150 manufactured by Analog Devices, Inc. These gyros may have a relatively small volume (such as less than 0.15 cm 3 ), low weight (such as less than 500 mg), and small size (such as 7 mm×7 mm×3 mm or less). In another embodiment of the present invention, a motion-compensating light-emitting device is provided which utilizes two or three miniature accelerometers (for example, MEMS, such as model ADXL203 manufactured by Analog Devices, Inc.) arranged to measure acceleration and changes of the gravity vector (changes in acceleration) or relative tilts with respect to the vertical axis in two orthogonal directions (i.e., yaw and pitch) and to obtain from this information the relative vertical and horizontal angular movements and translational movements. These accelerometers may have a relatively small volume 0.05 cm 3 (with dimensions of 0.5 cm×0.5 cm×0.2 cm). Additionally, the accelerometers may be provided in a hermetically sealed package.
[0047] The output of gyros 120 and 125 are amplified by two amplifiers 131 and 132 respectively and/or sampled by an A/D converter 133 in anti-vibration control circuit 130 . The sampled signal may be passed to a band frequency filter 134 where the portion of the signal associated with the rapid, unwanted angular motions of the pointer in this example, typically that portion between 1 and 5 Hz, is extracted. Although a band frequency filter having a range of 1 to 5 Hz is described, a variable frequency filter may be used to set the desired band of frequencies. The range of frequencies may be adjusted by utilizing an adjustment type device such as a variable resistor or digital switches.
[0048] The filtered signal may then be integrated by an integrating processor circuit 135 . Because gyros 120 and 125 measure angular velocity, the signal received by integrating processor circuit 135 may be integrated to obtain angular information from which an angular difference may be obtained. Although the embodiment of FIG. 1 utilizes gyros 120 and 125 that measure angular velocity, gyros 120 and 125 may measure an angular difference. In such instance, integrating processor circuit 135 may not be included in the anti-vibration control circuit 130 .
[0049] The integrated rate output or angular difference (proportional to the angle of the unwanted angular motion) may be conditioned by a correction amount normalization circuit 136 (which may include amplifying the signal by a necessary or predetermined amount) and supplied as an input for motors 140 and 150 , which may be connected to a movable lens 160 (which may be located between the laser diode 110 and a focusing lens 170 ). Movable lens 160 and focusing lens 170 may each be constructed from one or more convex lenses and/or concave lenses, or a combination of convex and concave lenses, or one or more convex/concave type lenses, or any combination thereof. The signals may be conditioned so that the feedback loops provide an input signal to the motion correction mechanisms such that the resulting circuits are stable in the region of interest. The conditioning may include adjusting the gain of the signal as well as adjusting for the null of the circuit and the zero offset of the gyros. Thus, if the integrated rate output measured is equal to 1 degree, the amplified signal has to equal a voltage (or current) that will produce a motor movement required to move the compensating lens for a one degree of motion.
[0050] The anti-vibration control circuit 130 may be part of a microprocessor or microcomputer, or could be constructed out of individual analog and digital elements depending on the cost, size and power consumption of each implementation. Additionally, an on/off switch may be provided in laser diode pointer 100 which may enable a user to turn off the anti-vibration control circuit if the user does not want to use the motion compensating function.
[0051] FIG. 2 is a diagram of a laser diode pointer 100 when it is tilted down. The gyros 120 and 125 may measure the angular velocity of the tilt, and their output signals (which may be in analog form) are proportional to the angular rate of the motion. Such signals may then be amplified, digitized and passed to the band pass frequency filter 134 . The band frequency filter 134 may extract the portion of the signal(s) associated with rapid unwanted angular motion (e.g. unwanted hand tremors which may be in the 1 to 5 Hz range). The filtered signal may then be integrated by the integrating processor circuit 135 . The normalizing and conditioning circuit 136 may receive the integrated signal and, in accordance therewith, may generate a voltage or current signal having a value or magnitude corresponding to the necessary compensation, and may cause the same to be supplied to compensating element(s) (such as motors 140 and 150 ). In response thereto, the motors 140 and 150 may cause the corrective lens 160 to move in a direction such that an exiting beam continues to exit the laser pointer 100 in a horizontal or a substantially horizontal direction. Without the movement of this corrective movable lens 160 the beam would exit at a downward angle. The motors 140 and 150 may be an electro-motor, an electromagnetic motor, a piezo-electric motor or any other type of actuator suited for this application.
[0052] Although not shown in this diagram, laser pointer 100 (which includes the gyros and the anti-vibration circuit) may be powered by a power source such as two 1.5V batteries connected in series as used for ordinary laser pointers. To save on power usage, the motion-compensation technology may be activated only upon activation of the laser pointer.
[0053] Although FIG. 2 depicts a laser diode pointer 100 tilted on one axis and its resulting compensation, tilting on the other axis would be compensated similarly (and independently) and is not illustrated in order to keep the drawings simple and easy to follow.
[0054] In another embodiment of the invention, and as shown in FIG. 3 , a laser diode pointer 200 may use a movable bellows 210 that may be filled with a high refractive index solution or material 220 instead of corrective movable lens 160 . The refractive index of the high refractive index solution or material 220 may be approximately 1.33 or higher. The high refractive index solution or material 220 may be stored between two sheets of glass 230 and 240 such that the portion of the high refractive index solution in the path of the optical beam may be adjusted (by squeezing or spreading the bellows) based on the angular rates measured by the two angular velocity sensors or gyros 120 and 125 . Instead of moving an optical lens to change the direction of the exiting beam the bellows filled with high refractive index solution may be contracted on one end and expanded on the other end so as to bend the exiting light beam in a direction opposite to the unwanted motion.
[0055] FIG. 4 shows how such a change in the thickness or arrangement of the bellows may cause the beam to bend so as to compensate for the unwanted motion. As in the previously described laser pointer having a movable lens, the laser pointer 200 may be powered by a power source such as a number of batteries arranged in a predetermined manner. Additionally, FIGS. 3 and 4 indicate how motion in the pitch or X axis is compensated; however, motion in the yaw or Y axis may be compensated similarly (and independently) and is not illustrated in order to keep the drawings simple and easy to follow.
[0056] FIG. 5 is a flow chart describing how a laser pointer in accordance with an embodiment of the present invention compensates for unwanted motion. The process starts in step S 100 where the laser pointer is turned on by pressing a button or the like. During operation of the laser pointer, a sensing means, which may include gyros or accelerometers or a combination thereof, measure movement and output a signal which may be processed by the anti-vibration control circuit. Such processing may include the analog to digital conversion performed by the A/D converter 133 . Processing may then proceed to step S 120 wherein the signal may be supplied through a band pass filter so as to effectively detect and extract signals corresponding to the unwanted motion of the laser pointer (unwanted motion may be in the 1 to 5 Hz range). If the sensing means does not detect unwanted motion, the method may proceed to step S 130 where the correcting lens or bellows is not moved and the beam exits the laser pointer with out any redirection. If there is unwanted motion detected by the sensing means, the method proceeds to step S 140 where the processed signal may be integrated and/or amplified. A voltage or current corresponding to the processed and/or amplified signal may be applied to the drive motors in step S 150 , which in turn, may move the prism or the bellows in step S 160 . In step S 170 , the beam may be redirected in the direction opposite the direction of the hand tremor.
[0057] FIG. 6 is a diagram of another embodiment of the laser diode pointer 300 wherein accelerometers are utilized instead of gyroscopes. Three angular velocity and/or translational motion sensors (accelerometers) 310 , 320 , and 330 , which may be aligned in orthogonal directions, may be used to measure the angular and/or translational movements in the pitch, yaw and roll axis (also referred to as the X, Y and Z axis) respectively. The output of accelerometers 310 , 320 , and 330 may be respectively amplified by three amplifiers 340 , 350 , and 360 , and then sampled by A/D converter 133 in the anti-vibration control circuit 330 . The portion of the signal associated with rapid unwanted angular and/or translational motions of the pointer (e.g., an unwanted hand tremor in the 1-5 Hz range) may be extracted by band pass filter 134 and integrated by integrating processor circuit 135 . Movements (tilts) of the laser pointer may be measured by comparing the measured acceleration to a gravity vector (g acceleration) as the laser pointer is tilting and/or computing the motions from the three orthogonal measurements of the acceleration.
[0058] The computed integrated rate output (proportional to the angle of the unwanted angular and/or translational motion) may be conditioned (which may include amplifying the signal by a necessary or predetermined amount) and/or used as the input for motor(s) that may be coupled to movable lens 160 located between the laser diode 110 and the focusing lens 170 . The anti-vibration circuit 330 may be included in a microprocessor or microcomputer or may be constructed out of individual analog and/or digital elements depending on the cost, size and power consumption requirements.
[0059] FIG. 7 is a block diagram of another embodiment of the present invention. A motion-compensated, laser diode pointer illustrated in FIG. 7 comprises a laser emitting diode 110 , motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 , yaw drive 150 , and mirrors 310 and 320 mounted on cantilevers 350 and 360 . Preferably, Bimorph ceramic cantilever strips 350 and 360 comprise Lead Zirconium Titanate (PZT)-metal sandwich strips, or other piezoelectric materials. Cantilevers 350 , 360 may be composed of single or multiple elements. Mirrors 310 , 320 may be moved by various other means in addition to bimorph ceramic strips of the type used for this application.
[0060] In operation, the function of laser emitting diode 110 , motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 and yaw drive 150 are described above and will not be repeated here. Voltage generated by these components are applied to cantilevers 350 , 360 , causing them to bend and thus to change the angle of mounted mirrors 310 , 320 . The voltage applied to cantilevers 350 , 360 deflects each cantilever proportional to the magnitude of the voltage applied. Mirrors 310 and 320 at the end of cantilevers 350 , 360 deflect the laser beam. A mirror deflection of one degree of angle will deflect light by a two degree of angle deflection—one degree of deflection for the incident beam and one degree of deflection for the reflected beam. Thus, moving a mirror is twice as efficient as moving a lens. The amount of deflection may be adjusted based on the angular rates measured by the two motion sensors 120 and 125 . Preferably, motion sensors 120 , 125 are angular velocity sensors or gyros.
[0061] In an alternate embodiment (not illustrated), a set of three to six accelerometers are connected to the body of the laser pointer to measure the unwanted vibrations by measuring the changes of the gravity vector during the unwanted vibration of the laser pointer. Three accelerometers would be the minimum number required and six accelerometers would provide additional accuracy for determining the amount of unwanted vibration present.
[0062] FIG. 8 is a block diagram of a motion-compensated light-emitting apparatus according to another embodiment of the present invention comprising a two axis MEMS based micro mirror. As illustrated in FIG. 8 , the system includes a two axis MEMS micro mirror 410 , in addition to the aforementioned components laser emitting diode 110 , motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 , yaw drive 150 . Two axis MEMS micro mirror 410 is preferably a commercially available unit, such as from Mirrorcle Technologies Inc., type SO308. The mirror changes angle with respect to the package in a similar manner as large scale galvanometer based optical scanners, except that MEMS micro mirror 410 requires several orders of magnitude less driving power. In addition, micro mirrors devices that change in both deflection axes are readily available in a single miniature device that is very compact, typically smaller than 8 mm×14 mm×2 mm.
[0063] In operation, the function of laser emitting diode 110 , motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 and yaw drive 150 are described above and will not be repeated here. In this embodiment, the angle of mirror 410 can be controlled independently in each of two axes (X and Y) by the applied voltage from independent mirror drives 140 and 150 . Mirror 410 will deflect the beam proportional to the applied voltage in each axis. The amount of deflection may be adjusted based on the angular rates measured by the motion sensors 120 and 125 . A voltage applied to the MEMS micro mirror tilts to change the angle of mirror 410 . As described above, moving a mirror is twice as efficient as moving a lens. Thus, with a mirror deflection of one degree of angle, the light is deflected two degrees—one degree of deflection for the incident beam and one degree of deflection for the reflected beam.
[0064] In an alternate embodiment (not illustrated), a set of three to six accelerometers are connected to the body of the laser pointer to measure the unwanted vibrations by measuring the changes of the gravity vector during the unwanted vibration of the laser pointer. Three accelerometers would be the minimum number required and six accelerometers would provide additional accuracy for determining the amount of unwanted vibration present.
[0065] FIG. 9 is a block diagram illustrating a motion-compensated light-emitting device for displaying a variety of stabilized rasterized and stabilized vector graphics as well as stabilized multi-frame animations at arbitrary refresh rates. As illustrated in FIG. 9 , the system comprises laser emitting diode 110 , motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 , yaw drive 150 and a two axis MEMS micro mirror 410 , all of which are described above. In addition, the system comprises a signal conditioning filtering and voltage control device 420 , a computer or microprocessor 430 , a self contained vector graphics or raster graphics generator 440 , a signal conditioning, filtering and voltage control unit 450 and a voltage adder 460 , which are used to generate a projected image 470 , for example, a symbol, letter, or figure.
[0066] Image 470 is represented by a low level signal that is transmitted to a signal conditioning, filtering and voltage control device 420 by computer 430 . Device 420 sends its output signal to a voltage adder 460 that combines this output signal with the motion compensation signal from normalization circuit 136 , to stabilize the projection of image 470 . In another embodiment, a self contained vector graphics or raster graphics generator 440 can be self contained within the proposed laser pointer system. The signal output of generator 440 is sent to a signal conditioning, filtering and voltage control unit 450 to ensure the proper dimensioning of the projected image 470 . Signal conditioning, filtering, voltage control system 450 sends an output signal to the voltage adder/combiner 460 . After the voltages for the vibration stabilization 136 and the generation of the image 470 have been combined, the signals are provided as input to the respective X and Y axis mirror drive units 140 and 150 . By superposition, the resulting system projects the desired rasterised or vector graphic with the motion reduction signal in a manner that would not be possible without the vibration stabilization portion as often the resulting projection would be unrecognizable or unreadable because of laser beam jitter.
[0067] The system is highly adaptable to projection onto various surfaces and in a variety of applications, including projection onto specially-coated transparent surfaces. Due to the low power consumption and vibration stabilized output of this device, the system is highly portable, especially mobile when used with a laptop small computer. A computer can be used for a generator 440 to project different letters, symbols, or graphics or other static or moving images 470 that can change and evolve over time as well as be a function of the material that is presented.
[0068] In an alternate embodiment (not illustrated), a set of three to six accelerometers are connected to the body of the laser pointer to measure the unwanted vibrations by measuring the changes of the gravity vector during the unwanted vibration of the laser pointer. Three accelerometers would be the minimum number required and six accelerometers would provide additional accuracy for determining the amount of unwanted vibration present.
[0069] FIG. 10 is a block diagram of a motion-compensated, holographic laser projector. As illustrated in FIG. 10 , a motion-compensated projection device is provided comprising motion sensors 120 , 125 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 , yaw drive 150 and a two axis MEMS micro mirror 410 , all of which are described above. In addition, the system comprises lasers 500 , collimating lenses 510 , mirrors 520 , demagnification lenses 530 , projected display 540 and micro display 550 .
[0070] The motion-compensated projection device displays full color, high-quality images that remain in focus at all distances using holographic laser projection technology. The term “holographic” refers not to the projected image, but to the method of projection. Three lasers of magenta, blue and green color 500 each generate a laser beam that is collimated by individual lenses 510 . The beams are reflected and combined into a single beam by three mirrors 520 . The combined beam is then reflected off micro display 550 . A diffraction pattern of the desired 2D image, calculated using holographic algorithms, is displayed on this phase-modulating Liquid Crystal on Silicon (LCOS) micro display 550 that is attached on top of a two axis MEMS micro minor 410 . When illuminated by coherent laser light, the desired image 540 is projected on various surfaces without being distorted by the micro-tremors of the projection system.
[0071] Rather than blocking light, the phase-modulating LCOS micro display 550 mounted on MEMS micro minor 410 steers the light to exactly where it is needed, making the system highly efficient. By combining the holographic laser projection technology with the vibration reduction technique a projection system is created that projects images without also projecting the various vibrations and tremors of the projection system or the support structure of the projection system. The resulting system projects the desired image in a manner that would not be possible without the vibration stabilization portion as often the resulting projection would be of much lower quality, unrecognizable or unreadable because of laser beam jitter, or jitter in all elements used to project the image on the desired surface.
[0072] Unlike conventional projection systems, this type of technology does not require a projection lens. Instead, a demagnification lens pair expands the diffracted image from the micro display, producing an ultra-wide throw angle greater than 100°. The projected images are in focus at all distances from the projector, eliminating the need for a focus control. The diffractive method of projection naturally lends itself to miniaturization and low cost implementation. It allows images to be projected onto curved and angled surfaces without distortion, and is highly tolerant to micro display pixel failure—essential in safety critical applications in markets such as automotive.
[0073] In an alternate embodiment (not illustrated), a set of three to six accelerometers are connected to the body of the laser pointer to measure the unwanted vibrations by measuring the changes of the gravity vector during the unwanted vibration of the laser pointer. Three accelerometers would be the minimum number required and six accelerometers would provide additional accuracy for determining the amount of unwanted vibration present.
[0074] FIG. 11 is a block diagram of a motion and position compensated laser pointer. As illustrated in FIG. 11 , the system comprises laser emitting diode 110 , signal amplifiers 131 , 132 , an A/D converter 133 , high pass filter 134 , integrating circuit 135 , normalization circuit 136 , pitch drive 140 , yaw drive 150 and a two axis MEMS micro mirror 410 , all of which are described above. In a preferred embodiment, the system further comprises a memory 560 , a computer 570 , X and Y accelerometers 580 and 590 , a digital magnetometer 595 , a location indicator 596 and a range indicator 597 .
[0075] The motion-compensated projection device stores in memory 560 the orientation of the laser or projection system at times directed by the user. For example, the user may mark a target by pressing a button (not shown). Signals from two angular position and/or translational motion sensors or accelerometers, in the X and Y orientation 580 and 590 and a digital magnetometer 595 (for azimuth orientation) indicate the orientation of the laser pointer when the user so indicates. In addition, location indicator 596 and range indicator 597 provide position and range to target information that is stored in memory 560 for later retrieval. Memory 560 is accessed by computer 570 . In an alternative method of operation, the desired positions could be downloaded from computer 570 into memory 560 . The system maintains the laser pointed in the marked orientation. In addition, several points can be marked in sequence, and the laser can scan and point at them in a round-robin fashion.
[0076] In an alternate embodiment (not illustrated), a set of three to six accelerometers are connected to the body of the laser pointer to measure the unwanted vibrations by measuring the changes of the gravity vector during the unwanted vibration of the laser pointer. Three accelerometers would be the minimum number required and six accelerometers would provide additional accuracy for determining the amount of unwanted vibration present.
[0077] Having thus described at least illustrative embodiments of the invention, various modifications and improvements will readily occur to those skilled in the art and are intended to be within the scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting.
[0078] Although the above embodiments describe laser pointers that may utilize specific combinations of gyroscopes or accelerometers, the present invention is not so limited. For example, the present invention may also utilize other types of motion sensing devices or may utilize a different number of gyroscopes or accelerometers or may utilize a combination of gyroscopes and accelerometers to sense unwanted motion. In addition, although a “light beam” is recited, the invention shall not be limited to a ray of visible light, but shall also encompass other forms of electromagnetic radiation that can be reflected or refracted, as is well known in the art, such as infrared, ultraviolet, or even x-ray or other non-visible radiation. Although preferred embodiments of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to those precise embodiments and modifications, and that other modifications and variations may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. | A light-emitting apparatus, for enabling a beam of light to be projected on a desired target located a distance away to project the beam on the desired target without any or substantially any undesired movement. The apparatus may include a housing, a light generating device located within the housing and operable to generate a beam of light, a sensing device or devices for sensing an undesired action of the housing, a control circuit operable to provide a control signal corresponding to the sensed undesired action, and a drive device operable to counter act all or at least some of the undesired action of said housing in accordance with said control signal. The sensing device or devices may be one or more gyroscopes, accelerometers or other such devices. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. national phase, under 35 U.S.C. 371, of PCT/EP2009/059698, filed Jul. 28, 2009; published as WO 2010/043340 A1 on Apr. 22, 2010, and claiming priority to DE 10 2008 042 813.2, filed Oct. 14, 2008, the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a system for securing a hazardous area in the region surrounding the automatic loading of reels on a reel changer. A contactless safety device is placed at access boundaries of the region. This safety device can be deactivated to allow a known object to pass in or out of the hazardous area in the region surrounding the automatic loading of the reels on a reel changer. The safety device includes an evaluation unit and is embodied as a light beam barrier which has multiple light beams passing parallel to one another.
BACKGROUND OF THE INVENTION
Technical systems, such as machine tools and industrial robots, for example, harbor the risk of injury to persons approaching the movable parts of the machine. Hazardous areas around a reel changer include particularly the pivoting region of the reel support arms, the area behind the reel changer in the pivoting region of the splicing frame, the loading area, and the pit below the reel changer, if provided. It is therefore necessary for machines to be provided with safety devices, which prevent injuries to persons caused by the working movement of the movable parts of the machine. In the past, primarily mechanical safety devices have been employed for this purpose. For instance, machine tools are frequently completely enclosed, with access being allowed via safety gates. Industrial robots are operated in areas enclosed by protective fencing.
However, mechanical safety devices are associated with disadvantages. Adequate space must be provided for the safety device itself and for the opening of any safety gates that may be present, which increases the amount of space needed for the entire system. Moreover, rapid intervention into the production sequence is not possible, as opening safety gates or protective fencing requires a corresponding amount of time and control. Furthermore, mechanical safety devices are not maintenance and wear free.
DE 10 2005 048 466 A1 describes a personnel safety device on a reel changer of a printing press, which is embodied, for example, in the form of a catch net on the loading side of the reel changer. This safety device is embodied to turn the loading side into a secured area whenever the residual paper reel approaches a critical diameter, i.e., is at risk of breaking. Persons near the reel changer are thereby to be reliably protected from fragments of bursting reels. For this purpose, the safety device is mounted on the transfer table that is used to supply new reels of material, and at a fixed point in relation to the reel stand on the loading side. To supply a new material reel, the transfer table moves up to the reel stand, thereby setting up the safety device. Therefore, the safety device is activated only when the described critical status of the residual paper reel is reached. At all other times, the area on the loading side of the reel changer can be accessed unimpeded. However, to inform persons present in the potentially hazardous area of the potential hazard even when the mechanical safety device is inactive, an additional securing of the area using photoelectric beam interruption detectors is proposed. On the basis of the signal emitted by the beam interruption detector, a visible or audible signal for a person present in the area of the reel changer is emitted.
From WO 2005/080241 A2 it is known to provide a zone safety device in the area surrounding large moved reels of material for purposes of occupational safety. In this case, the erection of fencing along the boundaries of a material reel storage area is proposed. To allow material reels to be transported into and out of the storage area, a lock can be provided in the zone safety device. In the lock area, a preferably contactless zone safety device is proposed, which can be implemented as photoelectric beam interruption detectors or ultrasonic sensors, for example. By arranging sensors of this type at different levels, complex sensing routines can be implemented, so that, for example, reels of material are allowed to pass through the lock without problems, whereas any unauthorized passage through the sensor areas will trigger an alarm and/or will halt the movement of the material reels, in order to prevent accidents.
EP 08 49 201 A1 relates to a method for detecting lateral position and for positioning a reserve web reel, wherein reel thickness and the respective lateral distance from the reel changer are measured and evaluated by directly opposite scanning elements in the form of sensors, for example, laser beam or ultrasonic sensors. Moreover, the scanning elements are connected to a programmable control system for a drive unit for positioning the spare web reel.
EP 15 93 630 A2 discloses a device for preparing a web of material wound onto a spare reel, which has a bearing for supporting and rotating the spare reel about a longitudinal axis. Sensors detect the radius of the spare reel during rotational movement. A plurality of sensors for detecting the radius are arranged parallel to the longitudinal axis of the spare reel.
The contactless devices described in the aforementioned publications serve to detect the positioning or the dimensions of a reel in the region surrounding the automatic loading of reels on a reel changer, and serve no safety or protective function.
From DE 31 34 815 C2, a contactless area safety system, for example, for securing or monitoring viewing windows is known. The area safety system has a source which emits radiation over its entire length, along one side of the area to be secured. Along the opposite side, a reflective strip is provided. The radiation is predominantly reflected in the plane spanned by the source and the reflective strip. At each end of the radiation source, a radiation detector is provided, which is connected to an evaluation circuit. This area safety system can be used as security against passage, for example, through hazardous areas by installing a multiple infrared beam barrier between two rods, which, when interrupted, triggers a signal. The disadvantage of this system for securing hazardous areas is that it is able to perform only a simple protective function.
From DE 199 38 639 B4, a device for securing a hazardous area, particularly the hazardous area of an automatically operating machine, is known, said device comprising first means for generating an optically monitored virtual barrier and second means for generating a switching command to stop the machine when a barrier is penetrated. The first means has an image recording unit and a defined target, the image of which is recorded by the image recording unit and compared by a comparison unit (second means) with a size which is characteristic for a reference image. The defined target is a structured, high-contrast pattern, which contains positioning marks for determining a current position. Using a point pattern, according to one embodiment example of the device, a virtual barrier can be generated, the shape of which corresponds approximately to that of a beam interruption detector. Alternatively, however, a plurality of point patterns can be placed in a row to generate a linear pattern. This device performs only a protective function. The evaluation and the comparison of the recorded images with the reference image are costly.
DE 296 02 098 U1 relates to a reel changer in a web-fed rotary printing press for loading a web of print substrate wound onto reels into a printing couple of the web-fed rotary printing press. The area surrounding the reel changer is monitored by at least one sensor, particularly an optical sensor, for example, a camera, which is connected to an image recognition computer. In the image recognition computer, a comparison is made between a recorded actual image of the area and a stored set image or a sequence of set images. In the event of deviations, a signal generating device generates a warning or alarm signal. The at least one sensor can also be assigned contact mats, contact strips, photoelectric beam interruption detectors, or similar contactless safety devices, which supply partial information or control or activate the sensor. The solution disclosed in this publication enables a monitoring of the region surrounding the reel changer, whereby selective protection is realized in that known objects are recognized and the entry thereof into the area without triggering warning or alarm signals is enabled. However, image recognition can be easily influenced by subjective factors in the monitored area, for example, a deviation in position of an object, which is to be recognized as known in the set image, on a recorded actual image, which can lead to disruptions or malfunctions.
DE 100 26 305 A1 describes an optoelectronic device for monitoring a protected area with at least one contactless safety device, which has an evaluation unit for generating an object detection signal when an object enters the protected area. The contactless safety device can be a light beam barrier, which comprises a transmitter unit which transmits light beams, a receiver unit which receives the light beams, and an evaluation unit connected to the receiver unit. To perform another function in addition to the protective function, the contactless safety device is coupled with an image recording unit for sensing a secondary monitoring area, which lies close to the protected area but outside of the protected area. This so-called muting function allows the short-term deactivation of the contactless safety device, to allow recognized objects to enter the protected area without generating an object detection signal. The muting function is implemented by the image recording unit, which detects the objects that enter the secondary monitoring area, wherein differentiation is made between permissible and impermissible objects. The detected objects may be classified. The disadvantage of this solution is that the recognition of known objects does not always function reliably. In addition, the setup of an additional image recording unit involves additional complexity and financial expense.
From DE 10 2005 030 829 A1 a method for operating a multiple infrared beam barrier is known, in which a switching signal is generated from the sequential interruption of the light beams with a stored reference profile.
DE 10 2004 038 906 A1 proposes transmitting a mark on an object to an evaluation unit, in addition to a multiple infrared beam barrier.
In DE 295 00 873 U1 the sequence of interruption of the light beams of a multiple infrared beam barrier is detected, in order to distinguish between permissible objects and persons, for example.
SUMMARY OF THE INVENTION
The problem addressed by the invention is that of devising a system for securing a hazardous area in the region surrounding the automatic loading of reels onto a reel changer.
The problem is solved according to the invention by the provision of the evaluation unit of the safety device with the ability to detect a sequence in the interruption of the light beams when an object passes into or out of the region being protected. On the basis of this detection sequence, the evaluation unit determines if the object is one that is known. If it is a known object, it is allowed access to the hazardous area. In this case, the evaluation unit deactivates the safety device. The system for securing the hazardous area also includes a second contactless safety device which is permanently active.
The advantages to be achieved by the invention consist particularly in that an improved system for securing hazardous areas is provided on the basis of contactless safety mechanisms for the region surrounding the automatic loading of reels onto a reel changer, which ensures a continuous securing of the protected area even in the case of different reel diameters and during the removal of residual cores.
The system for securing hazardous areas has a contactless safety device, which is connected to an evaluation unit. The safety device is embodied as a light beam barrier, which has multiple beams of light that run parallel to one another. The evaluation unit detects the sequence in which the light beams are interrupted when an object is introduced and/or removed, and on the basis of said sequence can identify a known object, and in predefined cases can deactivate the safety device.
The advantages of the invention are particularly that the safety device, in addition to a protective function, also has a muting function, which saves the cost of setting up an additional device for performing the muting function.
A muting function ensures a temporally limited deactivation of parts of a safety device or of the entire safety device. Preferably, this allows objects access without actuating the safety device.
In one preferred embodiment, the beams of light are spaced evenly from one another and extend inclined toward horizontal, wherein in other embodiments the light beams can also be arranged running horizontally with the surface of the light beam barrier inclined toward vertical.
At least one light beam of the light beam barrier, passing above the known object, can advantageously be permanently active, in order to detect the entry of a person or an impermissible object into the secured region surrounding the automatic loading of reels onto a reel changer, even if said person and object enter the secured area accompanying the known object that is allowed access, while the safety device is deactivated.
The known object that is allowed access can be, for example, a material reel, a residual core or a driverless, automatic transport vehicle.
Irrespective of this, the system for securing a hazardous area can have at least two photoelectric cells, for example, reflective photoelectric cells, for muting, which are connected to the evaluation unit. More particularly, in one preferred embodiment, four reflective photoelectric cells are installed as a muting group (two in front of and two behind the light beam barrier). In this manner, objects, particularly residual cores, can be identified on the basis of a reflective strip glued to the side thereof, for example, and the muting function can be activated, or the safety device can be deactivated. This can be necessary particularly during the removal of residual cores, which have a different shape from reels. For example, if only reels are implemented as known objects in the evaluation unit (on the basis of shape and the simple evaluation of the sequence of interruption of the light beams), the muting function can be implemented on the basis of the reflective strip on the residual core. Residual cores are frequently removed using automatic transport vehicles (AGV=automatic guided vehicle). To allow said vehicles access to the secured area, they must also be provided with reflective strips for muting, or a corresponding sequence of interruption of the light beams of the light beam barrier must be known in the evaluation unit, in order to identify the AGV as a known object that is allowed access to the secured area.
To secure the protected area against the entry of persons or objects accompanying the known object while the safety device is deactivated, the system for securing the hazardous area can have a second, permanently active, contactless safety device comprising at least two light beams, which intersect a slight distance above the known object, with the continued path of said beams passing close to the known object. These two light beams thus extend only a few millimeters to a few centimeters, at parallel spacing, from imaginary tangents lying against the upper half of the known object. The lower ends of the two light beams are therefore located clearly below the upper edge of the known object, and can lie near the axial plane of the known object, depending upon the chosen angle of inclination.
One advantage of the invention consists in that the second, permanently active, contactless safety device allows a reliable, permanent securing of a hazardous area, even when the known object is a reel having a greater reel diameter. The path of the beam does not allow anything to unintentionally pass over or under the beams of the second safety device. In any case, a person can pass below the beams only in a severely bent position. However, even the best safety device can provide only limited protection against all eventualities or against intentional circumvention. It cannot be the job of such devices to reliably protect against malicious entry in every case.
A further advantage of the invention is that the safety device can be attached directly to the reel changer. Therefore, in contrast to previously known solutions, which require an attachment point above the reel, no additional attachment points external to the reel changer are required.
According to one particularly preferred embodiment, the contactless safety device and/or the second, permanently active, contactless safety device comprise one transmitter and one receiver for each light beam. However, embodiments are also possible in which the safety devices comprise precisely one transmitter, one receiver and a plurality of deflecting mirrors for all the light beams together.
In one advantageous embodiment, in the aforementioned safety devices one-way beam interruption detectors are used, in which transmitter and receiver are arranged opposite one another, in separate housings.
The use of reflective beam interruption detectors for the described safety devices has proven particularly expedient. In these embodiments, a combined transmitting and receiving unit is arranged opposite a reflector. The emitted light beams are reflected back to the receiver by the reflector.
It is also advantageous for the positions of the transmitter, receiver, reflector and/or deflecting mirror to be adjustable. In this manner, adjustment can be made to different objects, which are known and which are allowed access to the secured area. In this case, it has proven particularly favorable for the system for securing a hazardous area to be equipped with a sensor for detecting the dimensions of the known object.
Particularly for the proper functioning of the second, permanently active, contactless safety device, it must be ensured that the beams do not come in contact with the known object, since they are intended to secure the hazardous area during the introduction and/or removal of a known object while the first safety device is inactive. Accordingly, the second safety device cannot be triggered when the known object is passing through the access boundaries. The adjustability to different objects ensures that the beams always remain outside of the region through which the known object is passing.
In another further developed embodiment, it is advantageous for the sensor to be connected to an adjustment device. Said adjustment device is used for the automatic adjustment of the transmitter, receiver, reflector and/or deflecting mirror to the known object. Using an adjustment device of this type ensures that the transmitter, receiver, reflector and/or deflecting mirror is always repositioned on the basis of the detected dimensions of the known object. Naturally, it is also possible to perform positioning manually. For this purpose, it could be conceivable for a corresponding scale to be attached to the reel changer in order to facilitate manual positioning.
This system for securing a hazardous area has proven advantageous for a reel having a reel diameter of up to 1,524 mm. With reels of this size, adequate safety measures are no longer possible using conventional safety devices, since shorter persons bending only slightly are able to walk under the light beams of the second safety device.
The system for securing a hazardous area can also comprise a photoelectric cell, which is arranged inside the secured area for the purpose of positioning a reel or an automatic transport vehicle in a starting position.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiment examples of the invention are illustrated in the set of drawings and will be specified in greater detail in what follows.
The drawings show:
FIG. 1 an arrangement illustrating the principle of a system for securing a hazardous area in the region surrounding the automatic loading of reels;
FIG. 2 a perspective illustration of a reel changer having a system for securing a hazardous area;
FIG. 3 a an illustration of the principle of a system for securing a hazardous area in the region surrounding the automatic loading of reels;
FIG. 3 b an illustration of the principle of a modified system for securing a hazardous area;
FIG. 3 c a multiple beam barrier for a contactless safety device of a system for securing a hazardous area in the region surrounding the automatic loading of reels, with a second, permanently active, contactless safety device;
FIG. 4 a frontal view of an embodiment of the system for securing a hazardous area in the region surrounding the automatic loading of reels, with a photoelectric cell for positioning a reel in a starting position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a system for securing a hazardous area in the region 01 surrounding the automatic loading of reels onto a reel changer 02 (see FIG. 2 ). The system for securing a hazardous area comprises a first contactless safety device, located at the access boundaries. Access boundaries to be secured are located not only on the reel intake side, but also opposite the reel intake side, if both sides are freely accessible to persons. The first safety device comprises two light beams 04 , which secure the region through which a reel 05 or a residual core can pass, wherein the first safety device can be deactivated to allow entry and exit. In what follows, when only a reel 05 to be introduced into the secured area is mentioned, this also applies similarly to a residual core or automatic transport vehicle to be introduced, and to the reverse sequence of movements executed when removing the reel 05 or the residual core or automatic transport vehicle.
For changing the reel 05 , the first safety device can be deactivated. The system for securing a hazardous area further has a second, permanently active, contactless safety device for permanently securing the region surrounding the reel 05 . The second safety device comprises a light beam 07 , which is spaced a distance of 50 mm from the greatest reel diameter (maximum processable reel diameter). However, with larger reel diameters, a second safety device of a similar embodiment has proven disadvantageous.
As is clear from FIG. 2 or 3 a , the danger exists that a shorter person, accompanying the reel 05 , could walk into the secured reel loading area, and could thereby be injured by the moving machine parts or the moved reel 05 .
FIG. 3 b shows a system for securing a hazardous area in the region 01 surrounding the automatic loading of reels. Here again, the system for securing a hazardous area comprises a first, contactless safety device at the access boundaries, having two light beams 04 , which secure the region through which the reel 05 or the residual core or automatic transport vehicle can pass. To permanently secure the area surrounding the reel 05 , a second, permanently active, contactless safety device is used. The second safety device comprises two light beams 07 , beginning from points located above the reel 05 and running laterally past the reel 05 , reaching the area near the floor. As is clear from FIG. 3 b , a safety device embodied in this manner also cannot offer adequate protection. Because the light beams 07 travel past the reel 05 , reaching almost to the floor, the danger exists that a person walking along next to the reel 05 during installation could step over the light beams 07 .
FIG. 3 c shows a system for securing a hazardous area in the region 01 surrounding the automatic loading of reels. In contrast to the known solutions, this system for securing a hazardous area has a light beam barrier 03 as a contactless safety device at the access boundaries of the secured region 01 surrounding the automatic loading of reels. The light beam barrier 03 can be deactivated to allow the reel 05 or residual core or automatic transport vehicle to be introduced or removed. In addition, a second, permanently active, contactless safety device is provided for permanently securing the region surrounding the reel 05 , which will be described in greater detail below. At this point it should once again be mentioned that access boundaries to be secured can be located not only on the reel intake side, but also opposite the reel intake side. Safety devices are to be situated on both sides if both sides are freely accessible to persons. The contactless safety device, in combination with the evaluation unit, secures every access boundary to be secured using a light beam barrier 03 .
In the embodiment example shown, the light beam barrier 03 is formed by multiple light beams 04 extending parallel to one another, which are uniformly spaced from one another by preferably 40 mm, and extend inclined toward horizontal. Of course, different spacing or different angles of inclination may also be chosen. The light beams 04 can also extend horizontally, and the surface of the light beam barrier can be arranged inclined toward vertical, with the angle of inclination preferably being 15°.
A transmitter and a receiver are assigned to the light beams 04 of the light beam barrier 03 , and are positioned at the end points of the light beams 04 . The light beam barrier 03 is connected to an evaluation unit, which is not illustrated here. The evaluation unit detects the sequence of interruption of the light beams 04 when a reel 05 or a residual core or an automatic transport vehicle is introduced and/or removed, and deactivates the system for securing the hazardous area comprising the light beam barrier 03 when a known object that is allowed access to the secured region is detected.
The evaluation unit evaluates whether the individual light beams 04 of the light beam barrier 03 are interrupted in sequence or are again uninterrupted. It is irrelevant how many individual light beams 04 are interrupted, or in what region they are interrupted.
Gaps in the interruption of the individual light beams 04 are not permissible, however.
Irrespective of this, the system for securing the hazardous area comprises four photoelectric cells 06 for muting, particularly reflective photoelectric cells 06 , wherein two reflective photoelectric cells 06 are arranged in pairs in front of the light beam barrier 03 and two behind the light beam barrier. The cells serve to deactivate (mute) the light beam barrier 03 when a known object, particularly a residual core, is detected, the shape of which makes evaluating the sequence of interruption of the light beams more difficult. Moreover, the reflective photoelectric cells 06 are connected to an evaluation unit not shown here. For detection purposes, the residual cores are equipped with reflective strips, which are positioned on the residual cores in accordance with the arrangement of the reflective photoelectric cells 06 . The light beam barrier 03 is muted (switched off) when the reflective strips are detected on a residual core. Once the residual core has passed through the system for securing the hazardous area, the fourth reflective photoelectric cell 06 no longer receives any reflection of the light beam, and therefore the light beam barrier 03 is reactivated.
In the case of an automatic transport vehicle, the muting function can be implemented via two reflective photoelectric cells 06 , since the automatic transport vehicle does not travel all the way through the light beam barrier, rather only a part of it enters the reel changer 02 in order to deliver the reel 05 . The first reflective photoelectric cell 06 detects the reflective strip which is positioned on the vehicle in accordance with the arrangement of the reflective photoelectric cells 06 , and switches the light beam barrier 03 off. When the second reflective photoelectric cell 06 no longer receives any reflection of the light beam during the removal of the automatic transport vehicle, the light beam barrier 03 is reactivated.
The two uppermost light beams 04 of the light beam barrier 03 remain permanently active, in order to prevent a person or an object accompanying the reel 05 or the residual core from entering the secured area in which reels are automatically loaded onto a reel changer 02 while the system for securing the hazardous area by means of the light beam barrier 03 is deactivated.
The second, permanently active, contactless safety device comprises at least two light beams 07 , which extend transversely to the longitudinal extension or axial direction of the reel 05 and intersect a slight distance above the reel 05 , with their continued extension passing close to the reel 05 or the reel core. The point of intersection of the two light beams 07 preferably lies only a few centimeters, for example, <15 cm, particularly <8 cm, preferably <5 cm, above the upper edge of the reel, and the light beams 07 then extend below the point of intersection at a distance of a few millimeters, for example, <15 mm, particularly <8 mm, preferably <5 mm up to a few centimeters, past the reel 05 . The upper end points of the light beams 07 are therefore above the reel 05 but beyond the reel extension. The lower end points lie below the upper edge of the reel, preferably at a height that is greater than ½ the reel diameter and corresponds to approximately ⅔ to ¾ the reel diameter.
As is clear from FIG. 3 c , the path of the two light beams 07 does not allow the light beams 07 to be unintentionally stepped over or unintentionally passed below. In any case, persons are able to pass below the light beams 07 only by moving in a severely bent position.
FIG. 4 shows a frontal view of an embodiment of the system for securing a hazardous area in the region 01 surrounding the automatic loading of reels. In the embodiment example shown, reflective fight beam interruption detectors are used. The second, permanently active, contactless safety device comprises a combined transmitting and receiving unit 08 for each light beam 07 . The light beam 07 is reflected back to the transmitting and receiving unit 08 by an opposing reflector 09 . This beam path can also be used with the light beams 04 of the light beam barrier 03 . Of course, one-way beam interruption detectors, in which transmitter and receiver are arranged opposite one another, can also be used with the second, permanently active safety device and/or with the light beam barrier 03 . In alternative embodiments, all the light beams 04 ; 07 of the light beam barrier 03 and the second, permanently active safety device can have precisely one transmitter and one receiver. In these cases, multiple deflecting mirrors are required for directing the light beams 04 ; 07 . A light-emitting diode or laser diode that emits infrared radiation or visible light can be used as the transmitter, and a phototransistor can be used as the receiver.
It has proven advantageous for the position of the transmitting and receiving units 08 and of the reflectors 09 to be adjustable. For this purpose, it is expedient to equip the second, permanently active safety device with a sensor (not shown) for detecting the reel diameter. The sensor can, in turn, be connected to an adjustment device (not shown), which performs an automatic positioning of the transmitting and receiving units 08 and of the reflectors 09 on the basis of the detected reel diameter. In this manner, an optimal path of the light beams 07 can always be ensured. Of course, the position of transmitting and receiving units 08 and of the reflectors 09 can also be manually corrected. It has proven favorable for a suitable scale to be applied to the reel changer 02 for this purpose.
If a person or an object that is not allowed access enters the secured area in which reels are automatically loaded onto the reel changer 02 , accompanying the reel 05 or the residual core, while the light beam barrier is deactivated, the person or the object that is not allowed access will interrupt the beam path of at least one of the light beams 07 . This disruption will be detected by the receiver and converted to corresponding adjustment signals, which will cause the reel changer 02 to switch off. In addition, an alarm device 11 can send out an alarm in the form of a visible and/or acoustic signal.
The system for securing a hazardous area preferably further comprises four reflective photoelectric cells 06 for muting and one photoelectric cell 12 , which is arranged inside the secured area in which reels are automatically loaded onto the reel changer 02 , for positioning the reel 05 in a starting position, and which is connected to an evaluation unit, not shown here. The reel 05 coming from loading upstream passes through the system for securing the hazardous area and the detection area of the photoelectric cell 12 downstream. The evaluation unit detects the release of the photoelectric cell 12 and stops actuation of the reel. The reel 05 is transported backward toward the starting position by the reel drive, until the light beam of the photoelectric cell 12 is again interrupted.
In every case, the light beams can also be deflected, generated and/or received and/or deflected by separate transmitters and receivers, and optionally by mirrors, rather than by transmitting and receiving units and reflectors.
While a preferred embodiment of a device for securing a hazardous area in the region surrounding the automatic loading of reels on a reel changer, in accordance with the present invention, has been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that various changes in, for example, the specific structures of the reel changers, the devices used to transport the reels to the reel changers, and the like, could be made without departing from the true spirit and scope of the subject invention which is to be limited only by the appended claims. | A hazardous area in the region surrounding a reel transport of a reel changer is secured. A contactless protective device is located at the access boundaries of the region. This protective device can be deactivated for feeding and/or removing a known object and comprises an evaluation unit. The protective device is configured as a light curtain that is comprised of a plurality of light beams that run in parallel to each other. The evaluation unit includes an assembly for detecting the sequence of the interruption of the light beams during the feeding and/or the removal of an object. Based on the detected sequence of interruption of the light beams, a known object, that is permitted to access the hazardous area, is detected. The protective device is deactivated in this situation. Securing the hazardous area further includes the provision of a second contactless protective device that is permanently active. | 1 |
FIELD OF THE INVENTION
The present invention relates to automated dispensing equipment which dispenses products or services (hereinafter collectively referred to as vending mechanics and more particularly to copy machines and computers which can be used on an as needed basis and operated by a user without an attendant.
BACKGROUND OF THE INVENTION
Credit and bank issued debit cards have been in wide spread use in business establishments. The majority of uses of these cards are referred to as attended uses. Personnel of the business establishment, or attendants, are required in order to process and complete a sale or transaction using a credit or bank issued debit card.
In the past, credit card transactions were made by imprinting information stamped on a credit card onto a multi part credit card receipt using a forced-contact device. It was a common business practice to contact a credit card company by telephone to verify the available credit limit on the card to ensure that there was sufficient credit to complete the transaction. If sufficient credit was available, the credit card company and\or credit card processor company provided an authorization number over the telephone which was manually printed onto the credit card receipt.
Magnetic strip technology has largely made the forced-contact devices unnecessary and has allowed for the expansion of credit card and bank issued debit card transactions. Using magnetic strip technology, information concerning a credit card (or bank issued debit card) owner's account is stored as magnetic information on a magnetic strip attached to a credit card or bank issued debit card. By passing the magnetic strip through a magnetic card reader the information about an individual's credit card (or bank issued debit card) account can be read. The information can then be transmitted over telephone lines to the credit card company (or other authorization service) to obtain an authorization for a particular credit card transaction. Imprints of credit card information onto a receipt using a forced-contact device is no longer necessary, as magnetic information is output to a printer which outputs credit card (or bank issued debit card) information (such as the credit card account number or bank issued debit card number) and the transaction information (such as amount, date and store where purchase was made) onto a receipt for the credit card owner.
Various self-service devices using credit cards and bank issued debit cards have been appearing in the marketplace. Automatic Teller Machines (ATMs) have allowed users to deposit, withdraw and transfer funds to and from bank accounts. Originally ATMs were only used with bank issued debit cards. It is now possible to use credit cards for transactions, such as withdrawals, at ATMs (this may be more accurately described as a loan against an available credit line). Neither credit cards or bank issued debit cards contain information about account content. Account content is stored on the computer of a credit card company or bank. This information is accessed with the credit card or bank issued debit card.
In the vending field, credit cards and bank issued debit cards can be used directly at the pumps at self-service gas stations for dispensing gasoline. Although self-service, this type of vend is still referred to as an attended vend (or attended transaction), as an operator must always be on duty at the gas station. Credit cards can also be used on airplanes for personal telephone calls. This use is also considered an attended transaction as flight attendants are available, as well as a telephone operator for assistance, collect calls, information, etc.
Vending machines, such as copy machines, are often used in a completely unattended state. After normal working hours in libraries, office buildings, post office, court houses or copy facilities, users can still operate a copy machine using either coins, cash or private debit cards. Private debit cards are often referred to as "stored value cards" or "prepaid cards" Prepaid cards differ from bank issued debit cards in that prepaid cards have a cash value encoded on the card's magnetic strip. The prepaid card does not require a connection to a database, as do bank issued debit cards and credit cards, to determine if a transaction is within an available credit limit (for a credit card) or within an available balance (for a bank issued debit card). Several problems or inefficiencies can occur, however, with the use of coin/cash operated or prepaid card operated machines.
Coin operated machines require that a user have sufficient change for the number of copies the user is reproducing. The user may not be aware before arriving at the copy facility how many copies are necessary or the cost per copy. Further, for large copy jobs, carrying a sufficient amount of change is burdensome both by the weight and space taken up by the coins and the need to acquire the coins from a bank or other financial institution. This can also pose security problems for a user late at night in a library, for example. Although coin changers are often found in the vicinity of coin operated vending machines, coin changers can also run out of change causing problems during unattended use. There is a lack of accountability, as there is no receipt for transactions.
From an operator's perspective, problems with coin operated vending machines include vandalism, theft, inaccurate counting/reporting, collection and depositing. Prepaid card operated vending machines, such as copy machines, require an inventory of cards (sometimes referred to as "copy cards") as well as equipment to encode the prepaid cards. This requires either an operator to carry out the encoding on the magnetic card (requiring equipment to both read from and write to the card) or a machine analogous to a change machine for dispensing prepaid cards and/or converting cash value to a prepaid card. During unattended use, both of these means for obtaining a prepaid card may be inoperable. In the case of a prepaid card dispensing machine, sufficient change or cash must still be carried by the user. A further problem occurs when a user consumes the available purchasing power on a copy card (the prepaid amount is zero or below the cost of a copy). When this occurs, the user must obtain a new prepaid card or purchase additional purchasing power for the existing card.
Further, generally, both coin and prepaid card operated vending machines do not provide transaction information concerning the type of transaction, location duration, time and other items or information concerning the various transactions. This information can prove useful to the operator of the vending machine.
Over the years, unattended self-service copy vending equipment have been improved with the addition of copier-based features, services and reproduction quality. The improvements for unattended transactions have relied predominantly on third party companies to provide the necessary equipment that would enable the vending machines to accept money and prepaid cards as a method of payment for unattended services (also referred to as "pay as needed" services). With a number of different technologies and a lack of an industry standard, interfaces among the manufacturers of vending machines, even among many inter-company models may not be compatible. This has required different interfaces/wiring schemes for coin mechanisms or different coin mechanisms for attachment to different vending machines. As a result, not all features of a copy machine may be available to a user or separately charged by a copy service provider. For example, a coin operated copy machine typically does not charge a different amount for copying onto larger paper, such as 11"×14" paper or A4 paper.
The coin mechanism's primary function is to accept standard coins and/or make correct change to enable the correct operation of a copy vending machine. Another problem with coin mechanisms is that all transactions must default to the lowest common coin accepted, which is typically a nickel. Although an attended copy machine or prepaid card operated copy machine can change other monetary increments for a transaction, a coin operated vending machine in either attended or unattended states, must default to the lowest common coin accepted by the machine. Hence all pricing increments must be made in multiples of $0.05.
Computer use is an additional area which can be operated as unattended vending. Computer use includes the operation of a computer, access to various on-line services such as databases and bulletin boards, other types of modem communications, scanning of documents and printing. Although not typically referred to as an "on-line service", information stored on compact discs (CDs) can be thought of as similar to on-line services in that a CD contains data stored in a database. Thus, a user's searching can be monitored on a time, per search, per database or per item (does not include per input and/or output) basis. These computer uses would be beneficial to users if made available for users and set up as a pay as needed device to allow cashless unattended use of these services. The type of use may determine the type of associated charge. For example, charges could be based on the amount of time used on the computer or per operation for printing or scanning. For on-line/database searching, there may be surcharges for particular services.
Users of microfilm and microfiche readers would also benefit from a credit card/bank issued debit card operated machine. Like copy machines and computers, microfilm and microfiche readers could then be made available for pay as needed, cashless unattended use.
The same limitations causing coin/cash operation and prepaid card operation problems/inefficiencies which appear in current vending machines would also be present with these computer/microfilm/microfiche uses.
SUMMARY OF THE INVENTION
The present invention comprises a system and method for interfacing a control device to a vending machine having input/output control lines along which are transmitted control signals for controlling the operation of the vending machine. The control device includes, means for connecting to the control lines of the vending machine, means for reading the control signal, means for determining operational responses/outputs of the vending machine which correspond to the control signals, means for storing the control signals and information concerning the operational responses and means for reading the stored information to control the vending machine.
The system and method of the present invention also includes means for determining which operational responses of the vending machine correspond to the control signals by adjusting the time period over which the control signals are read by the control device until the control signals read by the control device correspond to a list of control signals stored in a memory.
The system and method of the present invention also control and monitor transactions on a vending machine and comprise means for reading magnetically stored information from a magnetic card, means for obtaining an authorization amount for a transaction, means for storing the authorization amount, means for operating the vending machine without exceeding the authorization amount and means for storing transaction information.
BRIEF DESCRIPTION OF THE FIGURES
The invention will be described by way of non-limiting example, with reference to the attached drawings in which:
FIG. 1 shows a diagram of the present invention controlling a copy machine and interfacing with remote locations;
FIG. 2 shows a block schematic diagram of the operational aspects of the present invention;
FIGS. 3A and 3B show a flow diagram illustrating the operation of a main routine while awaiting credit card input in accordance with the present invention;
FIG. 4 is a flow diagram showing a subroutine for checking a system of the present invention;
FIG. 5 is a flow diagram showing a help message subroutine used in accordance with the present invention;
FIG. 6 is a flow diagram showing a card reader interrupt subroutine in accordance with the present invention;
FIG. 7 is a flow diagram showing a service subroutine for monitoring system performance and editing system operational parameters in accordance with the present invention;
FIG. 8 is a flow diagram showing a routine for sending batched transaction(s) information in accordance with the present invention;
FIGS. 9A and 9B are flow diagrams showing a transaction subroutine in accordance with the present invention;
FIG. 10 is a flow diagram showing a subroutine for ensuring that a proper vend has occurred and that the total number of copies is less than the maximum allowed in accordance with the present invention;
FIG. 11 is a flow diagram showing the general operation of the system in accordance with the present invention; and
FIG. 12 is a flow diagram showing the general operation of an additional embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
There is shown in FIG. 1 a system 10, which is an exemplary embodiment of the present invention. System 10 has a copy machine 28 as an example of a vending machine under control by vending machine control system (controller) 12. Other types of vending machines and computer operated devices for on-line searching, database searching or printing may be used as a vending machine instead of copy machine 28.
Copy machine 28 has a control panel 30 where various copy commands can be executed by the user. Copy button 32 is depressed for copying a document. Many commercial copy machines used for unattended, fee-based copying are only used for making single copies on one size paper. It is possible, however, that other copy functions can be selected such as choosing different paper sizes with paper size selection button 34 or other special features such as reductions and enlargements using special features button 36. With the present invention, additional copy features can be tracked and charged at different rates, if appropriate connections are made between copy machine 28 and controller 12 and appropriate programming of controller 12 is provided.
Copy machine 28 also has a control connection means 38, which may be one half of a connector plug for meeting with a complimentary connector plug. Control connection means 38 is connection point at copy machine 28, designed to allow for fee-based vending of copies. Many console or full size copy machines come equipped for the addition of equipment to convert a non-fee based copy machine to fee-based copying. On these models, it is only necessary to obtain the necessary complimentary connector plug to fit this connector. The removal or addition of a wire harness may be involved to provide for mounting the connector plug. On devices other than copy machines, such as a microfilm or microfiche reader, it will be necessary to make an appropriate connection to monitor, interrupt and control the device. In the case of a microfilm reader this could involve taking control of a print button by placing a second switch (controlled by controller 12) in series with the user operated print button. To allow a "print", both switches must be closed. In the case of a computer for on-line access, this could be a connection to provide a keyboard interrupt so access to the computer cannot take place until an appropriate keyboard control signal is provided.
Copier 28 is connected to controller 12 via electrical connection line 26. Controller 12 contains a text display screen 14 (LCD display screen), a magnetic card reader 16, a keypad 18, a printer 20 (shown with a receipt 24) and a speaker 22. Although shown separate from copier 28, controller 12 can be mounted on or near copier 28 as dictated by the copier service provider. Controller 12 is used to determine an available credit limit for copying (vending) for a given user on copy machine 28, as well as allowing/disallowing copier use. Alternatively, a bank issued debit card (such as a Money Access Center card, "MAC" card) can be used instead of a credit card. For purposes of this description, "magnetic card" will be the generic designation for a credit card or a bank issued debit card or a smart card.
A magnetic card (not shown) is passed through card reader 16 and the information from the magnetic strip of the magnetic card is read by card reader 16. Certain portions of or all of this magnetic information is transmitted over a communications line 40 to a remote credit verification location 46. Communication line 40 can take the form of a telephone line, dedicated telephone line or cellular communication line. The type of communication line required will depend upon the location and use of a particular vending machine. Appropriate communication hardware for the connection line being used, such as a cellular telephone, will be necessary to establish communication and will be understood by those skilled in the art.
Along with the magnetic card information, a predetermined dollar amount is transmitted to remote credit location 46. For example, a $10 amount may be transmitted, requesting an authorization for copying up to $10. In another embodiment, a user may select the dollar amount for authorization through keyboard 18. A grant or deny signal is then transmitted back over communication line 40 to controller 12 from remote credit verification location 46. Remote credit verification location 46 may be a credit card agency or processor in the case of a credit card, a bank in the case of a bank ATM card or a private organization in the case of a privately provided debit card.
Once controller 12 receives the return signal, controller 12 allows copying up to the authorized amount if a grant signal which authorizes a vend transaction, along with an available credit limit has been provided and refuses copying if a deny signal has been provided. Appropriate instructions to the user are provided by display 14.
Audible information (voice messages) can also be provided via speaker 22. An example of voice message is a reminder, repeated after a given time period, that a copy should be made or the transaction will be terminated. This could help a user from forgetting that there is an authorized credit still left on the machine which could be used by another if the user walks away. The problem of "forgetting" is also addressed by a timeout feature which terminates a transaction if no action is taken within a preset period of time. The allowable time between copies for a given transaction authorization can be set by the copy service provider.
Other audible or graphic messages, including instructions, pricing and advertising, can be provided as set up by the copy service provider.
A keypad 18 is also provided for entering key code information. A keypad with one or more keys can be provided, depending on the type of user input which may be required. In the case of a bank issued debit card, such as an ATM card, a personal identification number (PIN) may be required. In an exemplary embodiment of the past invention three keys are provided--a SERVICE key, a HELP key and an END key.
Controller 12 is shown connected to three types of remote locations through communication line 40. Remote credit verification location 46 has already been discussed. Remote service location 42 may be the same as or separate than remote credit verification location 46. Remote service location 42 receives and sends information concerning the operation of copy machine 28 and controller 12. Information such as additional copy paper or receipt paper required, or malfunctions may be communicated from copy machine 28 and controller 12 to remote service location 42.
Remote service location 42 may transmit a sleep signal or an out-of-order signal if it detects a malfunction in either device. Remote service location 42 may also be used to monitor when equipment is in use. Remote location 44 can also be the same as one or more of the other remote locations. It may have a function of receiving transaction information so that the types of use, rates of use and times of use can be monitored and analyzed to enhance copy service. With this information, deliveries of paper, toner and other supplies may be timed to enhance productivity of the vending machine and those servicing it.
In the embodiment of system 10 shown in FIG. 1, only a credit card reader 16 is shown. An alternate embodiment may use a coin mechanism or bill acceptor mechanism or prepaid card to pay for the copy vending. In such an embodiment, the transaction tracking and service capabilities of the present invention are still provided.
When a user has completed all of the user's copying, the number of transactions and cost per transaction are stored in a memory device of controller 12. This information, along with a predetermined transaction/cost information with other users will be settled by batch processing at a later time. The predetermined number of transactions may be related to the amount of memory, or requirements of the credit card company/processor (such as every 100 transactions). The batch settlement can also be related to a time period or combination of time period and number of transactions. Batch processing of transaction information is an efficient use of time, as a separate call is not required after every user's copying is complete. The operation of batch processing is discussed in more detail below. In an exemplary embodiment, batch settlement occurs daily.
Although not illustrated in system 10 shown in FIG. 1, it also possible to have multiple vending machines, such copy machines 28, attached to a single controller 12.
There is shown in FIG. 2 a block schematic diagram of the logic and communications circuits contained within controller 12.
Controller 12 contains a microprocessor 50 such as the Z0868108PSC by Zilog. Microprocessor 50 controls the input output (I/O) and memory functions of controller 12. Microprocessor 50 has a memory 52 for storing program information as well as transaction information. Memory 52 is shown consisting of a Read Only Memory (ROM) 54 and a Random Access Memory (RAM) 56. An example RAM is the DS1486 manufactured by Dallas Semiconductor. An example ROM is the 27C256-12/P by Microchip. This ROM chip is a 256K ROM. Microprocessor 50 may also be controlled by an instruction set stored in an Electrically Erasable Read Only Memory (EEROM) such as the 93C56-P serial EEROM also made by Microchip. Other types of memory including removable memory such as disks or removable cards may be used and will be understood by those skilled in the art.
Microprocessor 50 controls input and output through serial communications block 58 and I/O block 66.
Serial communication block 58 encompasses a communication section 60 for communicating with a modem (not shown); a communication block 64 for communicating with a card reader such as card reader 16; and a communication port for communication with a receipt printer such as receipt printer 20. In an exemplary embodiment, the on board modem used for communicating with remote locations is the CH17185 PCB mount modem 2400 by Cermetek. This modem provides communication at 2400 baud. Controller 12 also contains a 6252SA/6250SA by Xico as card reader 16 and a receipt printer 20 made by Citizen. Serial communication ports are commonly referred to as "COM" ports. Thus, communication ports 60, 62 and 64 may be referred to as COM1, COM2 and COM3 respectively. The necessary circuitry and print out connectors for the modem, card reading and receipt printing functions are well known. In an exemplary embodiment of the present invention, and RS232 output is provided by the ADM235LJN integrated circuit by Analog Devices.
Controller 12 also has an optional speech processor 76. Speech processor 76 provides synthesized speech as a source of output through speaker 22. In this way, text information can be provided audibly as well as graphically. Speech is provided through the MSM6295GSK speech controller manufactured by OKI. Whether or not speech processors are provided to the user is optional. This feature can also be remotely activated and modified from a remote location such as remote service location 42. If speech is provided, a volume control mechanism and appropriate amplification and preamplification may be provided.
Speech processor 76 is operated by receiving a control signal from CPU 75. CPU 75 is a Microchip PIC16C54-H-HS/P. CPU 75 receives enabling and menu selection data from microprocessor 50. Based on the enabling and menu data received from microprocessor 50 CPU 77 starts speech processor 76. CPU 70 provides speech processor 76 with control signals and instruct speech processor 76 to play particular prerecorded message accessed from memory 79. Memory 79 is a ROM in an exemplary embodiment of the present invention. Memory 79 contains all of the prerecorded speech data used by speech processor 76. Speech data from memory 79 is converted to an analog signal via digital to analog convertor in speech processor 76. The convertor analog signal is fed to low pass filter network 80. Low pass filter 80 has a corner frequency of 4 khz in an exemplary embodiment of the present invention. The filtered signal is fed from 80 to audio amplifier 78. Audio amplifier is a Sanyo LA4460 in an exemplary embodiment of the present invention. Finally, the amplified analog signal is passed to speaker 22. An additional embodiment of the present invention an additional speaker is provided for non-speech output such as "BEEP" tones.
Controller 12 can be used to interface with a vending machine, such as a console copy machine 28 by identifying the pulse widths of a copy enable signal. For example on the Minolta EP 1080 the Omron relay is inactive (off) and the output monitoring line is inactive (+24 volts) prior to a vend (copy) taking place. The transition from a low signal (0 volts) to a high signal (24 volts) is counted as one copy. Controller 12 monitors the line activity (in this case voltages) over a period of time. When the readings during this monitoring period agree with the transaction that is being requested, controller 12 stores the signal information in memory.
If the readings do not agree with the transaction that is being requested, the time period over which the control signal is monitored is increased or reduces a predetermined increment and a new reading is taken place and compared to the transaction being requested. This process is repeated until agreement between the readings and the desired transaction is achieved.
In an exemplary embodiment, an operator works interactively with controller 12, requesting a particular transaction (such as a single 8 1/2"×11" copy) and indicating to controller 12 through keypad 18 whether the reading of controller 12 (as shown through display 14) agrees with the requested transaction.
There is shown in FIGS. 3A and 3B flow diagrams showing a main routine which checks for system errors, and whether it is time to communicate with a remote location, while waiting for a user to pass a magnetic card through magnetic card reader 16 (or deposit coins or currency if another type of payment means is provided).
Processing begins by entering block 82 where initial conditions for each output port and each input/output device are set. As previously described, the exemplary embodiment of the present invention uses serial ports for serially communicating with peripheral devices.
Processing then continues to block 84 where the main routine is started. In block 86 magnetic card reader 16 is reset. In block 88 a test takes place to determine whether the maximum number of transactions has been reached.
As the exemplary embodiment of the present invention processes transactions as a batch, it has a maximum number of transactions (based on the RAM size) which can be stored in its memory. Accordingly, when a predetermined maximum number of transaction is reached, controller 12 will not take anymore magnetic card inputs and will prepare to forward the multiple transaction information as a batch job over communication line 40 to a remote location.
If the determination in block 88 is yes, processing goes to block 90 where the call home flag is set. The call home flag designates that it is time to call the remote location for batch processing. If the maximum number of transactions is not reached, processing moves to block 92 where it is determined if the call home flag has been set. If the flag has been set, a test is conducted to determine whether there has been a delay before the call home timer has expired. The call home flag can be set at any time in which system 10 is in operation. Controller 12 waits to place a call to a designated remote location ("home"), however, until a predetermined period of inactivity occurs. When the period of inactivity is exceeded, the call is placed. Other variables may be used to determine when to make a call. If the call home flag has been set, processing moves to system subroutine 200 which is shown in FIG. 8. If the call home flag has not been set, processing continues to block 94, where a determination is made as to whether a predetermined number of days between calls to the remote location has expired. If the predetermined number of days between calls to the remote location has expired, processing moves to block 96 where the correct time to call the remote location is checked.
If it is presently an allowable time to call the remote location, the call home flag is set in block 98 (the call home flag is cleared after a successful call is made). Processing then moves to block 100 (also on a negative condition from the determination made in blocks 94 and 96) where a check for certain system errors takes place. Examples of some system errors include printer out of paper, memory full and copier problems. If a system error has occurred, processing again moves to the system subroutine 200 shown in FIG. 8. If no system errors have occurred, processing continues to block 102 where a test is made to determine whether the out of service flag has been set. If the out of service flag has been set, processing moves to block 104 where an out of service message is displayed on display 14. Processing then moves back to block 84 and the main routine is once again started.
If the determination in block 102 is negative, processing moves to block 106 shown in FIG. 3B. In block 106 a title and logo are displayed on display 14. The title and logo are stored in one of the ROMs as ASCII characters to provide text and/or images. Processing next moves to Check System subroutine 120 shown in FIG. 4 to check the system. After returning from Check System Subroutine 120, processing moves to block 108 where it is determined whether card data has been obtained, from magnetic card reader 16. If magnetic card data has been obtained processing moves to Transaction Subroutine 20 to process the transaction. If no magnetic card data has been obtained, processing continues to block 110 where a first message is displayed on LCD display 14. In an exemplary embodiment, Message 1 provides identification information: Line 1--"CREDIT CARD COPY EXPRESS™"; Line 2--"USA ENTERTAINMENT CENTER, INC.".
While the first message is being displayed, a loop through check system subroutine 120 and determination block 108 and block 110 continues. A similar routine begins as processing move towards block 112 and block 114. Here, a second message is displayed on display 14. The second message provides operation information for the user: Line 1--"PRESS HELP"; Line 2--"FOR INSTRUCTIONS PRESS HELP." Processing continues to loop through Check System Subroutine 120 and determination block 112 and message display block 114 until the entire text of the second message has been displayed.
A similar process takes place as processing moves to block 116 and display block 118. Here, a third message is displayed. The third message provides instructions for using a magnetic card: Line 1--"SWIPE CARD"; Line 2--"TO MAKE COPIES, SWIPE A VALID CREDIT CARD". and the processing loop consisting of Check System Subroutine 120, determination block 116 and message three display block 118 is carried out. If no magnetic card date is determined in block 116 and message three has completed its display in block 118, processing returns to block 86 shown in FIG. 3A.
There is shown in FIG. 4 a flow diagram of the Check System Subroutine. Processing begins by entering block 122 where a determination is made whether the HELP button has been depressed. If the HELP button has been depressed, processing moves to the HELP Message Subroutine 140 shown in FIG. 5. If the HELP button has not been depressed, processing moves to block 124 where it is determined whether the SERVICE button has been depressed. If the SERVICE button has been depressed, processing moves to System Service Subroutine 170 shown in FIG. 7. If the SERVICE button has not been depressed, processing moves to flow diagram 160 shown in FIG. 6 to determine whether a magnetic card has passed through magnetic card reader 16.
In block 126 it is determined whether a magnetic card has passed through magnetic card reader 16. If yes, processing moves to block 128 where the correctness of the magnetic card data is tested. If the data is acceptable, processing is moved to block 132 where the magnetic card data is saved in memory and the card read flag is set. If the card data is not acceptable, processing moves to block 134 where an error message is displayed on display 14. Following the display of the error message, the routine is exited.
There shown in FIG. 5, Help Message Subroutine 140. In an exemplary embodiment, this routine plays a prerecorded audio (voice) message when called. It also cycles through three informative help messages. Either completing the three messages or detection of a magnetic card in magnetic card reader 16 forces an exit out of Help Message Subroutine 140. Pressing a HELP button in keypad 18 will start this routine from the beginning.
Help Message Subroutine 140 begins by entering block 142 where the audio speech message is started. Audio speech is an option which can be selected by the copy service provider. It can also be provided or set from remote location. Processing next enters Check System Subroutine 120 shown in FIG. 4. Processing then moves to decision block 144 where it is determined whether a magnetic card has been passed through magnetic card reader 16. If a magnetic card is detected, processing moves to Transaction Subroutine 220 shown in FIGS. 9A and 9B. If a magnetic card has not been detected, processing moves to block 146 where the first help message is displayed. Processing continues to loop through Check System Subroutine 120, determination block 144 and message display block 146 until either a magnetic card is detected or the first message has been fully displayed. Processing then moves back to Check System Subroutine 120 and then to decision block 148. Similar to the Check System Subroutine 120, decision block 144 and display block 146 loop above, a similar loop takes place through Check System Subroutine 120, decision block 148 and display block 150 with respect to the second message. Finally, a third message loop consisting of Check System Subroutine 120, decision block 152 and message display block 154 takes place. If by the end of the third message a magnetic card is not detected, the subroutine is exited.
In an exemplary embodiment of the present invention, the following HELP messages are provided.
______________________________________Message 1: Line 1: - "SWIPE CARD" Line 2: - "SWIPE CREDIT CARD FROM RIGHT TO LEFT, MAGNETIC STRIPE FORWARD"Message 2: Line 1: - "MAKE COPIES" Line 2: - "UPON RECEIVING AUTHORIZA- TION, MAKE ALL YOUR COPIES"Message 3: Line 1: - "PRESS END" "TO END COPYING, PRESS `END` AND TAKE RECEIPT".______________________________________
There is shown in FIG. 6 a flow diagram of Magnetic Card Detection Subroutine 160. This routine polls card reader 16 for an interrupt signal. If an interrupt signal is detected, data is transferred from magnetic card reader 16 to microprocessor 50. In an exemplary embodiment, a serial data link between magnetic card reader 16 and microprocessor 50 is used. This data is held in a scratch pad RAM buffer such as RAM 56.
This routine begins by entering block 162 where the magnetic card reader 16 data transfers are enabled. In block 164 a test in undertaken to determine if an interrupt is pending. If an interrupt is pending, processing moves to block 166 where magnetic card data is obtained via a serial data link 64 and saved in RAM memory 56. Processing then moves to block 168 where the data transfer from magnetic card reader 16 is disabled. When complete, this routine is exited.
There is shown in FIG. 7, Service Subroutine 170. The routine allows a user to view and change various service related fields. These fields may include the cumulative total of copies which have been made on the device (such as copier 28), the phone number(s) of remote location(s), controller 12/copier 28 ID number(s) and pulse delay number and other fields tailored to specific site equipment and conditions. The edit process involves using the HELP and END button located on keypad 18 to change the field information and move a cursor displayed on LCD display 14.
Processing begins by entering block 172 where the total number of copies made on copy machine 28 are displayed. Processing then continues to block 174 where a delay is effectuated until a SERVICE button is pressed or a time-out occurs. If a time-out occurs, the routine is exited and a hardware reset is generated in block 176. If the service button is pressed, processing moves to block 180 where a remote location phone number is displayed. If a time-out occurs, the routine is exited and a hardware reset is generated. If a service button is pressed, processing moves to block 182 where the copier ID number is displayed. At this time, the service operator can also edit the copier ID number. If a time-out occurs, processing moves to block 176 where the routine is exited. If the service button is pressed, processing moves to block 184 where the pulse window delay count is displayed. The service operator can also edit the pulse window delay count at this time. Again, if a time-out occurs, processing moves to block 176 where the routine is exited. If the service button is pressed, processing moves to block 186 where the call remote operator message is displayed. In an exemplary embodiment, a remote operator can be called by pressing the HELP and END buttons simultaneously. After block 186, processing moves to block 188 where the previous credit card transactions are settled and processed via modem if necessary. From block 190, Service Subroutine 170 is exited.
There is shown in FIG. 8 System Service Subroutine 200. This routine send 100% of the transactions data stored in memory. If a predetermined amount of credit card transactions require settlement, and controller 12 is configured to batch process transaction settlement data directly to a particular remote location (such as remote location 44), batch processing is accomplished first. Following the batch processing, a call is placed to remote service location 42. In an exemplary embodiment, a predetermined minimum amount of credit card transactions is used in the determination.
Processing begins by entering block 202 where a determination of how many credit card transactions are pending settlement. Processing then moves to block 204 where it is determined whether the amount of batch transactions waiting for settlement meet a predetermined batch size (such as a minimum batch size). If predetermined minimum batch size is not met, processing moves to block 210 where a call is made to remote service location 42. If the determination made in block 204 is yes, processing moves to block 206 where it is determined whether a flag has been enabled for sending the batch transaction settlement data. If the flag has not been set, processing moves to block 210 and a call is placed directly to remote service location 42. If the flag has been enabled processing moves to block 208 and the transaction settlement data is sent via modem to a remote location 44. Processing then moves to block 210. Following block 210, processing moves to block 212 where controller 12 transmits and receives data including configuration data, miscellaneous status and credit card transaction information via modem to remote service location 42.
There is shown in FIG. 9A Transaction Subroutine 220. This routine processes the magnetic card data. It also enables/disables a copier 28 for vending as required and terminates a transaction by updating memory variables and printing a receipt 24 on receipt printer 20.
Transaction Subroutine 220 begins by entering decision block 222 where it is determined whether a magnetic card read on magnetic card reader 16 is a valid accepted card type. If not, a message--"THAT CARD TYPE IS NOT ACCEPTED", is displayed on display 14. If the speech option is being used, the message is also played through speaker 22. Transaction subroutine 220 is then exited. If a valid card type is detected, processing moves to block 226 where it is determined whether receipt printer 20 is operating. If not, the message--"SORRY UNABLE TO PRINT RECEIPT SWIPE CARD AGAIN IF YOU DO NOT NEED A RECEIPT", is displayed on display 14. If the speech option is being used, the message is also played from speaker 22.
From block 228, processing moves to block 232 where it is determined whether the user passed a magnetic card through magnetic card reader 16. If no card is detected, Transaction Subroutine 220 is exited. If the magnetic card is detected, processing moves to block 230. Processing also moves to block 230 following a positive determination regarding operation of receipt printer 20. In block 230 it is determined whether a credit card or free vend card was read. If a credit card was read, a credit card verification takes place by contacting remote credit verification service 46 over a communication line 40. In block 238 it is determined whether the card is valid. This entails receiving an authorization signal from remote credit verification service 46. If a free vend card number was detected in block 230, processing moves to block 236. If a valid card is not determined in block 238, processing moves to block 242 where a message--"SORRY UNABLE TO AUTHORIZE CARD", is displayed on display 14. If the speech option is being used, this message is also output on speaker 22. Following block 242 Transaction Subroutine 220 is exited. If a valid card is detected in block 238, copier 28 is enabled in block 236.
Processing then moves to block 240 where it is determined whether a vend (copy) occurred. If yes, processing moves to Vend Copy Subroutine 270 and back to block 240. If a vend did not occur, processing moves to block 248 where it is determined whether a predetermined time-out has occurred. In an exemplary embodiment, a 40second time period is used as the predetermined amount of time. If a 40-second time-out has not occurred, processing moves to block 251 in FIG. 9B. If a 40-second time-out has occurred, processing moves to block 246 and a message--"YOUR TRANSACTION WILL AUTOMATICALLY END IN 15 SECONDS PRESS `END` TO END YOUR TRANSACTION NOW PRESS `HELP` FROM MORE TIME" is displayed on display 14. If the speech option is being used, the message is output through speaker 22. This is an audible reminder so that a user does not leave an enabled vending machine active.
If the 40-second time-out did not occur then processing moves to block 251 shown in FIG. 9B, a determination is made in block 251 regarding whether the user has pressed the help button. If a HELP button has been pressed, processing moves to block 250 where the time-out counter is reset. Processing then re-enters block 240 and it is again determined whether a vend has occurred. If the HELP button was not pressed, processing moves to decision block 252 where it is determined whether the 60-second time-out has occurred. If yes, processing moves to block 256. If no, processing moves to block 258 where it is determined whether the user has pressed the END button. If the END button has not been pressed, processing again returns to block 240 to determine whether a vend has occurred. If either determination block 252 or block 258 is in the affirmative, processing moves to block 256 where a delay is effectuated to allow any last copies to be output and counted. Processing then moves to block 260 where the transaction record stored in memory is updated and the total number of copies, the total number of sales, the time, the date and any other information preset by the copy service operator is recorded. Processing then moves to block 262 where a receipt 24 is printed on receipt printer 20. Following block 262 Transaction Subroutine 220 is exited and a hardware reset occurs to ready controller 12 and copier 28 for the next user.
There shown in FIG. 10 Vend Copy Subroutine 270. This subroutine performs a delay to ensure accurate copy pulse counting and determining if preset conditions (such as number of copies) have been reached. If a preset number of conditions has been reached, the transaction is terminated. As previously discussed, copier 28 copies based on supplying a COPY OK enable signal. Counting pulses allows controller 12 to control and monitor copier 28 output.
Vend Copy Subroutine 270 begins by entering block 272 where processing awaits any copy pulse delays to expire. Processing then moves to block 274 where the transaction record is updated; total copies are adjusted, total sales and other miscellaneous memory variables are updated. Processing then moves to block 276 where it is determined if the maximum allowed copies for the magnetic card being used has been made. If yes, processing moves to block 256 shown in FIG. 9B. If not, processing moves to block 278 where the LCD showing the number of copies and the time-out timer is reset. Following block 278 then copy subroutine 270 is exited.
As an example of operation, a VISA card may be used as the magnetic card to purchase copies on a Minolta EP 1080 copier (copier 28). A user passes the VISA card (swipes) through card reader 16. Track 2 of the multiple tracks on the credit card is read and serially transmits 37 bytes of data from the magnetic card reader to CPU 50. Controller 12 then takes the modem off hook and dials remote credit verification location 46. A $10 amount is transmitted from controller 12 to remote credit verification location 46 over telephone lines 40.
Remote credit verification location 46 verifies that the credit card account is valid and that the requested authorization amount is available. This amount of credit is reserved by the credit card processor according to its own terms and government regulations (typically several days).
When a successful authorization has taken place, remote credit verification location 46 transmits an authorization code (approval code) granting the authorizing the transaction. The approval code and credit card data are then stored in RAM 56. The modem is taken off hook, ending the communication.
The user is then prompted through display 14 and/or speaker 22 to begin making copies. The Omron relay within controller 12 is activated, enabling the vend circuit. On the EP 1080 the blue/green wire pair in the coin acceptor plug are connected to each other. If remote credit verification location returns any message other than an authorization code, the communication is also terminated and the user is prompted that the card can not be processed at this time.
While enabled, the user can make copies and use any of the copier features. During a copy cycle, the output monitoring line is toggled low (+0 volts) and returned high (+24 volts). In the EP 1080 the red/blue pair of wires in the coin acceptor plug provide the output pulses. The red wire in the coin acceptor plug provides a +24 volt reference voltage and the blue wire transitions to provide the negative output pulse. This logic transition or pulse is detected by controller 12 on control line 26 and counted as one copy.
Next, controller 12 checks to see if the maximum allowed number of copies per authorization amount has been reached. If the maximum has been reached or no copies have been made in the last 60 seconds, the transaction is terminated. Terminating a transaction involves saving the transaction information in RAM (which can include date, time, total copies, total sales, etc.), prompting the user that the transaction is complete and printing a receipt. The Omron relay is deactivated and copier 28 taken out of the vend mode.
On a daily basis (or other period of time), a phone call is placed to a remote location 44 which is designated to receive batch settlement information. When a communication link is established and appropriate security, if any, cleared, card data, approval codes and transaction amounts are transmitted. This Upload is a batch settlement. When the batch settlement is complete, a settlement approval code is received by controller 12 from remote location 44. The communication link is then terminated.
When the batch has been settled, a telephone call is placed to remote service location 42 which is the copy service operator. After a communication link is established, any system error messages, miscellaneous transaction information (such as dates, times, types of transactions, etc.) and batch settlement information (including the settlement approval code) is transmitted from controller 12 to remote service location 42. Remote service location 42 then transmits an acknowledgement signal to controller 12. The communication link is then terminated and memory cleared. System 10 is then ready for vending.
FIG. 11 is a flow diagram 280 showing general operation of one aspect of the present invention. In block 282 controller 12 is connected to output control line 26 of copier 28. Copier 28 is an exemplary embodiment of a vending machine which can be operated in accordance with the present invention. In block 284, the control signals which control copier 28 are read over a first time period. The first time period is preset for controller 12. Interfacing with a copier 28 or other vending machine is an iterative process of reading control signals and comparing them to a stored list in memory until a match is made. In block 286 copier responses are determined and compared to the control signals. This may be done interactively with an operator. As the operator depresses the copy button, controller reads the control signals at switch 38 put out by copier 28. When controller 12 identified a control signal indicating a copy is made, controller 12 displays this information to the operator through display 14.
In block 288, the determined response is checked for correctness. If the response is incorrect, the process proceeds to block 289 where the time period is adjusted and operation returns to block 284. If the determined response is correct, then, in block 290, the time period which generated a correct response is stored for subsequent monitoring of the vending machine.
There show in FIG. 12 flow diagram 300 showing another aspect of the present invention.
In block 302 magnetic card information such as information encoded on a credit card is read. As previously discussed, other types of magnetic card information can be read, depending upon the type magnetic card used. In block 304 an authorization amount for a particular transaction is obtained. In the case of copier 28 an authorization for a predetermined amount of copying is obtained. In an alternative embodiment, a user may enter the amount of credit the user desires.
In block 306, the authorization amount obtained in block 304 is stored in memory. In block 308 the copy machine is operated following the storage of an authorization amount from block 306. Finally, in block 310 following the completion of the copy transaction, the transaction information is stored in memory.
While particular embodiments of the present invention are disclosed herein, it is not intended to limit the invention to such disclosure, and changes and modifications may be incorporated and embodied within the scope of the following claims: | A vending control system and method for interfacing a control device to a vending machine having input/output control lines along which are transmitted control signals for controlling the operation of the vending machine. The control device includes, means for connecting to the control lines of the vending machine, means for reading the control signal, means for determining operational responses/outputs of the vending machine which correspond to the control signals, means for storing the control signals and information concerning the operational responses and means for reading the stored information to control the vending machine. Control and monitoring of vending transactions comprises means for reading magnetically stored information from a magnetic card, means for obtaining an authorization amount for a transaction, means for storing the authorization amount, means for operating the vending machine without exceeding the authorization amount and means for storing transaction information. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 08/749,690, filed Nov. 15, 1996, now U.S. Pat. No. 5,960,972 and is related to the subject matter of U.S. patent application Ser. No. 08/513,508, filed Aug. 10, 1995, now U.S. Pat. No. 5,615,788. The disclosures of the prior application and the prior patent are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to multiple improvements to a safety closure or cap for sealing a bottle or other container in which liquid, granular material, particulate material or any other material including solids is contained. The invention also relates to the combination of a container sealed by a closure or cap having such improvements. The improvements permit the closure to perform in a more efficacious way than prior closures.
2. Description of Related Art
In the prior combinations of a cap and a container, the cap is provided with an internal structure and an external structure. These structures are movable with respect to one another among closed, intermediate and open cap positions. A plurality of hooks is provided on the internal structure for grasping a bead on the container when the cap is in the closed and intermediate cap positions. Ribs, disposed on the external structure, include upper extremities which prevent the cap from being placed directly from the closed cap position into the open cap position. Pressure relief of the container, if any, occurs in the intermediate position. The external structure of the cap defines a safety seal for indicating that the cap has been moved from the closed position.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide improvements to the design of the previously described closures. These improvements add certain qualities to the nature of such a cap that will better result in the already achieved benefits and introduce new benefits so as to produce a more attractive closure in compliance with industry standards. The invention also attends to molding operations for manufacturing the cap, the stability of the closure from a production plant through a bottling plant and until the consumer acquires the main product, and the consumer's performance in handling the cap.
Various designs address nineteen different utilities that might improve the functionality of the closure. The new structures serve, in a more efficacious and efficient manner, to 1) improve the process of assembling both parts of the closure during the production process; 2) eliminate the hole previously defined in the roof of the external part to facilitate the production process and to add marketing appeal to the product; 3) redefine the disposition of the upstanding flanges of the internal part and their complementary structure in the external part, as alternated units, to facilitate the molding process; and 4) introduce a groove, in a perimetrical disposition, in the internal part so to improve flexing capabilities of the internal part.
The structures also serve to 5) include a mold oriented design for the channels of the internal part to diminish complexity in the needed production machinery; 6) propose a new gripping disposition for the skirt defined in the internal part that might facilitate the consumer's handling of the cap; 7) provide a structure to secure a mounted position of both parts of the closure in a stable status to minimize the risk of undesired closing of the closure before the bottling operation; 8) provide a method that reinforces the closed position of the cap to better resist hazardous treatment; 9) present an improved design for the disposition of the connectors between areas of the external part to be detached along the breach line when rotation of such an external part is made; and 10) present the design for a complete rib, present in the external part, that would add to the system the requirement for an unequivocally conducted twist operation to release the closure, voiding possibility of aleatory twisting.
The structures additionally serve to 11) present the design for an intermediate rib in the external part, not connected at its extremes to a top or inferior roof or flange, that would allow the consumer to perform opening and re-closing operations in a different manner than with a complete rib; such expands marketing possibilities by allowing a focus on different types of consumer preferences.
Moreover, the structures 12) present the possibility of closing and re-closing the closure with a snap-on operation of the cap over the extreme of the container in a way that assures hermetic standards; 13) provide a cooperation of structures that will grant to the consumer the capability of regulating and controlling the intensity of venting activity during the opening process with the intention of avoiding splashing of the liquid from inside the container when such a container has been shaken or for any other reason that would make this happen; 14) present a design for a structure that, composed of complementary patterns to be joined, guides other complementary structures of both parts to an effective joining action during the bottling process and secures the circular center area of the external part to the roof of the internal part in a way that avoids any possibility of rotation or horizontal displacement of such circular center area during a twisting operation of the external part; this assures a proper breach of the circular boundary line, defined as a breach line, to evidence tampering.
Additionally, the structures 15) optimize the venting process of releasing pressure contained in the bottle whenever such pressure is present; and 16) mathematically define a pattern for the disposition of complementary structures of both parts of the closure in a way that unequivocal interaction of such structures will be reached during handling of the cap by the consumer. Finally, the structures 17) present the existence of an equalizer effect to control the tolerances in the variation of the shape of the extreme of returnable type glass bottles so as to assure an hermetic performance of this plastic crown over such bottles; 18) present the alternative of an internal part of the closure that will minimize the height of the whole system and diminish the requirements of raw material for each closure; and 19) present an alternative tamper evidence device which provides resistance to rude treatment, avoids residual impact on the rest of the system after releasing the closure for the first time, and avoids the possibility of neutralizing the evidence of tampering by a voluntary action. All designs concern the capability of the closure to be molded or produced.
The above objects are accomplished with a closure for a container which is made of an internal structure and an external structure which cooperate to effect the above described qualities in a unique way.
The process of assembling both parts of the closure is improved in such a way that the structure to be described allows the parts to be joined, during the production stage of the cap, by a snap action. In a mounted position status, the closure is ready to be plugged over the neck of the bottle.
The suppression of the hole in the center of the previously mentioned external part of the closure minimizes complexity in the needed mold to produce the cap according to state of the art machinery, and adds attractiveness to the closure, from a marketing aspect, by defining an external surface that is continual and smooth. This is possible now because the cap can be compressed not only by rotation but by a snap operation too.
The alternated disposition for the upstanding flanges belonging to the internal structure addresses a concern associated with molding which requires that, once the "core" of the molding machine defines the shape of the structure around itself, it is necessary to rotate the core through the needed degrees to be freed from the undercut or structure that has recently been created when such "core" was in the immediate previous position. The circular in-line design of the upstanding flanges has to satisfy the need for a sufficiently large space between each flange to allow the core used for its creation to escape from the cavity of the mold without spoiling or damaging the recently created flange.
By introducing a groove in a perimetrical disposition in the internal part, flexing capabilities of the skirt defined in such an internal part are improved. By diminishing the thickness of the transition area from the main plate of the internal part to the skirt vertically disposed from it, the portions which form the lifting ring can flex radially downwardly to allow the external part to easily pass over the mentioned lifting ring in the assembling operation. Another benefit of the existence of the flexing capabilities induced by this perimetrical groove is obtained by the combination of this quality and another quality by which individual segments of the skirt can grip the bottle in such a way that an arching effect will be translated over the main plate of the internal part and thus enhance the capabilities of hermetically sealing the bottle. The arching effect is reached because the length of the skirt is a little bit shorter that the length that would be assigned to such a skirt if the extremes of the skirt fit perfectly in a groove of the bottle. When the length of the skirt is short, the skirt does not perfectly fit on the groove, but remains laying over the slope of the extreme of the bottle that leads to the groove. When the binding ring is downwardly projected as a result of a closing action of the system, the extremes of the skirt will fit in the groove, making a tension force in the horizontal plane of the closure. Consequently, an arch effect results.
A mold oriented design for the channels of the internal part will facilitate the design of the production machinery for this cap by diminishing complexity of the required tools and, subsequently, the cost of manufacturing such machinery. The channels are provided with a trapezoidal configuration which will perfectly accomplish the path function for which they were conceived and which is easily molded. Previous designs consisted of an oblique or inclined configuration channel which provided guidance with a right side and conducted the complementary rib of the external part in an upwardly twisting movement. The left side of the channel had no reason to be inclined with a disposition parallel to the right side, since such an oblique configuration did not attend to any needed specification. According to production techniques of the molding industry, with parallel sides of the channel design, a tool that could create this undercut and be freed of the structure surrounding it without spoiling what it had recently created might be difficult to make. A trapezoidal configuration will still satisfy the needed oblique path on the right side of the channel and allow the tool of the machinery to efficiently operate.
Another novelty is a new gripping disposition for the skirt, vertically disposed from the main plate of the internal part, that might facilitate the consumer's handling of the cap during de-capping and re-capping operations. The nature of this modification is to make the segments, forming part of the mentioned skirt, project radially, outwardly and downwardly as they grow distant from the main plate. This will not prejudice hermetic capabilities of the closure and will cooperate to enhance hermetic aspects, together with the above-mentioned principle of arch effect. The outward design of the skirt will facilitate the gripping action of the internal part when mounting the closure over the neck of the bottle and will enhance the arch effect desired to improve the hermetic aspect when segments of the skirt receive binding pressure. Moreover, during the process of releasing the closure, the potential expanding strength of the bonded segments to outwardly recover their original disposition once pressed by the flange of the external part, which acts as a binding ring, joined with the arch effect of the perimetrical groove, will, in a first stage, impulse, in cooperation with the twisting action performed by the consumer, the external part of the closure to axially and upwardly project itself as part of the opening operation towards the so-called intermediate position for venting purposes. In second stage, once the venting operation is performed, a twist and pull action of the external part follows to make the clamping surface extremes of the segments that configure the skirt release the groove of the neck of the bottle. This releasing action will be facilitated due to the original radially, outwardly, downwardly disposition of the skirt now re-acquired in the opening process.
In the mounted position, the telescopically projected closure is not able to close or axially compress itself by mistake before the bottling process, in which case the closure would be disabled or rendered useless. This objective is reached by synchronized interlocking disposition of two complementary structures created for this purpose. Once both parts have been created and need to be coupled to become a functional system, by positioning the external part over the internal part and snapping it on, the closure will become interlocked and ready to be applied by the bottling machinery over the container. Thus, the complete closed position is reached and the capabilities that define this system as a secure closure are achieved. This coupled, but not closed, status prepares the system to be efficiently applied by the corresponding machinery. The possibility of undesired closing of the closure before the convenient instance for bottling process is avoided. Undesired closing of the system before the bottling process would render the closure useless. This structure minimizes the probability of spoiling the closure during shipment from the production plant to the bottling plant. The parts can also be shipped from the production plant in an independent way (not joined yet), and be assembled in the bottling plant as a part of the bottling operation. If parts are shipped separately, there is no risk of ruined caps due to activated hooking situations between the parts, and the carriage itself is simplified and, hence, less costly. The cost of assembling both parts will be present anyway regardless of whether the operation is held in the production plant or in the bottling plant. If the assembling process is done in the bottling plant, the risk of ruined caps during the shipment is avoided.
The closed position, before closure is released by the consumer, has been reinforced so to effectively resist rude or hazardous treatment during the chain of processes from the bottling plant until the moment when the consumer releases the closure. The probabilities of ruining or spoiling the tamper evidence device of this closure due to poor treatment during distribution are diminished by the present structure. The result of this poor treatment previously would have been the ruin of the breach line, providing proof and evidence of a tampered status of the closure for reasons different from the consumer's voluntary releasing action. Due to the nature of the tamper evidence observed in this system, the difference of levels between external and internal parts along the external annular area of the cap could have been manifested as result of a voluntary opening performance of the closure by the consumer or as a result of a non-voluntary event like an external hit or scratch over the annular area of the external part, which was solely maintained by the breach line. It became necessary to provide the system with an internal support for this external annular area which supplements and reinforces the existing breach line. Now, no hit, scratch or poor treatment over this annular ring will make the breach line break and make part of the external annular area move down to lie over the annular area of the main plate of the internal part due to the difference in levels. An extension of the rib belonging to the external part is now the object of this needed support for the critical external annular area. The rib will be interlocked with a structure of the internal part in a way such that only a voluntary twisting action from the consumer will make the breach line break. Thus, by relating the breach line to the external annular area and supporting this external annular area by a rib, which is supported by a flange of the internal part, any hit over the external part will ultimately be supported by the internal part. Hence, only a voluntary and proper twist and pull force applied to the interaction of both parts will make the breach line break. No action different from this will make the breach line break.
A design for optimal performance of the breach line and providing tamper evidence quality is presented. The breach action will be efficiently observed due to a special disposition of the elements forming segments along the boundary to be broken. This special disposition consists of a radially oblique pattern of such elements which is to be aligned, for example, in the mentioned inclined segments that join the parts to be detached. These segments are the objects to be stretched until broken, by elongation, to disjoin these parts during the rotational force producing the opening movement. The tamper evidence quality to be observed is activated in conjunction with this feature and others.
Another object of these improvements is the inclusion of a design for a complete rib, belonging to the external part, that will add to the system the quality of an unequivocally conducted twist operation to release the closure. This minimizes aleatory or unnecessary twisting action. Positioned over the corresponding channel, these complete ribs will provide the system with a predetermined sequential operation that will improve a consumer decapping operation. The complete rib minimizes the probabilities of wrongful usage or mistaken operations from the consumer. Only voluntary and proper interaction of both parts will induce the breach line to break. Not even the consumer will be able to perform wrongful movements of the parts that may lead to undesired situations. Any voluntary act of the consumer will definitely lead to a proper use of the system. The closure will not be released in any other way than the expected one. This complete rib structure reduces the probability of breakage of the breach line by aleatory circumstances in the different stages occurring during shipping from the bottling plant to the place where the product is to be sold. Any stroke or hit that the external surface of the closure may receive during these processes will not cause the breach line to break. The integrity of the system is assured until the consumer decides to tamper with the cap.
Another specification related to the analysis of ribs will now be added. It is now intended to focus on the relation between the ribs and the venting process, and the relation between the ribs and the re-capping process. In this analysis, the ribs are in an intermediate disposition regarding the internal wall over which they have been conceived. Specifically, the superior top of the ribs does not reach the top horizontal plate of the external part. The inferior extreme of such ribs does not reach the binding flange of the external part. Both extremes of the ribs have functions complementing the opening and re-capping processes. The first function is related to the venting capabilities of the system and will be held during the opening process. While the external part is being elevated, the top extreme of the ribs push the flange present in the internal part upwardly. The flange is a frame for channels through which the ribs might be conducted. This pushing action, which impacts entirely in the internal part, will make the internal liner present in the ceiling of the internal part loosen or relax the pressure applied over the mouth of the container for hermetic purposes. Thus, the venting process takes place in a secure way, considering that the segments belonging to the internal skirt are not yet able to completely flex and release the neck of the bottle. A dangerous pop-off of the closure is avoided.
After the venting process is effectively made, a short counterclockwise twist, searching for the correspondent channel, will make the ribs continue their path to a complete opening status of the system. The venting process is perfectly controlled by the consumer to handle the positive pressure present in the container for security reasons. The consumer is unable to release the closure quickly and possibly cause the cap to pop off due to internal carbonated or positive pressure. The consumer is in charge of what he or she should be in charge of, but is not able to perform malicious or dangerous operations like voluntarily making the cap pop off. There is no possibility that, by chance or not, a continuous fast movement would make the cap to pop-off. The second object of this intermediate rib concerns its inferior extreme. After the venting process, the cap is completely projected upwardly to be released, and is finally released. If the consumer then desires to re-cap the closure to store unfinished beverage inside of the container, then the following operation might be implemented. The system would be in a state in which the ribs have completely passed through their corresponding channels in such a way that the external part can continue twisting over the internal part. Inferior extremes of the ribs are positioned over the outwardly disposed flange of the internal part, in which channels are defined. In this state, segments belonging to the internal skirt would be able to flex to grip the neck of the bottle if a snap-on force is applied over the external part. Pushing the external part towards the neck of the bottle allows intermediate ribs to put pressure over the flange and onto the internal part, which is axially downwardly projected. The internal part is able to grip the neck of the bottle. After this gripping action secures the internal part on the bottle, a clockwise twist of the external part searching for the channels to conduct the corresponding ribs, causes the ribs to find the channels. Performing the necessary downwardly twisting action secures the external part over the internal part and hermetically seals the system again.
The complete rib or the intermediate rib can include a common quality which would allow the closure to be reclosed by a straight snap-on action. When the external part is axially upwardly projected and complete ribs are positioned in the channels, or when the intermediate ribs are over the outwardly disposed flange, an axially downwardly snap-on hit over the external part would make the ribs pass over the outwardly disposed flange containing the channels. This is the case either when the ribs are positioned over the lifting ring that contains the channels (first case) or when the ribs are positioned in the channels (second case). The tensions and forces of the plastic to be used for the closure partially determine that a first snap-on action would make the force applied over the external part and thus over the ribs positioned over the lifting ring of the internal part cause the segments belonging to the skirt of the internal part to grip the extreme of the bottle. After the skirt has gripped the bottle, a continual but harder snap-on force would make the ribs positioned either over the lifting ring or in the channel belonging to the lifting ring pass over the lifting ring until reaching a closed status. The ribs may have a round shape along their inferior side which will confront the lifting ring during the snap operation. Thus, the passing over action of the ribs towards the lifting ring will be facilitated. This would provide the system with a quick way for re-capping the closure while maintaining all the advantages previously described that make this closure unique. Often, the elements specified in a capping system to achieve technical goals dictate processes to be performed even when the desired goal has already been achieved. With a commonly known screw cap, a long twist operation is required to release the closure during the opening process and perform the venting operation. The consumer should not have to re-cap the closure with a complementary analogous screwing process having the same degree of difficulty when there is no technical reason for making the re-capping process equally as difficult as the de-capping process. The consumer, after complimenting security procedures, should instead be able to perform, in a more comfortable way, re-capping of the closure.
The snap-on possibility presented by this system affords the consumer safety when it is needed during the venting process but allows the consumer to handle the closure most conveniently when no more safety or other technical specifications need to be accomplished. Certainly, all the rest of the qualities of the system will still be observed.
The existence of either complete or intermediate ribs has the purpose of avoiding the possibility that someone, voluntarily or not, could make the closure pop-off from the bottle as a result of the positive or carbonated pressure contained inside the container. The presence of the ribs dictates the unique way in which the external part could be upwardly projected up to a level at which the skirt of the internal part is allowed to flex and be released from the extreme of the bottle. Ribs must be conducted through their complementary channels to allow the external part to reach the projected level. During this transition process, venting activity is observed since there is no more hermetic pressure of the internal liner over the bottle. By the time the ribs have been totally conducted through the channels, enough pressure will have been released so to avoid the possibility of popped-off caps. The ribs exist solely for the purpose of a secured venting process, not for hermetic reasons or any other technical cause. Hence, disposition of such ribs and channels can be designed in order to maximize and optimize the purpose for which they were conceived. Both a structure including the complete rib disposition and with a structure including the intermediate rib disposition, a consumer will be able to handle the closure in a way that will allow regulation and control of the ratio or intensity of a venting process during an opening movement. The common situation in which splashes of the liquid from inside of the container during the venting process when carbonation is present and when the container has been shaken or exposed to high temperatures is avoided.
After the breach line is broken, either the superior oblique border of the complete rib or the top extreme of the intermediate rib can be axially pulled by a pure vertical movement towards the lifting ring containing the channels through which the ribs are going to be conducted. A resultant force elevates the internal part in a small but sufficient way so as to release the pressure applied by the internal liner, present in the ceiling of the internal part, over the perimetric area of the extreme neck of the bottle. This allows the positive pressure of carbonation present inside the container to be gradually freed through the vertical ducts present in the internal part. By pulling up or pushing down the external part, ribs, complete or intermediate, may or may not put pressure towards the lifting ring in a venting action, depending on the consumer's perception of the convenient ratio or intensity of venting activity. The capability of the consumer to choose this intensity of venting activity allows him or her to avoid being splashed as a result of a sudden venting activity that would release fluid from inside of the container. Each bottle opened by the consumer has been exposed to particular situations before the precise moment when the consumer takes it. When the consumer chooses the bottle, the consumer does not know whether or not the bottle has been exposed to a high temperature, movements or shaking. To minimize the probability of sudden splashes of fluid when the bottle has been exposed to the previously mentioned aleatory situations, this system provides a way for the consumer to regulate the intensity of the venting process according to what he or she observes at the very first venting instance.
Additionally, a particular structure that is present in the roof of the internal part of the closure and, in a complementary way, in the ceiling part of the external part is disclosed. Both structures are disposed in a complementary pattern, since, as many other structures of the system, when both parts of the closure are joined in a closed position, these complementary structures will cooperate and appear as one. Many units of complementary structures are present in the system, and it is intended here to define another one which will opportunely guide the rest of the complementary units to a proper joined status. The interaction to be observed, at any time of the handling of the closure that will activate the different tools, devices and mechanisms that define the qualities of the system, will be contained or guided by this main pattern which determines the positions of the parts relative to each other at the capping stage. At the same time, when the internal and external structures are joined, the complementary structures will eliminate the possibility that the central circular area of the external part will rotate during the opening process when the annular area of the external part is twisted. Hence, the correct breaking of the tamper evidence breach line is assured.
The venting process is improved by a modification in the design of the slots across which the positive pressure or carbonation contained inside the bottle is freed. This allows the venting process to be enhanced during a first stage of the opening operation in which, due to the nature of the closure, venting must be maximized.
The disposition and quantity of the channels in relation to their complementary ribs is defined in a pattern according to what in known as a mathematical geometric sequence. The usage of this geometric sequence in a closure design, as is the case here, determines a relative positioning and a quantity correlation between the two interacting technical devices. Since this interaction is critical to correct performance of the system, this pattern is chosen to define the nature of the mentioned relation and to optimize the situation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an exploded sectional view of the closure illustrating the process of assembling both parts of the system and in which the parts are about to be clamped to each other.
FIG. 1B is a similar view but showing the parts after they have been joined or clamped together.
FIG. 2 is a perspective view of the complete closure showing the smooth top or roof of the external part of the closure or cap.
FIG. 3A is a sectional view of the inner portion of the closure or cap and illustrates the alternating hooks on the upstanding flanges.
FIG. 3B illustrates complementary alternating grooves defined by flanges on the outer part into which the hooks on the flanges are received.
FIG. 4A is a sectional view showing the inner part of the cap with the mold oriented design of the channels evident.
FIG. 4B shows the same inner part from the top and illustrates the disposition of six channels around the circumference of the inner part.
FIG. 5A is a sectional view of the internal part showing the proposed alternative radially outwardly and downwardly extending skirt design.
FIGS. 5B-5E are various illustrations of the same internal part, in sectional and complete views, showing cooperation between a bottle and the internal part.
FIG. 6A is a view representing the interaction of internal complete ribs present on the external part and the channels defined in the internal part when the closure is in a closed state.
FIG. 6B is a similar view but showing the interaction when the system is in an open state.
FIG. 7 shows how the complete rib is disposed on the interior wall of the outer closure part.
FIGS. 8A and 8B are internal sectional views of the ceiling of the outer part of the closure showing the disposition of the segments which are detached during a counterclockwise twisting action to break a breach line forming the tamper evidence device.
FIGS. 9A-9D are views which show the disposition of the intermediate ribs relative to corresponding channels in different stages of opening the closure.
FIGS. 10A and 10B show the complementary structures to be joined which are present on the roof of the internal part and on the ceiling of the external part.
FIGS. 10C and 10D represent alternative shapes for the structures present in the center of the roof of the internal part and on the ceiling of the external part.
FIGS. 11-13 illustrate an alternative cap construction utilizing deformation of the internal part to produce hermetic sealing.
FIGS. 14-16 show a modified tamper evidence producing construction.
FIG. 17 shows a modified internal part structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B show both parts of the cap 20 before they are clamped to each other to become a functional closure. Important structures in these two figures are the binding ring 11 belonging to the external part 1 and the lifting ring 12 belonging to the internal part 2. As has been mentioned, the improvement in the design of these two rings is the convex shape or design that each of these structures has. When such convex designs interact during the assembling process, the binding ring 11 can easily pass over the lifting ring 12 as a result of an impulse or snap hit over it during the bottling process. Lifting ring 12 has, around its perimeter, spaces or channels 51 as can be observed in FIGS. 4A and 4B. These channels 51 can be present at more than one point on the perimeter. The mass remaining between each channel 51 will be the flange over which the binding ring 11 will have to pass during the assembling process. Convenient inter-disposition shapes of the binding ring 11 and the lifting ring 12 and a convenient small size of the remaining flanges on the lifting ring 12, between channels 51, over which the pass of binding ring 11 will be relatively easy to accomplish. Flexibility of lifting ring 12, to allow the assembling operation, is enhanced by a diminished thickness of the main plate 14 caused by the existence of a perimetrical groove 41 in a round path before the lifting ring 12.
This perimetrical groove 41, shown in FIGS. 1A, 1B, 3A, 4A and 4B, for example, provides an all around downward flexibility to the lifting ring 12 and to the skirt 15 depending from it.
The assembling techniques and operations can be performed by a snap hit over the external part 1 after it is positioned over the internal part 2. As a result of such a snap hit, binding ring 11 will-easily pass over lifting ring 12. During the pass over process, the lifting ring 12 will flex to allow the binding ring 11 which flexes as well to completely pass. This flexing action is caused by the complementary convexity of the facing structures, the small size of the remaining mass between the channels 51, the existence of the perimetrical groove 41 which adds flexibility to the lifting ring 12, assembling techniques, and flexibility of both parts as a whole. Once the binding ring 11 has completely passed over the lifting ring 12, the rings become interlocked in such a way that will never be able to be disjoined again.
In FIG. 2, the complete closure is observed in a closed state. The specific detail shown in this drawing is the external part 1, which now offers a complete and smooth roof. This is an improvement upon prior external parts which had a hole or perforations in the center.
In FIG. 3A, the internal part 2 is shown as including the alternated disposition for the upstanding flanges 31 conceived to hook in complementary grooves 32 present at the ceiling of the external part 1 shown in FIG. 3B. This alternated disposition is applied for the hooks 35 present in the extremes of the upstanding flanges 31. There exist upstanding flanges between the mentioned flanges 31, but these other flanges do not have the hook on their extremes. As there are non-hooking flanges between the upstanding flanges 31, there are complementary spaces in external part 1 between the parts 34. The hooks 35 belonging to the upstanding flanges 31 will engage in the parts 34 securing the external part to the internal part.
This alternated pattern responds to the necessity presented by the machinery to mold the two parts. Every time that an undercut is created upon a tool, such tool must be able to be freed from such undercut after the structure is created. The possibility presented here is for a rotational operation of such tool to free the tool from the recently created undercut without spoiling the undercut on the way out. After creating the mass, the tool can go out through the space.
In FIG. 3A, moreover, internal part 2 is shown as including the above-mentioned perimetrical groove 41. This perimetrical groove 41 can be present in the external top face of the main plate 14 or could be present in the internal face of such main plate 14. The object of this groove is to provide flexibility to the internal part 2. Two aspects of this flexibility are to be noted. The first aspect is applicable to the lifting ring 12 and skirt 15. The second aspect is applicable to the main plate 14.
The flexibility aspect for the lifting ring 12 and skirt 15 is important during the assembling process as described above. The second flexibility aspect on the main plate 14 is important, during closing and releasing operations, when the external part 1 performs over internal part 2. This second aspect can be referred to as the arch action of the internal part 2. This arch action is observed in the main plate 14 as a result of the binding action of the binding ring 11 over the skirt 15. The length of the skirt is a little bit shorter than that needed to comfortably lay in the groove 9 of the bottle. Thus, during the bottling operation, the extremes of the skirt 15 must be bound by the sliding down of the binding ring 11 to remain locked in the groove 9 of the bottle. In this state, the internal part 2 is in an arch tension. When de-capping occurs, the binding ring 11 slides upwardly, allowing the skirt 15 to upwardly flex and move from the groove 9. The arch tension previously allocated to the main plate 14 during the closed status of the system is relieved, making the skirt 15 return to its original state shown in FIGS. 5A-5E. As the skirt 15 reacquires its original shape and expands, it slightly pulls up or elevates the external part 1 which will have been in the opening process.
In FIGS. 4A and 4B, the internal part 2 makes evident the design of channels 51. The machinery for producing this undercut is less complex than that needed to produce the previously utilized channels. The left side of each channel 51 allows the machinery needed to create this undercut to be simple and, according to state of the art, with known tools.
FIGS. 5A-5E show the disposition for the skirt 15 vertically disposed from the main plate 14 of the internal part 2. This special disposition of skirt 15 will provide a better interaction of the internal part 2 with the bottle, making it easier to grip such an internal part 2 to such bottle, as well as to de-cap the closure from it. In both cases, the external part will be upwardly projected so that the binding ring 11 does not surround the cleats of the skirt 15. Further, this disposition is part of the arch effect of main plate 14 described above. When skirt 15 is radially outwardly disposed, the main plate 14 is straight. When the cleats of skirt 15 are surrounded be the binding ring 11, in a closed status, then, by action of the perimetrical groove 41 that provides flexibility, main plate 14 will be the one flexing. This arch action will enhance hermetic capabilities when the closure is closed, and will make the system almost automatically help the consumer in releasing the closure when this operation is performed. If a tension of the main plate 14 is held during the closed status, then when segments 92, shown in FIG. 10B, of the breach line 91 are broken, and the binding ring 11 is lifted upwardly by the effect of the perimetrical groove 41, the main plate 14 will recover its original straight status. The skirt 15 will as well.
FIGS. 6B and 7 show how the bottom part of ribs 81 has a special step 71 that interacts with the complementary channel 51 in such a way that the external part 1 will stay telescopically projected over the internal part in the mounted position, as shown in FIG. 1B, until the closure is voluntary closed. Either with a twisting action or by a snap-on action that will make the ribs 81 pass over lifting ring 12, the ribs 81 belonging to the external part 1 will take their closed state positions as shown in FIG. 6A. The existence of step 71 assures the stability of the closure in the mounted position. An increased thickness of the lower part of the rib, moreover, would provide frictional force to maintain the projected status of the cap until a voluntary action changes that status.
A similar aspect is noted in FIGS. 9A-9D in which the same principles are applied but a shorter rib 112 is present. Rib 112 is completely positioned over the lifting ring 12 in the mounted position state as is shown in FIG. 9D. The closure remains in the illustrated position until a voluntary twist or snap-on operation is performed to close the system as shown in FIG. 9A.
FIG. 7 shows the design for the complete ribs 81. Ribs 81 start at the binding ring 11 and end at the roof 83 of the external part 1. At the first stage of such ribs 81, a step 71 is provided. In this first stage, the rib 81 has an assigned thickness that grows bigger at the mentioned step 71. The larger thickness remains until the rib 81 reaches roof 83 of the external part 1. The specific quality to be noted is that ribs 81 go through the lifting ring 12 when in closed or compressed status and continue beyond it until they reach their ends. Segments 92 of the breach line 91 defined in the external part 1 will never be broken by an aleatory hit over the annular area defined outwardly from the breach line 91. This is because the annular area is supported by the interaction of the ribs 81 and the lifting ring 12. A similar situation is apparent from FIG. 9A, where a dot 111 belonging to the external part 1, and specifically positioned in a convenient place in relation to rib 112, is supported by the lifting ring 12. Again, no aleatory hit over the external part 1 will make the breach line 91 break down and ruin the closure. This dot 111 also performs as a guide for the intermediate rib 112 to find the path through the channel 51 even if the consumer performs a pure twisting action without applying a pulling force. The dot 111, in other words, acts as an extension of the intermediate rib 112 imitating the complete rib 81.
FIGS. 8A, 8B and 10B show segments 92 disposed in pairs along the breach line 91, which defines an already partially cut space between external annular area 93 and central area 94. This cut can be done during the production process when the piece is still in the mold. A circular blade can be projected from the mold to define the breach line. After the cut is done, the circular blade retires to its original position inside of the mold. The still soft conformation of the raw material due to the molding process allows the cut to be done and, after that, will try to recover its previous status by joining the walls defined by the cut, but without mixing the "after-the-cut" separated molecules. The cut will be almost imperceptible to the view, but still present. In the spaces between the pairs of segments 92, parts 34 are provided so as to define locations where upstanding flanges 31 will hook. This situation is fully evidenced in FIG. 10B. The segments 92 specify an oblique configuration in their centers, during the transition plane from the external annular area 93 to the central area 94, which will maximize the stretching performance to allow the external annular area 93 belonging to external part 1, to twist counterclockwise. Breach line 91 acts as a space boundary over segments 92 that specifies the point where the stretch of such segments 92 will be applied. The part belonging to the central area 94 of external part 1, will remain in place since such central area 94 does not rotate. The part of the segment 92 belonging to the external annular area 93 will rotate attached to such external annular area 93, producing the stretch in the oblique part of segments 92.
FIGS. 6A, 6B and 7 show the disposition of the complete ribs 81 around the closure. Ribs 81 belong to external part 1. In FIGS. 6A and 6B, the rest of the structures of the external part 1 have been disregarded to focus on the interaction between the mentioned ribs 81 and the channels 51. FIG. 6A shows the position that ribs 81 will have when the closure is in a closed status. The free space at the bottom of the ribs 81 is the one that the binding ring 11 will occupy. The free space at the top of the ribs 81 over the lifting ring 12 is the one observed until the ribs 81 reach the roof 83 of the external part 1. A counterclockwise twist of the external part 1 to release the cap will lead the ribs 81 through channels 51 until the binding ring 11 reaches the lifting ring 12, as shown in FIG. 6B. This one is the only possible and unequivocal operation that the consumer will be able to perform to release the system. After a complete twist is made, steps 71 engage the lifting ring 11 as shown in FIG. 6B. In this state, the closure can be easily released. If the consumer wants to re-cap the closure, he or she will be able to do so either by twisting the external part 1 clockwise to allow the ribs 81 to go back through channels 51 to their original state, or by snapping the cap back on with a hit over the external part 1 so to make ribs 81 pass over lifting ring 12 in a vertical axial way and become positioned in another channel different from the one in which each rib originally was, so as to be ready to perform the opening movement again.
FIG. 9A shows the system in the same state as shown in FIG. 6A, but with the presence of the intermediate ribs 112 instead of complete ribs 81. Intermediate ribs 112 do not start from the binding ring 11 and do not reach the roof 83 of the external part 1. They are defined in an intermediate place from the binding ring 11 belonging to the external part 1 and the lifting ring 12 when the system is in closed status. As the external part 1 is twisted and lifted to release the system, intermediate ribs 112 interact with lifting ring 12. Associated with intermediate ribs 112, and belonging to the same external part 1, are dots 111 that are positioned over the slope of lifting ring 12 to guide intermediate ribs 112 in convenient sequential movements towards the channels 51 through which the intermediate ribs 112 should be conducted.
As the counterclockwise twisting operation is performed, dots 111 will make the external part 1 containing intermediate ribs 112 lift towards the necessary point where intermediate ribs 112 will unequivocally reach the starting point of channels 51. Once the counterclockwise twist has been performed to make the intermediate ribs 112 pass through channels 51, the binding ring 11 releases its binding action over skirt 15, making release of the closure possible. Intermediate ribs 112 will be positioned as shown in FIG. 9D. In this situation, the binding ring 11 belonging to the external part 1 will be positioned towards lifting ring 12 from the bottom side in order to release the closure by pulling the external part 1 up. After consuming part of the product inside the container, if the consumer wants to re-cap the bottle, then he or she will have to position the closure over the bottle, and either twist the external part 1 clockwise to conduct intermediate ribs 112 through channels 51, or downwardly snap-on the external part 1 to make intermediate ribs 112 to pass over lifting ring 12 until they reach the original closed status observed when the system was hermetically positioned over the extreme of the bottle, in a situation similar to the one observed in FIG. 9A.
Shown in FIGS. 6A and 9B is a principle that allows the consumer to regulate the intensity that he or she thinks convenient to assign to the venting process according to the particular pressured or carbonated status of the beverage that they are about to open.
Each bottle is filled in the bottling plant with an assigned amount of pressure. This pressure, moreover, can vary according to the temperature to which the container is exposed as well as with movement or shaking situations to which the bottle is exposed. Usually, the consumer does not know the intensity of these factors that directly determine the intensity of the venting process that will be held when he or she releases the system. It is common when a consumer releases the closure for fluid from the inside to splash out if the aleatory situations above mentioned had happened.
When the closure is in a closed state as shown in FIGS. 6A and 9A, complete ribs 81 are positioned over channels 51 or intermediate ribs 112 in the expected compressed status. In this situation, after a short counterclockwise twist is applied to break the segments 92 of the breach line 91, a pure vertical movement--without twisting action of any sort--can be applied to make either of the ribs apply force towards the lifting ring 12. In the case of intermediate rib 112, see FIG. 9B. In this situation, binding ring 11 will not be lifted enough to release its binding action applied over skirt 15. Thus, even when considerable positive pressure is observed inside of the bottle, the closure will not pop-off, for skirt 15 can not expand to release the extremity of the bottle. However, the venting process will be held as a result of the slight lifting action observed on the internal part 2 as a result of the interaction of ribs and lifting ring 12. Internal liner 121 will be slightly moved from the extreme border of the bottle and, hence, will allow positive pressure to be released from inside of the bottle in a controlled manner. If the intensity of venting the pressure inside of the bottle is extremely high, then by pushing down the external part 1, ribs 81 or dots 111 belonging to the external part 1 will apply a downwardly force over the slope of the channels 51 belonging to lifting ring 12 of the internal part 2 which has the internal hermetic liner 121 attached on it's ceiling.
By vertically pulling the external part 1 and vertically pushing the external part 1, the consumer can regulate the intensity with which the internal hermetic liner 121 present in the ceiling of internal part 2 seals the extreme of the bottle. After the segments 92 of the breach line 91 have been broken by a short twist, if the external part 1 is vertically pulled up, then the venting process will start with a high level of control over such process. If, due to aleatory circumstances, the intensity of such a venting process is higher than is convenient, then a consumer can quickly diminish such intensity by downwardly pushing the external part 1 by applying pressure so as to replace the internal hermetic liner 121 over the opening of the bottle.
FIGS. 10A and 10B show structures with a clover shape. These structures are present on the roof of the internal part 2 and on the ceiling of the external part 1. The structures are complementary to each other and will become interlocked when the structure is joined and placed in a closed state. As a result, clover 141 belonging to internal part 2 and clover 142 belonging to external part 1 will fit between each other when external part 1 completely covers internal part 2 in a closed state. During the joining operation, upstanding flanges 31 belonging to internal part 2 will hook in alternated parts 34 belonging to external part 1. Central area 94 will now be immobilized and unable to be elevated since upstanding flanges 31 hook on parts 34 and are not able to rotate when a twisting opening action is performed over the external part 1. This is because the complementary clovers interlock with each other. Hence, when twisting action of the external part 1 is completed, segments 92 are going to be stretched to broke, activating the tamper evidence device.
The specific pattern in which internal clovers 141 can complementarily join external clovers 142 dictates the convenient pattern with which the rest of the complementary structures disposed in the rest of the system will conveniently join. The shapes of these structures can be modified according to the chosen number of upwardly disposed flanges 31 and complementary parts 34. If three upwardly disposed flanges 31 are disposed around the main plate 14, then a clover's shape would be the correct shape to assign to the structures described herein. If the number of upwardly disposed flanges 31 is to be four around the main plate 14, then four parts 34 will be present, and a convenient shape for the structures described here will be like a cross formed by four triangles joined in the center. This cross pattern will provide four possibilities for the clamping action between the upwardly flanges 31 and the complementary parts 34.
These complementary structures of the roof of the internal part 2 and the ceiling of the external part 1, are critical to good performance of the system. Its shape is defined by the number of ribs chosen to be present in the external part 1 and by the number of upwardly disposed flanges 31 to be present in the main plate 14 of the internal part 2. The number of ribs and the number of upwardly disposed flanges must be related directly. When the number of ribs is a pair number, then the number of upwardly disposed flanges must be a pair number too. If this pattern of pair numbers is observed, then the shape of the structures on the top of the internal part and in the ceiling of the external part can be either a cross formed by four triangles or just two confronting triangles. This pattern will provide the possibility of a pair number of possibilities to clamp these structures between each other as well as the pair number of flanges 31 with the complementary pair number of parts 34.
If the number of upwardly disposed flanges 31 and, subsequently, the number of parts 34 is chosen to be not a pair number, like three (3), then the convenient shape for the structures present in the roof of the internal part and in the ceiling of the external part must be like a clover's shape. This shape allows the system to be clamped in three different possibilities. Ribs, then, will have to be defined in a non-pair number, as will the channels. It must always be remembered that the number of channels can only be equal to or bigger than the number of ribs.
There exists a strong inter-relation between these three complementary units of structures: ribs with channels, flanges 31 with parts 34, and structure present in the roof of the internal part with structure present in the ceiling of the external part. The number of objects present in the different structures must always be either a pair number for all, or a non pair number for all of three units. Alternatives are defined by a geometric sequence.
The nature of the interrelation of the three units of structures will now be analyzed. Each unit of structure has two complementary structures which interact. One structure is present in the internal part of the system and the other is present in the external part of the system. This interrelation of the three units of structure is critical because it will assure a proper closing operation of the system when machinery or the consumer snaps on the external part over the internal part to compress the closure towards a hermetic state. If this interrelation is not applied, then the system will not optimize some of the rest of the qualities sought.
The first structure unit includes the structures 141 and 142 present in the center of the roof of the internal part and in the center of the ceiling of the external part. The second structure unit includes the flanges 31 and the parts 34. The third and last structure includes the ribs 81 or 112 and complementary channels 51.
Assembling machinery will position both parts of the system in such a way that, when assembled to a mounted position, ribs will become positioned inside channels. Later, in the bottling plant, bottling machinery will hit the external part, once the internal part is positioned over the extreme of the bottle, in such a way that ribs pass over the lifting ring 12 until other channels are reached with their upper extremes. In this situation, the structures 141 and 142 defined in unit one will be fitted, and structures 31 and 34 defined in unit two will be hooked. The way in which the assembly machinery positions both parts in a way for effective assembly and compression is described later.
The second structure unit, which includes flanges 31 and parts 34, and the third structure unit, which incudes ribs and channels, are critical to the proper compression of the system towards a hermetic state. This is why the units must follow a pattern dictated by the shape of structures belonging to the first unit. These two units of structures are critical because the second unit must assure a correct hooking action to hermetically secure the system and fix the central circular area of the external part on the internal part when the tamper evidence is activated during the opening process. Unit three, including the ribs and the channels, must assure that when the internal and external parts are assembled, the lower parts of the ribs will be positioned inside the channels. After the snap closing hit, the top extreme of the ribs must be positioned in a subsequent channel in a ready-to-be-opened status. Opening can then be performed by the consumer with a counterclockwise twist.
The shape of the structures defined in the first unit will dictate the number of radial possibilities for both parts of the closure to fit in a closed status. For example, if the shape of the complementary structures is to be a clover as shown in FIGS. 10A and 10B, then three radial possibilities for making the complementary structures fit exist. Since, when the internal and external parts fit, flanges 31 must hook in parts 34, these flanges 31 and parts 34 must be distributed in such a pattern that, in either of three fitting possibilities for the internal and external parts, flanges 31 and parts 34 will efficiently operate. Hence, as shown in FIGS. 10A and 10B, flanges 31 and parts 34 must be aligned to the shape of the complementary clovers (in this case) 141 and 142. In this case, there are three flanges 31 aligned with the spaces between clovers of the internal part to which they belong and three parts 34 aligned with the mass of the clover in the external part to which they belong. Any of the three fitting possibilities of internal and external parts, which are specifically dictated by the clover's shape of the complementary structures 141 and 142, will assure that flanges 31 and parts 34 cooperate in a proper hooking action.
Now, maintaining the analysis pattern in which the first unit of structures is understood to have a clover's shape, the flanges 31 and parts 34 allocated in the described way must be observed. Focus will be made on how the third unit of structures must be disposed. The third unit of structures is the one including the ribs and the channels. An allocation pattern to provide for efficient interrelation must be found. In the same way that the shape of structures in unit one dictated the allocation pattern for the structures in unit two, structures in unit one will also dictate the allocating pattern for the structures in unit three.
As described above, the objective sought in the first state is to position the lower part of the ribs inside the channels (in the case of a complete rib) or over the lifting ring (in the case of an intermediate rib) during the assembling process as shown in FIGS. 6B and 9D to reach the mounted position. In a second state, the object is to make the upper extremes of the same ribs fit inside another channel, as shown in FIGS. 6A and 9A, when a closing operation is made by a snap action. After the snap closing action is performed, upper extremes of the ribs 81 must be positioned inside the following or subsequent channel ready to perform the opening operation. The specific channel in which the rib will be located after the snap action depends on the quantity of channels created and their allocation around the lifting ring. When in the mounted position state or in the closed/compressed state, ribs 81 must always be positioned inside of a channel.
During a snap on action, structures in units one and two efficiently join. For the intermediate rib 112, the mounted position state is shown in FIG. 9D. The closed state, after the snap hit, is shown in FIG. 9A. With the alternative of intermediate ribs, units one and two must perform analogously to the complete rib case.
In the same way that structures were allocated in unit two to spaces or masses of structures in unit one, ribs and channels of unit three must be allocated to spaces or masses of structures in unit one. The relation defined between units one and two specifies that flanges 31 would be aligned with the spaces defined by the clover's shape. A clover's shape defines three spaces and three mass structures joined in the center. There are three the possibilities that the clover's shape allows for compressing the system. In any of the three possibilities, flanges 31 and parts 34 will hook. Thus the clover's shape dictates the number and disposition of flanges 31 and parts 34. Three is the non-pair number that is present in the pattern to be followed. Three will be also the number of ribs to be present in the external part as a consequence of the original election of the clover's shape for the structures included in unit one.
The main point is that there are two levels of restrictions. The first restriction is dictated by the shape of the structures in unit one. The second restriction follows from applying the geometric sequence pattern. The consistency of the system requires that the interrelation of these three units of structures must be according to the shape of unit one and, specifically, to the geometric sequence considerations when allocating ribs and channels.
First, when the shape of unit one is decided, in this case a clover, three radial possibilities for assembling both parts exist. Hence, three flanges 31 will be conveniently disposed. Three of the parts 34 will be conveniently disposed as well.
Three ribs will be disposed as well according to spaces or masses of unit one. Three complementary channels can be present (one channel for each rib). Alternatively, six (two channels for each rib), or twelve (four channels for each rib) channels can be provided. The pattern to follow when allocating channels to ribs must consider the geometric sequence results, starting with the same number elected for the ribs. In this case, if three ribs result, then the number of channels can be three, six, twelve, twenty-four, etc. The geometric sequence specified requires that each following number should double the previous one.
For a first unit with a clover shape, there are three closing possibilities. There can be three flanges 31, three parts 34, three ribs 81, and finally three, six, twelve, twenty-four, etc., channels 51, taking into account the geometric sequence considerations. This situation can be observed from the figures.
The other two alternatives for the shape of structures present in unit one will now be analyzed. The previous analysis was for a clover shape. Three possibilities for compressing the parts of the system were dictated.
The first of the two other alternatives is a structure named twin triangles, in which two triangles confront at their vertex as shown in FIG. 10C. If this shape is used for structures included in unit one, then two radial possibilities for compressing the parts of the system will be allowed. Since there are two possibilities, three will be two flanges 31 and two parts 34. This structure will have flanges 31 aligned with access between mass in the twin triangles of the internal part. Parts 34 will be aligned with mass in the twin triangles of the external part.
There will also have to be at least two ribs and, if there are two, at least two channels. The geometric sequence considerations must always be kept in mind. If there are to be two ribs, then there can be two, four, eight, sixteen, thirty-two, etc., channels.
If four ribs are chosen, then there can be four, eight, sixteen, etc., channels. Channels will always comply with geometric sequence considerations and will always start at the number of ribs elected. One will never have a number of channels less than the number of ribs. Clearly, if four ribs and two channels are present, then two of the ribs have no path to go through.
The pair quality of fitting possibilities defined by the shape of the structures forming part of unit one dictates that ribs must be conceived in a pair number too. For example, there may be two ribs, four ribs, or eight ribs, always attending to geometric sequence considerations.
The second alternative structure has a shape which represents a cross. In this structure, four triangles are joined at their vertexes as shown in FIG. 10D. This allows the parts of the system to fit in any four radial possibilities. Hence, the quantity of flanges 31 will be four. Four will also be the quantity of parts 34. Flanges 31 will be aligned with spaces between the cross and parts 34 will be aligned with the mass of the cross present in the ceiling of the external part. Further, it follows that there will be at least four ribs (there also could be eight). The number of channels can start at four and may be four, eight, or sixteen, always complying with the geometric sequence considerations such that each number must double the prior one.
These three possibilities for the shape of the structure present in the first unit are patterns for assigning radial distances between the different objects involved in units two and three regarding structure in unit one.
Regarding the convenient radial distances assigned to objects in units two and three, the number of structures (flanges 31 or ribs 81) can be smaller than advised when the spaces between the rest of the structures (the rest of the flanges 31 or the rest of the ribs 81) is maintained.
FIGS. 4A and 5A show the top parts of ducts 151. The top part of each duct 151 defines an ellipse 152 which will maximize the venting process performed during the opening operation. When, during the mentioned releasing operation, the internal liner 121 is at least partially removed from tightly contacting the extreme of the bottle, pressurized carbonation will be freed through these ellipses 152 all around the closure. The mentioned pressure is quickly evacuated at the same time vertically downwardly through the ducts 151 until the danger of popped-off closures is eliminated. As previously mentioned, when internal liner 121 is slightly removed and venting takes place, binding ring 11 on external part 1, will still bind the skirt 15 on internal part 2 in such a way that the skirt 15 will not be able to expand or outwardly radially flex to allow the closure to be released from the extreme groove 9 of the bottle.
The ellipses 152 allow the assembling machinery to effectively position both parts of the system for assembly into the mounted position, considering the dispositions of structures in units one and two. A distinctive device in some of the ellipses can be aligned to the spaces defined by the shape of unit one in the roof of the internal part. A complementary distinctive device in the external wall of the external part can be aligned with the mass belonging to the complementary structures. Optimum positioning, therefore, can be done. This situation is shown in FIG. 10A. This is the case of identification pattern 150, which depending on the pattern dictated in the structures of the ceiling of internal part, will allow the machinery to position both parts of the closure in a proper confrontation to be assembled.
Related to the mathematical formula that will effectively determine the convenient quantity of channels needed, according to the chosen quantity of ribs, the geometric sequence will dictate this information in the following way.
The general formula for the geometric sequence is denoted as:
R.sup.n-1 ×A
This pattern allocates the channels in relation to respective ribs. One example of this allocation is to define two (2) ribs that are supposed to find their paths through two (2), four (4), eight (8) or sixteen (16) channels distributed around the lifting ring. It is always convenient to assign possibilities for the disposition of these complementary structures so that the number of channels is in a multiple of the number of ribs, for example, two (2), four (4), eight (8), sixteen (16), etc., when the decided number of ribs is to be two (2). If the decided number of Ribs is to be three (3), then the number of channels must be three (3), six (6), twelve (12), twenty-four (24), and so on.
In the formula described above, the letter R represents the ratio over which the number of channels will grow. R, for example, may be two (2) or three (3). The letter n represents the step of the alternative that is to be chosen once the formula is displayed. If the case of two (2), four (4), eight (8) or sixteen (16). Here, alternative eight (8) would mean that n equals turn 3. Finally, A represents the number of ribs chosen, after which the ratio of growth of channels will be dictated. If the number of ribs is two (2), then alternative numbers of channels will duplicate the previous one. If there are three (3) ribs, then alternative numbers of channels will triple the previous number.
If, for example, one chooses to use two (2) ribs, then since two (2) ribs have been chosen, possibilities for a number of channels will have to duplicate each other, so R will be two as well. A (Ribs) was chosen to be two (2). n will be one (1), two (2), three (3), four (4), as the steps of the formula evolve.
Main formula:
R.sup.n-1 ×A
In the first step:
2.sup.1-1 ×2=2.sup.0 ×2
Any number powered to zero equals to one, so we have:
1×2=2. Two will be the first step in our chain of possibilities.
In the second step, when n is equal to two (2), we will have: 2 2-1 ×2=2 1 ×2=2×2=4. Four will be the second step in our chain of possibilities.
In the third step, when n is equal to three (3), we will have: 2 1-1 ×2=2 2 ×2=4×2=8. Eight will be the third step in our chain of possibilities.
In the fourth step, when n equals to four (4), we will have: 2 4-1 ×2=2 3 ×2=8×2=16. Sixteen will be the fourth step in our chain of possibilities.
Results following from this exercise show that they duplicate the previous answer. This pattern is chosen to rule disposition of relative quantities of ribs and channels. The number of ribs forms the INPUT in this formula and the possible number of channels to choose forms the OUTPUT or final result.
2: 2,4,8,16, . . .
INPUT=2
OUTPUT=2, 4, 8,16, . . .
As can be observed, results from applying this geometric sequence formula to a defined number of ribs will dictate possibilities of convenient numbers of channels to be assigned to the lifting ring during the production process.
When the ribs are not to be already positioned over the channels and the upper extreme does not reach the ceiling of the external part, as the quantity of channels elected gets bigger, the twist of the external part gets shorter during the opening process. In an analogous way, as the quantity of channels elected gets smaller, the twist of the external part gets bigger during the opening process. By the joined action of twisting and pulling, the upper extreme of the ribs will search for their path through the channels. The more channels there are, the faster the ribs will find their path. Conversely, the fewer channels there are, the longer it takes for the ribs to find their path. This allows certain systems to perform more quickly than others.
The number of ribs chosen (e.g., two (2) or three (3)), is related to the shape of the complementary structure described as being present in the roof of the internal part 2 and in the ceiling of the external part 1. In this preferred embodiment elements 141 and 142 are defined as clovers. If three (3) ribs are chosen, then the clover shape is correct, since it provides three (3) possibilities for clamping with its complementary structure. If the number of ribs chosen is two (2), then the convenient shape for this complementary structure will be two confronting triangles or, more precisely, sectors, since this shape provides two possibilities for clamping. The chosen number of channels, according to the possibilities that the geometric sequence provides, will be equal to or bigger than the number of possibilities of clamping that the shape of the complementary structures of unit one on top and ceiling of both parts can offer. Hence, if the shape of such structure is like a cross, with four (4) triangles joined in the center, then the number of channels chosen from the results of the geometric sequence would have to be four (4), or eight (8), or sixteen (16), etc.
Another modification will now be described with reference to FIGS. 11-13. In any kind of bottle, hermetic qualities are mainly obtained by a vertical force downwardly applied by the cap towards the liner and hence over the edge of the bottle's mouth. For assuring hermetic qualities, a level of precision between the parts interacting in sealing is substantial. This issue is a major concern in bottling industries. Regarding the precision of the different objects present in the sealing interaction, variations on measures in the same type of containers due to different reasons is present, particularly in returnable glass type bottles. These, when washed in the bottling process, suffer an erosion which provokes changes in measures of the extreme of the neck of the bottle, just where the closure will be positioned. Differences due to the ages of the bottles between each other, and to the different providers of such bottles, are observed as well. In order to assure hermetic standards, these differences have to be compensated for and neutralized by the equalizing capabilities of the capping system implemented therefor. Through elasticity, an equalizer capacity provides the compensation for such possible differences.
The elasticity of the plastic forming the parts of the system is a quality that, applied by the shape of the internal part, produces as a result the effect here named "equalizer" for its equalizing qualities over the differences or variations that the part of the bottle where the cap will be positioned might have. The equalizer effect is achieved as a result of the flexible quality of the material conforming to the part, plus the shape given to that part. This effect will assure that, despite the existence of the mentioned variations of the shape of the extreme of the container, which are commonly expressed as a critical tolerance, the hermetic capabilities that the capping system must achieve will be reached in each bottle as a result of the adaptation performance that the "equalizer effect" generates.
The equalizer effect, which is the result of the joining of the flexible property of the material and the shape of the internal part of this system, is significant.
The mentioned shape of the internal part will provoke the flexible quality, and eventual elongation, of the material to create a force that will be applied to achieve hermetic standards. The quality following from this shape is specifically generated around the point where the "main plate" 5 (or horizontal plane) of the internal part turns into the skirt 20 (or vertical plane) of the same part.
According to what is described in the previous applications of this invention, this specific transition area 90 is represented as a right angle (90 degrees). In order to maximize the possibilities of the "equalizer effect" by creating a variation range for the intensity of such effect, the transition area 90 in where the effect is generated, can be defined as one or more than one solely angle of 90 degrees. This possibility understands the transition area 90 as a continuity of angles to make such transition more smooth and round looking. The groove 80 positioned in the ceiling of the internal part will help in the flexing operation of the annular area outwardly placed from the groove 80, turning it to an oblique pattern to let the stripes 22 be downwardly pulled as a result of the compressing operation. The different possibilities of shapes for the Internal Part described herein, guide and assign the forces and tensions resultant from the flexible quality of the material, towards achieving an specific effect, the "equalizer effect". Tensions and forces object of this effect, can be managed with a bigger range and tolerance. The wider of the range of tolerance that we are able to handle in the adapting quality of the effect, bigger will be the variation range that the system will be able to contain when applied to the tolerance observed in the variations of the bottles.
When the cap is positioned as shown in FIG. 11 by the bottling machinery over the neck of the bottle, in the internal part of the system, the transition area 90 has a 2 mm×2 mm (0.0787 inches×0.0787 inches) area which is not in contact with the bottle. It can be identified for not copying the oblique contour 10 of the neck of the bottle. This fact provides to such area the possibility of flexing towards copying the bottle's shape, when being downwardly pulled by the short stripes 22 belonging to the skirt 20. As proposed here, the length of the stripe 22 should not be reaching the critical point 12 of the bottle groove 14 without a special pulling force. During the compression process of the system, these stripes 22 will be displaced by an overlapping force applied in their external side 24 by the binding ring 30, so to make them downwardly slide along the slope 11 defined by the groove 14 of the bottle until reaching an optimal fit over such groove. The pressure that the binding ring 30 asserts over the external extreme 24 of the stripes 22, when being downwardly slid, makes the internal shape of such extremes, known as vertex 26, interact with the slope 11 of the groove 14 of the bottle. That interaction makes the extreme 24 of the stripes 22 to fit in the groove 14. This displacement, which means a temporary modification of the part's shape, is possible due the mentioned flexing capabilities of the angles in the transition area 90, which are part of the arch effect quality.
In FIG. 12 the layout shows the same cap in two different moments. At left, the hermetic status shows the binding ring 30 surrounding the extreme 24 of the stripes 22. It can be seen how the stripes 22 were induced to a tighten and secured status. As the binding ring 30 slides down, the vertex 26 slides along the slope 11 from the status observed on the right hand to the one observed on the left hand. The liner 8 has also been influenced to better grip the shape of the bottle. Groove 80 serves as turning point to allow the main plate 5 to become part of the gripping action when tension is applied over the transition area 90. During the arch effect, while the system is in closed status, the mentioned transition area 90 suffers a temporary deformation towards the contour 10 of the shape. Groove 80 helps the part to flex in order to efficiently gripping the shape of the bottle. Liner 8 is modified as well by the flexing action of the main plate 5. In that situation, hermetic capabilities of the system are maximized while neutralizing possible variations of the bottle's neck shape that could threaten hermetic standards. During the closed status, the system remains in a potential reaction force to return to it's original form, when the pressure of the external part over the internal one is released. The equalizer capability is obtained by the arch effect. It is named arch effect because it is obtained from the radial sum of the arches defined from each stripe 22 to the opposite stripe 22 and the union of these two in the main plate 5.
When the system is in closed status and the "equalizer effect" is active as shown in FIG. 13, the extremes of the stripes 22 conforming the "skirt" 20 are fitted over the groove 14 of the neck of the bottle. Such stripes 22 were forced to reach that point by the external pressure of the "binding ring" 30 of External Part. The "liner" 8 present in the ceiling of the Internal Part is snugly fitted towards the border of the extreme of the bottle, assuring hermetic standards.
The vertex 26 works sliding like a wedge/quoin over the oblique plane of the slope 11 in groove 14 as the binding ring 30 is downwardly sled. This effect makes the stripes 22 to be pulled down provoking the tension in the transition area 90. The tolerance of that tension will be according to the surface that the vertex 26 finds in its path. If a highly eroded surface is found, deeper the vertex 26 will go, and tighter the tension in the transition area 90 will be. If a standard surface is found, the vertex 26 will perform without equalizing erosions, and the tension observed in the transition area 90 will be the expected one to a standard bottle. Certainly, the tension assigned to the system to work in standard bottles, will be enough to assure hermetic standards. The surplus tension observed in eroded bottles, will equalize the differences in the bottles shape, assuring hermetic standards as well.
If the tolerance of the shapes of the bottles varies, for example in 0.6 mm/0.0236 inches, a tension tolerance of 0.8 mm/0.0315 inches will be assigned to the transition area 90. Since the tolerance of the equalizer effect is wider than the tolerance of the shapes to be equalized, the system will assure that, either with high tension or with standard tension, hermetic standards will be reached as a result of the equalizer effect. As previously mentioned, the standard tension already assures hermetic standards for standard bottles. In standard bottles, vertex 26 won't grip as deep in groove 14 as in the case of eroded bottles. Hermetic quality will be achieved by the solely fact that stripes 22 will anyway be pulled down in the compression operation. If extremes of the stripes 22 don't grip deeply, Binding ring 30 has absorbing capabilities to bind the skirt 20 anyway. The surplus of tension will be applied according to the kind of surface that the vertex 26 finds in its path on the groove 14. The surplus tension resulting from each case, will have a direct correlation with the level of erosion found. In all cases, the resulting tension will provide an analogous hermetic status to the one found in standards cases. Transition area 90 and binding ring 30 have capability to elongate and support (or provide) tension. Stripes 22 themselves have as well, capability to elongate. In either case of an eroded bottle, the functionality of the system will grip the neck of the bottle to assure hermetic standards.
Erosion of the bottles are mostly observed either in the top of the neck or/and the groove 14. In either case, the tensions generated by the external part compressing over the Internal one, will seal the bottle. The existence of a liner in the ceiling of the Internal Part is substantial to the sealing performance once the equalizer effect is generated. The first variable (the erosion found), dictates to the system the needed performance for the second variable (the needed tension), to make the hermetic standards to prevail.
When the closure is in compressed status, binding ring 30 will have been downwardly sled surrounding external extremes 24 of stripes 22. As vertex 26 becomes externally pressed, it will slide along the slope 11 of groove 14, until the external part is completely compressed over Internal one. According to the shape of the groove 14, vertex 26 will generate different degrees of tension to transition area 90. The more erosion the groove 14 has, the more degree of tension will be generated. In the case of a bottle which groove 14 is in standard status, standard tension will assure hermetic standards, and elongation qualities of the binding ring 30 will absorb what the groove 14 did not, and should have in the case of an eroded groove.
One of the features associated with this equalizer effect is the fact that the length of the stripes 22 is not longer enough to reach the critical point 12 in groove 14 by itself. Stripes 22 are shorter and must be pulled down as the binding ring 30 compresses the skirt 20. The term "pulled down" means that, as a result of the pressure applied by the binding ring 30, vertex 26 will downwardly slide along slope 11 of groove 14. This will provoke the reaction of a force or tension observed in the transition area 90. This tension is the quality assuring hermetic standards. The tolerance that the tension provoked in transition area 90, is the quality that allows the system to be hermetic in bottles which tolerance of erosion is lower than the tolerance of the transition area 90.
As can be observed in FIG. 13, binding ring 30 applies pressure over the external extreme 24 of the stripes 22. A critical fact is that binding ring 30 applies its pressure below the horizontal level of vertex 26. If we draw an outwardly horizontal line from the vertex 26, binding ring 30, will be positioned below that line. This makes the stripes 22 to maximize their griping performance on the groove 14.
Due to the gripping nature of the internal part to the extreme of the bottle, such internal part will be fixed on its place without moving nor rotating. The gripping disposition of the internal part performs in an axial way, gripping with the main plate 5 from the top, and with the vertex 26 from the bottom. The vertex 26 will be applying an upwardly force towards the oblique plane 11 of the groove 14, when binding ring 30 surrounds it. This situation will be held until the "binding ring" 30 is upwardly sled to release surrounding force towards the extreme of the stripes 22. During the opening operation, which includes a twist of the external part, the internal part will remain in place without rotating.
Yet another modification will now be described with reference to FIGS. 14-16. In the external and internal parts, the main 5 plate, the breach line 70 and the interlocking parts as shown in the drawings, have in this embodiment two special dispositions. The first of these is a difference of levels. The exterior annular area 60 of the external part delimited by the breach line 70, has its base in contact with the point 50 of the internal part when the cap is compressed but before an interlocking was done. This external annular area 60 is taller than the central circular area 40 in the other side of the breach line 70. The interlocking structures of both parts have not interlocked yet. The second special disposition is that shape of the roof of the external part is convex molded. In order to make both parts interlock, it has been preestablished, by the effect of the convex molding of the external part, that an applied force is needed to downwardly flex the center 45 of the circular area 40 of the external part. The center of the inner face of the circular area 40 will hook with the opposite area in Internal Part. The perimeter 47 of such a central area 40 remains in soft tension, not in contact with the internal part as a result of the difference of levels previously mentioned and the fact that the breach line 70 has not yet been detached. This perimetrical area 47 of the central circle 40 does not touch the internal part before the break of the Breach Line 70.
The perimetrical area 47 of the central circle 40 will not be in contact with the roof of the internal part since it will be sustained by the bars (similar to the segments 92 in FIG. 10B) of the breach line 70. In this situation, the area will remain stable and with soft tension, until recovering its original form, which will be possible only after the break of the bars in the breach line 70. When the break happens, this perimetrical area 47 of the central circle 40 will downwardly flex in response to its original convex molding conformation until entirely touching the roof 52 of the internal part of the system.
In this situation, with the cap in closed position but with the breach line 70 broken, there will be evident a difference of levels in the opposite sides around the broken breach line 70.
FIG. 14 shows the closure compressed but still not interlocked between the parts. A hit at point 45 is necessary to interlock both parts. FIG. 15 shows the closure interlocked after the bottling machinery applied the hit in point 45. This is how the consumer will receive the product. After tampering with the breach line 70 and consuming part of the product, the consumer may want to re-cap the closure over the bottle. When the re-capping operation is done, and the external part is compressed over the internal part, the difference in levels provide evidence of the previous tampering of the closure. FIG. 16 shows this state.
In FIG. 17, internal part 2 is shown in a perspective view. This view illustrates the conformation of the main plate 5, roof 52, flanges 54 and spaces 56. Liner 8 and point 50 are also evident. It can be seen from this figure how flanges 54 will allow hooks, belonging to the external part, to interlock while spaces 56 will avoid any possibility of rotation of the central circle 40 of the external part over the internal part. A special structure belonging to the external part will be positioned in a complementary way in spaces 56 while hooks belonging to the external part will lock with flanges 54. The central circle 40 of the external part will not be able to rotate; complementary structure placed in spaces 56 will be laterally contained by flanges 54. Rotation of the central circle 40 is avoided to allow the breach line 70 to break during the twisting action of external annular area 60 of the external part. This disposition of flanges 54 and spaces 56 allows the system to unify its interlocking tools with its anti-rotational tools in one single structure. In other embodiments, hooking tools were independent from the anti-rotational tools, and were differentiated regarding their position, for example, with different diameters. In this embodiment, the flange 54 serves as a hooking tool and as a parameter for anti-rotational structure. This embodiment simplifies the design of the part and the mold needed to produce it.
Before the system is bottled during the shipment to the bottling plant, it is intended to minimize the probability of the system interlocking itself by accident during the shipment from the production plant to the bottling plant. If this happens before the system is positioned over the container, then the cap would become useless.
With the new design described above, the key factor to turn the system into an interlocked status, is a specific hit in the center point of the central circular area. This hit makes the structure flex and hook to the internal part. If the caps are shipped in a compressed status, the annular area would be positioned over the roof of the internal part and the hit that would activate the interlocked status would become quite specific. Such specificity can be applied by bottling machinery but hardly by chance. This specificity is the factor that minimizes the risk of ruining the system by accident before the bottling process takes place. Shipping the caps in a compressed status but obviously without the parts being interlocked might be an acceptable way of minimizing risks of ruinous systems before the caps are applied.
After the system was bottled during the distribution process, the caps have already been applied over the bottles and the interlocking status was obviously activated. The convenient difference of levels between the areas of the external part is estimated in approximately 0.6 mm (0.0236 inches).
Since the bars to be detached in the breach line during the upward sliding of the external part need 1 mm (0.0394 inches) to be broken, an aleatory downward hit over the external part will not provoke an accidental broke of the breach line that could ruin the integrity of the system. If an accidental hit over the external face of the central circular area is done, then nothing critical happens. A similar scenario is observed if the hit is performed over the annular area of the part. The roof of the internal part supports both areas of the external part. The only way to break the breach line is by a twisting action of the annular area around the central one, or by upwardly sliding the annular area. Neither of these operations happen in an aleatory way. The probability of an accidental break of the breach line during the chain of processes until the product gets to the outlay stage is minimized.
Another advantage of this embodiment compared to those previously proposed in the previous patent application is that the annular area does not need to surpass the edge of the border of the central area if the consumer wants to release the closure after having it re-capped. No friction between edges of the detached breach line will occur when releasing the closure for a second time. Another advantage is that there cannot be any situation that could neutralize the effect of the tamper evidence after the closure is released by positioning both the annular area and the central area at the same level as if the closure were not tampered with. Further, the bay structure of the internal part shown in FIGS. 14, 15 and 16 allows the system to minimize its height of the closure above the top level of the container in order to improve the aesthetic aspects sought in the industry. This embodiment diminishes the quantity of raw material needed to produce the closure. Special means, similar to those previously presented to fix the central area of the external part to the central area of the internal part during the compressed status, are provided to prevent the mentioned central area of the external part from undergoing rotational movement during the twisting action to release the closure.
An alternative to the above described embodiment makes the annular area the one operating to make evident the difference of levels instead of the perimeter of the central circle. The tension to be released after the break of the Breach Line to allow the structure to recover its original conformation will be located in the annular area of the Part, not in the perimeter of the central circular area.
In the previously described process, the perimetrical area of the central circle is the one operating to make evident the difference of levels when the breach line is detached. In the following description, is the annular area the one operating to make evident the difference of levels in that main plate after tampering the system.
The basic design is the same, but the difference is that the annular area will not lean over the main plate of the internal part before the cap is interlocked. During the closing operation performed by a hit over the roof of the external part, the annular area 60 pivots on the point 50 to allow the central circle 40 reach the interlocking ˜one. After that operation, the central circle 40 will be interlocked. The annular area 60 will be positioned over the internal part, but a tension will be present as a result of the forced pivot that the annular area 60 made over the point 50 to allow the center of the circular area 40 to reach the interlocked status. After the bars or connectors of the breach line 70 are broken in the opening operation, nothing will be downwardly holding the annular area 60, so it will recover its original horizontal plane, evidencing the difference of levels with the central circle 40 that remains snugly interlocked to the roof of the internal part.
The critical aspect here is that the annular area is the one that recovers its original status by upwardly flexing after detaching the breach line 70. This upwardly flexing capability is due to the "pivot" action on the Point 50 which is elevated. This makes the difference of levels evident between both areas of the external part.
These alternatives to the tamper evidence can be applied separately or joined to mutually enhance the difference of levels between areas after the system was tampered.
The description set out above is not to be considered limiting. Protection for the invention as defined by the following claims, and all equivalents, is sought. | One form of a cap for a container includes an internal part and an external part relatively movable with respect to one another among closed, intermediate and open cap positions. Complementary structures protrude from the internal and external parts for dictating relative positions of the internal and external parts as the parts are initially joined together. Interengaging elements on the internal and external parts secure a selected portion of one of the internal and external parts to the other after joining the parts together. A breakable seal between the selected portion of the one of the internal and external parts and the remainder of the one of the internal and external parts, when broken, allows the internal and external parts to move relative to one another. Variations are also disclosed. | 1 |
BACKGROUND OF THIS INVENTION
1. Field of this Invention
This invention relates to circuits and methods for generating a stimulus signal and evaluating a response signal for testing of logic and memory located on an integrated circuit. More particularly, this invention relates to circuits and methods for generating test pattern signals and evaluating test response signals to verify operation and function of random access memory (RAM) integrated circuits.
2. Description of Related Art
FIG. 1 shows a typical random access memory (RAM) block diagram. The RAM 150 has address input terminals 141 , data input terminals 142 and timing and control input terminals 143 . The input decode logic 140 consists of address decoders which convert the address input terminals to array selection lines. These array selection lines can select a single memory bit within the RAM memory array 150 of memory cells or bits. The input decode logic also uses the timing and control input terminals 143 to produce electrical signals which facilitate the selection, reading and writing of the required memory bits. This selection of the memory bits is synchronized to timing clocks 143 so as to synchronize the RAM reading or output and the RAM writing or input with an access clock. This access clock synchronization allows capture of data at input terminals at a specified time with respect to the access clock waveform. It also allows presentation the RAM data at an output terminal 160 or memory read results at a specified time with respect to the access clock waveform.
The most common technique used currently in automatic test pattern generators is the D-algorithm, which is based on path sensitization. The main idea of path sensitization is to select a path through the combinatorial logic from the site of a potential fault to a primary output. Next, a path is followed through the logic circuit from the site of the potential fault to a primary output of the combinatorial logic, specifying the values along this logic path that are required to propagate the signal value on the faulty line to a primary output. The process of propagating a signal through a circuit is called forward drive. Similarly, the process of determining the primary inputs necessary to produce all of the signals required during the forward drive is called the backward trace.
The unique problem of testing sequential logic, which has both combinatorial logic and registers or flip-flops, is solved using scan testing. The idea is to scan in a predefined set of ones and zeros into a set of registers These ones and zeros become the applied inputs to a section or island of combinatorial logic. The results of combination of these inputs through the specified combinatorial logic are captured in output registers. These output registers are connected in a serial chain and can be shifted out serially (scanned out) to allow the testing of the ones and zeros with the expected outputs of the combinatorial section of logic under test. In summary, the D-algorithm is used on the combinatorial islands of logic, which the scan in of the input registers and the scan out of the output registers is used to test the sequential logic designs.
The specific example of memory testing, including dynamic random access memory (DRAM) and static random access memory (SRAM) is understood by reviewing the standard march memory test patterns. A march algorithm has several sets of up/down address settings, read/write operations, read/write data values, and different lengths of read/write data values. The objective of march test patterns is to store and read out alternating ones and zeros in the memory array to check for various known types of memory faults. Some of the memory faults that can be tested and located are stuck-at-one or stuck-at-zero faults, address decoder faults, transition from 1 to 0 and from 0 to 1 faults, stuck open faults, coupling faults, neighborhood pattern sensitive faults, and data retention faults. The required memory test patterns can be presented on parallel inputs, can be scanned in from an external tester via shift registers or can be internally generated via on-chip self test logic.
FIG. 1 also shows other blocks, which serve as testing circuitry for the RAM. A built-in self-test (BIST) circuit 110 represents on-chip self-testing circuit. Typically, this self-testing circuitry provides testing of an entire chip, which includes RAM, logic, and even potentially analog circuitry. The outputs of the BIST go to the RAM test pattern generator 120 and to other test pattern generators 170 . This BIST output 180 includes command and background data lines. The command lines instruct the TPG 120 , which RAM tests to perform. The background data lines tell the TPG 120 what the expected RAM testing output results should be. Using this command and expected result information, the TPG 120 outputs a serial chain of stimulus or input values 124 to be applied to the RAM under test via the RAM data and control input block 140 . The RAM outputs go into the RAM output data and control block 160 . These RAM outputs are serially shifted through the test data output 164 into the comparator 130 shown in FIG. 1 . In addition, the TPG 120 delivers the expected test pattern results to the comparator 130 . The comparator compares the expected results to the actual RAM test results 164 and activates a Pass/Fail output 190 to indicate the results of the compare. The RAM 150 can be replaced by any logic function, and the same on-chip self-test methodology applies. This methodology is typical of the self-test techniques presently in use.
The input decode circuit 140 and the output buffer circuit 160 generally will each include a scan register. The scan register is effectively transparent during normal operation, but allows the transfer of test stimulus signals TS from the test pattern generator TPG 120 to the test access port TAP 144 of the input decode circuit. It is well known in the art that the test stimulus signals are transferred by way of a single connection to the test access port 144 and to the input of the scan registers in the input decode circuit. The normal operational signals, Address 141 , Data 142 , and timing and control 143 are disabled or alternately controlled by testing circuitry.
The test stimulus signals 124 are “scanned” in the scan register until the test stimulus signals 124 are aligned with the signal path for the normal operational signals. The appropriate timing signals are activated and the input decode circuit performs the operation indicated by the test stimulus signal TS 124 . A selected memory cell or cells of the RAM array 180 are written to or read from and the resultant output signals are transferred to the Output Buffer 160
The scan register Output Buffer 160 is connected to the Test Data Output port TDO 164 . At the completion of the transfer of the test stimulus TS to the test access port TAP 144 , the resultant output signals are “scanned” from the scan registers of the Output Buffer 160 through the Test Data Output port TDO 164 to the Q input of the comparator 130 .
The test expected results signal 125 is transferred from the Test Pattern Generator 120 to the comparator 130 . The comparator 130 compares the resultant output signals from the test data output port 164 with the test expected result signals 125 . The pass/fail signal 135 provides an indication of the success of the comparison. If the test is successful, the pass/fail signal 135 indicates a first logic level (1), and if the test is unsuccessful, the pass/fail signal 135 indicates a second logic level (0).
U.S. Pat. No. 5,377,148 (Rajsuman) describes hardware and methods to test variable size RAMs in a constant period of time. This is accomplished by partitioning the memory array into a plurality of individually accessible equivalently sized memory blocks.
U.S. Pat. No. 5,764,657 (Jones) presents a method for generating an optimal serial test pattern for sequence detection. The serial test pattern comprises a first plurality of bits and is generated by a pattern generator.
U.S. Pat. No. 6,061,817 (Jones et al) presents a method and apparatus for generating a serial test pattern for sequence detection. The serial test pattern has a first plurality of bits and is generated by pattern generator.
U.S. Pat. No. 6,094,738 (Yamada et al.) presents a test pattern generation apparatus and method for an SDRAM by adding a wrap address conversion circuit. Yamada et al. also describes a method of testing SDRAMs by converting address data from the pattern generator to the burst address of predetermined modes.
Kim et al., “On Comparing Functional Fault Coverage and Defect Coverage for Memory Testing,” IEEE Transactions on Computer - Aided Design of Integrated Circuits and Systems . Vol. 18, No. 11, November 1999, IEEE, describes the evaluation of the effectiveness of the memory testing algorithms based on the defect coverage by comparing the defect coverage of known memory testing algorithms using the same defect statistics.
BRIEF SUMMARY OF THIS INVENTION
An object of this invention is to provide a circuit for testing to determine if the logic or memory meets the design specifications.
Another object of this invention is to provide methods for testing to isolate the errors found during any logic or memory tests, which fail the pass criteria.
Further, another object of this invention is to provide a test pattern generator circuit that is added to an integrated circuit during silicon compilation to automatically generate integrated photo masks for fabrication.
To accomplish these and other objects, an integrated test pattern generation and comparison apparatus is in communication with a built-in-self-test controller and functional integrated circuits formed on a semiconductor substrate. The integrated test pattern generation and comparison apparatus has a background and command decoder that is connected to receive test background and command codes from the test controller, to translate the test background and command codes to test stimulus signals that, when applied to the functional integrated circuits, create test response signals from the functional integrated circuits. The test stimulus signal is formed of a digital word having a number of bits.
The test pattern generation and comparison apparatus further has a number of latency buffers connected to the background and command decoder receive the test stimulus signals and to adjust in time the relationship of the test stimulus signals as required by the functional integrated circuits. There will be one set of latency buffers for each test access port of the functional integrated circuit. Each latency buffer is a plurality of serially connected flip-flop circuits. A first flip-flop circuit of the plurality of serially connected flip-flop circuits has a data input connected to the background and command decoder to receive one bit of the test stimulus signal and an output connected to a subsequent flip-flop circuit of the serially connected flip-flop circuits, whereby each subsequent flip circuit of the serially connected flip-flop circuits has an output connected to the input of a following flip-flop circuit of the plurality of serially connected flip-flop circuits, and whereby a last flip-flop circuit has an input connected to an output of a previous flip-flop circuit and an output containing a delayed bit of the test stimulus signal. The number of flip-flop circuits of each latency buffer is the number of bits in one test stimulus signal. The test stimulus signals are adjusted in time as a function of the number of flip-flop circuits in the plurality of serially connected flip-flop circuits.
The test pattern generation and comparison apparatus has a plurality of parallel-to-serial converters. Each parallel-to-serial converter is connected to one group of the plurality of latency buffers, to convert the test stimulus signals to a serialized test stimulus signals to be scanned to a scan register of the functional integrated circuit.
The parallel-to-serial circuit has a first plurality of flip-flops. Each flip-flop has a data input to receive one of a first portion of bits of the test stimulus signal and a clock input to receive a first clocking signal to latch the first portion of the bits of the test stimulus signal. The parallel-to-serial circuit further has a first plurality of multiplexor circuits. Each multiplexor circuit has a first input to receive one of a remaining portion of bits of the test stimulus signal, second input to receive an output of one of the first plurality of flip-flops, and a select input to receive a second docking signal to selectively transfer the remaining bit of the test stimulus signal and the output of one of the first plurality of flip-flops to an output of the multiplexor circuit. The parallel-to-serial circuit additionally has a second plurality of flip-flops. Each flip-flop of the first plurality of flip-flops has a data input connected to an output of one of the first plurality of multiplexor circuits, and a clock input connected to receive the first clocking signal to latch the output of one of the first plurality of multiplexor circuits to the output of the flip-flop of the plurality of flip-flops. Finally, the serial-to-parallel circuit has a second plurality of multiplexor circuits. Each multiplexor circuit has a first input connected to a first flip-flop of the plurality of flip-flops, second input connected to a second flip-flop of the second plurality of flip-flops, and a select input connected to the first clocking signal to alternately transfer the first input to an output of the multiplexor circuits and the second input to the output, as the first clocking signal changes from a first level to a second level and from the second level to the first level.
The test pattern generation and comparison apparatus has a test response comparison circuit. The test response comparison circuit is connected to the background and control decoder to receive an expected test response signal providing a correct response expected from the integrated circuits in response to the test stimulus signals, and connected to the integrated circuit to receive a test response signal that is the response of the integrated circuit to the test stimulus signal. The test response comparison circuit has a comparator circuit to receive the test response signal and the expected test response signal, compare the test response signal to the expected test response signal and produce a test results signal indicating functioning of the integrated circuits. The comparator circuit is comprised of comparator logic of exclusive-ORs and ORs which compare the data out read from the RAM under test and the expected value from the Background logic section. The output of the comparator circuit is the Pass/Fail signal where a high level indicates Pass or equality or a low level indicates a Fail or inequality.
The test response comparison circuit further has a error-handling module to receive the test response signal and the expected test response signal and creates a diagnostic signal indicating a location of any fault determined to exist within the integrated circuits. The error handling module includes a parallel-loadable shift register. The input of this shift register are the data outputs from the RAMs. The load signal for the shift register comes from the Pass/Fail signal of the comparator. The diagnostic output is the serial output of the shift register.
The test pattern generation and comparison apparatus is structured such that a hardware description of the test pattern generation and comparison apparatus requires the number of bits of the test stimulus signal and the adjusting in time of the test stimulus signal as parameters to automatically create a physical description of the test pattern generation and comparison apparatus during an automatic physical design of the integrated circuit for placement on the semiconductor substrate.
The test pattern generation and comparison apparatus is applicable to testing logic circuits and memory array circuits. However, the preferred embodiment of this invention is applicable for the testing of random access memories (RAM) such as dynamic RAM, static RAM, and other known RAM arrays.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram of on-chip self testing of the prior art.
FIG. 2 is a high level diagram of an embodiment of an on-self testing circuit of this invention.
FIG. 3 is a detailed block diagram of a test pattern generation and comparison circuit of this invention.
FIG. 4 is a logic diagram of the latency buffer of this invention.
FIG. 5 is a logic diagram of the parallel to serial converter of this invention.
FIG. 6 is a timing diagram of a command decode to form test stimulus signals as output of the test pattern generator of this invention.
FIG. 7 is a timing diagram that illustrates the latency and serial-to-parallel signals of the test pattern generator of this invention.
FIG. 8 is a block diagram of the serial-to-parallel circuit of this invention.
FIG. 9 is a timing diagram that illustrates the operation of the serial-to-parallel circuit of FIG. 8 .
FIG. 10 is a block diagram of the background and command decoder of this invention.
FIG. 11 is a block diagram of the comparator circuit of the test pattern generation and comparison circuit of this invention.
FIG. 12 is a block diagram of the error handling module of the test pattern generation and comparison circuit of this invention.
FIG. 13 is a flowchart of the method for generation of test stimulus signals and the analysis of test response signals to verify function of integrated circuits of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Refer now to FIG. 2 for a discussion of a test pattern generation and comparison circuit of this invention built into or embedded within an integrated circuit. The test circuit of this invention is used to verify the function and operation of an integrated circuit. The built-in self test (BIST) logic 200 is a logic circuit, which controls the testing of the various logic and memory sections of the integrated circuit chip. It consists of a BIST controller 230 , which triggers the beginning and ending of the various chip self tests. The BIST logic also consists of the Sequencer 240 which contains the individual programmable memory and logic test algorithms and individual test pattern generator interface TPG signals. The sequencer 240 drives the individual test pattern generators, TPG's, for logic 270 and memory 250 . The Sequencer communicates with the TPG blocks via a Command bus and a Background bus 245 . The RAM TPG 250 presents test pattern input signals 210 and receives test pattern output results 220 from the RAM 260 . The serial output from the RAM 220 is sent to a Comparator 255 where it is compared with the expected RAM test results that came from the Command/Background bus. The results of the RAM results comparison are communicated via the DIAG bus 259 and the PASS/FAIL line 257 . The DIAG bus 259 contains information on the exact location of the error found. Similarly, the Logic TPG 270 presents test pattern input signals 285 and receives test pattern output results 295 from the Logic 280 . The serial output from the Logic 295 is sent to a Comparator 275 where it is compared with the expected Logic test results 290 that came from the logic test pattern generator 270 . The results of the Logic results comparison are communicated via the DIAG bus 279 and the PASS/FAIL line 277 . The DIAG bus 279 contains information on the exact location of the error found. The PASS/FAIL line 277 indicates whether and error has occurred with no indication of the type of error or its location.
FIG. 3 illustrates the test pattern generation and comparison circuit 250 of this invention. The serial test data outputs 310 , . . . , 315 , 320 provide the appropriate data, control and timing signals to the RAM such that the RAM may be tested for correct operation. The serial test data output 310 , . . . , 315 , and 320 collectively form the test stimulus signals 210 of FIG. 2 . The test response signals Q A 326 , Q X 327 , . . . , Q Y 328 of FIG. 3 represent the serial test data output TDO 220 of FIG. 2 . The background and command decoder 330 accepts input from the high level command bus 331 and the encoded background bus 332 . The number of commands acceptable from the command bus 331 is 2 n commands, where n is number of terminals or bits of the command bus 331 . The number of connections or bits of the background bus 332 depends on the word length in memory. The access clock is used to synchronize the test pattern and generation circuit with the remaining integrated circuits to be placed on the chip. The access clock loads the flip-flops of the latency buffers 340 , . . . , 345 , 350 , 355 , 375 , and is, in the preferred embodiment, the master clock of the remaining integrated circuits to be placed on the chip. The test stimulus signals 334 , 335 , 336 , and 337 are structured to form the memory data, address and control signals to be applied to the RAM array 260 of FIG. 2 . The test stimulus signals 334 , 335 , 336 , and 337 are each connected to latency buffers 340 , 345 , 350 , and 355 . In addition, the output enable signal 374 and the parity signal 376 from the background and command decoder 330 is applied to latency buffers 356 .
As is known, the structure of the integrated circuit may be such that the test stimulus signal 210 generated by the test pattern generator 250 of FIG. 2 may be multiple test stimulus lines fed to multiple test access ports for the input data and decode circuitry for other RAM arrays 260 placed in the integrated circuit. Further, each RAM array 260 may require its own unique set of test stimulus signals. Thus to accomplish this, the background and command decoder 330 provides multiple test stimulus signals 334 , 335 , 336 , and 337 to the latency buffers A, . . . , Z 340 , 345 , 350 , and 355 . The latency buffers 340 , 345 , 350 , and 355 adjust or delay the test stimulus signals 334 , 335 , 336 , and 337 such that are delayed in time by a predetermined amount relative to the Access Clock. The delayed test stimulus signals 342 , . . . , 347 are transferred to the parallel-to-serial converter circuits 380 , . . . , 385 . The parallel-to-serial converter circuits 380 , . . . , 385 converts the parallel delayed test stimulus signals 342 , . . . , 347 to the serial test stimulus signals 310 , . . . , 315 .
The delayed test stimulus signals 352 are transferred to the parallel-to-serial converter 390 . The serialized test stimulus signal is then transferred to the tri-state buffer 395 . The output of the tri-state buffer 395 is the serial test data 320 . The delayed test stimulus signal 367 acts as the tri-state control for the tri-state buffer 395 . The tri-state buffer 395 is employed in test structures including input/output pads where the output of the RAM test pattern generator 210 of FIG. 2 must be brought to a high impedance or disabled to prevent interference with normal operation.
Refer now to FIG. 10 for a discussion of the structure and operation of the background and command decoder 330 . The high level command bus 331 and the encoded background bus 332 are connected to the combinatorial logic 1030 . This block of logic produces an output enable signal OE, which when equal to zero tells the Comparator 360 in FIG. 3 to compare the background pattern 1050 in FIG. 10 to the parallel data from the serial-to-parallel block 325 in FIG. 3 . The parity output 1040 tells the Comparator 360 that the background pattern has been inversed. The high level commands are decoded in the combinatorial logic and the RAM signals X, Y, W[ 0 ], and W[ 1 ] are generated and funneled through parallel-to-serial converters. These serial signals are then presented to the RAM inputs.
Refer now to FIG. 4 for a discussion of the structure of the latency buffers 340 , 345 , 350 , 355 and 356 . Each set of latency buffers 400 includes multiple register sets 405 a , . . . , 405 z . Each register set 405 a , . . . , 405 z includes a group of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n . One of the test stimulus signals 420 a , . . . , 420 z from the background and command decoder 330 of FIG. 3 provides the data input to the first flip-flop 410 a , 415 a of the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n . The outputs of each flip-flop of the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n are connected to the input of each subsequent flip-flop. The output of the last flip-flop 410 n , 415 n of the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n form the delayed test stimulus signals 425 a , . . . , 425 z . The access clock provides the timing signal to cause the test stimulus signals 420 a , . . . , 420 z to be transferred through each of the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n.
Refer now to FIG. 7 for a discussion of the operation of the latency buffers 400 . At a time t 0 the background and command decoder 330 of FIG. 3 receives a command CMD such as test write or test read from the sequencer 240 of FIG. 2 . The command is decoded to create the test stimulus signals A[ 0 ], A[ 1 ], A[ 2 ], and A[ 3 ]. The test stimulus signals A[ 0 ], A[ 1 ], A[ 2 ], and A[ 3 ] are, in this example, the inputs 334 to the latency buffer 340 . The latency buffer 340 delay the test stimulus signals A[ 0 ], A[ 1 ], A[ 2 ], and A[ 3 ] by the time λ during the time period t 1 . The time delay λ is a fixed number of cycles or period of the access clock and determines the number of flip-flops in the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n . The number of flip-flops in the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n is determined by the formula:
N = λ ϕ
where:
N is the number flip-flops in each of the groups of serially connected flip-flops 410 a , 410 b , . . . , 410 n , 415 a , 415 b , . . . , 415 n. λ is the required delay time. φ is the period of the access clock.
The test stimulus signals A[ 0 ], A[ 1 ], A[ 2 ], and A[ 3 ] that have been delayed by the delay time λ form the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d that are active at the time period t 2.
FIG. 5 illustrates an embodiment of the parallel-to-serial converters 380 , 385 , 390 of FIG. 3 . In this implementation of the embodiment of this invention the background and command decoder 330 produce one test stimulus signal having a width of 4 bits, represented by the test stimulus signals A[ 0 ], A[ 1 ], A[ 2 ], and A[ 3 ]. These signals are then delayed as described above through the latency buffer 340 to form the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d. The delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d are the inputs to the parallel-to-serial converter 500 . The low order bit A[ 0 ]_d of the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]d is one input to the two bit multiplexor 510 . The next higher even bit A[ 2 ]d of the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d is the data input to the flip-flop 530 . The output of the flip-flop 530 is a second input to the multiplexor 510 . The output A_even of the multiplexor 510 is the data input to the flip-flop 540 . The lowest order odd bit A[ 1 ]_d of the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d is the first input of the two bit multiplexor 520 and the highest order bit A[ 3 ]_d of the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d is the data input of the flip-flop 560 . The output of the flip-flop 560 is the second input to the two bit multiplexor 520 . The output A_odd of the multiplexor 520 is the data input to the flip-flop 550 . The outputs of the flip-flops 540 and 550 are the input to the two bit multiplexor 570 . The output of the two bit multiplexor 570 is the serial test data out 580 .
The load signal 515 provides the select signal to determine which of the two signals applied to the inputs of the two bit multiplexors 510 and 520 is transferred to the outputs A_even and A_odd. The memory clock 535 provides the clock signal for the flip-flops 530 , 540 , 550 , 560 , that “latches” the input signals present at the inputs of the input of the flip-flops 530 , 540 , 550 , 560 to their respective outputs. Further, the memory clock 535 provides the select signal for the two bit multiplexor 570 .
Refer again to FIG. 7 for a discussion of the function of the parallel-to-serial converter 500 . At the time ti, the delayed test stimulus signals A[ 0 ]_d, A[ 1 ]_d, A[ 2 ]_d, and A[ 3 ]_d are applied to the input terminals as above-described. During the beginning of the time segment t 1 , the load signal remains at a high logic level (1) and the two bit multiplexor 510 transfers the low logic level (0) of the lowest order bit A[ 0 ]_d to the flip-flop 540 . Simultaneously the two bit multiplexor 520 transfers the high logic level (1) of the second lowest order bit A[ 1 ]_d to the flip-flop 550 . The bits A[ 2 ]_d, and A[ 3 ]_d of the delayed test stimulus signals A[ 0 ]_d, A[ 1 ] d, A[ 2 ] d, and A[ 3 ] d are respectively the data inputs of the flip-flops 530 and 560 . At the change of the memory clock from the low logic level (0) to a high logic level (1) the data inputs of the flip-flops 530 , 540 , 550 , and 560 are “latched” to the outputs of the flip-flops 530 , 540 , 550 , and 560 . The multiplexor 570 is activated with the high level (1) of the memory clock during the time t 3 to transfer the low logic level (0) of the test stimulus signal A[ 0 ]d from the first input of the multiplexor 570 to the serial data output 580 . At the beginning of the time t 4 the memory clock changes from the high logic level (1) to the low logic level (0) and the output of the multiplexor 570 now receives the contents A[ 1 ]_d of its second input which is the output of the flip-flop 550 The test stimulus signal A[ 1 ]_d is now the serial data output 580 . During the time period t 3 and prior to the change of the memory clock from the high logic level (1) to the low logic level (0) at the beginning of the time period t 4 , the load signal changes from the high logic level (1) to the low logic level (0). This causes the multiplexors 510 and 520 to be activated to respectively transfer the contents A[ 2 ]_d, and A[ 3 ]_d of the output of the flip-flops 530 and 560 respectively to outputs A_even and A_odd of the multiplexors 510 and 520 . At the beginning of time t 5 , the memory clock changes from the low logic level (0) to the high logic level (1) and the test stimulus data A[ 2 ]_d, and A[ 3 ]_d is “latched” to the outputs of the flip-flops 540 and 550 . During the time t 5 the test stimulus data A[ 2 ]_d is transferred to the serial data output. When the memory clock changes from the high logic level (1) to the low logic level (1), the multiplexor transfers the second input which is the contents A[ 3 ]_d of the output of the flip-flop 550 to the serial data output.
Refer now to FIGS. 3 and 6 for a discussion of the operation of the test pattern generator 250 of this invention. The memory clock, the access clock, and the load signal provide the timing and control signals for the test pattern generator 250 . A command signal CMD 331 is applied to the background and command decoder 330 . The background and command decoder 330 decodes the command signal CMD to form the test stimulus signals 334 , 335 , and 336 . In this example, the command signal CMD forms four serial test data signals A, B, C, and D that would be illustrative of the signal contents of the serial test data ports 310 , 315 , and 320 . The parameters that determine the structure of the decoded test stimulus signals are the latency and the packet length. The latency determines the relative timing of the serial test data signals A, B, C, and D for each of the serial test data ports 310 , 315 , and 320 in relation to the application of the command CMD signal. The packet length is the number of serial test data bits to be provided by a particular command signal CMD.
The command signal CMD is decoded to form the signals A[ 0 ], B[ 0 ], B[ 1 ], C[ 0 ], C[ 1 ], C[ 2 ], C[ 3 ], D[ 0 ], D[ 1 ], D[ 2 ], and D[ 3 ] that are the test stimulus signal 334 , 335 , 336 , and 337 . In the case of the test stimulus signal for port A the number of bits is one A[ 0 ], the number of bits for port B is two B[ 0 ], B[ 1 ], for ports C and D the number of bits is four C[ 0 ], C[ 1 ], C[ 2 ], C[ 3 ], D[ 0 ], D[ 1 ], D[ 2 ], and D[ 3 ]. The serial test data signals for ports A, B, C, and D of FIG. 6 illustrate by example the timing relationships of the test data signals for ports A, B, C, and D. Since the test stimulus signal for the port A has one bit, the serial test data signal of port A has packet length of one during one access clock. The latency of the serial port A is set to zero or, in other words, the serial test data for port A coincides with the command signal CMD. Since the test stimulus signal for the port B has two bits, the serial test data signal of port B has packet length of two during one access clock. The latency of the serial port B is set to one or the serial test data for port B is delayed one access clock cycle with respect to the command signal CMD. Since the test stimulus signal for the port C has four bits, the serial test data signal of port C has packet length of four during one access clock. The latency of the serial port C is set to zero or the serial test data for port A coincides with the command signal CMD. The test stimulus signal for the port D has four bits, the serial test data signal of port D has packet length of four during one access clock. The latency of the serial port D is set to four or the serial test data for port D is delayed four access clock cycles with respect to the command signal CMD.
If the access clock frequency equals the memory clock frequency, the maximum packet length would be two. If the memory clock frequency equals to twice the access clock frequency, the maximum packet length would be four. In general, the maximum packet length equals two times the memory clock frequency divided by the access clock frequency.
The serial test data 310 , 315 , 320 is scanned to the respective test access ports for the testing the RAM array 260 of FIG. 2 . The appropriate controls are activated to test the function of the RAM array 260 . The test data output TDO 220 contains the serial test results data that is transferred to one serial data input Q A , . . . , Q X , Q y of the test pattern comparison circuit 255 . Each serial test results data input Q A 326 , . . . , Q X 327 , Q Y 328 is received by the serial-to-parallel converter 325 . The serial test results data inputs Q A 326 , . . . , Q X 327 , Q Y 328 are converted to a parallel test result data word 362 , 364 , and 366 .
Refer to FIG. 8 for discussion of the structure and function of the serial-to-parallel converter 325 . FIG. 8 shows two serial outputs 860 from the RAM 870 . These two serial signals are converted to four parallel signals via the connection of several flip-flops (FF) such as 810 . The memory clock 820 captures RAM Data Out 0 860 . The Access clock shifts the data from the input FF to the output FF to produce Data Out 0 850 .
FIG. 9 is a timing diagram of the operation of the serial-to-parallel converter 325 . As explained above, the memory clock, the access clock and the load signal provide the timing and control signals for the serial-to-parallel converter. The serial data output for test result data port D is by example, illustrative of two successive data packets Wd[ 0 ] and Wd[ 1 ]. The bits of the packet word Wd[ 0 ] are transferred serially to the data input Q of port D during the times t 0 , t 1 , t 2 , and t 3 . The bits of the packet word Wd[ 1 ] are transferred serially to the data input Q of port D during the times t 4 , t 5 , t 6 , and t 7 . The test results data word Wd[ 0 ] is contained in the parallel test response word D[ 0 ], D[ 1 ], D[ 2 ], and D[ 3 ] during the times t 4 , t 5 , t 6 , and t 7 . The bit D[ 0 ] contains the test result data of the time t 0 , the bit D[ 1 ] contains the test result data of the time t 1 , the bit D[ 2 ] contains the test result data of the time t 2 , and the bit D[ 3 ] contains the test result data of the time t 3 . The test results data word Wd[ 1 ] is contained in the parallel test response word D[ 0 ], D[ 1 ], D[ 2 ], and D[ 3 ] during the time t 8 . The bit D[ 0 ] contains the test result data of the time t 4 , the bit D[ 1 ] contains the test result data of the time t 5 , the bit D[ 0 ] contains the test result data of the time t 6 , and the bit D[ 3 ] contains the test result data of the time t 7 .
Referring back now to FIG. 3 , the parallel test result data words 362 , 364 , and 366 are the inputs to the comparator 360 and the error handling module 370 . The comparator 360 receives the expected test response data 372 decoded from the encoded background data 332 by the background and command decoder 330 . Further, the background and command decoder 330 provides the output enable signal 374 , and the parity signal 376 . The output enable signal 374 , and the parity signal 376 are appropriately delayed by the latency buffer 375 and applied to the comparator 360 and the error handling module 370 . The function of the latency buffers 375 is as described in FIG. 4 to delay the output enable signal 374 , and the parity signal 376 . The output enable signal OE determines if the comparator needs to compare the expected data and the data output from the serial to parallel modules. The function of the parity signal is to select whether the expected output should equal the background data directly or the inverse of the background data. If parity is 1, the expected data equals the background data. If parity is 0, the expected data equals the inverse of the background data.
The comparator 360 compares the expected test result data pattern 332 to the parallel test result data words 362 , 364 , and 366 and provides a pass/fail signal 373 indicating whether the tested integrated circuit is functioning properly. Refer now to FIG. 11 , for a discussion of the comparator 360
The comparator in FIG. 11 receives the Data Out 1160 from the Serial-to-Parallel module and compares it to the Background data pattern 1110 . The Parity signal 1140 indicates whether to negate the background data. The output enable signal 1150 indicates whether to perform the compare if OE=0. If the Background=the Data, Pass/Fail=Pass. If the Background does equal the Data, Pass/Fail=Fail. If OE=1, the comparator does not compare and the Pass/Fail 1170 equals Pass The comparison takes place via the XOR and OR logic tree 1130 .
An optional function of the test pattern comparison circuit 255 is the error handling module 370 . The error handling module compares the expected test result data pattern 332 to the parallel test result data words 362 , 364 , and 366 and further compares them to identify and locate any faults present in the RAM array 260 of FIG. 2 .
Refer now to FIG. 12 for a discussion of the structure and operation of the error handling module 370 . The parallel data (0-n) 1250 from the S2P module is captured into a shift register of length n, if there is a failure indicated by the Pass/Fail signal 1240 from the comparator. The shift register which is loaded with the incorrect data result is then shift out serially on the DIAG output 1230 . This diagnostic output can be used to analyze the location and type of logic faults.
Refer now to FIG. 13 for a summary flowchart of the method for generating a test stimulus pattern to be applied to an integrated circuit such as a RAM array and for comparing a test result from the integrated circuit to verify function of the integrated circuit of this invention. The first step is to transmit the command and background codes 1310 from the BIST logic to the test pattern generation (TPG) logic. Next, the TPG decodes 1320 the Command and Background codes to determine which test to perform and to extract the expected test results for the requested test. Then, test signals 1330 are generated for the logic or memory under test. The test signals are delayed 1340 with respect to the access or memory clocks in order to be compatible with the timing requirements of the logic or memory under test. Next, the delayed test signals are serialized and transferred to the logic or memory under test 1350 . After the specified test is performed on the logic or memory, the test results are received by the test comparison circuit 1360 . The test comparison circuit analyzes 1370 the test results and reports a pass or fail. In addition, the test report can optionally include a diagnostic, which isolates the circuit location of any test failures.
One of the aspects of this invention is that this architecture of the TPG blocks for both logic and memory testing is compatible with silicon compilation systems. These systems generate integrated circuit designs and fabrication masks from a high level hardware design language, such as VHDL. The high level hardware design language provides a software description of the logic and memory. The latency parameter λ is used by the silicon compilers to determine which latency buffer circuit to use. Further, the packet length is determined as a function of the standardized tests chosen to test the integrated circuit. This silicon compiler decision is based on the amount of delay through the memory logic required to establish proper timing relationships of the test signals to properly exercise the operation of the integrated circuit. The high level hardware description language coding the latency parameter λ and the packet-length permits automatic specification of the test pattern generation and comparison circuit of this invention within and integrated circuit for inclusion on a semiconductor substrate.
While this invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of this invention. | A test pattern generation and comparison circuit creates test pattern stimulus signals for and evaluates response signals from logic or memory such as random access memory (RAM). It utilizes both parallel and serial interfaces to the logic/memory under test. The test pattern generation and comparison circuit further provides a method for testing logic and memory utilizing built-in self test (BIST) techniques. The method uses a programmable logic/memory commands which are translated into physical logic signals and timings for the logic or memory under test. The results of the test pattern generated and applied to the logic or memory are compared to expected results. The result of the comparison is a pass/fail designation. In addition, the comparison of the expected test results with the actual test results provides information on the exact location of the failure. Also, since the test pattern generation and comparison circuit architecture is compatible with hardware description languages such as Verilog HDL or VHDL, the test pattern generation and comparison circuit can be automatically generated with a silicon compiler. | 6 |
TECHNICAL FIELD
[0001] The present invention relates generally to pressure measurement in a wellbore. More specifically, the invention relates to real time pressure measurement in a wellbore during fracturing operations to better detect screen-out.
BACKGROUND OF THE INVENTION
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Hydraulic fracturing is a process whereby a subterranean hydrocarbon reservoir is stimulated to induce a highly conductive path to the formation, increasing the flow of hydrocarbons from the reservoir. A fracturing fluid is pumped at high pressure to crack the formation, creating larger passageways for hydrocarbon flow. The fracturing fluid may include a proppant, such as sand or other solids that fill the cracks in the formation, so that, when the fracturing treatment is done and the high pressure is released, the fracture remains open.
[0004] Key to a successful fracturing operation is the accurate monitoring of the bottom hole pressure in the wellbore, and determining when to stop pumping fracturing fluid and initiate flush of the wellbore. Early initiation of the flush results in less than optimal fracturing of the hydrocarbon bearing formation and a less productive well. However, surface pressure measurements are prone to result in just such early initiation of the flush. This is because the pressure at the surface does not accurately reflect the conditions at the bottom of the wellbore. In particular, surface measurements include additional effects such as the friction of the flowing slurry along the length of the wellbore or the constantly changing hydrostatic pressure of the proppant laden fracturing fluid. Modeling these effects is typically not accurate enough to determine precisely when to initiate the flush based upon the surface pressure. On the other hand, if the flush is initiated too late, the pumping of additional slurry leads to wellbore screen-out, where the proppant backs up into, and fills the wellbore.
[0005] Wellbore screen-out is undesirable because the proppant restricts the free flow of hydrocarbons in the wellbore and, in the extreme, can trap downhole assemblies in the wellbore. If the wellbore screen-out is significant enough, the entire process of perforation and fracturing must be stopped while wellbore repair is performed. During repair, the overpressure is released, permitting ball sealers, put in place after previous fracture treatments, to fall out, and precluding further fracturing after the repair is completed, without the placement of additional wellbore plugs. Therefore, repair of a wellbore after a wellbore screen-out is expensive and time consuming.
[0006] From the foregoing it will be apparent that there remains a need to measure bottom hole pressure during fracturing operations to accurately detect tip screen-out and prevent wellbore screen-out.
SUMMARY OF INVENTION
[0007] Some embodiments of the invention are methods of operating a perforating gun system in a wellbore penetrating a subterranean formation, using a system comprising an array of perforating guns and a sensor package adjacent the array of perforating guns. These methods may generally comprise at least placing the perforating gun system proximate a treatment zone in the wellbore; measuring at least one parameter in the wellbore with the sensor package; transmitting the measurement of the at least one parameter to a monitoring and controlling system; and adjusting at least one operational parameter of the perforating gun system in response to the transmitted measurement to achieve improved treatment efficiency and reservoir optimization.
[0008] In another aspect, methods for fracturing a subterranean formation penetrated by a wellbore are disclosed. These methods comprise conveying a perforating gun system through the wellbore to a treatment zone wherein the system comprises an array of perforating guns and a sensor package adjacent the array of perforating guns, introducing a fracturing fluid into the wellbore at a pressure sufficient to fracture the formation, measuring at least one parameter in the wellbore with the sensor package, transmitting the measurement of the at least one parameter to a monitoring and controlling system, and adjusting at least one operational parameter of the perforating gun system in response to the transmitted measurement.
[0009] In yet another aspect, the invention is a method of treating a subterranean formation penetrated by a wellbore comprising conveying a perforating gun system through the wellbore to a treatment zone wherein the system comprises an array of perforating guns and a sensor package adjacent the array of perforating guns, measuring at least one parameter in the wellbore with the sensor package, and adjusting on a real time basis at least one operational parameter in response to the measurement
[0010] The sensor packages used in accordance with the invention may comprise one or more of a pressure sensor, temperature sensor, pH sensor, or any combination thereof, while the parameters measured are at least one or more of pressure, temperature, or pH. Of course, any other suitable sensor or sensed parameter may be used as well. Preferably the sensor is a pressure sensor used for measuring pressure. When pressure is measured, in response to measured pressure a sudden buildup in pressure in the wellbore at the location of the perforating gun system during the operation wherein a proppant is being pumped into a formation adjacent to the wellbore may be detected; and in response to the detection of a sudden buildup in pressure in the wellbore, a flushing operation may be commenced in the wellbore, thereby removing excess proppant from the wellbore and preventing the wellbore from filling with excess proppant. Also, the sudden buildup of pressure that causes the flushing operation may be such that, when the pressure measurement is plotted against time on a Nolte-Smith Plot, the slope of the pressure measurement exceeds one (1.0).
[0011] Embodiments of the invention may also include moving the perforating gun system, and repeating at least one of the placing, measuring, transmitting and adjusting steps.
[0012] Monitoring and controlling system may comprise surface equipment to make the measurement transmitted readable by one or more of a computer or operator. Alternatively, the monitoring and controlling system comprises equipment to make the measurement transmitted readable by a computer located in the wellbore. Also, the monitoring and controlling system may comprises equipment to make the measurement transmitted readable by one or more of a computer or operator, wherein the equipment is located in the wellbore and at the surface. The monitoring and controlling system may comprise at least one or more of a data transmitting means, a computer, and a general user interface
[0013] In some aspects of the invention, the measuring of at least one parameter, transmitting of the measurement of the at least one parameter, and the adjusting of at least one operational parameter may be conducted on a real time basis. Any suitable and/or readily known operational parameter to one of skill in the art may be adjusted, including treatment fluid components, treatment fluid flow rate, treatment fluid pressure, or treatment fluid properties, or any combination thereof. Fluids introduced into the wellbore include pad fracturing fluids, proppant laden fluids, flushes stage, prepad fluids, cleanout fluids, acidizing fluids, and the like. The fluids may be injected at any suitable pressure, including pressures equal to, below, or above the fracturing initiation pressure of the formation penetrated by the wellbore. In some cases, the fluids are at least partially injected prior to the measuring at least one parameter.
[0014] In accordance with the invention, the perforating gun system may be conveyed by any suitable conveyance system including wireline, tractor, coiled tubing jointed tubing, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 illustrates a wellbore with the associated perforation and hydraulic fracturing equipment.
[0016] FIG. 2 shows a wellbore with a perforating gun in place in a fracture treatment zone with perforations made in the wellbore casing.
[0017] FIG. 3 shows the wellbore of FIG. 2 with the perforating gun moved and the hydraulic fracturing completed.
[0018] FIG. 4 is an example of a Nolte-Smith plot.
[0019] FIG. 5 shows the wellbore of FIG. 3 with partial wellbore screen-out.
[0020] FIG. 6 shows the wellbore of FIG. 5 with complete wellbore screen-out.
[0021] FIG. 7 shows a flowchart of a method of performing a hydraulic fracturing according to one embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In the following detailed description, reference is made to the accompanying drawings that show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that the various embodiments of the invention, although different, are not necessarily mutually exclusive. For example, a particular feature, structure, or characteristic described herein in connection with one embodiment may be implemented within other embodiments without departing from the spirit and scope of the invention. In addition, it is to be understood that the location or arrangement of individual elements within each disclosed embodiment may be modified without departing from the spirit and scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, appropriately interpreted, along with the full range of equivalents to which the claims are entitled. In the drawings, like numerals refer to the same or similar functionality throughout the several views.
[0023] It should also be noted that in the development of any such actual embodiment, numerous decisions specific to circumstance must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0024] Disclosed herein is a method of measuring bottom hole pressure during perforation/hydraulic fracturing (perf/frac) operations, and using the bottom hole pressure profile to determine when to stop pumping proppant laden fracturing fluid and initiate the flush of the wellbore. In some aspects, the invention relates to real time pressure measurement in a wellbore during fracturing operations to better detect screen-out.
[0025] Hydraulic fracturing is a process whereby a subterranean hydrocarbon reservoir is stimulated to increase the permeability of the formation, increasing the flow of hydrocarbons from the reservoir. A fracturing fluid is pumped at high pressure to crack the formation, creating larger passageways for hydrocarbon flow. The fracturing fluid includes a proppant, such as sand or other solids that fill the cracks in the formation, so that, when the fracturing treatment is done and the high pressure is released, the cracks do not just close up (i.e., the cracks remain propped open).
[0026] FIG. 1 illustrates a perforation/hydraulic fracturing operation, depicted generally as 100. A wellbore 102 is drilled through an overburden layer 120 , through a productive formation 122 , and further into the underlying formation 124 . Casing 104 is placed into the wellbore 102 and the annulus between the wellbore 102 and the casing 104 is filled with cement 106 . To this point, the productive zone 122 is isolated from the well 113 , the area within the casing. The productive zone 122 is further isolated from the underlying formation 124 by a plug 112 . A tubing string 110 runs from the surface through the wellbore cap 111 into the well 113 in the productive zone 122 .
[0027] As noted above, the productive zone 120 is isolated from the well 113 by the casing 104 and the cement 106 . Therefore, before any fracturing operations or production can commence, the casing 104 and the cement 106 have to be perforated. The perforating gun 135 is a device that has several shaped charges 134 A, 134 B, 134 C and 134 D. The perforating gun 135 is lowered into the well 113 on a wireline 108 by the perforating rig 130 and the perforating rig winch 132 to the first fracture treatment zone 126 A. The perforating gun 135 is connected by the wireline 108 to a monitoring and control computer 152 that controls the triggering of the individual shaped charges 134 A, 134 B, 134 C or 134 D. The monitoring and control computer 150 also monitors inputs from a perforating gun sensor package 136 and from a surface sensor package 150 during the perforation/hydraulic fracturing operation. When the first set of shaped charges 134 A is proximate to the first fracture treatment zone 126 A, as shown in FIG. 2 , the monitoring and control computer 150 triggers the first set of shaped charges 134 A. The first set of shaped charges 134 A then emit streams of super hot gas which burns holes 138 , called perforations, through the casing 104 and the cement 106 , and into the fracture treatment zone 126 A, opening up access to the hydrocarbons in the productive zone 122 . The perforating gun 135 is then lifted out of the way of the perforations 138 to the second fracture treatment zone 126 B by the perforating rig 130 and the perforating rig winch 132 , and the fracturing operation commences, as illustrated in FIG. 3 .
[0028] The perforations 138 permit only limited communication of hydrocarbons from the productive formation 122 into the well 113 . In order to improve the flow of hydrocarbons from the productive formation 122 , a fracturing fluid 140 is combined with a proppant 142 in a mixer 144 to form a slurry 145 . The proppant 144 is any suitable proppant may be used, provided that it is compatible with the formation, the slurry, and the desired results. Such proppants (gravels) can be natural or synthetic, coated, or contain chemicals; more than one can be used sequentially or in mixtures of different sizes or different materials. Proppants and gravels in the same or different wells or treatments can be the same material and/or the same size as one another and the term “proppant” is intended to include gravel in this discussion. In general the proppant used will have an average particle size of from about 0.15 mm to about 2.5 mm, more particularly, but not limited to typical size ranges of about 0.25-0.43 mm, 0.43-0.85 mm, 0.85-1.18 mm, 1.18-1.70 mm, and 1.70-2.36 mm. Normally the proppant will be present in the slurry in a concentration of from about 0.12 kg proppant added to each L of carrier fluid to about 3 kg proppant added to each L of carrier fluid, preferably from about 0.12 kg proppant added to each L of carrier fluid to about 1.5 kg proppant added to each L of carrier fluid.
[0029] Preferably, the proppant materials include, but are not limited to, sand, resin-coated sand, zirconia, sintered bauxite, glass beads, ceramic materials, naturally occurring materials, or similar materials. Mixtures of proppants can be used as well. Naturally occurring materials may be underived and/or unprocessed naturally occurring materials, as well as materials based on naturally occurring materials that have been processed and/or derived. Suitable examples of naturally occurring particulate materials for use as proppants include, but are not necessarily limited to: ground or crushed shells of nuts such as walnut, coconut, pecan, almond, ivory nut, brazil nut, etc.; ground or crushed seed shells (including fruit pits) of seeds of fruits such as plum, olive, peach, cherry, apricot, etc.; ground or crushed seed shells of other plants such as maize (e.g., corn cobs or corn kernels), etc.; processed wood materials such as those derived from woods such as oak, hickory, walnut, poplar, mahogany, etc., including such woods that have been processed by grinding, chipping, or other form of particalization, processing, etc, some nonlimiting examples of which are proppants supplied under the tradename LiteProp™ available from BJ Services Co., made of walnut hulls impregnated and encapsulated with resins. Further information on some of the above-noted compositions thereof may be found in Encyclopedia of Chemical Technology, Edited by Raymond E. Kirk and Donald F. Othmer, Third Edition, John Wiley & Sons, Volume 16, pages 248-273 (entitled “Nuts”), Copyright 1981, which is incorporated herein by reference.
[0030] The slurry 145 is pumped through the tubing string 110 by the pump 146 and forced through the perforations 138 and on into the productive formation 122 , forming cracks or fractures 139 in the productive formation 122 . The proppant 142 in the slurry 145 is wedged into the fractures 139 , holding the fractures 139 open after pumping stops. In this way, the fractures 139 filled with proppant 142 form a permeable conduit for the continued flow of hydrocarbons from the productive formation 122 to the well 113 .
[0031] A method of perforation/hydraulic fracturing is described in U.S. Pat. No. 6,543,538, to Tolman, et al., (Method for treating multiple wellbore intervals), which is hereby incorporated by reference. Described therein is a perforating gun 135 with four “select-fire perforation charge carrier[s]” 134 A, 134 B, 134 C and 134 D, that can be independently fired. The method described begins by perforating 138 the wellbore 102 at the first fracture treatment zone 126 A, and then moving the perforating gun 135 to the second fracture treatment zone 126 B. Next, the slurry 145 is pumped in to the perforations 138 , cracking the formation 139 and setting the proppant in the cracks. When the fracturing is completed, a method of isolation is employed to prevent any further treatment of the completed zone. Several examples of isolation are described, including ball sealers 137 and mechanical flapper valves (not shown). In either case, the process is then repeated, starting with perforating the wellbore at the second, third, fourth, or any suitable number of fracture treatment zones 126 B, 126 C and 126 D, with no necessary limitation on the number of treatment zone. This method permits perforation and fracturing operations to proceed in one continuous process, without having to remove equipment from the wellbore 102 after each step. This method also permits a constant overpressure to be applied to the wellbore to hold ball sealers 137 in place, as is known in the art.
[0032] More particularly, hydraulic fracturing operations typically consist of mixing various chemicals (not shown) and proppants 142 into a fracturing fluid 140 and pumping the slurry 145 into a hydrocarbon bearing formation 122 to crack the formation 139 and wedge the proppant 142 into the cracks 139 . The pumping occurs in three stages. First, a pad is pumped into the formation to initiate the fracturing of the formation and to buffer the formation against excessive fluid leak-off. The pad does not contain proppants. Next, the slurry 145 is pumped into the productive formation 122 . Finally, when the productive formation 122 can accept no more proppant 142 , the mixing 144 of fracturing fluid 140 and proppant 142 is halted, but pumping of the fracturing fluid 140 alone continues and a fluid return valve 148 on the surface is opened, permitting circulation of fracturing fluid 140 to flush the wellbore 102 .
[0033] During hydraulic fracturing, the pressure in the wellbore is closely monitored. The pressure is typically plotted on, but not limited to, a Nolte-Smith plot 200 , shown in FIG. 4 , which plots the logarithm of net pressure 210 versus the logarithm of time 220 . Formation characteristics and fluid friction combine to limit the effective length of a given fracture. The ideal Nolte-Smith plot 200 reflects the pressure in the wellbore 102 at the fracture treatment zone 126 . Here, an increase in net pressure with a slope of less than 1.0 230 indicates that the fracture has a confined height and unrestricted propagation. A slope at or near 0.0 (zero) 240 can indicate restricted height growth with reduced propagation of the fracture, or, if a critical net pressure has been reached, it can indicate the opening of natural fissures in the productive formation 122 which cause greater leak-off of fracturing fluid. A negative slope 240 indicates unrestricted height growth. A slope of 1.0 260 indicates that propagation of the fracture has ceased near the tip of the fracture, a condition known as tip screen-out. A slope of greater than 1.0 270 indicates that the fracture is no longer accepting proppant 142 .
[0034] The pressure in the wellbore is typically measured at the surface by the surface sensor package 150 and monitored by the monitoring and control computer 152 . While the pressure, as plotted on the Nolte-Smith plot 200 is used to approximate the conditions in the fracture treatment zone 126 , the actual pressure measured by the surface sensor package 150 is not an accurate measure of the pressure in the fracture treatment zone 126 . In particular, the pressure as measured by the surface sensor package 150 has to be adjusted to compensate for the fluid friction of the fracturing fluid 140 flowing through the tubing string 110 and the casing 104 , the hydrostatic pressure of the column of slurry 145 in the wellbore 102 , and for the density of the slurry 145 , among other factors. Modeling for these effects is not typically accurate enough to determine precisely when tip screen-out occurs. However, accurate detection of tip screen-out is required for successful hydraulic fracturing operations. Early initiation of the flush results in less than optimal fracturing of the productive formation 122 and ultimately to a less productive well 113 . Of greater concern is the result of initiating the flush to late. As shown in FIG. 5 , when the flush is delayed after tip screen-out, the pumping of additional slurry 145 leads to wellbore screen-out, a condition where the excess proppant 142 backs up into and fills the wellbore 102 . When the excess proppant 142 obstructs the perforations 138 , the flow of hydrocarbons from the productive formation 122 is restricted and pumping efficiency is limited. If the estimate of the onset of tip screen-out, as detected by the surface sensor package 150 is highly inaccurate, the wellbore screen-out can be extreme, as shown in FIG. 6 . Here, the excess proppant 142 not only obstructs the perforations 138 , but also buries the perforating gun 135 . In this case, the perforation/hydraulic fracturing operation must be ceased to fish out the perforating gun 135 , pump out the excess proppant 142 and restart the perforation/hydraulic fracturing operation. Such fishing operations are not only costly, but also, they present a potential safety hazard if the perforating gun 135 has unfired charge carriers 134 . The situation is further complicated if ball sealers 137 are used to isolate the fracture treatment zones 126 , because, in normal operation, the ball sealers 137 are held into their respective perforations 138 by the constant application of over-pressure on the wellbore 102 . The over-pressure must be released to fish out the perforating gun 135 and pump out the excess proppant 142 , and so the ball sealers fall out of their respective perforations 138 , precluding subsequent perforation/hydraulic fracturing operations on the wellbore 102 .
[0035] Perforating gun sensor package 136 may include a pressure sensor, pressure gauge, temperature gauge, temperature sensor, pH sensor, or any combination thereof, to measure conditions during the course of the treatment, transmit such measurement(s) to a monitoring and control computer, for real time adjustment of the treatment (i.e. fracturing treatment). As used herein, the term “real time adjustment” means measuring a downhole parameter (i.e. pressure, temperature, pH, etc.), transmitting the measurement to a monitoring system, analyzing and adjusting controllable parameters in the course of treatment, all in order to achieve treatment efficiency and reservoir optimization, and in one embodiment, particularly by detecting a screen out event, or even an upcoming screenout event. The monitoring equipment may be at the surface, or located in the wellbore. The monitoring system may comprise a computer, an operator, or both, or any other suitable means for monitoring, or even analyzing.
[0036] In one embodiment, the perforating gun sensor package 136 includes at least a pressure gauge 136 A that transmits its reading through the wireline 108 to the monitoring and control computer 152 . FIG. 7 is a flowchart that describes one embodiment of the present disclosure. Here, the perforating gun 135 is placed at 302 at the level of a fracture treatment zone 126 (e.g., 126 A) prior to the initiation of hydraulic fracturing. Hydraulic fracturing is initiated at 304 , and the pressure measurements from the pressure gauge 136 A are sent at 306 to the monitoring and control computer 152 , where an operator monitors the measurements. While at 308 the pressure remains steady, or increases only slowly, the operator continues to monitor at 306 the pressure from the pressure gauge 136 A. When at 308 , the operator sees a sudden buildup in the pressure measurement from the pressure gauge 136 A, he initiates at 310 the flush of the wellbore 102 . In one embodiment of the present disclosure, measurements from the pressure gauge 136 A are monitored by plotting them on a Nolte-Smith plot 200 . Here, when the slope of the logarithm of the net pressure 210 versus the logarithm of time 220 exceeds 1.0 260 , the operator initiates the flush of the wellbore 102 .
[0037] Because the pressure of the fracturing fluid is measured at the bottom of the wellbore, in the fracture zone, and not at the surface, the method herein described results in more accurate detection of tip screen-out. By more precisely detecting tip screen-out, both premature wellbore flushing, resulting in a less efficient well, and delayed wellbore flushing, resulting in wellbore screen-out, can be avoided.
[0038] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. In particular, every range of values (of the form, “from about A to about B,” or, equivalently, “from approximately A to B,” or, equivalently, “from approximately A-B”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values. Accordingly, the protection sought herein is as set forth in the claims below. | A method of determining when to stop pumping proppant during hydraulic fracturing in a wellbore is described. By accurately detecting tip screen-out with a bottom hole pressure gauge mounted to a perforating gun, the optimal amount of proppant can be supplied to a fracture while avoiding the risks associated with wellbore screen-out. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of laundry and other article-drying equipment and, more specifically, to dryer-conditioners used in the commercial laundry industry.
2. Description of the Prior Art
An overall view of the prior art in industrial laundry dryer-conditioners, often referred to in the industry as merely "dryers", can be had by referring to my earlier-issued U.S. Pat. Nos. 2,604,313, 2,643,463, 3,443,323, and 3,861,865. The dryers described in those patents and industrial dryers in general require large volumes of air having a temperature in the tumbler in the range of 300°-350° F, in addition to providing the tumbling action to the laundry to achieve rapid but safe drying. In the present state of the art, the "washing" is generally independent of the "drying", or "conditioning", and each operation utilizes separate and detached apparatus, wherein the wet articles are transported from the washing apparatus to the dryer, in some convenient form such as "cakes" or "batches" of wet articles, and loaded therein to start the drying cycle. While the loading is under way, the dryer remains inoperative. Once loaded, however, the dryer would be operated until the load was dry or properly conditioned, after which the dryer would again remain inoperative while the finished laundry was removed and another load added, thus repeating the cycle.
However, the advent of continuous-flow, high-production industrial washing apparatus, in which laundry is added and extracted continuously, has created the necessity for more advanced industrial dryers that will automatically accommodate the continuous output flow of wet articles as they are being emitted from such washing apparatus.
SUMMARY OF THE INVENTION
In general, arrangements in accordance with the present invention avoid the need for industrial-type dryers to be inoperative while they are being loaded or unloaded. I have, in essence, invented an industrial dryer that may be put into continuous operation, without any down time, while wet laundry or other articles to be conditioned, are being added continuously to the dryer while at the same time dried laundry, or finished articles, are continuously being extracted.
One object of this invention is to provide an integrated, self-contained industrial dryer that will automatically receive wet articles, either individually or in cake loads, from continuous-flow type industrial washers.
Correspondingly, another object of this invention is to automatically eject the finished laundry when properly conditioned.
Another object of this invention is to accomplish a total conditioning cycle with a self-contained, single-module dryer that has an adjustable conditioning-time cycle to accommodate the various compositions, and moisture contents, of the articles being conditioned.
A further object of this invention is to provide an integrated dryer and hot air source that eliminates both the refractory end closure and the asbestos covering of conventional combustion chambers.
Still another object of this invention is to provide a dryer housing with a single hot air inlet source, and a corresponding single outlet air return, in which the hot air flow first contacts the wet articles while at its highest temperature, immediately after they are admitted, and then progressively drops in a temperature as the air flow continues around and through the articles towards the outlet air return.
Similarly, an associated object of this invention is to provide an in-rush of cool air onto the conditioned articles at the time they are being ejected from the dryer.
It is an important objective of this invention to provide a dryer-conditioner that will maintain an internal pressure less than ambient during normal operation.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects of the invention, along with other objects and advantages thereof, will become apparent from a reading of the detailed description which appears hereinafter, in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view, in elevation, of a dryer-conditioner system incorporating my invention;
FIG. 2 is a side view, in elevation and partially broken away, of the dryer-conditioner part of the system of FIG. 1;
FIG. 3 is a side view, in elevation, of the blower and combustion chamber of FIG. 1 with one combustion chamber wall partially cut away and the air-fuel mixing and introduction means simplified;
FIG. 4 is a sectional view of the combustion chamber of FIG. 3 taken along the line 4--4 of FIG. 3;
FIG. 5 is a frontal view, in elevation, of the dryer-conditioner system; and
FIG. 6 is a rear view, in elevation, of the dryer-conditioner system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates the general configuration of the dryer-conditioner system 10. Air is heated in combustion chamber 14 and circulated through housing 11 by blower 45. Control center 27 provides the controls for operating combustion chamber 14 and positioning housing 11 on base 16 which supports housing 11 in a tiltable fashion. Advancing belt 23 transports the wet laundry articles to frontal opening 18, in housing 11, and also to batch door opening 54, in batch door 53 when in place over opening 18. It may be observed that during the normal operation of dryer-conditioner system 10, batch door 53 remains secured in place and in cooperation with seal 19 to form an air seal. The function of this seal will be discussed subsequently. An important aspect of this invention is that the pressure inside the system remains below ambient pressure during normal operation. This is accomplished by additional seals 65 and 63 in cooperation with seal 19. Accordingly, it is important that entry roller 24 form a sealable contact on advancing belt 23 when in contact thereon.
Returning to FIG. 2, drum 12 is rotatably mounted in housing 11 and has openings at both ends through which the articles being conditioned may pass. The walls of drum 12 have perforations 15 throughout to promote the conditioning process through the circulation of heated air around and through the articles that are being conditioned inside the drum. Partitions 13 in drum 12 extend interiorly around the internal periphery of drum 12, leaving an opening 55. In the preferred embodiment, I have included two of these partitions, thus dividing the drum into three equal sections. However, a lesser or greater number of these partitions may be used, thus dividing the drum into fewer or more sections, without affecting the mechanism of this invention for conditioning articles. As may also be observed, there is no requirement that the partitions be equally spaced, as this will not affect the basic mechanisms by which the drum, as hereinafter described, controls the flow of articles therein.
Hot air inlet aperture 29 admits hot air into the system near the end in which the wet articles are loaded. It will be noted that the hot air circulates, as mentioned above, through perforations 15 in drum 12 and exits through hot air outlet aperture 30. A process for the conditioning and circulation of this hot air will be described more fully later; however, at this point it is important to note that the air in its hottest state is imposed upon wet laundry as it enters the system. At this point in the conditioning cycle, the laundry contains its highest moisture content, and will safely endure the higher temperatures without the damage of scorching or burning. In essence, first the hot air expends its energy in vaporizing the high moisture content from the wet articles and causes a relatively small rise in temperature of the articles. Then, as the moisture content is further removed from the articles, the temperature of the conditioned articles will more closely approach the air temperature being impressed on the aritcles at that time. Accordingly, it is important that, as the articles have their moisture content reduced by the circulating hot air, the temperature of the hot air correspondingly decreases to temperatures below that which will cause scorching of the articles. In effect, the hot incoming air is continually decreasing in temperature, by expending thermal energy to reduce the moisture content of the articles, as it progresses through and around the articles within drum 12 and out hot air outlet aperature 30.
As shown in FIG. 2, housing 11 is pivotable about journal 17 on base 16. The means for accomplishing this pivoting action is by housing actuator 26, which may be either hydraulic or pneumatic, and is controllable by control center 27. I have found that the rate in which articles pass through this system is dependent in part upon the particular backward tilt of conditioner dryer system 10 during operation. This phenomenon is explainable by assuming a backward tilt, in which the frontal end of housing 11 is raised above the rear section. In this configuration, the wet articles tend to ride the rotating drum upwardly from its lowest rotational side and then fall back towards this side. However, since the drum is tilted backwardly, each time an article rides the wall upwardly and then falls back, it would also progress axially toward the exit end of the drum. It is evident that the greater this tilt, the more rapid this axial progression would become. However, were it not for partitions 13, this progression could become totally random with the lighter synthetic articles progressing much faster than the heavier cotton articles, for example. The function of partitions 13 controls this rate of progression by essentially metering the amount of the load that will be passed through opening 55 with each revolution of the drum 12. This principle is observed by noting that the top side of partition 13 will have a gravity vector displaced rearwardly of the corresponding bottom portion of partition 13 when the drum 12 is in a backward tilt. Accordingly, as the articles closest to the partition rise and fall in the drum, they will tend to fall through opening 55 on their descent. The percentage of the load that passes through opening 55, in partition 13, is controllable by the amount of backward tilt of housing 11. This feature is important so that dryer-conditioner 10 can be adjusted to properly condition articles of various compositions and with various ranges of moisture contents.
Also indicated in FIG. 2, the finished articles exit between exit roller 69 and idler roller 66. Exit roller drive 61 provides continuous rotation to exit roller 69, which in turn rotates idler roller 66. Both rollers 69 and 66 are made of resilient material that is safe to the articles being conditioned. It is my experience that neoprene rubber is a suitable material for the rollers 69 and 66; however, other materials having similar characteristics could serve just as well. Main roller covering 62 is a thin nylon sheath that is wrapped around exit roller 69 to provide a smooth contamination-free surface that will neither stain nor abrade the articles. Conveyor 71 is provided to remove the dried articles which are ejected from the dryer exit rollers 66, 69.
As stated earlier, it is important that the internal pressure be less than ambient pressure during normal operation of dryer-conditioner system 10. Seals 65 and 63 are installed to provide continuous sealing contact along the full length of their respective rollers. FIG. 6 shows how these rollers 66 and 69 span the full internal width of housing 11.
Returning again to FIG. 2, the mechanism for automatically ejecting the finished articles may be described as follows: as the finished articles progress through the rear opening of drum 12, they are urged by the rotation of roller 69 and roller 66 to move outwardly between the two rollers. Roller 66 is rotatably mounted to right-angle arm 64 which is pivotably connected to lever 67 at point C and connected to housing 11 by tension spring 52. A function of tension spring 52 is to counterbalance the contact force of roller 66 against roller 69 such that the force of an article passing between the two rollers will force roller 66 to pivot away from roller 69 at point C. Exit door 50 rotates outwardly from B when roller 66 is forced away from roller 69. As roller 66 moves away from roller 69, point C will rotate downwardly around point A. In this manner, roller 66 will be moving away from roller 69 by simultaneously pivoting both about point C and point A. When the article has passed through, the rollers will reestablish contact.
As the rollers open to eject an article, atmospheric air is drawn into the housing, through the rollers, to cool the exiting load. As discussed earlier, this occurs due to the pressure inside the housing being less than ambient pressure. In this manner, the articles being ejected are additionally cooled to render them more amenable to immediate human handling.
As can be seen from FIG. 4, housing 11 has hot air inlet aperture 29 which is positioned in alignment with aperture 25 in combustion chamber 14. It should be noted, however, that apertures 25 and 29 are not joined by positive seal during operation of the system. A space is provided between apertures 25 and 29 so that the air which is emerging from aperture 25 (and may have temperatures approaching 1700° F) is mixed with relatively cool air from the environment surrounding the system. As a result, the air entering the drum 12 has a temperature approximating 500° F. The need for tempering the air exiting from the combustion chamber is recognized and discussed in my three U.S. Pat. Nos. 2,604,313, 2,643,463, and 3,861,865.
Aperture 30 in housing 11 is provided for channeling air out of housing 11 and is positioned so that aperture 30 is aligned with the blower 45, which is described more fully in connection with FIG. 3.
In FIG. 3, combustion chamber 14 has an outer wall 31 and an inner wall 32 separated therefrom by spacer 33 shown more clearly in FIG. 4. Air may enter freely from either end of combustion chamber 14 and pass through the space between outer wall 31 and inner wall 32 of combustion chamber 14. Inner wall 32 has aperture 34 therein which communicates with hot air exit aperture 25 in outer wall 31 and with the space between inner wall 32 and outer wall 31. The fuel introduction and burning system shown in FIG. 3 comprises a fuel-gas mixing chamber 35 which receives fuel through pipe 36 and air, usually under pressure as developed by blower 45 in FIG. 1. Stack 40 removes the moisture-laden exhaust air from blower 45 which is not recirculated in the system. Additional details on this hot air-blower system may be obtained in my U.S. Pat. No. 3,861,865 and the disclosure of that patent is hereby incorporated by reference.
Referring now to FIG. 5, the ingress of articles to be conditioned is described more fully. As can be observed, advancing belt 23 advances to the base of opening 54 in batch cover 28. Roller 24 normally rests on advancing belt 23 with the movement of advancing belt 23 causing roller 24 to rotate. It is important that roller 24 form a sealable contact on advancing belt 23 when in contact thereon, as previously discussed. The bottom of sliding door 22 is affixed to the two roller end support members 57a that provide the rotatable support for roller 24. Extending the length of roller 24 and affixed to the lowest edge of sliding door 22 is seal 56 which provides continuous sealing between roller 24 and door 22. The outer edges of door 22 are slidably mounted in door slides 51. Actuators 21, located on each side of sliding door 22, provide means for raising door 22 when activated as hereinafter described. In my invention these actuators are pneumatic; however, hydraulic actuators may be used if desired. A light source 59 mounted on either side of advancing belt 23 provides a collimated beam directed toward a photoelectric cell 58 mounted on the opposite side of advancing belt 23. Associated with the light source 59 and photoelectric cell 58 are the necessary controls, as known in the art, such that when the light source is broken by an ingress of laundry articles, an energizing source will be directed to actuators 21, causing door 22 and roller 24 to be raised. In this manner, as larger loads are fed into housing 11, having a height sufficient to break the light beam, an opening will automatically occur to receive them. The height of light source 59 and photoelectric cell 58 may be adjusted such that any article that does not break the beam from light source 59 will pass freely between advancing belt 23 and roller 24 and into housing 11 from the combined urging of advancing belt 23 and roller 24 forcing door 22 to raise sufficiently to pass the article thereunder, after which the door will automatically close under gravitational force.
It will be appreciated that only the significant details of the present invention are shown in the drawing, others of conventional configuration having been omitted for simplicity. Thus, for example, the input and output conveyors, the outlet rollers, the drum and the blower are all driven by electric motors, coupled and controlled by conventional means. These details need not be shown herein, as they are known in the art.
While a particular dryer-conditioner system has been shown and described herein for the purpose of illustrating the manner in which my invention may be used to advantage, it will be appreciated that my invention is not limited thereto. Accordingly, any and all modifications, variations, or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of my invention. | A new industrial laundry dryer-conditioner is provided, within a single module, that has continuous flow capabilities for integration with advanced industrial washing apparatus, of the continuous flow type, for continuously and automatically processing laundry items through both the washing and the drying cycles. | 3 |
BACKGROUND
[0001] 1. Field of the Disclosure
[0002] The present disclosure relates to a door catch mechanism, and more particularly, to a bullet catch mechanism.
[0003] 2. Description of Related Art
[0004] A Bullet Catch is generally used as a soft latching mechanism for an entry door or a cabinet door. The mechanism usually includes a recessed “catch” portion, such as a striker plate with a recessed groove, and a bullet detent “engaging” mechanism. The “catch” mechanism is usually installed on a door-jam structure, while the detent engaging mechanism is usually installed in the door itself. In operation, when the door is closed from an open position, the bullet detent in the engaging mechanism is pushed inward against a spring as the bullet engages the catch, and when the bullet engages the recessed groove in the catch mechanism, the spring forces the bullet outward to engage the recess and retain the door in the closed position. The operation is reversed when the door is opened. It is noted that a Ball Catch device is similar to the Bullet Catch, with one difference being that the detent engaging portion is shaped like a ball rather than being oblong like a bullet.
[0005] It is common to install bullet/ball catch devices into doors by boring a hole in the door and installing the device in the hole. Both slip fits and slight interference fits are used, with the latter forming a tight (slight interference) fit between the interior of the hole in the door and the outer circumference of the bullet catch housing.
[0006] Some interference fit devices are known to merely have a smooth cylindrical housing body that is installed into the bore with an interference fit by driving (e.g., hammering) the device into the hole, with the wood of the door giving somewhat to allow the device to be driven into the hole. These devices, however, are often difficult to remove in the event of a failure of the mechanism due to wear and tear over time.
[0007] Some devices have also been known to use a slip-fit between the hole and the housing, and these devices employ a mounting flange that attaches the device to the door using screws so that the device will not slide out of the door. While this type of device is easy to install and remove for replacement by simply removing the screws, it requires that the door be mortised in order to recess and screw the flange into the door.
[0008] Another type of prior art device includes recessed grooves about the outer circumference of the housing. This type of device allows the installer to apply an adhesive that fills the recessed grooves to retain the device in the door. This type of device may utilize a slight slip fit or an interference fit, but requires an adhesive in order to retain the device in the door. The need for an adhesive, however, makes it difficult to remove the device when a replacement is required.
[0009] Another prior art device, although not a bullet/ball catch per se, but rather, a flat-headed magnetic catch mechanism, includes threads about the circumference of the housing so that the device can be screwed into the hole of the door. This type of attachment is not readily conducive for a bullet/ball catch, however, since a screw head is required on the magnetic catch and such is not practicable with a bullet/ball catch.
[0010] One of the more common Bullet/Ball catch devices in use today utilizes a sleeve, separate from the bullet catch mechanism itself, with a raised spring-type engaging member on its outer circumference. When the sleeve and catch mechanism are installed in the bore together, the raised engaging members bend to form a tight fit with the hole in the door. Additionally, the ends of the raised engaging members hold the detent mechanism within the sleeve. This type of device, however, requires additional parts that can make it more expensive, and it also makes it difficult to remove for replacement.
SUMMARY
[0011] The present invention aims to address the foregoing problems by providing a bullet/ball catch mechanism with a housing that is easy to install and subsequently remove if needed, but yet provides a tight fit at final installation. Specifically, the present disclosure relates to door catch mechanism in which a housing has a generally cylindrical body having an outer surface of a first diameter, a first end and a second end, a flange located on the first end of the body, the flange having an outer diameter greater than the first diameter of the body, a first bore formed within the housing and a shoulder forming a floor of the first bore, the shoulder including a hole there through. The housing also has a plurality of longitudinal vanes formed on the outer surface of the body, each vane being formed lengthwise along a portion of the outer surface of the body between the flange and the second end of the body opposite the flange, each vane being tapered from a smaller height to a larger height when traversing the outer surface of the body from the second end toward the first end of the housing. The mechanism has a detentable bullet catch mechanism retainably installed within the bore of the housing such that a bullet head of the detentable bullet catch mechanism protrudes beyond the first surface of the housing and is detentable into the housing.
[0012] Thus, upon installation, a slight slip-fit is provided for between the hole diameter and the outer diameter of the housing so that the housing can readily fit into the hole. As the housing is driven into the hole, the vanes engage the surface of the hole to form a tight fit that increases in pressure as the housing continues its inward travel during the drive-in process. Upon final positioning, each vane forms a tight fit with the hole to retain the device. The vanes also provide an anti-torque effect so that, when the bullet detent is rotated to adjust its exerted force, the housing will not rotate within the hole. The device is also easy to remove and replace since the interference fit is between the small vanes and the wood of the hole, rather than between the entire outer surface of the device and the hole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of one embodiment of a bullet catch mechanism according to the present disclosure.
[0014] FIG. 2 is an expanded view depicting component parts of one embodiment of a bullet catch mechanism according to the present disclosure.
[0015] FIG. 3 is a cross-sectional view of one embodiment of a bullet catch mechanism according to the present disclosure.
[0016] FIG. 4 is a side view of one embodiment of a bullet catch mechanism according to the present disclosure.
[0017] FIG. 5 is a top view of one embodiment of a bullet catch mechanism according to the present disclosure.
[0018] FIG. 6 is a bottom view of a bullet catch mechanism according to the present disclosure.
[0019] FIG. 7 is a cross-sectional view of a housing according to one embodiment of a bullet catch mechanism according to the present disclosure.
[0020] FIG. 8 is a detail view depicting the general shape of a vane on the housing of FIG. 7 .
[0021] FIG. 9 depicts a perspective view of the bullet catch mechanism of the present disclosure and a catch/striker plate that the bullet catch engages.
DETAILED DESCRIPTION
[0022] The following description will be made with reference to the accompanying drawings. It is to be understood that the following description is made with reference to one or more embodiments of the claimed invention, although any number of modifications and other embodiments are intended to be applicable to the claims herein below without departing from the spirit or scope of the invention.
[0023] Referring to FIG. 1 , depicted therein is a perspective view of one embodiment of a bullet catch mechanism 1 of the present disclosure. FIG. 2 is an expanded view depicting component parts of a bullet catch mechanism according to the present disclosure. As seen in FIGS. 1 and 2 , the bullet catch mechanism 1 includes a housing 2 , which includes a flange 6 . The housing 2 preferably has a generally cylindrical outer shape and includes on its outer periphery a plurality of vanes 4 , which will be described in more detail below. The bullet catch mechanism also includes a bullet head 3 , which is connected to a threaded rod 9 . A nut 8 is engaged and screwed on to threaded rod 9 and one end 10 of threaded rod 9 is mechanically deformed after installation of nut 8 so as to retain nut 8 on threaded rod 9 . A spring 12 is installed around threaded rod 9 so as to allow the threaded rod 9 and bullet head 3 , as an assembly, to detent into the housing 2 when pressure is applied to the head 3 , and to also retain the rod/head assembly in an extended position when pressure is not applied to the rod/head assembly. The assembly of the component parts will now described with reference to FIG. 3 .
[0024] FIG. 3 is a cross-sectional view of the bullet catch mechanism according to the present disclosure. In FIG. 3 , housing 2 contains a bullet detent assembly that is comprised of bullet head 3 , threaded rod 9 , spring 12 and nut 8 . Threaded rod 9 is fixedly engaged with bullet head 3 so that rod 9 does not turn relative to head 3 . Bullet head 3 includes a blind hole 13 into which threaded rod 9 is inserted. Here, one end of threaded rod 9 may be pressure fit (interference fit) into blind hole 13 . In this case, bullet head 3 may be heated to expand the size of blind hole 13 and threaded rod 9 may be cooled to reduce the diameter of rod 9 , and the two components may then be assembled so that, upon both parts reaching room temperature, an interference fit is formed between them and rod 9 is fixedly engaged to bullet head 3 . In another aspect, rod 9 may simply be manually forced into blind hole 3 , and an adhesive may be used to retain the rod in hole 13 . With the use of a pressure fit between the component parts, it can be understood that threaded rod 9 is not threaded along its entire length, but rather, may be threaded only partially along its length from the end which engages nut 8 . That is, a portion of the end of rod 9 that engages the bullet head is not threaded, but rather, is merely a solid cylindrical surface. As an alternative, rod 9 may be threaded along its entire length, and blind hole 13 may also be a threaded hole. In one embodiment, the rod may be an M5-0.8 metric size threaded rod and blind hole 13 may be a corresponding M5 internal thread. In this case, rod 9 is screwed into hole 13 and use of a thread locking compound may be employed so that rod 9 will be fixedly engaged with bullet head 3 . Regardless of the technique employed, it is preferable that rod 9 and bullet head 3 are fixedly engaged with one another so as to more or less form a single unit.
[0025] Referring to FIGS. 2 and 3 , bullet head 3 is seen to be formed with a cylindrical portion and an integrally formed spherical head portion. The end of the cylindrical portion is relatively flat and blind hole 13 is formed in the center of the flat end. The spherical head portion includes a small, relatively flat surface 20 on its outermost tip. This small flat surface 20 of the bullet head is for engaging with a flat surface 22 of the bottom of a recessed catch bowl 23 in catch/striker plate 21 that is installed on the door-jam and to which the bullet catch engages to hold the door closed. (See FIG. 9 ). Bullet head 3 is also seen to include a through-hole 5 through the spherical portion. Through-hole 5 may be about 1 mm in diameter and as will be described below, may be used for adjusting the amount of protrusion of the bullet head assembly from the housing 2 .
[0026] Once bullet head 3 and rod 9 have been fixedly engaged to form a single unit, a spring 12 is installed around rod 9 . Spring 12 preferably has an 8 mm outer diameter and is formed with a 1 mm wire. The length of the spring and the compression ratio is chosen to provide a tensile force when the bullet head assembly is fully extended (to be described below), and to not require an excessive force to compress the bullet head assembly inward into the housing when the bullet head assembly is compressed inward. Once spring 12 has been installed over rod 9 , the assembly is inserted into a cylindrical bore 11 within housing 2 . Bore 11 is sized so as to form a slight slip fit between its inner diameter and the outer diameter of the cylindrical portion of bullet head 3 so as to allow the bullet head assembly to slide freely in an out of the housing 2 . The end of rod 9 opposite the bullet head 3 is inserted through a hole 16 in a shoulder 14 of the housing 2 .
[0027] The bullet head/rod/spring assembly is inserted into housing 2 so that the threaded end of rod 9 opposite the bullet head protrudes through hole 16 in housing 2 and into a hexagonal shaped bore 15 in housing 2 . A nut 8 , which is preferably a 12 mm×2.5 mm nut, with M5 internal threads, is inserted into the hexagonal shaped bore 15 . Here, hexagonal bore 15 is formed with a size so as to provide a slight slip fit between its internal surfaces and the outer surfaces of nut 8 . The threaded end of rod 9 is inserted and screwed into the threads of nut 8 so that the end of rod 9 protrudes through nut 8 . In this regard, the bullet head/rod assembly may be turned using a tool inserted into through-hole 5 of the bullet head so as to turn the bullet head/rod assembly to screw the assembly into nut 8 . Once the bullet head/rod assembly has been inserted so the threaded end of rod 9 protrudes through nut 8 , the bullet head/rod assembly is compressed into housing 2 so that the protruding threaded end of rod 9 extends outside of the hexagonal shaped bore 15 of housing 2 . At this point, the protruding threaded end of rod 9 is deformed (See. Ref 10 , FIG. 6 ) using a compression-deformation technique so that the deformed end portion 10 of rod 9 has an interference fit with the threads of nut 8 and rod 9 will no longer freely thread through the inner threads of nut 8 . The deformed end 10 of rod 9 forms a stop mechanism that, when the bullet head/rod assembly is turned to extend the bullet head outward of housing 2 , the stop engages the nut to prevent the bullet head/rod assembly from further extension.
[0028] FIG. 4 depicts a side view and FIG. 5 depicts a top view of a bullet catch mechanism according to the present disclosure. In FIGS. 4 and 5 , housing 2 is seen to include a plurality of vanes 4 and a flange 6 . The vanes 4 will be described in more detail below. As for flange 6 , it is seen to be integrally formed on one end of housing 2 and is generally circular in shape and larger in diameter than that of housing 2 . While flange 6 is depicted as being circular in shape in the figures, it can be understood that other shapes (e.g., square, triangular, etc.) may be employed instead. Moreover, although flange 6 is depicted as being integrally formed on housing 2 , it may be a separate element that is attached to the housing (e.g., screwed on, welded, etc.) In one embodiment, the outer diameter of flange 6 may be about 21.8 mm, and its thickness may be about 1.5 mm. Flange 6 is also depicted with a chamfer or rounded-over edge on its outermost edge, although a chamfer or round-over is not necessarily required. In one embodiment, the chamfer may be about 30 degrees as seen in FIG. 7 . A shoulder surface 19 of flange 6 engages a surface of a door when the bullet catch assembly is installed in a hole in the door.
[0029] FIG. 6 is a bottom view of a bullet catch mechanism and FIG. 7 is a cross-sectional view of housing 2 taken along line A-A in FIG. 6 . In the figures, housing 2 is seen to be formed as a single unit, and is preferably formed by a die casting method using a zinc alloy material. Of course, die casting is not necessarily required and the housing may be manufactured via other methods, such as machining, molding, lithography, etc. and may be made of other materials instead of a zinc alloy. In one embodiment, housing 2 is formed to be generally cylindrical shaped with an outside diameter of about 15.2 mm and overall length of about 40 mm. As described above, flange 6 is integrally formed on housing 2 with the dimensions discussed above. Internally, housing 2 is formed with a cylindrical bore 11 from the flange end face 18 of the housing to a shoulder 14 . In one embodiment, the bore 11 is formed to be about 12 . 7 mm in diameter and about 26 mm in depth from the surface 18 of flange 6 to shoulder 14 . Shoulder 14 is formed to be about 2 mm thick and has a through-hole 16 formed therein at a diameter of about 5.6 mm.
[0030] Formed in an end 17 of housing 2 is a hexagonal shaped bore 15 . Hexagonal shaped bore 15 may be formed to be about 10.8 mm across its opposing side surfaces and about 12 mm deep. Of course, bore 15 is formed in a hexagonal shape to coincide with the use of a hex nut 8 , but it can readily be understood that other shapes may be used instead, so long as it is formed to accommodate a nut or other type of retaining device used to retain the bullet head/rod assembly with the mechanism.
[0031] Housing 2 also has a plurality of integrally formed vanes 4 along its outer surface. In FIG. 6 , six vanes 4 are seen to be formed at 60 degrees apart from one another. While six vanes are depicted in the figures, it can be understood that more or less vanes can be employed instead. Referring to FIG. 4 , it can be seen that the vanes 4 are tapered along the length of the housing 2 . That is, as shown in the figures, vanes 4 taper in a generally triangular manner from a size roughly equal to the outer diameter of housing 2 nearest end 17 to a larger size at the intersecting surface 19 with flange 6 . That is, vanes 4 are generally formed in a triangular shape lengthwise along the outer surface of the housing 2 as viewed from a side view of the housing. This triangular shape along the length of the housing can be generally seen in FIG. 4 . A more detailed view of vanes (Detail view B of FIG. 6 ) is depicted in FIG. 8 .
[0032] Referring to FIG. 8 , a vane 4 is shown to be formed approximately 0.8 mm in height nearest its intersection with the surface 19 of flange 6 , and as one traverses the vane along the length of the housing away from surface 19 toward end 17 of the housing, the height of vane 4 tapers down from the about 0.8 mm to be roughly equal to the outer diametrical surface of the housing 2 . Additionally, vane 4 is seen, from an end 17 viewpoint of the housing 2 (i.e., the viewpoint of FIG. 6 ), to be formed with a generally pyramidal cross sectional shape formed at a 60 degree angle.
[0033] While the drawings depict vanes 4 as being triangular in shape, different variations in the shape may be employed instead. For instance, rather than being triangular, vanes 4 may be formed with a curved profile so as to increase in height lengthwise when traversing across the surface of housing 2 from end 17 toward end 18 . In addition, while vanes 4 are shown as being connected with flange 6 at their intersection, it can be understood that the vane may terminate before the flange so as to form a gap between the end of the vane 4 and the surface 19 of flange 6 . Further, while vanes 4 are depicted as commencing at a point between end 17 and flange surface 19 along the outer surface of housing 2 , it can be understood that vanes 4 may commence near or equal to surface 17 of housing 2 . Moreover, any combination of the foregoing may employed. For example, two opposing vanes 4 may be as shown in the figures and connect with flange surface 19 , while two other vanes may be formed with a gap between the end of vane 4 and flange surface 19 , and two other vanes 4 may be formed in yet a different manner. Further yet, any alternative profile rather than a pyramidal shape may be used instead (e.g., curved profile as seen from FIG. 8 rather than a 60 degree pyramid).
[0034] In installing the bullet catch mechanism for operation, a hole is formed in a door. The hole is preferably about 15.875 mm (⅝ inch) so as to allow the bullet catch mechanism to be inserted into the hole with an initial slight slip fit. As the bullet catch mechanism is inserted into the hole in the door, the vanes 4 will start to form an interference fit with the hole in the door, and the bullet catch mechanism is then driven into the hole so that the vanes deform the wood in the door and form a tight fit to retain the bullet catch mechanism in the door. The bullet catch mechanism is driven into the hole in the door until the surface 19 of flange 6 engages the surface of the door. At this point, the bullet catch mechanism is fully installed and retained in the door via the interference fit with the vanes.
[0035] The arrangement of the bullet catch mechanism also allows for fairly easy removal and replacement, if necessary, due to, for example, wear and tear of the mechanism over time. In particular, a tool may be inserted into through-hole 5 in the bullet head so that a pulling force may be exerted on the bullet catch mechanism. The pulling force can loosen the tight fit between the vanes and the wood and as the mechanism begins to be removed from the hole in the door, the tapered shape of the vanes allows for the mechanism to become looser and eventually disengage from the door. If a replacement bullet catch is necessary, the new bullet catch can simply be rotated to a point where the vanes of the new mechanism will engage the hole in the door at an offset angle (for example, 30 degrees) from the location where the prior mechanism was installed. This provides the ability to insert a new mechanism without the need to replace the entire door. Thus, the mechanism of the present disclosure provides for easy installation and removal as compared with the prior art devices.
[0036] The catch/striker plate 21 is installed on the door jam/frame so that the center of the catch bowl 23 is aligned with the center of the bullet catch mechanism. Once both the catch/striker plate 21 and the bullet catch mechanism 1 are installed, the protrusion of the bullet head from the housing 2 can be adjusted. In particular, a tool may be inserted into the through-hole 5 of the bullet head 3 and the bullet head/rod assembly can be rotated using the tool to either extend the amount of protrusion or to retract the amount of protrusion. In this manner, the amount of protrusion, and the amount of tensile force exerted by the spring 12 when the bullet head is detented inward when the door is closed can be adjusted to fit the needs of the user.
[0037] While the mechanism of the present disclosure has been described with reference to particular embodiments, it is readily understood that various alternative arrangements and variations may be used instead without departing from the spirit and/or scope of the invention. | A door catch mechanism includes a housing that has a generally cylindrical body having an outer surface of a first diameter, a first end and a second end, a flange located on the first end of the body, the flange having an outer diameter greater than the first diameter of the body, a first bore formed within the housing and a shoulder forming a floor of the first bore, the shoulder including a hole there through. The housing also has a plurality of longitudinal vanes formed on the outer surface of the body, each vane being formed lengthwise along a portion of the outer surface of the body between the flange and the second end of the body opposite the flange, each vane being tapered from a smaller height to a larger height when traversing the outer surface of the body from the second end toward the first end of the housing. The mechanism further includes a detentable bullet catch mechanism retainably installed within the bore of the housing such that a bullet head of the detentable bullet catch mechanism protrudes beyond the first surface of the housing and is detentable into the housing. | 4 |
TECHNICAL FIELD
The present invention relates generally to computer systems, and more particularly to a system and methodology to mitigate navigation costs associated with browsing, saving and opening files by determining and providing a relevant substructure of likely candidate nodes wherein a user can save, open and/or browse a desired file.
BACKGROUND OF THE INVENTION
Computer systems and related technologies have become a staple in all aspects of modern society. Thus, people have come to rely on these systems as a tool for both personal and professional needs, wherein many systems process and store vast amounts of data, files and other information on a daily basis. For example, it is not uncommon for a single user to access, generate and/or save a plurality of text files, spread sheet files, presentation files, Internet files, and E-mail files, to name but a few examples, each day. Since computers have become tools of necessity for processing these ever growing amounts of data and files, users have increasingly become burdened with managing larger quantities of such information. These burdens and associated inefficiencies generally increase as the amount of data and files increase on the computer system. For example, files are often stored on a computer in a vertical and horizontal tree structure, wherein files stored at the same directory level maintain a horizontal relationship with each other and files stored in lower subdirectories maintain a vertical relationship with those directories and subdirectories higher up in the tree. Unfortunately, as computer systems have evolved, and as more data is stored on each system causing these tree structures to grow, conventional file access and management systems require users to spend more and more time navigating throughout these structures when accessing, saving and/or browsing files. This becomes expensive since users are spending greater amounts of time navigating and searching for desired file destinations as opposed to actually operating on the files.
One example of time inefficiency associated with conventional file management systems relates to saving files. Often times, as users are operating upon files, the need arises to save files in another directory. When presented with options and/or locations for saving such files, the user many times has to search and navigate through a complex tree of directories and files to find the location wherein the files are ultimately saved. For example, when saving an opened file in another directory than the current file directory, the user must often navigate up or down to another subdirectory (e.g., mouse stroke clicking on alternate directory nodes), and then peruse an exhaustive list of related directories and subdirectories at various levels before finding a desired directory to store the file. Moreover, the user often has to scan large lists of files on the way to a destination directory thereby increasing the time of finding the desired directory. As is usually the case, the user can expend significant amounts of time merely traversing the directory tree structures searching for the desired directory or subdirectory to store the file. When operating upon many such files every day, these time inefficiencies are multiplied and can become quite costly. Another common scenario of time inefficiency relates to E-mail systems and processing. As an example, files are often attached or appended to an E-mail wherein the E-mail recipient often desires to detach the file and save/place the file in a directory or subdirectory. This usually involves searching and “drilling down” through many unrelated directories in a somewhat linear manner before finding the desired directory to save the associated file.
File navigation and searching problems also relate to other aspects of conventional file management systems. For example, users often desire to open/read a related file when operating upon another file. This may occur when a first file (e.g., text, spreadsheet file) is currently opened and a second file needs to be opened for review and/or for retrieving portions of the second file for utilization in the first file. As is the case with finding a suitable location for saving a file, opening a desired file presents similar navigation and searching problems. Often extensive searches are conducted in the directory tree structure to find the desired file to open. In a similar context, merely browsing a tree structure for a desired file to initially open and/or retrieve, can require tedious searching through a list of unlikely directories and subdirectories before finding the file of interest.
In view of the above problems associated with conventional file management and access systems, there is a need for a system and/or methodology to mitigate navigation costs associated with traversing directory tree structures to facilitate improved efficiency file access, save and browsing operations.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The present invention relates to a system and methodology to enable intelligent display and accessing of likely candidate subdirectories during file save, access, browsing and/or other directory operations. In accordance with the present invention, a user's long-term and recent directory activities (e.g., file accesses) are profiled in order to determine and display the most likely subdirectory tree structure the user is likely to employ when directory access is required. In this manner, exhaustive searches and traversals through unlikely potential subdirectories are mitigated during file access operations. A user when attempting to open, save and/or browse a file for example, may be presented with a candidate tree structure by harnessing a decision-theoretic analysis that employs probabilistic information on the likelihood of different target directories that are inferred based upon recent and/or long-term directory activity and/or document properties (e.g., the type of document such as an MS Word file, an MS Excel file, etc., and the content of the document), as well as the costs of navigating from candidate nodes in the directory structure to other nodes to find the desired or target information. Thus, a reformulated, focused directory structure, potentially including multiple views or perspectives composed from tree fragments drawn from the comprehensive directory structure, is provided to enable efficient (e.g., reducing the number of subdirectories to traverse or browse) accessing of the desired file. The analysis is based on considering the expected costs of navigating from different target nodes to the target files.
More particularly, the present invention utilizes decision-theoretic analysis to present users with likely candidate substructures to access, save, and browse desired files. The candidate substructures provided to the user represent a reduced subset of all possible directories in which the user must peruse and traverse during directory operations. In this manner, time is saved and computer efficiency is increased since users are presented a compact and highly relevant list of the most likely directories in which to operate as opposed to having to navigate and search through a maze of intermediate nodes and associated file lists before selecting a desired destination. The likely candidate structures are constructed by first assigning probabilities to directories based upon recent and long-term file activities. For example, long-term probabilities are increased if a directory has had many files stored in that directory in the past. Likewise, a directory having many files of a similar type will also have a higher probability of being a likely destination and/or target directory. Recent activity probabilities may be assigned based upon frequency that a directory or subdirectory has been accessed within a predetermined amount of time (e.g., background monitor counting number of times files in a directory are opened in past two weeks). Directories that are accessed more often are assigned higher probabilities of being the likely destination directory.
After probabilities have been assigned, an expected utility evaluation is conducted for a plurality of nodes within a predetermined proximity to the current directory. Expected utility is a measure of how likely a directory is the intended target directory. Expected utility may be determined by assigning a utility factor to each directory node under consideration, multiplying the utility factor of each node times the probabilities assigned to each node, and summing these products for all nodes under consideration. The utility factor is inversely related to the costs associated with navigating to another node to perform a desired directory operation. Additionally a penalty factor may be included with the utility factor that indicates a cost of viewing a list within a directory based upon the number of files or nodes appearing in the list. As the utility factor decreases, and/or penalty factor increases, the likelihood that a directory is the target directory decreases. After determining expected utility for each directory node, a likely candidate substructure may be presented to the user in order of the highest expected utility that the displayed directories are most likely to be selected, and thus mitigate having to traverse through unrelated and/or unwanted directories.
In accordance with an aspect of the present invention, a system is provided for predicting a target file directory. The system includes a component which analyzes probabilities and utilities associated with determining potential target directories for storing and accessing data and a component for building a subset of the potential target directories that are predicted to be the target directory, wherein the probabilities and/or utilities are functions of navigation costs associated with traversing from a displayed directory to at least one of the potential target directories.
According to another aspect of the present invention, a method is provided for determining a potential target node for directory operations. The method includes:
assigning probabilities and utilities to a plurality of potential target nodes; determining an expected utility from the probabilities and utilities associated with the plurality of target nodes; and displaying a candidate list of likely nodes to a user based upon the expected utility.
In accordance with another aspect of the present invention, a system is provided for determining a potential target node for directory operations. The system includes: means for assigning probabilities and utilities to a plurality of potential target nodes; means for determining an expected utility from the probabilities and utilities associated with the plurality of target nodes; and means for displaying a candidate list of likely nodes to a user based upon the expected utility.
According to yet another aspect of the present invention, a signal adapted to be transmitted between at least two processes is provided. The signal comprises a predicting component for communicating information associated with predicting a target file directory; and an analyzing component which analyzes probabilities and utilities associated with determining potential target directories via the signal for storing and accessing data.
The following description and the annexed drawings set forth in detail certain illustrative aspects of the invention. These aspects are indicative, however, of but a few of the various ways in which the principles of the invention may be employed and the present invention is intended to include all such aspects and their equivalents. Other advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram illustrating a directory analysis and display system in accordance with an aspect of the present invention;
FIG. 2 is a diagram illustrating an exemplary node analysis and display subset in accordance with an aspect of the present invention;
FIG. 3 is a diagram illustrating assigning background probabilities to nodes under consideration in accordance with an aspect of the present invention;
FIG. 4 is a diagram illustrating updating node statistical probabilities with recent activity in accordance with an aspect of the present invention;
FIG. 5 is a diagram illustrating a decision-theoretic evaluation of nodes in a sub-level and higher-level structure in accordance with an aspect of the present invention;
FIG. 6 is a diagram illustrating building a likely candidate list accordance with an aspect of the present invention;
FIG. 7 is a diagram illustrating restructuring and re-sorting a candidate subdirectory by expected utility in accordance with an aspect of the present invention;
FIG. 8 is a diagram illustrating an exemplary display of a candidate directory structure in accordance with an aspect of the present invention;
FIG. 9 is a diagram illustrating an exemplary display of an alternative candidate directory structure in accordance with an aspect of the present invention;
FIG. 10 is a flow diagram illustrating a methodology providing improved directory access in accordance with an aspect of the present invention; and
FIG. 11 is a schematic block diagram illustrating a suitable computing environment in accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout.
The present invention relates to a system and methodology to facilitate improved directory operations and manipulations within a local or remote computer system. This is achieved by providing a reduced subset of likely candidate directories that are determined based upon a decision-theoretic evaluation of expected utility that a potential target directory is the directory a user desires to access. In this manner, time is saved since users have fewer directories to traverse and smaller lists of nodes/files to peruse when searching for a destination directory.
Referring initially to FIG. 1 , a system 10 illustrates a computer system with directory analysis and display in accordance with an aspect of the present invention. The system 10 includes a directory operations subsystem 20 , and a directory analysis subsystem 24 that evaluates a directory tree structure 30 via interface 40 . It is noted that the interface 40 may be a local bus connection within the computer system 10 for communicating with the local directory tree structure 30 and/or may be a remote connection, such as a network connection or wireless connection wherein the directory tree structure 30 resides on a remote computer system (not shown). In accordance with the present invention, a user invokes a directory operation via a user input 44 (e.g., mouse, keyboard) that is directed to the directory operations subsystem 20 . The directory operations subsystem 20 may be invoked by substantially any application executing on the computer system 10 . These operations may include file access, save, and browsing operations associated with the directory tree structure 30 , for example. As an example, a text editing application may invoke a save operation directed to the directory tree structure 30 wherein the current file being edited is to be saved in an alternative directory node. Another example may include a file open operation wherein a subsequent file is to be opened along with the current file being operated upon by the user. Still yet another example of a directory operation may include a remote web access scenario (e.g., browsing) wherein a remote directory tree structure 30 (e.g., web site with associated directory levels). It is to be appreciated that substantially any directory operation that interfaces to the directory tree structure 30 may be employed in conjunction with the present invention.
After the user has initiated a directory operation via the directory operations subsystem 20 , the directory analysis subsystem 24 evaluates the directory tree structure 30 , and provides a reduced subset of selectable candidate nodes at a display output 50 . This enables the user to select a directory or subdirectory from a minimal set of candidate nodes that are probabilistically determined to have a high likelihood of being the directory destination for the desired directory operation. For example, the user may be presented with a list of candidate directories 1 through K and associated subdirectories at the display output 50 . If the user were to select a file open operation via the directory operations subsystem 20 for example, the user possibly may select subdirectory 1 shown at reference numeral 52 from the presentation of likely candidate directories 1 through K, K being an integer, in order to open a desired file. By selecting from the reduced subset of likely candidate directories 1 through K at display 50 , time is saved and efficiency is increased since the user does not have to navigate, peruse and search through a plurality of possible and perhaps irrelevant directories and subdirectories in the directory tree structure 30 during directory operations. As illustrated, the directory tree structure 30 may include a plurality of directories, depicted as directories 1 through N, each directory associated with a plurality of possible levels of subdirectories, depicted as levels L 1 through LL, and each subdirectory level including a plurality of possible subdirectories, depicted as subdirectories 1 through M, wherein L, M, and N are integers.
The directory analysis subsystem 24 evaluates the plurality of directories, subdirectory levels, and associated subdirectories in the directory tree structure 30 to provide a minimal/optimal set of likely directories and subdirectories in the display output 50 wherein the user selects from a few highly relevant alternatives when initiating directory operations. As will be described in more detail below, the directory analysis subsystem 24 utilizes a decision-theoretic analysis of the directory tree structure 30 in order to provide the reduced subset of candidate directories and subdirectories at the display output 50 . The decision-theoretic analysis includes assigning probabilities to all nodes associated with the directory tree structure 30 as potential target nodes. The probabilities may include prior probabilities of node targets for document types saved within a longer term time horizon and more recent evidence of node activity, within a shorter time horizon of document content and activity to update potential target probabilities (e.g., increase the sample size of documents in directory folders). Expected utilities are then evaluated for each node. In the evaluation of each candidate or “target” node, the target itself is considered, and then nodes that are down one and two levels, and nodes that are up one level, and also down one level from the upper level. A list of display candidates is then started beginning with the node with the maximum expected utility and then removing that node from consideration. A re-evaluation of all nodes remaining in the directory tree structure 30 is then conducted, adding the new node, and scanning again to see that the new node is optimal before continuing to build a list of up to N display items. A list of all targets is then created and sorted by expected utility. The list is then displayed in a manner that preserves the overall utility ordering for each level of abstraction.
Referring now to FIG. 2 , a directory tree structure 80 is illustrated in accordance with the present invention. It is noted that the directory tree structure 80 depicts an exemplary structure and that more or less directory nodes and node levels may be analyzed in accordance with the present invention. The directory tree structure 80 is represented by a plurality of directory nodes 90 through 99 . Each node 90 through 99 is evaluated for expected utility wherein each node is assigned a value of being a likely destination or target node. Nodes may then be sorted and presented to the user as a subset of all the nodes under consideration based upon the expected utility determination. As an example, three possible exemplary node subsets are depicted at reference numerals 102 , 104 and 106 that represent smaller subsets of the larger directory tree structure 80 . By providing the user with a compact view of likely candidate directories such as node subsets 102 – 106 , time is saved and efficiency is increased since the user does not have to peruse, search and navigate through all directory nodes 90 – 99 during directory operations.
The present invention provides a decision-theoretic node evaluation to order all target directories by expected utility to determine the node subsets. Each top-level directory (e.g., C:\, D:\), are followed by listings of more and more detailed targets. The top-level directories are thus ordered by expected utility. Each top-level directory is sorted and populated with the highest levels of the next level of detail by expected utility. The next levels of each subdirectory are then recursively populated, again by expected utility. A set of pruning heuristics may be employed to limit the size of the set of files contained by each top-level directory (e.g., by considering a maximum size as well as a minimum expected utility).
In order to determine the node subsets 102 – 106 , a target node (i), 96 may first be evaluated for expected utility. As illustrated, the target (i) 90 has a parent node (k) 91 that has two other associated nodes at level (l), 92 and 93 . The target (i) 90 has three sublevel nodes (j) 94 – 96 wherein one of the (j) levels 96 also has three exemplary sublevel nodes (m) 97 – 99 .
For each node 90 – 99 , a probability is assigned that the node is a target node, such that p(Target i|Recent, Long-term Evidence) as will be described in more detail below. For each node under consideration such as the target node (i) 90 , an evaluation of the children of that node j 1 . . . j n 94 – 96 and the parent of the node, k and its children one level down, l 1 . . . l n may be conducted, for example. It is to be appreciated that other nodes (not shown) may also be included in the determination. The expected utility of a potential target node is the probability that the node is the target node weighted by the utility of that node being the target, then summed together with the probabilities that the target location is in some near proximity to the target, weighted by the utility of making a navigational move to an adjacent node from the target and the cost of reviewing a list associated with the navigation.
Referring now to FIGS. 3–5 , a more detailed description is provided for the expected utility determination and decision-theoretic evaluation described above. Turning initially to FIG. 3 , background probabilities are determined and assigned to each node in the directory tree structure 80 . These probabilities may be determined from a plurality of factors that indicate that a potential node is a likely target node. For example, a predetermined file activity horizon may be defined for all files in each node in the directory tree structure 80 . For example, each file in each directory node may be checked for file activity within an amount of time (e.g., check file save operations within the last 2 weeks). Directory nodes with more files that have been saved and/or acted upon within the predetermined amount of time are assigned higher probabilities of being the target node.
Referring now to FIG. 4 , the background probabilities described above may be updated in real-time and based upon more recent file and directory activities associated with a particular application and/or file type. These probabilities may include the frequency that a particular file and/or directory has been accessed by the user. For example, these probabilities may be determined from file similarities associated with an application. If a text file is being saved or opened for example, nodes containing large numbers of text files will have a higher probability of being a target node than nodes containing large numbers of drawings files. Other factors may include determining document or item similarities (e.g., with a cosine similarity metric for text similarity or a classification technology that provides a probability that an item belongs in a category based on its content), and may include a language model analysis of the files within each node, wherein file elements or structures within each file may be compared with the current file being operated upon by the user. Still other factors may include long and short term statistical analysis based upon application type.
For example, it may be determined that a particular user generally saves text applications in one high-level directory (e.g., C:/documents) and generally saves spread sheet applications in another high-level directory (e.g., D:/spread sheet). Depending on the directory operation to be performed from a particular application, the probabilities assigned to each node may thus change. It is to be appreciated that a background monitor can be included with the computer system described above to monitor file and directory activities associated with the user actions. In other words, the background monitor can determine how frequently a particular file has been accessed by associating a counter with each file, and updating the counter each time the file and/or directory operation is attempted by the user. Frequency can be determined by dividing the number of counts in the counters over a predetermined time period. Thus, files with a higher frequency of access may be assigned higher probabilities.
Turning to FIG. 5 , a decision-theoretic evaluation of the tree structure 80 is illustrated in accordance with the present invention. As described above in relation to FIGS. 3 and 4 , all nodes in the tree structure 80 are assigned background probabilities and are updated in real time with probabilities that are associated with the type of application being operated upon. After the probabilities have been assigned, a utility factor is assigned to each node. The utility factor assigns a penalty for navigating to an adjacent node to perform a directory operation. For example, when the target (i) node 90 is under evaluation, the utility factor may be set to (l) since there are no assumed penalties associated with staying at the target node (i). If traversing down one level to nodes (j) 94 – 96 , a utility factor may be assigned as 0.6, for example. It is to be appreciated that the utility factor may be assigned by the user at run time, and/or may be encoded as default values for each level of navigation. If traversing down two levels to nodes (m) 97 – 99 , a utility factor may be assigned as 0.1, for example. Similarly, if traversing up one level to node (k) 91 the utility factor may be assigned 0.4 and similarly, up one level and down one level to nodes (l) 92 , 93 a utility factor may be assigned as 0.05, for example. It is noted that these utility factors are provided for exemplary purposes and may be assigned or encoded as substantially any factor that provides a penalty for navigating to an adjacent node.
A list scan penalty may also be assigned to each node in the directory tree structure 80 . The list scan penalty assigns a penalty for displaying a number of items in a list. For example, an exponential function (e.g., Size 1/n ) may be selected as a penalty function, wherein N is an integer and represents the number of files in the list. In the example tree structure depicted by the tree structure 80 , no scan penalty is assigned to node (k) 91 , since this node would appear by itself, without any other nodes on the (k) level, in a list of nodes. Nodes (j) 94 – 96 on the other hand, are each associated with three items at the (j) sublevel. Likewise, nodes (m) 97 – 99 are each associated with three items at the (j) sublevel and are thus assigned a list scan penalty.
After assigning the utility factor and list scan penalties to all nodes in the directory tree 80 , an expected utility evaluation for each node can proceed. This involves evaluating each node in the directory tree structure 80 as a potential target node. For example, the target node (i) 90 may be the first node to be considered. For each node in the tree structure 80 a multiplication occurs utilizing the probabilities determined for that node multiplied by the utility factor and list scan penalty to navigate to that node to create an expected utility product for each node. The expected utility for a node, such as the target node (i) 90 , is then the sum of all the expected utility products for each node 90 – 99 . The following equation illustrates this computation of the expected utility for the target node (i) 90 .
Equation
1
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wherein n, m, and o are integers, and p(Elsewhere) is 1−(the sum of all of the probabilities in consideration for node i). Thus, p(Elsewhere)=1−[p(Target i)+Σ j=1 . . . n p(T=j)+p(T=k)+Σ 1=1 . . . m p(T=l)]. Equation 1 can be simplified by dropping the last term of Equation 1 by setting the utility of u[Target is elsewhere, Guess is i, f(m)] to zero. Thus, the following Equation may be employed:
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wherein f( ) is the list scan penalty that grows as the number of items that need to be scanned grows. The utility factor can be considered as a list-scan size independent utility that is modified by the multiplicative factor, f(n). Thus, the utilities factors are assigned for navigating from one level to the next from the target node (i) under consideration. For example, if:
navigating down one level, then u[Target is j, Guess is i]=0.6*penalty with size of list navigating up one level, then u[Target is k, Guess is i]=0.4*penalty with size of list navigating down two levels, then u[Target is m, Guess is i]=0.1*penalty with size of list
As described above, more or less directory sublevels may be similarly analyzed in accordance with the present invention, and that other utility factors assigned based on a user-assigned and/or encoded penalty for navigating from one sublevel to the next. After target node (i) 90 has been evaluated for expected utility, each node in the directory tree structure 80 may be similarly evaluated whereby that node (the node under evaluation) is made a potential target node and analyzed in relation to all other nodes. For example, node (j) 94 may next be analyzed for expected utility, wherein the node (j) 94 is analyzed similarly to target node (i) 90 described above. Similarly, all nodes in the directory tree structure 80 may be analyzed and assigned an expected utility.
Referring now to FIG. 6 , a candidate list of relevant directory nodes is separated from the directory tree structure 80 after determining expected utility as described above in FIG. 5 . A candidate list 120 is illustrated with two nodes 122 and 124 that have been sorted from the directory tree structure 80 based upon the expected utility that candidate nodes 122 and 124 are likely to be the desired destination/target directories for performing directory operations. According to this aspect of the invention, the list of candidates may be built by identifying a “best node”, based upon the highest expected utility determined for all nodes in the directory tree structure 80 . The node with the highest expected utility is then added to the list of candidates 120 , and then removed from consideration. The expected utility evaluation described above is then repeated without the previously added node 122 being considered. The next best node is then determined based upon expected utility, and added to the list of candidates 120 . For example, the node 122 , may be the first node added to the candidate list 120 and is thus removed from consideration of the next expected utility calculation for the directory tree structure 80 . The node 124 , which may have the next highest expected utility and is then added to the list 120 . The node 122 , is then returned as an original node to the directory tree 80 and an expected utility determination is attempted again to determine if a summation of the candidate list 120 is greater than the prior list. If not, a return to the prior candidate list is provided, if so, the determination of the candidate list continues on until another candidate node is determined. This process is continued in this manner, with replacement of nodes from the candidate list 120 back into the directory tree structure 80 until reaching a max number of candidates or exhausting the search of the directory tree structure 80 .
Referring now to FIG. 7 , an exemplary output display of candidate nodes 120 is illustrated in accordance with the present invention. The nodes that where extracted in the expected utility determinations described above may be listed in order of expected utility as illustrated in the list 120 . As an alternative, the final list 120 may be displayed by utility of items, wherein a display 130 is sorted with a metaphor defined by a global file system (e.g., dynamically created sub-trees created with indentation, and/or actual tree structure).
Referring to FIG. 8 , an exemplary output display and candidate list is illustrated in accordance with the present invention. A user, may attempt a file “save as” operation as is well understood. It is to be appreciated that other directory operations such as open or browse may be similarly initiated. An auxiliary display window 140 may be provided in order to list display candidate directories 142 through 148 . As described above, the entire directory structure of the local or remote computer may be analyzed to determine the candidate directories based upon expected utilities. As illustrated, a document type file is being saved in an alternative directory. The display 140 provides a sorted list based on expected utility and represents a reduced subset of directories that the user must search though in order to find a destination or target directory to save the document file. In this example, the user has selected the directory at reference 144 as the ultimate destination directory. In a similar example, a presentation file (e.g, Power Point) is saved as illustrated in FIG. 9 . In this case, the user selects from the display 140 at reference 150 as the ultimate destination for the save operation.
FIG. 10 illustrates a methodology for providing improved directory access in accordance with an aspect of the present invention. While, for purposes of simplicity of explanation, the methodology is shown and described as a series of acts, it is to be understood and appreciated that the present invention is not limited by the order of acts, as some acts may, in accordance with the present invention, occur in different orders and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the present invention.
Referring to FIG. 10 , and proceeding to 160 , probabilities are assigned to each node under evaluation in a directory tree structure. As described above, this may be based on recent and/or long-term file activity. At 162 , utilities and scan list penalties are assigned to each node under evaluation. Utilities reflect the cost of navigating up or down to another directory from the directory node currently under analysis. Scan list penalties are assigned as a function of the number of items appearing in a list associated with a node under evaluation. At 164 , an expected utility product for each node under consideration is formed by multiplying the probabilities, utilities, and scan list penalties described above. At 166 , all the expected utility products for all the nodes under evaluation are summed to determine an expected utility for the current node being evaluated as a potential target node. At 168 , a candidate node display is constructed from the expected utility determinations performed in 166 . The candidate node display enables a user to select from a reduced subset of directories when performing directory operations, and thus improve computer efficiency.
In order to provide a context for the various aspects of the invention, FIG. 11 and the following discussion are intended to provide a brief, general description of a suitable computing environment in which the various aspects of the present invention may be implemented. While the invention has been described above in the general context of computer-executable instructions of a computer program that runs on a computer and/or computers, those skilled in the art will recognize that the invention also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks and/or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods may be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like. The illustrated aspects of the invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. However, some, if not all aspects of the invention can be practiced on stand-alone computers. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
With reference to FIG. 11 , an exemplary system for implementing the various aspects of the invention includes a computer 220 , including a processing unit 221 , a system memory 222 , and a system bus 223 that couples various system components including the system memory to the processing unit 221 . The processing unit 221 may be any of various commercially available processors. Dual microprocessors and other multi-processor architectures also may be employed as the processing unit 221 .
The system bus may be any of several types of bus structure including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory may include read only memory (ROM) 224 and random access memory (RAM) 225 . A basic input/output system (BIOS), containing the basic routines that help to transfer information between elements within the computer 220 , such as during start-up, is stored in ROM 224 .
The computer 220 further includes a hard disk drive 227 , a magnetic disk drive 228 , e.g., to read from or write to a removable disk 229 , and an optical disk drive 230 , e.g., for reading from or writing to a CD-ROM disk 231 or to read from or write to other optical media. The hard disk drive 227 , magnetic disk drive 228 , and optical disk drive 230 are connected to the system bus 223 by a hard disk drive interface 232 , a magnetic disk drive interface 233 , and an optical drive interface 234 , respectively. The drives and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, etc. for the computer 220 . Although the description of computer-readable media above refers to a hard disk, a removable magnetic disk and a CD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, and the like, may also be used in the exemplary operating environment, and further that any such media may contain computer-executable instructions for performing the methods of the present invention.
A number of program modules may be stored in the drives and RAM 225 , including an operating system 235 , one or more application programs 236 , other program modules 237 , and program data 238 . The operating system 235 in the illustrated computer may be any commercially available operating system.
A user may enter commands and information into the computer 220 through a keyboard 240 and a pointing device, such as a mouse 242 . Other input devices (not shown) may include a microphone, a joystick, a game pad, a satellite dish, a scanner, or the like. These and other input devices are often connected to the processing unit 221 through a serial port interface 246 that is coupled to the system bus, but may be connected by other interfaces, such as a parallel port, a game port or a universal serial bus (USB). A monitor 247 or other type of display device is also connected to the system bus 223 via an interface, such as a video adapter 248 . In addition to the monitor, computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 220 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 249 . The remote computer 249 may be a workstation, a server computer, a router, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 220 , although only a memory storage device 250 is illustrated in FIG. 11 . The logical connections depicted in FIG. 11 may include a local area network (LAN) 251 and a wide area network (WAN) 252 . Such networking environments are commonplace in offices, enterprise-wide computer networks, Intranets and the Internet.
When employed in a LAN networking environment, the computer 220 may be connected to the local network 251 through a network interface or adapter 253 . When utilized in a WAN networking environment, the computer 220 generally may include a modem 254 , and/or is connected to a communications server on the LAN, and/or has other means for establishing communications over the wide area network 252 , such as the Internet. The modem 254 , which may be internal or external, may be connected to the system bus 223 via the serial port interface 246 . In a networked environment, program modules depicted relative to the computer 220 , or portions thereof, may be stored in the remote memory storage device. It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be employed.
In accordance with the practices of persons skilled in the art of computer programming, the present invention has been described with reference to acts and symbolic representations of operations that are performed by a computer, such as the computer 220 , unless otherwise indicated. Such acts and operations are sometimes referred to as being computer-executed. It will be appreciated that the acts and symbolically represented operations include the manipulation by the processing unit 221 of electrical signals representing data bits which causes a resulting transformation or reduction of the electrical signal representation, and the maintenance of data bits at memory locations in the memory system (including the system memory 222 , hard drive 227 , floppy disks 229 , and CD-ROM 231 ) to thereby reconfigure or otherwise alter the computer system's operation, as well as other processing of signals. The memory locations wherein such data bits are maintained are physical locations that have particular electrical, magnetic, or optical properties corresponding to the data bits.
What has been described above are various aspects of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. | A system and methodology is provided for improving directory operations within a system providing an electronic hierarchical directory of items. The system includes a component which analyzes probabilities and utilities associated with determining potential target directories for storing and accessing data, and a component for building a subset of the potential target directories that are predicted to be the target directory. The probabilities and/or utilities are functions of expected navigation costs associated with traversing from a displayed directory to at least one of the potential target directories. Methods in accordance with the present invention can be coupled with displays of substructures that format the substructures into a coherent hierarchical view. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a wet friction material that generates a torque by applying a high pressure to an opposite surface while being immersed in oil. In detail, this invention relates to a segment-type friction material made by joining friction material substrates that were cut into a segment piece onto one or both surfaces of a core metal of a flat ring shape along an entire circumference thereof with an adhesive. Otherwise, this invention relates to a ring-shaped friction material made by joining ring-shaped friction material substrates onto one or both surfaces of a core metal of a flat ring shape thereof with an adhesive.
[0003] 2. Description of the Related Art
[0004] In recent years, for the purpose of reducing a shift-shock by multistage of an automatic transmission, which may be referred to as “AT” hereafter, of an automobile or the like, it is required to improve a shift transmission feature (engagement/disengagement feature) in a wet friction material which is used for AT. To improve a disengagement feature, it is effective to make it harder for an oil film which is cased by an automatic transmission fluid, which may be referred to as “ATF” hereafter, to generate between a friction surface of a wet friction material and a counterpart plate in a disengaged state by making a pore diameter of the wet friction material large or by increasing a porosity. (“ATF” is a registered trademark of Idemitsu Kosan Co., Ltd.) According to an invention described in Japanese Laid Open Patent Publication No. 2004-138121, there is provided a wet friction material that it includes silica of an average particle size 1 μm to 10 μm and a disk-shaped diatom earth in paper substrates. Also, this wet friction material uses a hardened material of liquid resin composition that can be obtained by mixing resol-type phenolic resin and silicone resin as a bounding material. Accordingly, it can obtain a wet friction material that is greater in heat resistance (resistant heat spot) and is improved a positive μ-V slope characteristic while having a high friction coefficient.
[0005] However, in the wet friction material described in the above Japanese Laid Open Patent Publication No. 2004-138121, it contains diatom earth that an absolute specific gravity is low, which is 25% by weight to 45% by weight of paper substrates, and inter-fiber pores of paper substrates are filled in with the diatom earth. Therefore, a pore diameter becomes small and there is a possibility that it can not obtain a preferable disengagement feature. In contrast, if it increases fibrillation of fibers of paper substrates or decreases lining density so as to increase pore diameter or porosity, there is a problem that it generates negative effects such as strength reduction or increase in settling quantity etc.
[0006] Then, an object of this invention is to provide a wet friction material that it is greater in a disengagement feature by increasing a pore diameter of a wet friction material as well as reducing a drag torque, while it is greater in a positive μ-V slope characteristic without generating such negative effects, strength reduction or increase in settling quantity etc.
BRIEF SUMMARY OF THE INVENTION
[0007] According to a first aspect of the invention, there is provided a wet friction material made by joining friction material substrates that it impregnates a paper body containing fiber component and filler component with the thermosetting resin and makes it harden by heat to form onto one or both surfaces of a core metal of a flat ring shape. In the above filler component, it contains one or more than two kinds of inorganic fillers that: an average particle size is within a range of 0.3 μm to 10 μm; an absolute specific gravity is within a range of 4 to 6; Moh's hardness is within a range of 3 to 8, within a range of 5% by weight to 40% by weight of an entire paper body mentioned above.
[0008] Here, “a wet friction material” includes a segment-type friction material made by joining friction material substrates that were cut into segment pieces onto a surface of a core metal of a flat ring shape thereof with an adhesive. Also, this wet friction material includes a ring-shaped friction material made by joining ring-shaped friction material substrates onto the surface of the core metal of the flat ring shape thereof with an adhesive.
[0009] Additionally, “an absolute specific gravity” is a corresponding term for “a bulk specific gravity”. That means an inherent specific gravity of a material which makes up inorganic filler, not a bulk specific gravity (apparent density) when there is a space in inorganic filler. For “inorganic filler” that meets a requirement described in claim 1 , there are zinc oxide, barium sulfate, and titanium oxide etc. Especially, it is preferable to use zinc oxide of the average particle size 0.3 μm to 1.0 μm, the absolute specific gravity of 5.5 to 6.0, and the Moh's hardness of 4 to 5 or barium sulfate of the average particle size 3 μm to 10 μm, the absolute specific gravity of 4.0 to 4.5, and the Moh's hardness of 3 to 4 as inorganic filler.
[0010] According to a second aspect of the invention, there is provided a wet friction material made by joining friction material substrates that it impregnates a paper body which is formed by that a part of filler component and fiber component is carried out papermaking with the thermosetting resin after adding inorganic filler which is a remnant of the above filler component and then makes it harden by heat to form onto one or both surfaces of the core metal of the flat ring shape thereof with an adhesive. Otherwise, this wet friction material is made by joining friction material substrates that it impregnates the paper body which is formed by that a part of the filler component and the fiber component with the thermosetting resin added the inorganic filler which is a remnant of the above filler component and then makes it harden by heat to form onto one or both surfaces of the core metal of the flat ring shape thereof with an adhesive. The above inorganic filler is one or more than two kinds of inorganic fillers that: the average particle size is within a range of 0.3 μm to 10 μm, the absolute specific gravity is within a range of 4 to 6 and the Moh's hardness is 3 to 8, and that is added within a range of 5% by weight to 40% by weight of the entire paper body mentioned above.
[0011] According to a third aspect of the invention, in one of compositions of claim 1 or claim 2 , there is provided a wet friction material that a content in the above fiber component is within a range of 30% by weight to 60% by weight in the above paper body, and a content in the above filler component is within a range of 40% by weight to 70% by weight in the above paper body.
[0012] According to a fourth aspect of the invention in one of compositions of claim 1 to claim 3 , there is provided a wet friction material that a peak of a pore diameter distribution of the above friction material substrates measured by a mercury intrusion technique is within a range of 1 μm to 20 μm, and a porosity of the above friction material substrates is within a range of 30% to 70%.
[0013] According to the first aspect of the invention, there is provided a wet friction material made by joining friction material substrates that it impregnates the paper body containing fiber component and filler component with the thermosetting resin and makes it harden by heat to form onto one or both surfaces of the core metal of the flat ring shape thereof with an adhesive. Also, this wet friction material includes one or more than two kinds of inorganic fillers that: the average particle size is within a range of 0.3 μm to 10 μm; the absolute specific gravity is within a range of 4 to 6; and the Moh's hardness is 3 to 8, within a range of 5% by weight to 40% by weight to the entire paper body.
[0014] Here, “a wet friction material” includes a segment-type friction material made by joining friction material substrates that were cut into segment pieces onto a surface of a core metal of a flat ring shape, and it also includes a ring-shaped friction material made by joining ring-shaped friction material substrates onto the surface of the core metal of the flat ring shape. Additionally, “absolute specific gravity” is a corresponding term for “a bulk specific gravity”. That means an inherent specific gravity of a material which makes up inorganic filler, not a bulk specific gravity (apparent density) when there is a space in inorganic filler. For “inorganic filler” which meets a requirement described in claim 1 , there are zinc oxide, barium sulfate, and titanium oxide etc. Especially, it is preferable to use zinc oxide of the average particle size 0.6 μm, the absolute specific gravity 5.5 to 6.0 and the Moh's hardness 4 to 5 or barium sulfate of the average particle size 3 μm to 10 μm, the absolute specific gravity 4.0 to 4.5 and the Moh's hardness 3.0 to 4.0 as inorganic filler.
[0015] As a result of an accomplishment of keen and hard experimental study on improvement of disengagement feature of the wet friction material by this inventors, they have finally found that it requires to include one or more than two kinds of inorganic fillers: the average particle size is within a range of 0.3 μm to 10 μm; the absolute specific gravity is 4 to 6; and the Moh's hardness is 3 to 8 in the filler component within a range of 5% by weight to 40% by weight to the entire paper body so as to improve a disengagement feature keeping strength of the wet friction material. Then, they have completed this invention on the basis of this knowledge.
[0016] That is, it can obtain an effect to improve strength of friction material substrates by that the inorganic fillers attach to inter-fiber by adding small-particle inorganic fillers and it connects the inter-fiber when hardening the impregnated resin. Moreover, it can secure the pore diameter of friction material substrates without being filled in pores of the friction material substrates with inorganic fillers, while compounding quantity becomes small by keeping the absolute specific gravity of inorganic fillers. Thus, it becomes faster to absorb ATF from the friction surface and the disengagement feature can be improved.
[0017] At this point, in case that the average particle size of the inorganic filler is less than 0.3 μm, it is harder to entwine with fibers when carrying out papermaking and can not mix them in stable condition since it runs with water from a paper net. In contrast, if the average particle size is more than 10 μm, pore diameter becomes small by that inter-fiber pores are filled in with inorganic fillers, and also an effect to improve the strength of friction material substrates by connecting the inter-fiber becomes low, which is caused by reducing a number of particles of inorganic fillers.
[0018] Moreover, if the absolute specific gravity is less than 4, pores are filled in because it increases the compounding quantity and the particle number, also it can not obtain a preferable disengagement feature by getting small the pore diameter or lowering the porosity. In contrast, if the absolute specific gravity is more than 6, it decreases the compounding quantity and the particle number, therefore, an effect to improve the strength of friction material substrates by connecting the inter-fiber becomes low, and also it can not be dispersed in friction material substrates uniformly by deteriorating dispersibilty when carrying out papermaking.
[0019] Furthermore, if the Moh's hardness is less than 3, there is possibility that it deteriorates a friction coefficient or inorganic filler becomes worn away when the friction surface is engaged with the counterpart plate. In contrast, if the Moh's hardness is more than 8, it rises an aggression against the counterpart plate and makes the counterpart plate become worn away. Also, if inorganic filler is less than 5% by weight to paper body, it can not secure a pore diameter because other compounding ratio of filler or fiber is large. On the other hand, if the inorganic filler is more than 40% by weight to the paper body, it also increases the compounding quantity and the particle number. Therefore, it can not secure the pore diameter.
[0020] Thus, there is provided a wet friction material that is superior to the disengagement feature by extending the pore diameter of the wet friction material as well as reducing the drag torque, while it is greater in the positive μ-V slope characteristic without generating such negative effects as strength reduction or increase in settling quantity etc.
[0021] According to a second aspect of the invention, there is provided a wet friction material made by joining friction material substrates that it impregnates a paper body which is formed by that a part of filler component and fiber component is carried out papermaking with the thermosetting resin after adding an inorganic filler which is a remnant of the filler component and makes it harden by heat to form onto one or both surfaces of the core metal of the flat ring shape thereof with an adhesive. Otherwise, this wet friction material is made by joining friction material substrates that it impregnates a paper body which is formed by that a part of filler component and fiber component is carried out papermaking with the thermosetting resin added the inorganic filler which is a remnant of the filler component and makes it harden by heat to form onto one or both surfaces of the core metal of the flat ring shape thereof with an adhesive. Additionally, the above inorganic filler is one or more than two kinds of inorganic fillers that the average particle size is within a range of 0.3 μm to 1.0 μm, the absolute specific gravity is within a range of 4 to 6 and the Moh's hardness is 3 to 8, and that is added within a range of 5% by weight to 40% by weight of the entire paper body mentioned above.
[0022] In the wet friction material according to this invention, only a production method is different a little between friction material substrates and wet friction materials according to the first aspect of the invention, and it can obtain substantially equivalent friction material substrates. Therefore, it is possible to obtain a similar working effect with the same reason as the wet friction material according to the first aspect of the invention.
[0023] Thus, there is provided a wet friction material that is superior to the disengagement feature by extending the pore diameter of the wet friction material as well as reducing the drag torque, while it is greater in the positive μ-V slope characteristic without generating such negative effects as strength reduction or increase in settling quantity etc.
[0024] According to a third aspect of the invention, there is provided a wet friction material that a content of fiber component is within a range of 30% by weight to 60% by weight in a paper body. Also, a content of filler component is within a range of 40% by weight to 70% by weight in the paper body.
[0025] If a content of the fiber component is less than 30% by weight, there is possibility that it deteriorates the strength of the friction material and it is harder for the filler component to entwine with fibers and can not compound in stable condition when carrying out papermaking. In contrast, if a content of the fiber component is more than 60% by weight, it gets small the pore diameter and lowers the porosity, thus there is possibility that it can not obtain a preferable disengagement feature. Therefore, it is preferable that the content of the fiber component is within a range of 40% by weight to 70% by weight in the paper body of the filler component.
[0026] In a relative relation with this, if a content of the filler component is less than 40%, there is possibility that it gets small the pore diameter and lowers the porosity by fibers, and it can not obtain a preferable disengagement feature. In contrast, if a content of the filler component is more than 70% by weight, there is possibility that it deteriorates the strength of the frictional material because the fiber component decreases. Also, there is possibility that it is harder for the filler component to entwine with fibers when carrying out papermaking and can not compound in stable condition. Therefore, it is preferable that a content of the filler component is within a range of 40% by weight to 70% by weight in the paper body.
[0027] Thus, there is provided a wet friction material that is superior to the disengagement feature by extending the pore diameter of the wet friction material as well as reducing the drag torque, while it is greater in the positive μ-V slope characteristic without generating negative effects such as strength reduction or increase in settling quantity etc.
[0028] According to a fourth aspect of the invention, there is provided a wet friction material that a peak of the pore diameter distribution of the above friction material substrates measured by a mercury intrusion technique is within a range of 1 μm to 20 μm, and a porosity of the above friction material substrates is within a range of 30% to 70%. In case that a peak of the pore diameter distribution measured by the mercury intrusion technique is less than 1 μm or the porosity is less than 30%, there is possiblity that it deteriorates the disengagement feature or the heat resistance by decreasing ATF absorbing effect of the wet friction material and its discharging effect. Also, in case that a peak of the pore diameter distribution of friction material substrates measured by the mercury intrusion technique is more than 20 μm or the porosity is more than 70%, there is possibility that it deteriorates the strenght of the wet friction material or occures a biting shock by that ATF absorbing effect and the discharging effect are too high Accordingly, it is preferable that a peak of the pore diameter distribution of friction material substrates measured by the mercury intrusion technique is within a range of 1 μm to 20 μm and the porosity is within a range of 30% to 70%.
[0029] Thus, there is provided a wet friction material that is superior to the disengagement feature by extending the pore diameter of the wet friction material as well as reducing the drag torque, while it is greater in the positive μ-V slope characteristic without generating negative effects such as strength reduction or increase in settling quantity etc.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0030] FIG. 1 a is a graph showing a disengagement feature of a wet friction material according to an embodiment of this invention. FIG. 1 b is a graph showing a disengagement feature of a conventional wet friction material.
[0031] FIG. 2 is a graph showing shear strength of friction material substrates of the wet friction material according to the embodiment of this invention compared to comparative examples.
[0032] FIG. 3 a is a view showing a frame format of an inner structure of conventional friction material substrates. FIG. 3 b is a view showing a frame format of an inner structure of friction material substrates of the embodiment of this invention.
[0033] FIG. 4 is a graph showing a pore diameter distribution of friction material substrates of the wet friction material according to the embodiment of this invention compared to comparative examples.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Next, a wet friction material according to preferred embodiments of the invention is described hereinafter referring to FIG. 1 to FIG. 4 .
[0035] FIG. 1 a is a graph showing a disengagement feature of a wet friction material according to an embodiment of the invention.
[0036] FIG. 1 b is a graph showing a disengagement feature of a conventional wet friction material.
[0037] FIG. 2 is a graph showing shear strength of friction material substrates of the wet friction material according to the embodiment of the invention compared to comparative examples.
[0038] FIG. 3 a is a view showing a frame format of an inner structure of conventional friction material substrates.
[0039] FIG. 3 b is a view showing a frame format of an inner structure of friction material substrates according to the embodiment of the invention.
[0040] FIG. 4 is a graph showing a pore diameter distribution of friction material substrates of the wet friction material according to the embodiment of the invention compared to comparative examples.
[0041] First, a production method or composing materials that make up friction material substrates of the wet friction material according to preferred embodiments of the invention are described referring to TABLE 1.
[0000] TABLE 1 Unit: % by weight Third Fourth Fifth Particle Absolute First Second compara- compara- compara- Composing size specific Mohs First Second Third Fourth comparative comparative tive tive tive material [μm] gravity hardness example example example example example example example example example Fiber 55 50 50 35 50 45 50 35 55 Filler 40 30 10 60 30 35 35 45 40 Inorganic 6 2.3 7 — — — — 20 — — 10 — filler A Inorganic 1 2.3 7 — — — — — 20 — 10 5 filler B Inorganic 0.6 5.5 5 5 — 20 — — — — — — filler C Inorganic 10 4.2 3 — 20 20 — — — — — — filler D Inorganic 0.3 4.3 7.5 — — — 5 — — — — — filler E Inorganic 2 2.7 3 — — — — — — 15 — — filler F Total [wt %] 100 100 100 100 100 100 100 100 100 Phenolic resin [wt %] 35 35 35 35 35 35 35 35 35 Porosity 65 50 40 55 40 50 55 60 50 Disengagement feature ⊚ ⊚ ◯ ◯ X X Δ Δ Δ Strength ◯ ◯ ◯ ◯ X ◯ X X Δ
As shown in TABLE 1, as a composition of friction material substrates of a wet friction material according to the embodiment of the invention, it produces friction material substrates making use of four kinds of compositions according to a first example to a fourth example. And for comparison, it produces another friction material substrates making use of five kinds of compositions according to a first comparative example to a fifth comparative example. In composing materials shown in TABLE 1, it uses aramid fiber, pulp for a fiber and diatom earth, graphite and carbon fiber for filler. Also, it makes use of diatom earth for “inorganic filler A, B”, zinc oxide for “inorganic filler C”, barium sulfate for “inorganic filler D”, titanium oxide for “inorganic filler E” and calcium carbonate for “inorganic filler F” each.
[0042] At this point, the inorganic filler C (zinc oxide), the inorganic filler D (barium sulfate), and the inorganic filler E (titanium oxide) that are used for four kinds of composing materials according to the first example to the fourth example meet all of the following requirements of claim 1 of the invention: the average particle size is within a range of 0.3 μm to 10 μm; the absolute specific gravity is within a range of 4 to 6; and the Moh's hardness is within a range of 3 to 8. The average particle size of the inorganic filler C, D and E each is a value measured by a laser diffraction method or an air permeability method. In contrast, the absolute specific gravity is low in the inorganic filler A, B (diatom earth) and the inorganic filler F (calcium carbonate) also and it does not meet any requirements of claim 1 .
[0043] According to the compounding quantity shown in TABLE 1, it compounds these composing materials each and makes slurry by dispersing those mixtures in water, and then it produces paper substrates by drying paper that was carried out papermaking from the slurry. As shown in TABLE 1, it impregnates 35 by weight of phenolic resin against 100 by weight of paper substrates each, and then it dries and heats at 200 degrees for 30 minutes to harden the phenolic resin and produces friction material substrates. Regarding the resultant friction material substrates, it evaluated a disengagement feature and strength each. These evaluation results including an evaluation result of the porosity described below are shown in lower stage of TABLE 1.
[0044] For the evaluation of the disengagement feature, the resultant friction material substrates were cut into segment pieces at prescribed shape and it joined the 40 segment-piece-shaped friction material substrates each onto both surfaces of the core metal of the flat ring shape having an outer diameter Ø of 176 mm and an inner diameter Ø of 154 mm in a disk size so as to make a segment-type friction material. Then, it evaluated the disengagement feature in a test condition that: a number of disks is 3; a relative rotating speed is 3000 rpm; ATF oil temperature is 40 degrees; ATF oil quantity 2.4 l/min; a surface pressure is 0.8 MPa; and weight sweeping time is about 4 seconds.
[0045] Additionally, in the same test condition, it obtained the same test result when it evaluated a disengagement feature in a ring-shaped friction material made by that the resultant friction material substrates were cut into as the ring shape and it joined the ring-shaped friction material substrates onto both surfaces of the core metal of the flat ring shape of the outer diameter Ø 176 mm and the inner diameter Ø 154 mm in the disk size and applied 40 oil grooves per one side by pressing thereof. That is, evaluation result hereinafter described is common to the wet friction material that there are 40 oil grooves per one side. The test result is shown in FIG. 1 a.
[0046] As shown in FIG. 1 a, according to a composition of the first example of this embodiment, there is provided a wet friction material that the torque reduces smoothly as it becomes free from a pressure and it turns out that it can obtain an ideal disengagement feature. In contrast, as shown in FIG. 1 b, according to a composition of the first comparative example, there is provided a wet friction material that it generates a rapid torque fluctuation at a portion where it is surrounded by a circle written with a chain double-dashed line, and it found that there is a problem in the disengagement feature.
[0047] Also, regarding an evaluation of strength, it measured tensile shear strength for each of a plurality of test specimens that the resultant friction material substrates were cut into as 20 mm×20 mm at a tensile speed of 5 mm/min. The test result is shown in FIG. 2 . As shown in FIG. 2 , friction material substrates according to four kinds of compositions of the first example to the fourth example have a shear strength which is the same or more than that of friction material substrates according to compositions of the second comparative example and the fifth comparative example, and it has a higher shear strength than friction material substrates according to the third comparative example and the fourth comparative example.
[0048] As the evaluation result, the friction material substrates according to compositions of the first example to the fourth example of this embodiment are greater in the disengagement feature and the shear strength also compared with the friction material substrates according to compositions of the first comparative example to the fifth comparative example in case of using the segment-type friction material and the ring-shaped friction material. Especially, as shown in lower stage of TABLE 1, it found that it is preferable to use zinc oxide (inorganic filler C) of the average particle size 0.6 μm, the absolute specific gravity 5.5, and the Moh's hardness 5 or barium sulfate (inorganic filler D) of the average particle size 10 μm, the absolute specific gravity 4.2, and the Moh's hardness 3 as an inorganic filler.
[0049] For this reason, as shown in FIG. 3 a, according to the compositions of the first comparative example to the fifth comparative example, regarding conventional friction material substrates 6 , the absolute specific gravity of used inorganic filler 7 there is low and it is bulky, therefore that fills a gap of inter-fiber 3 and pore diameter 8 becomes small. In contrast, as shown in FIG. 3 b, according to the compositions of the first example to the fourth example, regarding friction material substrates 1 , the absolute specific gravity of used inorganic filler 2 there is high and the average particle size is small, therefore it attaches the inorganic filler 2 to the inter-fiber 3 and can obtain an effect to improve the strength of the friction material substrates 1 by connecting the inter-fiber 3 when hardening the impregnated resin as well as increasing the pore diameter 5 , which is considered as a reason above.
[0050] Consequently, it compared a pore diameter distribution of friction material substrates according to compositions of the first example and the second example of this embodiment to a pore diameter distribution of friction material substrates according to compositions of the first comparative example and the fourth comparative example. The pore diameter distribution is measured by mercury intrusion technique and the test result is shown in FIG. 4 . As shown in FIG. 4 , a peak of the pore diameter distribution of friction material substrates according to the first example and the second example is located at a side where the pore diameter is large. In contrast, a peak of the pore diameter distribution of friction material substrates according to the first comparative example and the fourth comparative example is located at a portion where the pore diameter is less than 1 μm.
[0051] Additionally, the pore diameter distribution of friction material substrates according to the first example and the second example is to be broad compared to the pore diameter distribution of friction material substrates according to the first comparative example and the fourth comparative example. And in the friction material substrates according to the composition of the first example, the peak of the pore diameter distribution locates at a portion around 12 μm, and in the friction material substrates according to the second example of this embodiment, the peak of the pore diameter distribution locates at a portion around 3.5 μm each. Therefore, the peak of the pore diameter distribution of the friction material substrates according to the first example and the second example measured by mercury intrusion technique is within a range of 1 μm to 20 μm.
[0052] This made faster to absorb ATF from the friction surface, therefore it improves the disengagement feature. Moreover, there is provided a wet friction material that is greater in the positive μ-V slope characteristic as well as reducing the drag torque by the rapid absorption of ATF from the friction surface.
[0053] In this embodiment, an example making use of a phenolic resin powder as a thermosettig resin is described, however, it can also use other powdery or not powdery thermosetting resins such as modified phenolic resin or epoxy resin. Especially, these phenolic resins, modified phenolic resin, epoxy resin are easily obtainable and greater in the heat resistance, therefore those are preferable as a thermosetting resin of a material of the wet friction material.
[0054] Moreover, a case of a wet friction material that a number of oil grooves is 40 per one side is described, however, the number of the oil grooves is not limited to 40 and it can set freely according to required characteristics.
[0055] Furthermore, in this embodiment, a case to make friction material substrates by that it makes a paper body containing a filler component which includes a fiber component and inorganic filler, and it impregnates this paper body with a thermosetting resin and then makes it harden by heat to form is described. However, it is also available to make friction material substrates by that after adding inorganic filler which is a remnant of a filler component to a paper body which is made by that a part of the fiber component and the filler component is carried out papermaking, it impregnates the thermosetting resin and makes it harden by heat to form. Otherwise, it is possible to make friction material substrates by that it impregnates the paper body which is made by that a part of the fiber component and the filler component is carried out papermaking with a thermosetting resin added the inorganic filler which is a remnant of the filler component and then makes it harden by heat to form.
[0056] In the practice of this invention, it is not limited to each embodiment regarding a structure, a component, a composition quantity, a material, a dimension, a production method or the like of other portions of the wet friction material.
[0057] Also, the numeric value which is described in the embodiment of this invention is not anything to indicate a critical value, but to indicate the preferred value that is suitable for enforcement. Therefore, it is not anything to deny the enforcement even if the numeric value mentioned above is changed a little. | In a wet friction material, to be able to reduce a drag torque, while being greater in a disengagement feature and a positive μ-V slope characteristic by keeping a pore diameter large without generating strength reduction or increase in settling quantity.
By adding small-particle inorganic filler 2, it attaches the inorganic filler 2 to inter-fiber 3 and it can obtain an effect to improve strength of friction material substrates 1 by connecting the inter-fiber 3 when an impregnated resin is hardened. Moreover, by keeping an absolute specific gravity of the inorganic filler 2, its compounded capacity becomes small and it can secure a pore diameter 5 of the friction material substrates 1 without being filled in pores of the friction material substrates 1 with the inorganic filler 2. As a result, it makes faster to absorb ATF from a friction surface. Therefore, it improves the disengagement feature and the positive μ-V slope characteristic, while reducing the drag torque. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a seal for a chambered doctor blade of a printing machine, in the form of a rubber-elastic body, which is inserted at the end of the chambered doctor blade in a seal holder and, with an obliquely applied lip, lies against the periphery of a roller, in contact with which the chambered doctor blade is placed.
A chambered doctor blade is used, for example, in a flexographic printing machine, for inking an anilox roller, which then, in turn, transfers the printing ink to the block of the printing cylinder. The chambered doctor blade forms a chamber, which extends in the longitudinal direction of the anilox roller, is filled with printing ink during the printing operation and is bounded on the side, facing the anilox roller, by two doctor blades, which are placed at an angle against the periphery of the anilox roller. The seals, which form the object of the invention, are intended to close off the chamber tightly at both ends. Consequently, the seal must lie against the peripheral surface of the rotating anilox roller and is consequently exposed to appreciable mechanical stresses as well as to much wear. The stiffer the seal and the greater the force, with which it is pressed against the anilox roller, the higher is the sealing action and the greater is also the wear resulting from the friction of the anilox roller. Conversely, if the seal is relatively soft, leaks can occur not only at the contact line between the anilox roller and the seal, but also between the seal and the seal holder. Furthermore, the sealing problem is made more difficult owing to the fact that, during the operation of the printing machine, there is wear of the doctor blades, so that the geometry of the cross section, which is to be sealed, is changed. The places, at which the seal, the anilox roller and the doctor blade adjoin one another, are particularly susceptible to leakage.
From the art, a seal of the type mentioned above is known, which has a continuous lip, set at an angle, on the side, facing the anilox roller, as well as on the side, facing the seal holder. The compliance of the lip can be adjusted by the inclination and profile of the lip, so that a suitable compromise is achieved between sealing properties, wear susceptibility and tolerance equalization.
SUMMARY OF THE INVENTION
It is an object of the invention, to improve the sealing properties of such a seal.
Pursuant to the invention, this objective is accomplished owing to the fact that the seal has a second lip, which forms a V-shaped cross section with the first.
Due to the second lip, a redundancy and, with that, an improvement in the sealing properties is achieved. In addition, the V-shaped configuration causes the two lips to contact the roller at an angle in opposite directions, so that the sensitivity with respect to changing mechanical stresses is reduced appreciably.
In practice, the seal frequently is exposed to a changing pressure gradient between the interior of the chambered doctor blade and the surroundings. During the printing operation, there is generally an overpressure in the chambered doctor blade. On the other hand, while the inking system is being cleaned and the chambered doctor blade is being flushed with a cleaning fluid, there is frequently a reduced pressure in the chamber. In the case of the inventive seal, these changing pressure stresses always have the effect that one of the lips is swiveled away from the anilox roller, so that its sealing action is reduced. However, to compensate for this, the other lip is pressed all the more tightly against the anilox roller. In this way, a high sealing effect is achieved, independently of the direction of the pressure gradient. Because of this effect, the seal is also less sensitive to changing stresses, which can come about, for example, due to an axial clearance of the anilox roller and/or the thermal expansion of the anilox roller.
Advantageous developments of the invention arise out of the dependent claims.
Preferably, the lips are formed not only in the part of the seal, which is in contact with the anilox roller, but also in the parts, which are in contact with the doctor blade. A high compliance of the seal is achieved in this way, particularly at the points, at which the peripheral surface of the anilox roller, the sealing lip and one of the doctor blades coincide, so that the sealing lip can also adapt itself well to any wear at the doctor blade.
In a particularly preferred embodiment, the contact lines, made by the two sealing lips with the peripheral surface of the anilox roller, run parallel to one another, whereas the contact lines in the region of the doctor blade diverge obliquely to the outside. The sealing lips are under a slight pressure at the periphery of the anilox roller and at the doctor blades and, as a result, are bent apart slightly. If there is wear at the edge of the doctor blade, the obliquely diverging parts of the contact lines of the sealing lips with the anilox roller come into frictional contact and the frictional forces ensure that the sealing lips in this region are restored somewhat to the upright position once again in this region. In this way, good contact of the sealing lip with the anilox roller and with the doctor blade is achieved especially at the point, at which the peripheral surface of the rotating anilox roller runs out at an acute angle onto the doctor blade. Good contact of the sealing lip is particularly important especially at this point, because the printing ink is carried along by the rotating anilox roller and pushes against the edge of the doctor blade, so that good sealing against the dynamic pressure of the printing ink is required at this point.
The above-described course of the contact lines of the sealing lips at the anilox roller and at the doctor blades is achieved preferably owing to the fact that the seal, in its part facing the anilox roller, tapers in pyramid fashion towards the anilox roller. At the same time, this has the advantage that the parts of the sealing lips lying in contact with the anilox roller can be bent apart more or less, depending on the contacting force, without coming up against the walls of the seal holder.
At the inner sides, the two sealing lips preferably are bounded by a V-shaped notch, which passes in the peripheral direction of the anilox roller through the seal. Since the surface regions of the seal, on which the two doctor blades rest, brace obliquely from the periphery of the anilox roller, the notch in these regions runs out into an acute angle, so that the cross section of the sealing lips increases progressively from here to the ends of the seal. In this way, the stiffness of the sealing lips is controlled so that the latter, are relatively compliant in the region of the anilox roller and at the transitions between the anilox roller and the doctor blades and become stiffer in the regions, which support the doctor blades, so that a firm contact with the stationery doctor blades is achieved.
At the outside of the seal, the sealing lips are bounded preferably by pockets, which are constructed in the flanks of the tapering part of the seal and also extend into the regions, in which the seal is in contact with the doctor blades. The stiffness of the sealing lips can be adjusted, as required, by means of the geometry of these pockets.
Preferably, each of the two sealing lips has, on the inside, an auxiliary sealing lip, which extends at a small distance from and parallel to the main ridge and ensures additional sealing in the region of the peripheral surface of the anilox roller.
The part of the seal, taken up in the seal holder, preferably is constructed as a solid, rectangular block, which is surrounded at the two longitudinal sides and at one end face by an assemblage of continuous tolerance equalization lips, which compensate for the clearance between the sealing body and the seal holder. On the other end face and, moreover, on the side, which is located in the direction of rotation of the anilox roller, the seal is supported, on the other hand, over the whole of its surface at the wall of the chambered doctor blade. Due to frictional forces, the rotating anilox roller has the tendency to carry along the seal in the direction of rotation, so that the seal is pressed firmly against the wall in question of the chambered doctor blade. At this place, the contact of the seal over its whole surface has the advantage that the supporting forces can be absorbed stably. On the other hand, at the three remaining sides, at which the tolerance equalization lips are formed, the seal behaves more softly, so that good sealing at the inner surface of the seal holder is achieved over the whole periphery.
In addition, at least at the end face, the seal has a rib, which extends at right angles to the tolerance equalization lips there and blocks the grooves formed between the tolerance equalization lips and thus prevents printing ink flowing around the seal in these grooves. On the opposite end face, on which the whole surface of the seal lies in contact with the chambered doctor blade, a corresponding rib can be formed by the joint seam, which is formed anyhow during the production of the seal with the help of a two-part mold. In this way, a reliable seal is ensured also here.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of the invention is explained in greater detail in the following by means of the drawing, in which
FIG. 1 shows a section through a chambered doctor blade with an inventive seal;
FIG. 2 shows a section along the line II—II of FIG. 1;
FIG. 3 shows a side view of the seal;
FIG. 4 shows an enlarged section along with line IV—IV in FIG. 3; and
FIG. 5 shows the seal of FIG. 3 in plan view.
DETAILED DESCRIPTION
FIG. 1 shows a cross section of a chambered doctor blade 10 , which is in contact with the periphery of an anilox roller 12 rotating in the clockwise direction. The chambered doctor blade 10 has a gutter profile, by means of which a chamber 14 is bounded, which is closed off at the side, facing the anilox roller 12 , by two doctor blades 16 , which are disposed in roof-shaped fashion, as well as by the peripheral surface of the anilox roller 12 . The doctor blade 16 scrapes along the periphery of the anilox roller 12 with one edge.
The chamber 14 is closed off at both ends by a seal holder 18 and by a seal 20 , which is inserted therein. The seal holder 18 is fitted liquid-tight into the gutter profile of the chamber 14 and, in turn, forms a U-shaped gutter, which extends transversely to this gutter profile and into which the seal 20 is inserted, as can be seen more clearly in FIG. 2 .
The seal 20 consists of a rubber-elastic material with Shore hardness of 60 to 90 and preferably of 80 and forms a rectangular support 22 , which is fitted tightly into the cavity bounded by the seal holder 18 and the walls of the chamber 14 . On the upper side, that is, on the side facing the anilox roller 12 , the seal forms two lips 24 , which extend in the peripheral direction of the anilox roller 12 , are constructed symmetrically to one another and together form a V-shaped cross section. These lips 24 lie against the peripheral surface of the anilox roller 12 as well as against the inner surfaces of the doctor blade 16 , forming a seal. The angle between the lips 24 and the surface of the support 22 in each case is about 50° so that the lips enclose an angle of about 80° with one another.
The seal 20 is shown in detail in FIGS. 3 to 5 . In the side view of FIG. 3, the lips 24 in each case have a concave middle part 26 , which is adapted to the curvature of the anilox roller 12 . Adjoining each end of the middle part, there is a linear supporting zone 28 for the doctor blade 16 in question. At the transitions between the middle part 26 and the supporting zones 28 , the main ridge of each lip forms an obtuse-angled crest 30 , which, in the ideal case, lies at the place at which the edge of the doctor blade contacts the anilox roller. In practice, however, this point cannot be determined with sufficient accuracy, because the doctor blade is subject to wear during the printing operation.
On the outside, the lips 24 are bounded in each case by a pocket 32 , which follows the contour of the concave middle part 26 ; however, it extends also some distance below the supporting zones 28 .
As shown by FIG. 4, the two lips 24 are bounded on the inside by a V-shaped notch 34 , which, following the curvature of the concave middle part 26 , passes through the center of the seal and at the bottom of which there is a deeper and narrower groove 36 . The stiffness of the lips 24 can be adjusted by the cross section of the notch 34 and the depth of the groove 36 .
Furthermore, each lip 24 also has a somewhat shorter auxiliary lip 38 on the inside of its main ridge. When the chamber doctor blade 10 is placed against the anilox roller and the lips 24 contact the anilox roller 12 and the doctor blades 16 with a slight pressure, the auxiliary lips are bent somewhat apart. In this way, the auxiliary lips 38 come into contact with the peripheral surface of the anilox roller 12 , at least when there has been some wear of the main ridges.
FIG. 4 furthermore shows that the part of the seal 20 , which forms the lips 24 , at least in the concave middle part 26 , has a smaller width than does the support 22 . As can be seen more clearly in the plan view of FIG. 5, this lesser width comes about owing to the fact that the part of the seal 20 , which forms the lips 24 , tapers as a whole in pyramid fashion towards the top. The supporting zones 28 therefore have a trapezoidal configuration.
As can furthermore be seen in FIG. 5, the main ridges of the lips 24 change over into the supporting zones 28 in a slightly raised edge 40 , which extends continuously over the whole of the peripheral edge of the seal. With their main ridges and the edge 40 , the two lips 24 accordingly form a closed contact line, with which they lie tightly against the anilox roller and against the two doctor blades.
The V-shaped notch 34 runs out in the supporting zones 28 into the oblique, flat, trapezoidal surfaces of the seal and therefore decreases there in width, so that the cross section and, with that, the hardness of the lips 24 increase correspondingly towards the ends. In this way, on the one hand a sufficient hardness of the lips is achieved in the zones, which support the doctor blades 16 . On the other, a sufficient compliance is achieved especially at the crests 30 , so that the lips 24 can adapt there to the transition places between the periphery of the anilox roller and the doctor blades.
On an end face, at the left in FIGS. 3 and 5, the support 22 forms a smooth surface 42 , with which the seal is supported stably and over the whole surface at the wall of the chamber 14 , when it is exposed to the frictional forces of the rotating anilox roller 12 . At the three remaining sides, the support 22 is surrounded by several continuous tolerance equalization ribs 44 , which are separated from one another by grooves 46 . The tolerance equalization ribs 44 compensate for dimensional tolerances between the seal 20 and the seal holder 18 , so that the support 22 of the seal can be impressed easily and, nevertheless, tightly into the seal holder 18 . At the end face, which is opposite to the smooth surface 42 , the grooves 46 are interrupted by a rib 48 . Should the printing ink have penetrated into the grooves 46 , it is prevented by rib 48 from flowing from the inside, facing the chamber 14 , to the outside of the seal into the groove 46 .
On the opposite end face, 42 , a flat rib 50 has a similar function. In contact with the wall of the chamber 14 , the flat rib is pressed flat, so that the sealing effect is increased without affecting the stable support of the seal at this wall.
The seal 20 preferably is a molded part, which is prepared by injection molding. The rib 50 can then be formed simply by a parting ridge between the two halves of the mold.
At the lower edge, the support 22 has a continuous chamfer or channel 52 , which enables the seal 20 to be seated correctly in the seal holder 18 even when dried ink residues have collected in the inner edges of the seal holder. | A seal for a chambered doctor blade ( 10 ) of a printing machine, in the form of a rubber-elastic body, which is inserted at the end of the chambered doctor blade in a seal holder ( 18 ) and, with an obliquely applied lip ( 24 ), lies against the periphery of a roller ( 12 ), against which the chambered doctor blade is placed, wherein the seal ( 20 ) has a second lip ( 24 ), which forms a V-shaped cross section with the first. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority under 35 U.S.C §119 with respect to Japanese Patent Application 2008-064438, filed on Mar. 13, 2008, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to an air conditioning system and an accumulator thereof. In particular, the invention relates to an air conditioning system having a compressor and a liquid pump, more particularly, the invention relates to an air conditioning system, using a two phase refrigerant, and an accumulator thereof. Furthermore, the invention relates to an air conditioning system including a compressor, which is able to compress the two phase refrigerant, and an accumulator.
BACKGROUND
[0003] Recently, needs for conducting cooling operation even in wintertime arises for cooling rooms such as a computer room in which the temperature is high through a whole year. However, when cooling operation is conducted by a normal air conditioner having only a heat pump, i.e. a compressor, under the condition that the temperature of the outdoor air is lower than the room temperature (hereinafter, referred to as low temperature cooling operation), drawbacks occurs. For example, a difference between high and low pressures of the refrigerant is not sufficiently generated, a limitation exists for lowering the rotation number of the compressor, or the operation efficiency deteriorates.
[0004] According to JP 2000-193327A (for example, FIG. 1 ), an air conditioning system, conducting normal cooling operation only by using a compressor and conducting the low temperature cooling operation only by using a liquid pump, is disclosed. Specifically, when conducting the normal cooling, an on-off valve of the compressor side is released and an on-off valve of the liquid pump side is closed. Consequently, the refrigerant is supplied only to the compressor side and thus the normal cooling is operated only by the compressor. On the other hand, when conducting the low temperature cooling operation, the on-off valve of the compressor side is closed and the on-off valve of the liquid pump is released. Consequently, the refrigerant is supplied only to the liquid pump side and thus the low temperature cooling operation is conducted only by the liquid pump. Generally, the power required for driving a liquid pump is approximately one tenth of that of the compressor.
[0005] In JP 2006-322617A, another type of air conditioning system is disclosed. Referring to FIG. 1 of JP 2006-322617A, the compressor is connected in series with the liquid pump. More specifically, the compressor, the outdoor heat exchanger, the outdoor expansion valve, the receiver, the liquid pump, the liquid flow connecting pipe, the indoor heat exchanger, and the indoor expansion valve are connected in the stated order, and an electromagnetic valve connects in parallel with the liquid pump. When conducting the cooling operation by the compressor, the electromagnetic valve is released and the refrigerant is not supplied to the liquid pump. In case that natural circulating operation is conducted when the temperature of the outdoor air is low, the electromagnetic valve is closed and the refrigerant is supplied to the liquid pump.
[0006] Further, another type of air conditioning system is disclosed in JP 2006-322617A. Referring to FIG. 4 , the compressor is connected with the gas refrigerant side of the gas-liquid two phase receiver and the liquid pump is connected with the liquid refrigerant of the receiver, thus connecting the compressor in parallel with the liquid pump. Meanwhile, a circuit diagram of the overall system corresponding to FIG. 4 is not shown, and a circuit diagram and a control configuration used for operating the compressor and the liquid pump simultaneously are not disclosed in JP 2006-322617A.
[0007] In JP 2002-106986A, another type of air conditioning system, which selects the operating mode according to the temperature of the outdoor air during cooling operation, is disclosed. The cooling operation is conducted by operating one of the compressor and the liquid pump or operating the compressor and the liquid pump alternately. Further, another air conditioning system is disclosed in JP 2002-106986A, the air conditioning system includes a valve opening control means and a liquid pump rotation number controlling means for increasing the refrigerant flow circulated during the operation of the liquid pump.
[0008] Further, in association with detecting the liquid surface of the refrigerant in the accumulator, another type of air conditioning system is disclosed in JP H1-107071A. The air condition system includes an inlet pipe for supplying the refrigerant into the accumulator and further includes an outlet pipe and a bypass pipe. One end of the outlet pipe inserts into the accumulator and opens above the refrigerant liquid surface and the other end connects with a suction line of the compressor. One end of the bypass pipe opens on an inner wall surface of the accumulator and the other end thereof connects with the suction line of the compressor. A first heater and a temperature sensor are installed at the inlet pipe, and a second heater and a temperature sensor are installed at the bypass line. The air conditioning system estimates the level of the refrigerant liquid surface based on the first and second heater control and the detection results of the first and second temperature sensors.
[0009] According to JP H4-222366A, JP H8-49930A, and JP H8-296908A, another type of air conditioning system is disclosed. The air conditioning system estimates a level of the refrigerant liquid surface in the accumulator by using a sensor, such as an optical sensor, installed in the accumulator.
[0010] The air conditioning system disclosed in JP2000-193327A is configured so that the compressor, which mainly operates the cooling, is deactivated and the cooling operation is conducted only by the liquid pump during the low temperature cooling operation, thus improving cooling efficiency. On the other hand, when conducting the normal cooling operation, the liquid pump is not used. Therefore, the air conditioning system disclosed in JP2000-193327A has a drawback that value=function/cost is low.
[0011] The air conditioning system shown in FIG. 1 of JP 2006-322617A has a similar drawback as JP 2000-193327A. As described above, the overall circuit diagram, corresponding to the air conditioning system in which the compressor is connected in parallel with the liquid pump, is not disclosed in JP 2006-322617A. Further, the circuit diagram and the control configuration of the air conditioning system, operating the compressor and the liquid pump simultaneously, are not disclosed.
[0012] The air conditioning system disclosed in JP 2002-106986A has a similar drawback as JP 2000-193327A. Further, according to JP 2002-106986A, the air conditioning system increases the flow of the refrigerant circulating in the system at the time of the liquid pump operation. However, the liquid pump is operated without taking the degree of superheat and dryness of the refrigerant into account. Thus, limitation exists on the efficiency improvement.
[0013] The refrigerant liquid surface detection is configured redundantly in the air conditioning systems disclosed in JP H1-107071A, JP H4-222366A, JP H8-49930A, and JP H8-296908A. Specifically, according to JP H1-107071A, the bypass pipe is newly provided to the air conditioning system in addition to the inlet pipe and the outlet pipe of the accumulator. An optical liquid surface detection sensor is provided at the accumulator of the air conditioning systems in JP H4-222366A, JP H8-49930A, and JP H8-296908A.
[0014] A need exists for an air conditioning system and an accumulator which are not susceptible to the drawback mentioned above.
[0015] Further, a need exists for an air conditioning system using the two phase refrigerant, which promptly detects a liquid surface of the refrigerant in an accumulator with a simple configuration and contributes to improvement of an operation efficiency during the low temperature cooling operation.
SUMMARY OF THE INVENTION
[0016] An aspect of the present invention provides an air conditioning system which has an outdoor heat exchanger and an indoor heat exchanger between which a refrigerant circulates to effect a heat exchange between the refrigerant and outdoor air at the outdoor heat-exchanger and to effect another heat exchange between the refrigerant and indoor air at the indoor heat exchanger and which includes a compressor sucking the refrigerant to compress and discharging resultant refrigerant, a liquid pump sucking the refrigerant to discharge, an expansion valve expanding the refrigerant, and an accumulator serving for gas-liquid separation of the refrigerant and accumulating the refrigerant in gas-phase, wherein when the compressor is brought into operation for indoor air cooling, the compressor, the outdoor heat exchanger, the expansion valve, the indoor heat exchanger, and the accumulator are connected in such an order to circulate the refrigerant therethrough, wherein suction lines of the respective compressor and liquid pump are in parallel to suck the refrigerant from the accumulator, and wherein when the compressor and the liquid pump are concurrently operated for indoor air cooling, a discharge line of the liquid pump is connected to the outdoor heat exchanger for discharging the refrigerant therefore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawings, wherein:
[0018] FIG. 1 is a circuit diagram of an air conditioning system according to a first embodiment of the invention;
[0019] FIG. 2A is a graph showing a relation between pressure and entropy when an air conditioning system shown in FIG. 1 is operated only by a compressor, and FIG. 2B is a graph showing a relation between pressure and entropy when operating the air conditioning system by the compressor and a liquid pump;
[0020] FIG. 3 is a circuit diagram of an air conditioning system according to a second embodiment of the invention;
[0021] FIG. 4 is a circuit diagram of an air conditioning system according to a third embodiment of the invention;
[0022] FIG. 5 is a structural diagram of a compressor having a reducing function for compressing liquid, which is used in the air conditioning system shown in FIG. 4 ;
[0023] FIG. 6 is a structure diagram of an accumulator having a liquid surface detection hole according to a fourth embodiment of the invention;
[0024] FIG. 7 is a structural diagram showing a modification of FIG. 6 ;
[0025] FIG. 8 is a graph showing a relation between a local heat transfer rate and degree of dryness; and
[0026] FIG. 9 is a graph showing a relation between the local heat transfer rate and liquid holdup.
DETAILED DESCRIPTION
[0027] In an air conditioning system according to embodiments, a compressor and a liquid pump are simultaneously operated at least in a predetermined mode. For example, when the low temperature cooling operation is conducted, in particular, when the operation is not properly conducted only by the liquid pump, the compressor and the liquid pump are simultaneously operated.
[0028] According to the embodiment, an air conditioning system includes a bypass circuit for switching the section, to which a discharge line of a liquid pump connects, from an outdoor heat exchanger side to an indoor heat exchanger side when the air conditioning system is operated only by the liquid pump. The bypass pipe enables the liquid pump, which requires smaller driving power in comparison with the compressor, to conduct the low temperature cooling operation, thus improving operation efficiency.
[0029] In the embodiment, a first detecting means includes a high-pressure sensor and a discharge temperature sensor. The high-pressure sensor detects the pressure of the refrigerant discharged from the compressor, and the discharge temperature sensor detects the temperature of the refrigerant (discharge temperature). The saturation temperature is calculated from the detected value of the high-pressure sensor, and the flow of the liquid pump is controlled based on a difference between the saturation temperature and the discharge temperature.
[0030] In the embodiment, the opening of a flow control valve is adjusted so that the refrigerant discharged from the compressor becomes equal to or approximates the saturation temperature. Thus, the refrigerant discharged from the compressor is efficiently condensed and liquefied in the outdoor heat exchanger during the cooling operation.
[0031] In the embodiment, the liquid pump is controlled so that the discharged pressure of the liquid pump becomes equal to or approximates the discharged pressure of the compressor. The control prevents back-flow or pulsation of the refrigerant. An axial pump is used as the liquid pump and the discharge pressure of the liquid pump is adjusted by controlling the rotation number.
[0032] According to the embodiment, the air conditioning system includes a second detecting means and an expansion valve which connects with the circuit between the outdoor heat exchanger and the indoor heat exchanger. The second detecting means detects the state quantity of the refrigerant suctioned into the compressor, and the opening of the expansion valve is adjusted based on the detection result of the second detecting means. The adjustment allows the expansion valve to adjust the degree of superheat or the degree of dryness of the two phase flow refrigerant evaporated in the indoor heat exchanger during the cooling. The second detecting means includes a low-pressure sensor and a heat exchanger outlet temperature sensor. The low-pressure sensor detects a pressure of the refrigerant suctioned into the compressor, and the heat exchanger outlet temperature sensor detects the temperature of the refrigerant (suction temperature). The saturation temperature is calculated from the detected value of the high-pressure sensor, and the opening of the expansion valve is controlled based on a difference between the saturation temperature and the heat exchanger outlet temperature.
[0033] In the embodiment, when the compressor and the liquid pump are simultaneously operated, the opening of the expansion valve is adjusted so as to be larger, compared to when only the compressor is operated. In this mode, the expansion valve may be adjusted so that the degree of superheat of the indoor heat exchanger is approximately 0 degree.
[0034] In the embodiment, the compressor is able to compress the liquid refrigerant as well as the gas refrigerant. When the refrigerant is excessively compressed, the compressor releases the refrigerant. This type of compressor may be used in air conditioning systems in which the compressor and the liquid pump connect in parallel with the accumulator, and the liquefied refrigerant may be suctioned into the compressor or a predefined or greater amount of the refrigerant may be suctioned into the compressor. Further, this type of compressor may be used in air conditioning systems in which a liquid surface detection hole is provided at an outlet pipe of an accumulator, connecting with a suction line of the compressor. In particular, the compressor may be used in the air conditioning system in which the liquefied refrigerant is introduced into the suction line of the compressor via the liquid surface detection hole and the outlet pipe with which the liquid surface detection hole communicates, depending on the level of the refrigerant liquid surface in the accumulator.
First Embodiment
[0035] Hereinafter, a first embodiment will be described with reference to drawings. FIG. 1 is a circuit diagram of an air conditioning system according to the first embodiment.
[0036] Referring to FIG. 1 , the air conditioning system according to the first embodiment circulates a refrigerant between an indoor heat exchanger 1 and an outdoor heat exchanger 2 . The indoor heat exchanger 1 conducts heat exchange between the refrigerant and the indoor air, and the outdoor heat exchanger 2 conducts heat exchange between the refrigerant and the outdoor air. The air conditioning system includes a compressor 3 , a liquid pump 4 discharging the suctioned refrigerant, an expansion valve 5 expanding the refrigerant, and an accumulator 6 . The compressor 3 compresses the suctioned refrigerant to discharge, and the accumulator 6 separates the refrigerant into gas and liquid and accumulates the refrigerant.
[0037] At least when the cooling is conducted, the compressor 3 , the outdoor heat exchanger 2 serving as a condenser, the expansion valve 5 , the indoor heat exchanger 1 serving as an evaporator, and the accumulator 6 are connected by refrigerant pipes P so that the refrigerant circulates through the elements in the stated order. A suction line 11 of the compressor 3 and a suction line 12 of the liquid pump 4 connect in parallel with the accumulator 6 . At least when the compressor 3 and the liquid pump 4 are simultaneously operated during the cooling operation, a discharge line 14 of the liquid pump 4 connects with the outdoor heat exchanger 2 through a common line 15 which is also used for connecting the compressor 3 with the outdoor heat exchanger 2 .
[0038] The accumulator 6 includes an inlet pipe 7 , from which the refrigerant enters, and the inlet pipe 7 connects with the indoor heat exchanger 1 . The accumulator 6 further includes first and second outlet pipes 8 and 9 . One end of the first outlet pipe 8 inserts into the accumulator 6 so as to open above a liquid surface of the refrigerant reserved in the accumulator 6 and the other end connects with the suction line 11 of the compressor 3 . On the other hand, one end of the second outlet pipe 9 inserts into the accumulator 6 so as to open below the liquid surface of the refrigerant reserved in the accumulator 6 and the other end connects with the suction line 12 of the liquid pump 4 .
[0039] The air conditioning system includes a high-pressure sensor 21 and a discharge temperature sensor 22 , which serve as a first detecting means 20 for detecting the state quantity of the refrigerant discharged from the compressor 3 . The high-pressure sensor 21 detects a pressure of the refrigerant discharged from the compressor 3 or the liquid pump 4 and the discharge temperature sensor 22 detects the temperature of the refrigerant (discharge temperature). The air conditioning system further includes a low-pressure sensor 24 and a heat exchanger outlet temperature sensor 25 , which serve as a second detecting means 23 for detecting the state quantity of the refrigerant suctioned into the compressor 3 . The high-pressure sensor 24 detects a pressure of the refrigerant suctioned into the compressor 3 , and the heat exchanger outlet temperature sensor 25 detects the temperature of the refrigerant suctioned into the compressor 3 (suction temperature).
[0040] Further, a flow control valve 10 connects in series with the circuit between the accumulator 6 and the liquid pump 4 for controlling the refrigerant flow discharged from the liquid pump 4 . The flow control valve 10 controls the refrigerant flow based on a difference between a saturation temperature calculated from the detection result of the high-pressure sensor 21 and a discharge temperature detected by the discharge temperature sensor 22 , thus adjusting the degree of superheat of the two phase refrigerant flow which is condensed in the outdoor heat exchanger 2 during the cooling operation.
[0041] The opening of the expansion valve 5 is controlled based on a difference between a saturation temperature calculated from detection result of the low-pressure sensor 24 and an outlet temperature of the indoor heat exchanger 1 detected by the heat exchanger outlet temperature sensor 25 , thus adjusting the degree of dryness of the two phase refrigerant flow which is evaporated during the cooling operation.
[0042] Each control means of the flow control valve 10 and the expansion valve 5 is made of a central control means, a control valve, and the like. The central control means receives detection signals output from each sensor 21 , 22 , 23 , 24 and outputs predetermined control signals based on the detection signals. The control valves are respectively attached to the flow control valve 10 and the expansion valve 5 to adjust the opening based on the control signals.
[0043] [Operating Only the Compressor During the Normal Cooling]
[0044] The operation of the air conditioning system according to the foregoing first embodiment will be described with reference to FIG. 1 . Firstly, a case that the cooling operation is conducted only by the compressor 3 will be described. The refrigerant is separated into a gas refrigerant and a liquid refrigerant by the accumulator 6 . Generally, the gas refrigerant containing 5 to 10 degrees of superheat is suctioned into the compressor 3 through the first outlet pipe 8 and the suction line 11 . The gas refrigerant is adiabatically compressed in the compressor 3 (isentropic process and the like) and becomes a high temperature, high-pressure gas refrigerant. Then, the gas refrigerant is condensed in the outdoor heat exchanger 2 to be liquefied. The liquid refrigerant is depressurized by the expansion valve 5 disposed at the inlet side of the indoor heat exchanger 1 to become a two phase (the degree of dryness is approximately 0.2 degrees), low temperature refrigerant. The refrigerant is heated in the indoor heat exchanger 1 to evaporate, thereby lowering the room temperature. The two phase (the degree of dryness is approximately 0.2 degrees), low temperature refrigerant is gasified in the above-mentioned heating process, obtaining 5 to 10 degrees of superheat. Meanwhile, the degree of superheat in the foregoing description is obtained by adjusting the opening of the expansion valve 5 . The gasified refrigerant containing the 5 to 10 degrees of superheat returns the accumulator 6 to be separated into the gas and the liquid.
[0045] [Operating the Compressor and the Liquid Pump Simultaneously During the Low Temperature Cooling Operation]
[0046] Next, the operation of the air conditioning system, in which the compressor 3 and the liquid pump 4 are simultaneously operated during the low temperature cooling operation, will be described. The following controls are conducted in this mode.
[0047] (1) Firstly, the rotation number of the liquid pump 4 is adjusted so that the discharge pressure of the compressor 3 becomes equal to that of the liquid pump 4 .
[0048] (2) The flow of the liquid pump 4 is controlled by adjusting the opening of the flow control valve 10 so that the discharge temperature of the refrigerant, discharged from the compressor 3 and the liquid pump 4 to be supplied to the outdoor heat exchanger 2 , becomes equal to the saturated temperature of the gas. In other words, the flow of the liquid pump 4 is controlled so that the degree of superheat becomes smaller.
[0049] (3) The opening of the expansion valve 5 is adjusted so as to be larger, compared to when the air conditioning system is operated only by the compressor 3 . Specifically, the opening of the expansion valve 5 is adjusted so that the degree of superheat of the refrigerant becomes approximately 0 degree or the degree of dryness becomes 0.9 to 0.95 at the outlet of the indoor heat exchanger.
[0050] The operation of the air conditioning system in this mode will be described. The compressor 3 suctions the gas refrigerant in an upper portion of the accumulator 6 through the suction line 11 and discharges the gas refrigerant to the discharge line 13 after compression. At the same time, the liquid pump 4 suctions the liquid refrigerant in a lower portion of the accumulator 6 through the suction line 12 to increase the pressure. Subsequently, the liquid refrigerant is discharged to the discharge line 14 at the same level of the pressure as the compressor 3 . The discharged refrigerant is a saturated gas and thus the refrigerant is efficiently condensed and liquefied in the outdoor heat exchanger 2 .
[0051] The liquefied refrigerant is depressurized by the expansion valve 5 disposed at the inlet side of the indoor heat exchanger 1 to become a two phase (the degree of dryness is approximately 0.2 degrees), low temperature refrigerant. Subsequently, the refrigerant is heated in the indoor heat exchanger 1 to evaporate, thereby conducting the cooling operation. At that time, the degree of superheat becomes approximately 0 degree (the degree of dryness should be approximately 0.9 to 0.95 degrees). The refrigerant returns to the accumulator 6 to be separated into the gas and the liquid.
[0052] FIG. 2A is a graph showing a relation between pressure and enthalpy when the air conditioning system of FIG. 1 is operated only by the compressor, and FIG. 2B is a graph showing a relation between pressure and enthalpy when the air conditioning system of FIG. 1 is operated by the compressor and the liquid pump.
[0053] Comparing FIG. 2A with FIG. 2B , it can be seen that the following three effects are achieved by operating the compressor and the liquid pump simultaneously and the operation efficiency or coefficient of performance (COP) is improved.
(1) The liquid pump, requiring approximately one-tenth of driving power of the compressor, is used, thus reducing the power in the compression process between a and b. (2) The refrigerant flows into the outdoor heat exchanger (condenser) as the saturated gas, thus improving the condensation efficiency in the condensation process between b and c. (3) The refrigerant flows into the indoor heat exchanger (evaporator) containing a low degree of superheat, thus improving the evaporation efficiency in the evaporation process between d and a.
Second Embodiment
[0057] FIG. 3 is a circuit diagram of an air conditioning system according to a second embodiment of the invention. Referring to FIG. 3 , the air conditioning system according to the second embodiment includes a bypass circuit 19 . The bypass circuit 19 is used for switching the section, to which the discharge line 14 of the liquid pump 4 connects, from the outdoor heat exchanger 2 to the indoor heat exchanger when the air conditioning system is operated by the liquid pump 4 . Hereinafter, differences between the first and second embodiments will be mainly described. As for overlapped features and configurations, refer to the description of the first embodiment.
[0058] The air conditioning systems according to the first and second embodiments include a four way valve 16 , a non-return valve 17 , and an on-off valve 18 . The four way valve 16 connects with the circuit between the compressor 3 and the outdoor and indoor heat exchangers 1 and 2 to change the refrigerant flow when the operation is switched between heating and cooling operations. The non-return valve 17 connects with the circuit between the outdoor and indoor heat exchangers 1 and 2 . The on-off valve connects with the circuit between the discharge line 14 of the liquid pump 4 and the common line 15 .
[0059] The bypass circuit 19 includes a bypass pipe 19 a , a three way valve 19 b , and on-off valves 19 c and 19 d . The bypass pipe 19 a connects with the circuit between the liquid pump 4 and the expansion valve 5 . The three way valve 19 b switches the section, to which the indoor heat exchanger 1 connects, between the accumulator 6 and the outdoor heat exchanger 2 . The on-off valve 19 c connects with the bypass pipe 19 a , and the on-off valve 19 d connects the outdoor heat exchanger 2 with the accumulator 6 when the operation is conducted only by the liquid pump 4 .
[0060] When conducting the cooling operation, in particular, when the low temperature cooling operation is conducted only by the liquid pump 4 , the on-off valve 18 is closed and the on-off valves 19 c and 19 d are released. Further, the three way valve 19 b connects the indoor heat exchanger 1 with the outdoor heat exchanger 2 . In the connection, the refrigerant circulates through the liquid pump 4 , the expansion valve 5 , the indoor heat exchanger 1 , the three way valve 19 b , the outdoor heat exchanger 2 , and the accumulator 6 in the stated order.
[0061] According to the second embodiment, the operation other than the normal cooling and heating operation, such as the low temperature cooling operation, may be conducted only by the liquid pump requiring the driving power which is smaller than that of the compressor. For example, the cooling operation may be conducted only by the liquid pump when the temperature of the outdoor air is less than or equal to 10 degrees. Hence, the operation efficiency may be improved during the low temperature cooling operation.
Third Embodiment
[0062] FIG. 4 is a circuit diagram of an air conditioning system according to a third embodiment of the invention. FIG. 5 is a structure diagram of a compressor having a reducing function for enabling liquid compression. The compressor may be used in the air conditioning system shown in FIG. 4 . Hereinafter, differences between the third embodiment and the first and second embodiments will be mainly described. As for overlapped features and configurations, refer to the description of the first embodiment.
[0063] Comparing FIG. 1 with FIG. 4 , the air conditioning system according to the third embodiment shown in FIG. 4 is different from the air conditioning system according to the first embodiment shown in FIG. 1 in that the liquid pump 4 , the suction line 12 and the discharge line 14 for the liquid pump 4 are not included in the air conditioning system.
[0064] Referring to FIG. 5 , a liquid compressible scroll compressor 30 , which may be used in the air conditioning system of FIG. 4 , has a fixed wall 30 a , a movable wall 30 b , and a relief valve 30 c , which is attached to a chamber surrounded by the fixed wall 30 a and the movable wall 30 b . When the liquid refrigerant is excessively suctioned into the compressor 30 and excessive compression may be caused due to pressure increase, the relief valve 30 c opens automatically in response to the pressure increase for releasing the pressure to a predetermined line such as the suction line 11 or the discharge line 13 .
[0065] In the air conditioning system according to the third embodiment, even if the refrigerant has a high heat transfer rate in the indoor and outdoor heat exchangers 1 and 2 (condenser and evaporator), the compressor 30 is safely driven due to the reducing function to enable the liquid compression. Thus, the high efficiency operation is achieved without using the liquid pump.
[0066] In order to adjust the liquid refrigerant suctioned into the compressor 30 at a high level, an accumulator 6 shown in FIG. 6 , having a liquid surface detection hole 8 b , should be used. Details of the accumulator 6 will be described below.
Fourth Embodiment
[0067] FIG. 6 is a structural diagram of the accumulator according to a fourth embodiment, which has a liquid surface detection hole. The accumulator having the liquid surface detection hole 8 b may be used in the air conditioning systems shown in FIG. 1 , FIG. 2 , and FIG. 4 . In particular, the accumulator may be used in the air conditioning system shown in FIG. 4 , which includes the liquid compressible compressor shown in FIG. 5 .
[0068] In particular, referring to FIGS. 4 and 6 , the accumulator 6 according to the fourth embodiment may be used in the air conditioning system which circulates the refrigerant between the foregoing indoor and outdoor heat exchangers 1 and 2 by using the compressor shown in FIG. 5 , which has the reducing function. The accumulator 6 connects with the suction line 11 of the compressor between the indoor heat exchanger 1 and the outdoor heat exchanger 2 to separate the refrigerant into the gas and the liquid or accumulate the refrigerant.
[0069] The accumulator 6 includes the inlet pipe 7 , from which the refrigerant enters, and the inlet pipe 7 connects with the indoor heat exchanger 1 . The accumulator 6 further includes the first outlet pipe 8 having an opening 8 a . One end of the first outlet pipe 8 inserts into the accumulator 6 so that the opening 8 a opens above the liquid surface of the refrigerant reserved in the accumulator 6 . The other end of the first outlet pipe 8 connects with the suction line 11 of the compressor 30 .
[0070] The liquid surface detection hole 8 b is formed at a predetermined position of the first outlet pipe 8 and opens in the accumulator 6 . The liquefied refrigerant flows into the liquid surface detection hole 8 b depending on the liquid surface level of the refrigerant reserved in the accumulator 6 . The predetermined position is set so that the refrigerant liquid surface flows through the liquid surface detection hole 8 b depending on the operation state. Moreover, the position is set so that the degrees of superheat and dryness of the refrigerant are optimized. The first outlet pipe 8 further includes an oil return hole 8 c opening below the liquid surface of the refrigerant reserved in the accumulator 6 . The oil return hole 8 c opens in a position which is lower than the liquid surface detection hole 8 b.
[0071] Functions of the accumulator 6 according to the fourth embodiment and the air conditioning system including the accumulator 6 will be described. Referring to FIGS. 5 and 6 , when the liquid surface detection hole 8 b is positioned above the refrigerant liquid surface in the accumulator 6 , the liquid refrigerant is substantially prevented from flowing into the liquid surface detection hole 8 b.
[0072] On the other hand, when the liquid surface detection hole 8 b is positioned below the refrigerant liquid surface in the accumulator 6 , in other words, when a large amount of the refrigerant is reserved in the accumulator 6 and a small amount of the refrigerant circulates, the liquid refrigerant flows into the liquid surface detection hole 8 b and returns to the suction line 11 through the outlet pipe 8 to be suctioned into the compressor 30 shown in FIG. 5 . Thus, the two phase refrigerant flow, containing a low degree of superheat, is supplied to the outdoor heat exchanger 2 during the cooling operation, and the local heat transfer rate is improved in the condensation process. In addition, when the liquid refrigerant flows in the liquid surface detection hole 8 b during the cooling operation and the discharge temperature sensor 22 or the heat exchanger outlet temperature sensor 25 detects the excessive reduction of the temperature of the refrigerant suctioned into the compressor 30 , the opening of the expansion valve 5 is adjusted so as to be small. Then, the degree of superheat increases in the indoor heat exchanger 1 , thus preventing the compressor from suctioning the liquid refrigerant excessively.
[0073] When the liquid refrigerant accumulates in the suction line 11 of the compressor 3 , the refrigerant may be returned to the accumulator 6 through the liquid surface detection hole 8 b and the first outlet pipe 8 .
[0074] FIG. 7 is a structure diagram illustrating a modification of FIG. 6 . Referring to FIG. 7 , instead of a configuration in which the liquid surface detection hole 8 b is directly formed at the first outlet pipe 8 , a curved pipe 8 d connects with the first outlet pipe 8 and an opening of the curved pipe 8 d is used as the liquid surface detection hole 8 b.
[0075] The air conditioning systems according to the foregoing embodiments may be applied to stand-alone type air conditioning systems or multi type air conditioning systems.
[0076] According to the embodiment described above, the compressor 3 and the liquid pump 4 are operated simultaneously or individually by using one accumulator 6 in the air conditioning system. Thus, the operation efficiency is improved during the low temperature cooling operation with a simple configuration, exhibiting smaller loss. Further, the liquid refrigerant is discharged in the air conditioning system. Hence, the accumulator 6 needs only one third of the capacity of a known accumulator.
[0077] In a known air conditioning system having only a compressor 3 , the occurrence of the liquid pressure in the compressor 3 is prevented for protecting the compressor 3 . Specifically, the refrigerant suctioned into the compressor 3 , i.e. the refrigerant supplied from the indoor heat exchanger side to the compressor side, is excessively superheated to prevent the liquid compression.
[0078] On the other hand, in the air conditioning system according to the embodiment, the liquid pump 4 , which is able to discharge the liquid refrigerant, connects in parallel with the compressor 3 and the liquid pump 4 and the compressor 3 are simultaneously operated. This configuration allows the compressor 3 to avoid handling the refrigerant, which contains the low degree of superheat and is easily condensed. Even if the refrigerant, which is in a desirable damp state for heat transfer efficiency (the degree of dryness is less than or equal to 1, preferably, is 0.9 to 0.95) is supplied from the indoor heat exchanger 1 (evaporator) to the compressor 3 and the liquid pump 4 during the cooling operation, the liquid refrigerant and the gas refrigerant are respectively suctioned into the liquid pump 4 and the compressor 3 through the accumulator 6 . Thus, the liquid compression is prevented in the compressor 3 . When the compressor 3 , which is able to compress the two phase refrigerant flow, is used, the degree of superheat and the damp state of the refrigerant is more flexibly set. The reason that the operation efficiency is improved by the air conditioning system according the embodiment described above will be stated below. FIG. 8 is the graph showing the relation between the local heat transfer rate and the degree of dryness. FIG. 9 is the graph showing the relation between the local heat transfer rate and the liquid holdup.
[0079] Firstly, the heat transfer rate, i.e. an average heat transfer rate, is improved in the evaporation process (in the indoor heat exchanger 1 during the cooling operation). In the normal evaporation process, when the compressor 3 suctions the liquid refrigerant, damage may occur due to liquid compression in the compressor 3 . In order to prevent the damage, the expansion valve 5 is adjusted so that the degree of superheat is set to approximately 5 to 10 degrees. However, referring to the graph showing the relation between the local heat transfer rate and the degree of dryness in FIG. 8 , the local heat transfer rate (kW/m2·K) of the evaporator, i.e. the indoor heat exchanger 1 during the cooling operation, varies depending on the degree of superheat or the degree of dryness of the two phase refrigerant flow. Specifically, when the degree of dryness approximates 1, the local heat transfer rate rapidly lowers. Further, when the refrigerant contains the superheat, the local heat transfer rate further lowers. Namely, in order to improve the heat transfer rate in the evaporator (the indoor heat exchanger 1 ), the air conditioning system should be operated in the condition that the degree of dryness of the refrigerant is less than or equal to 0.1, in particular, 0.9 to 0.95. In the air conditioning system according to the embodiments, the refrigerant in the damp state (the degree of dryness is less than or equal to 1) is supplied to the compressor 3 and the liquid pump 4 . Furthermore, the refrigerant in the damp state may be compressed by the compressor 3 which is able to compress the two phase refrigerant.
[0080] Secondly, the heat transfer rate, i.e. an average heat transfer rate, is improved in the evaporation process (in the indoor heat exchanger 1 during the cooling operation). Referring to the graph showing the relation between the local heat transfer rate and the liquid holdup in FIG. 9 , as in the evaporation process, when the refrigerant contains a certain degree of superheat, the local heat transfer rate lowers. According to the embodiment, the refrigerant containing a comparatively small degree of superheat, which is easily condensed or saturated, is supplied to the condenser (the indoor heat exchanger 1 during the cooling operation) by using the liquid pump 4 . Therefore, the heat transfer rate is improved in the condenser.
[0081] Thirdly, the power for driving the compressor 3 is reduced. Normally, in order to obtain the same amount of the pressure increase, the liquid pump 4 requires the power which is approximately one tenth of that of the compressor 3 . Thus, comparing the use of the compressor 3 with the use of both the compressor 3 and the liquid pump 4 , or with the use of the liquid pump 4 , the efficiency is improved when the liquid pump 4 is used or when the compressor 3 and the liquid pump 4 are used.
[0082] According to the embodiment, when the liquid pump 4 is operated during the low temperature cooling operation, the flow of the liquid pump 4 is controlled based on the state quantity of the circulating refrigerant. Consequently, the temperature of the refrigerant, discharged from the liquid pump 4 or the compressor 3 and the liquid pump 4 to be supplied to the outdoor heat exchanger 2 (condenser), becomes equal to or approximates the saturated gas temperature. Thus, the condensation efficiency is improved and the operation efficiency is improved during the low temperature cooling operation. Further, since the existing detecting means, such as the high-pressure sensor 21 attached at the discharge line 13 of the compressor 3 , may be utilized. Therefore, the foregoing effects are achieved with a simple configuration.
[0083] According to the embodiment, the compressor 3 having the relief valve mechanism for releasing the pressure during the compression and compressing the liquid is used, and the accumulator 6 controls the supply amount of the liquid refrigerant to the compressor 3 . This configuration may improve the operation efficiency during the low temperature cooling operation without using the liquid pump 4 . The accumulator 6 accumulates the excessive liquid refrigerant and supplies the predetermined amount of the liquid refrigerant to the suction line 11 of the compressor 3 through the liquid surface detection hole 8 b . Hence, the proper amount of the liquid refrigerant is supplied to the compressor 3 , and the compressor 3 discharges the liquid refrigerant in the damp state, which is desirable for the heat transfer rate. As just described, in the air conditioning system according to the embodiment, the liquid refrigerant is discharged, thus reducing the capacity of the accumulator 6 to one third of the know accumulator.
[0084] According to the embodiment, the liquid surface detection hole 8 b is formed in the outlet pipe 8 of the accumulator 6 , and the pressure or the temperature of the refrigerant, circulated, suctioned, or discharged, varies between when the liquid surface detection hole 8 b is positioned above the refrigerant liquid surface in the accumulator 6 and when the liquid surface detection hole 8 b is positioned below the refrigerant liquid surface. Such variations are easily detected by the existing detecting means such as the high-pressure sensor 21 , the discharge temperature sensor 22 , the low-pressure sensor 24 or the heat exchanger outlet temperature sensor 25 . Thus, the accumulator 6 is configured so as to detect the refrigerant liquid surface level in the accumulator 6 with the simple configuration utilizing the existing components. Further, the flow or the rotation number of the liquid pump 4 , the rotation number of the compressor 3 , and the opening of the expansion valve 5 are controlled based on the detection result of the liquid surface. Hence, the refrigerant in the damp state, which is desirable for the heat transfer rate, is generated and the operation efficiency is improved during the low temperature cooling operation.
[0085] The principles, of the preferred embodiments and mode of operation of the present invention have been described in the foregoing specification. However, the invention, which is intended to be protected, is not to be construed as limited to the particular embodiment disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents that fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby. | An air conditioning system having an outdoor heat exchanger and an indoor heat exchanger between which a refrigerant circulates to effect a heat exchange between the refrigerant and outdoor air at the outdoor heat-exchanger and to effect another heat exchange between the refrigerant and indoor air at the indoor heat exchanger, the air conditioning system which includes a compressor sucking the refrigerant to compress and discharging the resulting refrigerant, a liquid pump sucking the refrigerant to discharge, an expansion valve expanding the refrigerant, and an accumulator serving for gas-liquid separation of the refrigerant and accumulating the refrigerant in liquid phase, wherein when the compressor is brought into operation for indoor air cooling, the compressor, the outdoor heat exchanger, the expansion valve, the indoor heat exchanger, and the accumulator are connected in such an order to circulate the refrigerant therethrough, wherein suction lines of the respective compressor and liquid pump are in parallel to suck the refrigerant from the accumulator, and wherein when the compressor and the liquid pump are concurrently operated for indoor air cooling, a discharge line of the liquid pump is connected to the outdoor heat exchanger for discharging the refrigerant therefrom. | 5 |
DESCRIPTION
[0001] 1. Technical Field
[0002] The present invention concerns the technical sector relating the construction and fitting of gratings to be placed across windows, doors and/or other openings. In particular, it relates to the technical sector relating the fitting of movable but stable gratings, for the protection of the opening they are applied to.
[0003] 2. Background Art
[0004] At present, security gratings across doors and/or windows are known, whose structure is characterized by a border frame over which vertical and/or horizontal axes are soldered, or otherwise fixed; this structure is then placed across the opening by embedding part of it inside the wall next to the opening.
[0005] The fitting of said structure involves an inevitable destructive action on the spans to be protected, in order to permit the insertion of hinges, or any part forming the grating, inside the stonewall and successively embed the grating support to the wall.
[0006] This process entails, besides a huge manual labour, a particular attention to the grating being parallel and perpendicular compared with the span, which, as it often happens especially in non-recent buildings, can be geometrically not regular. Said system, which is at present the only one known, has also the relevant drawback of being very expensive and needing the work of a skilled worker. In addition, once the grating has been fitted in the aforesaid way, it's difficult to remove it from its position and place it elsewhere, and even if one decides to do it anyway, it's necessary to destroy the wall in the part where the hinges have been walled.
DISCLOSURE OF INVENTION
[0007] The present invention aims at eliminating the above-mentioned and other drawbacks, supplying a fitting device essentially consisting of two telescopic elements, which support both the building part and the security grating, equipped with register elements that, if rotated, let the two sides of the telescopic parts lengthen, so that joining the ends of the span, they show the exact position of tracer for the drilling. Another facilitation is given by the eccentric construction of the supports, provided with this device, which will avoid possible linearity errors in the drilling. By analogous process, the upper element will be fixed by means of the double rotation of the register for the right and left extension, so as to correct the imperfections of the spans and to allow a perfect vertical alignment of the hinge and lock ferrules. Said system is still valid for different types of doors or windows, providing the appropriate building modifications that diversify the dimensions, but not the original solution of the invention.
[0008] The inventiveness and functionality of the present invention can be better understood by reading the following description and referring to the enclosed drawings.
[0009] Reduced to its essential structure and with reference to the figures of the enclosed drawings, a device for the construction and fitting of gratings, according to the invention, comprises:
[0010] Means to support the body of the grating, by a rectangular metallic tube ( 1 ) shorter than the horizontal or vertical span of the opening ( 2 ) across which it must be applied, which is the distance between the two horizontal or vertical jambs ( 3 ). Said tube is provided, along its longitudinal axis, with holes at a distance equivalent to the distance between hinge and lock of the window grating, inside which a number of metallic ferrules ( 4 ) are fitted, in order to contain the hinge and lock pivot and act as guide of the telescopic part of the device, since their length has been beforehand calculated to form inside a geometrically compatible guide (Sect. A-A of FIG. 2).
[0011] Means to regulate the length of the tube, by a notch ( 5 ) at the centre of the tube, where two registers ( 6 , 7 ) are inserted, which have respectively fitted a spiral rod ( 8 , 9 ) into the thread of the plugs ( 10 , 11 ) comprised in the inner part of the components ( 12 , 13 ) forming the extendable part of the system. These components, led both by the internal plane of the tubing body and, on the opposite side, by the ferrule ( 4 ) and the particular shape of the final part of the body of the invention, are pushed by independent rotation of the registers in extension or traction, so that these symmetrical movements allow a perfect position of the device at the centre of the span.
[0012] Means to block the registers, by two holes, made on the central body ( 1 ) at the vertical axis of the registers ( 6 , 7 ), able to block them by means of screws or other means, thanks to a suitable spiral drilling ( 16 ) made on the same registers, without causing bulk on the upper part of the device, which will comprise the grating door and/or window.
[0013] Means to apply the tube on the sides of the opening across which the grating must be placed, by wall pivots, consisting of a lock pivot ( 17 ) to which a support ( 23 ) is fixed, which permits the alignment and therefore the insertion of the ends ( 19 , 20 ) of the telescopic elements ( 13 , 12 ) constituted by an open ferrule embedded inside their ends.
[0014] Conveniently, in order to support the grating, the tubes to be applied to the window or other similar opening, are at least two, both placed horizontally or vertically across the opening to be protected and parallel each other.
[0015] Conveniently, on the surface of the tubes facing the inside of the opening across which the grating must be applied, there are a number of ferrules ( 4 ) comprising the hinge and lock pivot of the grating. Said grating is constructed in such a way that it can be either kept always closed or opened like a normal window, acting on the axis fixed on the lock pivot that works also as releasing element of the lock (FIG. 7).
[0016] Conveniently, the two registers ( 6 , 7 ) autonomously rotate, so allowing the user to extend or pull one of the two spiral rods ( 8 , 9 ) without causing effect on the other or vice versa. Conveniently, the two registers ( 6 , 7 ) can freely rotate around their central axis, causing the spiral rods ( 8 , 9 ), joint to them, rotate either in one direction or in the other, respectively extending or pulling the elements ( 12 , 13 ) connected to the ends of the rods opposite to the ones where the registers are applied.
[0017] Conveniently, once the registers have been rotated enough to make the spiral rods reach the desired extension, in order to avoid tampering or involuntary rotations, they are locked with suitable lock screws ( 15 ), type TSCE, which enter the holes ( 16 ) on the outer part of the same register.
[0018] Conveniently, the part of the tube where the lock screws are fixed is later covered with suitable metallic protection, in order to avoid tampering and not to alter the overall aesthetic of the tube.
[0019] Conveniently, in order to embed the tube in the wall, a lock pivot ( 17 ) must be applied to the wall on which the same tube must be fixed, being said pivot ( 17 ) possibly equipped, in the the walls are made of airbricks, with a clutch ( 18 ) that contains the injection of the pouring resin.
[0020] Conveniently, in order to avoid possible slight errors in the drilling, the support ( 23 ) has an eccentric hole (FIG. 4), so that, by rotating, it permits the perfect alignment and insertion of the final parts of the telescopic elements ( 19 , 20 ), which consist of an open ferrule embedded and soldered inside their ends.
[0021] We are now going to describe the fitting process.
[0022] Once the telescopic element has been centred, like in FIG. 2, we proceed with the tracing necessary to locate the drilling point for fixing the pivots to the wall. Rotating the registers, the telescopic parts will extend outside up to their insertion in the supports (FIG. 5).
[0023] In order to fit the upper telescopic element, the same grating ( 21 ) is used as natural locating apparatus. FIG. 6 shows how, by similar process, problems of alignment are solved, thanks to the possibility of the device to move independently along the horizontal axis, positioning in perfect vertical alignment for hinge and lock.
[0024] The versatility of the device is demonstrated in FIGS. 7, 8, 9 , 10 showing how this device can naturally suit several types of doors and/or windows, only by providing different position and number of the hinge/lock ferrules. FIG. 7 shows the fitting of a security grating across a simple one-shutter window. FIG. 8 shows the fitting of the same grating by a different method, using a third telescopic element ( 22 ) forming an upper fixed part. Even if in this case it's necessary to align three points per axis, the device will avoid possible errors of parallelism between the walls thanks to its automatic regulation.
[0025] Conveniently, the fitting of a security grating, according to the present invention, is carried out by means of two telescopic elements acting as fixing and supporting base of the same grating, through the following phases.
[0026] We insert, in the lower part of the opening, the telescopic element forming the base, which consists of a metallic section properly shaped and aesthetically compatible with the grating. We proceed extending the telescopic parts towards the walls, by means of two independent never-ending screw devices placed inside them. These elements, reaching the walls, acts as tracer for the following drilling that will be carried out avoiding possible linearity errors by means of the eccentric holes over the support connecting the telescopic element to the pivot fixed at the end. Then, once the spiral rod or sleeve has been inserted on the sides, we wait for the complete hardening of the suitable resin. The following insertion of the telescopic element will allow the lock of the same to the wall by means of the suitable registers. In a similar way, placing the shutter forming the grating on the fitted lower telescopic element, we'll proceed placing the upper telescopic element into the specific holes along the longitudinal axis of the device, properly equipped with metallic embedded ferrule that will act respectively as hinge and lock. By analogous process, we'll proceed with the tracing of the holes to be made on the sides of the opening by means of similar telescopic side extension of the device that, because of the independent extensions towards right or left, will avoid any possible irregularity of the span. Then, by equivalent process, we'll definitively fit the grating across the opening.
[0027] In practice, the constructing details may, however, vary as regards shape, size, position of elements, and type of materials used, but still remain within the range of the idea proposed as a solution and, consequently, within the limits of the protection granted by this patent for invention.
BRIEF DESCRIPTION OF DRAWINGS
[0028] [0028]FIG. 1 shows the exploded view of the device consisting of the telescopic element ( 1 ), the hinge-lock ferrules ( 4 ), the notch for the registers ( 5 ), the left ( 6 ) and right ( 7 ) extending registers, the left ( 8 ) and right ( 9 ) spiral rods, the left ( 10 ) and right ( 11 ) plugs with spiral hole, the rectangular left ( 10 ) and right ( 13 ) tube, the holes ( 14 ) for the TSCE screws ( 15 ) fixing the registers, the spiral holes ( 16 ) on the plugs, the mobile left ( 20 ) and right ( 19 ) ends.
[0029] [0029]FIG. 2 shows the assembled device with relative section, highlighting the span ( 2 ) and the jambs ( 3 ).
[0030] [0030]FIG. 3 shows a perspective view of the telescopic elements supporting the grating, with the lock pivot ( 17 ), the clutch ( 18 ) and the support ( 23 ).
[0031] [0031]FIG. 4 shows the detail of the fixing of the telescopic part to the opening, with the support ( 23 ) and the lock pivot ( 17 ).
[0032] [0032]FIG. 5 shows the fitting of a first telescopic element at the base.
[0033] [0033]FIG. 6 shows a front view of the complete fitting, highlighting the perfect alignment.
[0034] [0034]FIG. 7 shows a fitted device.
[0035] [0035]FIG. 8 shows the perfect alignment in a more complex type of opening, with a third telescopic element for an upper fixed part ( 22 ) and with the grating ( 21 ) below.
[0036] [0036]FIGS. 9 and 10 shows the compatibility of the invention with different types of opening. | The present invention consists of a device for fitting security gratings in a simple way, without any complicated walling operations and with no need of skilled workers. It permits to place a grating by means of two guides parallel each other, which represent the base and the top of the grating. Since they are provided with telescopic parts at their ends, they suit any span to be protected, ensuring a perfect fitting. This device and its fitting process can get, by the realization of an industrial product, the same effects obtained by the realization of a handmade product, but a very low costs and with considerable saving of time in fitting. | 8 |
BACKGROUND OF THE INVENTION
In the field of non-impact printing, the most common types of printers have been the thermal printer and the ink jet printer. When the performance of a non-impact printer is compared with that of an impact printer, one of the problems in the non-impact machine has been the control of the printing operation. As is well-known, the impact operation depends upon the movement of impact members, such as print hammers or wires or the like, which are typically moved by means of an electromechanical system and which may, in certain applications, enable a more precise control of the impact members.
The advent of non-impact printing, as in the case of thermal printing, brought out the fact that the heating cycle must be controlled in a manner to obtain maximum repeated operations. Likewise, the control of ink jet printing, in at least one form thereof, must deal with rapid starting and stopping movement of the ink fluid from a supply of the fluid. In each case of non-impact printing, the precise control of the thermal elements and of the ink droplets is necessary to provide for both correct and high-speed printing.
In the matter of ink jet printing, it is extremely important that the control of the ink droplets be both precise and accurate from the time of formation of the droplets to depositing of such droplets on paper or like record media and to make certain that a clean printed character results from the ink droplets. While the method of printing with ink droplets may be performed in either a continuous manner or in a demand pulse manner, the latter type method and operation is disclosed and is preferred in the present application when applying the features of the present invention. The drive means for the ink droplets is generally in the form of a well-known crystal or piezoelectric type element to provide the high-speed operation for ejecting the ink through the nozzle, while allowing time between droplets for proper operation. The ink nozzle construction must be of a nature to permit fast and clean ejection of ink droplets from the print head.
In the ink jet printer, the print head structure may be a multiple nozzle type with the nozzles aligned in a vertical line and supported on a print head carriage which is caused to be moved or driven in a horizontal direction for printing in line manner, while the ink droplet drive elements or transducers may be positioned in a circular configuration with passageways leading to the nozzles.
Alternatively, the printer structure may include a plurality of equally-spaced, horizontally-aligned, single nozzle print heads which are caused to be moved in back-and-forth manner to print successive lines of dots in making up the lines of characters. In this latter arrangement, the drive elements or transducers are individually supported along a line of printing.
In a still different structure, the nozzles are spaced in both horizontal and vertical directions, and the vertical distance between centers of the ink jets equals the desired vertical distance between one dot and the next adjacent dot above or below the one dot on the paper. The horizontal distance is chosen to be as small as mechanically convenient without causing interference between the actuators, reservoirs, and feed tubes associated with the individual jets. The axes of all jets are aligned approximately parallel to each other and approximately perpendicular to the paper. Thus, if all nozzles were simultaneously actuated, a sloped or slanted row of dots would appear on the paper and show the dots spaced both horizontally and vertically. In order to produce a useful result consisting of dots arranged as characters, it is necessary to sweep the ink jet head array back and forth across the paper, and to actuate each individual nozzle separately when it is properly located to lay down a dot in the desired position. A vertical row of dots is created by sequentially actuating the nozzles rather than simultaneous actuation thereof, the latter being the preferred practice in the more common nozzle arrangements.
In the concept of dot matrix printing, it is generally desired to place the print element actuators in a position to allow characters to be printed in serial manner and this placement requires that the print wires, nozzles, electrodes or other like print actuators be very closely spaced with respect to each other. Since the print actuators are generally larger in size than the diameter of the printed dot, a relatively long wire, channel or like element must be provided to bring the desired print activity from its source, such as a moving armature or plunger or a pressure generating piezoelectric crystal or the like, to a vertical, closely-spaced, column arranged in a pattern such that a column of closely-spaced tangentially coincident or overlapping dots will be produced on the record media if all actuators are fired or actuated at one time. However, it is likely seen that the use of long wires or channels are known to lower the performance of the actuators.
Since it is desirable to eliminate the long curving transition section between the drive elements and the nozzles, as in the case of the circular arrangement mentioned above, it is proposed to provide an array of ink jet transducers in a spaced configuration or manner for use in a compact print head.
Representative documentation in the field of ink jet print heads and in energization thereof includes U.S. Pat. No. 3,397,345, issued to R. J. Dunlavey on Aug. 13, 1968, which discloses an electrode assembly for ink fluid transfer devices wherein a plurality of electrode structures are formed by etching plates of copper-clad glass and making electrical strapping connections between selected electrodes.
U.S. Pat. No. 3,832,579, issued to J. P. Arndt on Aug. 27, 1974, discloses a well-known pulsed droplet ejecting system wherein a liquid carrying conduit includes a portion capable of conducting pressure waves in the liquid by means of an electro-acoustic transducer having leads surrounding the conduit portions and pulsed for causing ejection of droplets from the nozzle.
U.S. Pat. No. 4,180,225, issued to T. Yamada on Dec. 25, 1979, discloses an ink jet recorder which has an inner metal electrode and an outer metal electrode attached to either side of a ceramic wall end of the reservoir around the outlet thereof. A voltage is applied to the electrodes to provide a vibration to the ink stream for ejection of ink from an orifice in the outer electrode.
SUMMARY OF THE INVENTION
The present invention relates to ink jet printers and, more particularly, to an array of ink droplet drive elements or transducers arranged in a compact configuration. In accordance with the present invention, there is provided a print head support in the form of a circuit board which carries a plurality of the drive elements or transducers in closely-knit and compact manner. The drive elements include piezoelectric or like crystal elements which are pulsed or energized by use of portions operably associated with and forming a part of the circuit board. The drive elements also include a coaxial nozzle formed with an orifice to generate or create the ink droplets by the pulse-on-demand method.
The circuit board includes a plurality of apertures therethrough and arranged in an inclined, symmetrical pattern and equally spaced to hold the piezoelectric drive elements in position and to enable serial printing of dot matrix characters during travel of the printing mechanism in one direction. Each of the piezoelectric drive elements is secured to the circuit board by soldering the outside diameter portion of the piezoelectric crystal to a copper-coated surface of the circuit board after placing the glass tubular portion of the drive element through an aperture in the circuit board. The other surface of the circuit board includes a plurality of copper runs, each of such copper runs being positioned for connection to the terminal or solder tab of a respective drive element.
In view of the above discussion, the principal object of the present invention is to provide an ink jet print head for generating droplets of ink on demand.
Another object of the present invention is to provide an ink jet print head of compact design having a plurality of ink droplet-producing elements or devices.
An additional object of the present invention is to provide means for supporting a plurality of ink droplet-producing elements in a compact symmetrical arrangement.
A further object of the present invention is to provide a substrate having conductive material on the surfaces thereof for use in pulsing a plurality of ink droplet-producing elements secured thereto.
Additional advantages and features of the present invention will become apparent and fully understood from a reading of the following description taken together with the annexed drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a view of one surface of a substrate having a plurality of apertures therethrough and a coating of conductive material thereon;
FIG. 2 is a sectional view taken on the line 2--2 of FIG. 1;
FIG. 3 is a view of the opposite surface of the substrate and showing runs of conductive material thereon; and
FIG. 4 is an assembly, partially in section, of an ink droplet-producing element and incorporating the features of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, FIGS. 1, 2 and 3, respectively, illustrate one surface 10 of a substrate 12, a section taken on the line 2--2 therethrough, and the opposite surface 14 of the substrate. The substrate 12 has three apertures 16 therethrough in an inclined, closely-spaced, symmetrical pattern for receiving three ink jet printing transducers or spritzers which may be of the type described in U.S. Pat. No. 3,832,579, mentioned above.
The surface 10 of the substrate 12 is copper-clad or like covered or coated with a layer 18 of copper, except for a circular portion 20 surrounding each of the apertures 16. The layer 18 of copper thus is commonly associated with the apertures 16, however spaced therefrom by the circular portion 20 to provide for seating the transducers on the substrate 12, as later described. The opposite surface 14 has three runs 22 of copper secured thereto, spaced from each other, with each run terminating in a ring 24 surrounding the respective aperture 16. Each run 22 of copper is associated with its respective aperture 16 for connection with a transducer.
FIG. 4 shows the assembly of one of the three spritzers or transducers 28 to be carried by the substrate 12, which includes a glass capillary tube 30, a solder tab 32 and a piezoelectric crystal or like element 34. The glass tube 30 is usually connected in suitable manner to a supply of ink through conduit means 39, which may be flexible tubing. The piezoelectric element 34 surrounds the tube 30 substantially the length thereof but just short of the nozzle 36. The solder tab 32 is secured to the tube 30 and located in a space formed by a removed interior or cut-out portion 37 on the inside diameter of the crystal 34. The unclad circular portion 20 of the surface 10 of the substrate 12 is sized to fit the outer diameter of the crystal 34 and to permit soldering therearound so that the copper layer 18 is common to the exterior portion or outside diameter of all spritzers 28. The crystal 34 is soldered as at 35 to the copper layer 18 adjacent and around the outside diameter portion of the crystal, and the tab 32 is soldered as at 38 to the respective copper run 22. The effect of the solder connections 35 and 38 is that the three spritzers 28 are securely fastened to the substrate 12 in an arrangement for operation as a multiple-element print head. The exterior portion or outside diameter of each crystal 34 is one pole surface connected with the layer 18 of copper and the interior portion or diameter is the other pole surface connected through the tab 32 with its respective copper ring 24. In well-known manner, the ink is caused to flow through the ink supply conduit 39 and into the glass tube 30, and the crystal 34 then is pulsed on demand to cause ejection of a droplet 40 of ink onto paper or like record media 42. Suitable and appropriate connections may be effected by use of cardedge connectors operably associated with the copper layer 18 on the surface 10 of the substrate 12 and with the several copper runs 22 on the surface 14 of the substrate for pulsing the crystal 34 in printing operation.
It is thus seen that herein shown and described is a novel way of supplying an electrical pulse to the outside diameter and to the inside diameter pole surfaces of an ink jet spritzer or transducer for operating same and for supporting the several spritzers by means of a substrate in an arrangement for multiple-element printing operation. The apparatus of the present invention enables the accomplishment of the objects and advantages mentioned above, and while a preferred embodiment has been disclosed herein, variations thereof may occur to those skilled in the art. It is contemplated that all such variations not departing from the spirit and scope of the invention hereof are to be construed in accordance with the following claims. | A circuit board is utilized to hold a plurality of ink droplet producing elements in compact manner and conductive portions of the board are connected to actuate the elements in pulse-on-demand type printing. | 1 |
This application is a continuation-in-part of Ser. No. 087,732, filed Oct. 24, 1979 now abandoned.
TECHNICAL FIELD
The present invention relates to closure devices and valving devices for oil field kellys. Even more particularly, the present invention relates to a remotely operable kelly cock which closes flow of fluid through the kelly even while the kelly is in a spinning operative position by using, preferably hydraulic power through a liquid interface.
Background Art
In the oil field, it is known to use a kelly having an inner flow conveying bore which is operated by a rotary table in drilling for oil or gas with the kelly applying the necessary rotational force to the drill string and its attached drill bit. The kelly forms a portion of the conduit through which fluids (such as drilling mud and additives) flow from the surface to the drill bit area. The kelly thus spins during the drilling operation.
During the drilling process, unsafe conditions can arise as in the case of a blowout in which situation it is desirable that the kelly be closed and the flow of fluid through its inner provided bore valved to a shut or closed position. Failure to close the bore allows formation pressures to force oil/gas, drillings fluids and the like back up the well bore to the surface where explosion or fire can result. The national news media has frequently covered scenes of offshore drilling rigs uncontrollably ablaze after a blowout. Such disaster is frequently accompanied by loss of life and by significant loss of property. Often environmental destruction is produced as oil is thrust into the surrounding waters of an offshore rig creating a "slick" which can extend for miles polluting water and beaches.
Valving devices to solve these problems by closing the kelly bore are known in the art as "kelly cocks. These kelly cocks can close the kelly bore usually only when the kelly is not spinning. The are for the most part manually operated.
Such devices usually require that the kelly be stopped before closure can be effected, and an operator climb up and shut the device. Manual type kelly cocks are known which require manual operation by means of a hand operable tool such as an allen wrench or the like. These types of kelly cocks are known in the art and available from a variety of manufacturers. See, for example, the kelly cock safety valve as manufactured by Hydril.
U.S. Pat. No. 1,494,764 issued to J. McDonald Wishart discloses an "Adjustable Stroke Compressor".
In U.S. Pat. No. 1,780,329 issued to F. N. Bard there is seen the patent entitled "Reversing Gear Mechanism" which relates in general to reversing gear mechanism and more particularly to mechanism of the character referred to operable by mechanical power, and has special reference to the provision of an improved form of fluid pressure driven reversing gear mechanism.
A "Servomotor" is seen in U.S. Pat. No. 2,536,565 issued to G. Ostergren which patent relates to a servo-motor and more particularly to a reciprocating hydraulic servo-motor for actuating the blades of a propeller.
U.S. Pat. No. 2,847,868 discloses "Hydraulic Steering Gear with a Gear Rack Disposed Intermediate Piston Heads" which issued to P. A. Newman.
A "Discharge Valve Mechanism" is disclosed in U.S. Pat. No. 3,104,862 issued to B. A. Pearson, et al, which relates to discharge valve mechanism, and particularly discharge valve mechanism capable of passing solid objects and which can be operated by remote means.
U.S. Pat. No. 3,146,681 entitled "Plug Valve Operator" issued to J. M. Sheesley relates to an apparatus for hydraulic or pneumatic operation of valves, particularly plug valves, or other valves which require only a relatively small movement to be operated from fully open to fully closed.
A "Fluid Motor Actuator" issued to J. T. Looney is seen in U.S. Pat. No. 3,148,595 which discloses a fluid motor actuator by which linear motion is converted to rotary motion. More specifically the invention relates to the specific construction of a fluid motor actuator which is especially adapted for rotating a shaft back and forth between predetermined adjustable limits in each direction.
U.S. Pat. No. 3,338,140 issued to J. M. Sheesley entitled "Actuator" relates to fluid operated means for converting longitudinal movement to rotary movement, and more particularly it relates to improvements in fluid operated actuators for actuating plug valves and the like.
U.S. Pat. No. 3,982,725 entitled "Valve Actuator" issued to Clark discloses a low profile fluid powered actuator particularly for valves of the type in which the valve element is rotated to open and close the flow passageway through the valve body, the actuator having a novel internal porting system, means for direct attachment of the valve stem to the shaft of the actuator, and a novel manual override for manually operating the valve.
U.S. Pat. No. 3,806,082 entitled "Power Kelly Cock" discloses a mechanical-type transmission for powering a kelly cock to close off the drilling kelly during operation.
U.S. Pat. No. 3,941,348 issued to James Mott and entitled "Safety Valve" provides a remotely operable safety valve mounted between the swivel and the kelly during drilling operations including a spherical shaped valve element which is mounted in a tubular housing rotatable with the swivel sub, the kelly and the drill string. The valve is moved between open and closed positions in order to control flow through the drill string and prevent end line blowouts. As an additional safety feature, a spring means moves the valve element to a closed position in the event of a failure of the hydraulic means.
In U.S. Pat. No. 3,887,161 there is provided "An Arrangement for Closing a Kelly Cock Supported on a Rotary Swivel with a Stem Therefrom".
It would be desirable to provide a remotely operable kelly cock or a kelly valve apparatus which would function in both static and spinning conditions. Such a valve or kelly cock apparatus would be operable while the kelly is still spinning or stopped and would be preferably automatically operable from a remote location.
In blowout conditions, it is not always possible to close the kelly manually since danger exists, and the oil rig workers can panic and retreat from the drilling area.
The present invention solves these prior art problems in a simple, inexpensive and straightforward manner by providing an automatic remotely operable (as well as manually operable) kelly valving apparatus which can be opened or closed in either a static or spinning condition of the kelly. A hydraulic operator is provided with a liquid interface through which hydraulic fluid flows to the operator even when the kelly is spinning.
DISCLOSURE OF INVENTION
The present invention provides a kelly cock apparatus which is both automatic and manual in operation being operable from a remote location if desirable. The apparatus provides attached to the well drilling kelly a valve structure having an associated operator. A hydraulic driving fluid powers the operator between open and closed flow positions.
In order that operation of the operator can be maintained in both spinning and static condition of the kelly, a driving fluid flows to operate the valve and the valve structure itself. In the preferred embodiment, the fluid interface is in a form of an annular collecting ring which provides at least one annular groove filled with fluid and connected to the operator for applying driving force thereto. The operator in the preferred embodiment could be, for example, hydraulic, having a drive arm mounted for rotation with the valving member and powered by a pair of hydraulically operated cylinders, with one cylinder moving the drive arm to open the valve while the other cylinder closes the valve.
Therefore, it is an object of the present invention to provide a kelly valve apparatus which is operable in both static and spinning positions of the kelly.
It is the further object of the present invention to provide a kelly cock or valving apparatus which is both manually and automatically operable.
Still another object of the present invention is to provide a kelly cock or valve apparatus which is remotely operable and manually operable at the valve itself.
It is another object of the present invention to provide a remotely operable kelly cock valve apparatus which can be added to existing manually operable kelly cock devices.
It is another object of the present invention to provide a supplementary kelly cock operator which is attached to manual type kelly cocks and transforms them from manual to automatic operation.
Another object of the present invention is to provide a remotely operable kelly valving apparatus which is safe and easy to operate.
Another object of the present invention is to provide a kelly valving system having indications to the driller as to the position of the kelly valving member portion thereof.
Another object of the present invention is to provide an entirely hydraulic kelly closure apparatus, remotely operable, in either static or opening positions of the kelly.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which like parts are given like reference numerals and wherein:
FIG. 1 is a front sectional view of the preferred embodiment of the apparatus of the present invention;
FIG. 1A is a front sectional view of the collection ring assembly portion of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a front view of the upper sub portion of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is a front view of the lower sub portion of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a sectional view taken along lines 4--4 of FIG. 1;
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 1;
FIG. 6 is a top view of the upper housing base portion of the preferred embodiment of the apparatus of the present invention;
FIG. 7 is a sectional view taken along lines 7--7 of FIG. 6;
FIG. 8 is a sectional view taken along lines 8--8 of FIG. 6;
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 6;
FIGS. 10A-10B are side and front views respectively of the drive arm portion of the preferred embodiment of the apparatus of the present invention;
FIG. 11 is a front sectional view of the collector seal holder portion of the preferred embodiment of the apparatus of the present invention;
FIG. 12 is a sectional view of the upper housing cylinder portion of the preferred embodiment of the apparatus of the present invention;
FIG. 13 is a sectional view of an alternate embodiment of the apparatus of the present invention;
FIG. 14 is a perspective view of an alternate embodiment of the apparatus of the present invention;
FIG. 15 is a perspective view of an alternate embodiment of the apparatus of the present invention illustrating the operator portion thereof;
FIG. 16 is a top sectional view of an alternate embodiment of the apparatus of the present invention illustrating with particularity the valve and operator portions thereof;
FIG. 17 is a top partial sectional view of an alternate embodiment of the apparatus of the present invention;
FIG. 18 is a side view of the embodiment of FIG. 17; and
FIG. 19 is a side partially exposed view of the embodiment of FIGS. 17 and 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 best shows the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. Kelly valving apparatus 10 provides a kelly valve 20 having an operator assembly 30 which as will be described more fully hereinafter moves the valve between open flow and closed flow positions which respectively allow fluid flow through the kelly valve bore 11 between the upper sub 24 and lower sub 26 and in the closed flow position shut off flow though the bore. Operator assembly 30 in the preferred embodiment provides a hydraulically powered operator with hydraulic fluid being dispensed in a pressurized fashion through collector ring assembly 44 to operator assembly 30.
As will be described more fully hereinafter, the kelly valving apparatus 10 of the present invention can be remotely operated as, for example, from the driller's panel on an oil and gas drilling rig without regard as to whether or not the kelly is spinning or static, using hydraulic fluid to power the operator.
The apparatus of the present invention thus provides an inside blowout preventor for oil and gas drilling rigs which can be quickly operated from a remote location in any drilling situation.
In FIG. 1 in the drawings there can be seen an upper sub 24 which connects at joint 12 with kelly valve 20 with a lower sub 26 attaching at the lowermost portion of kelly valve 20 at joint 14. Lower sub 26 would attach to the drilling kelly K with apparatus 10 valving flow of fluids through the kelly.
Kelly valve 20 is, for example, a conventional manually operated kelly cock which is commercially available. Presently, such devices are manually operated by use of an allen wrench or the like. This manual operation requires that a human operator or other personnel on the drilling platform climb or otherwise obtain access to the kelly cock and place the allen wrench in position and manually close the valve. Problems exist in that time may be of the essence and significant danger might be presented by an operator approaching the kelly cock to close it in a blowout situation where the entire rig may at any second be subject to explosion or fire.
Upper sub 24 is best seen in FIG. 2 and provides a length of drill pipe having, for example, a lower pin connection 25 and an upper box connection 23 with a uniform fluid conveying bore 27. An annular groove 21 is milled about the exterior of upper sub 24 being of a thickness T which corresponds to the thickness T of plate 51 as seen in FIG. 1. A threaded connection could be provided at groove 21 for disassembling sub 24 thus allowing it to be assembled to support plate 51 at groove 21. Plate 51 would provide a central opening having an inner diameter (I.D.) substantially equal to the outer diameter (O.D.) of sub 24 at groove 21.
Upper sub 24 connects to kelly cock 20 at joint 12 which is a box-pin type connection known in the oilfield drill pipe art.
The lowermost portion of kelly cock 20 provides a connection at joint 14 to lower sub 26. Lower sub 26 (FIG. 3) would have an upper box connection 28 and a lower pin connection 29 with a pin connection provided on kelly cock 20 assembling to the box connection 28 of lower sub 26. The connection of upper sub 24 and lower sub 26 to kelly cock 20 is similar to the connections made with manual type kelly cocks in the oilfield. A bore 22 is also provided in lower sub 26. Kelly K attaches by pin and box-type connections to sub 26.
FIG. 1, FIGS. 4-5, and FIGS. 10A-10B show operator assembly 30. Operator 30 is, for example, a hydraulically powered operator having connection through drive arm 35 to kelly cock 20. It should be understood that a provided hexagonal key 36 on drive arm 35 attaches to a provided hexagonal recess on kelly cock 20 which is receptive of key 36 and which thereafter is connected to a central valving member of kelly cock 20 which could be, for example, a ball valving member of the like as is the case in conventional kelly cocks.
It will be understood by one skilled in the art that once drive arm 35 and more particularly hexagonal key 36 mates with the provided socket on kelly cock 20, rotational movement thereafter of drive arm 35 will effect a rotation of the provided valving member of kelly cock 20 effecting an opening and closing of the kelly cock 20 valving member between open flow and closed flow positions. The provided socket is available on conventional manual kelly cocks and normally is manually operable by an allen wrench or like hand tool.
Left and right hydraulically operative cylinders 32, 33 will rotate drive arm 35 approximately 90 degrees between open flow positions and closed flow positions of kelly cock 20 responsive to alternate extensions of hydraulic cylinders 32, 33 and their provided rams 32A, 33A.
The opposite end of drive hex key 36 provides a drive sleeve 39 having an internal socket 40 which is hexagonal. This allows drive arm 35 to be manually operated as a backup, if desired, by the placement of a hexagonal allen wrench or the like hand tool into socket 40 and turning effected. Drive sleeve 39 on its outer surface would otherwise be rounded and would fit into a provided opening on yoke 45. Thus, drive arm 35 would be supported at the end portions of hex key 36 which would be anchored into the socket of kelly cock 20 and at its opposite end with sleeve 39 at shoulder 41 resting in and rotating within a provided opening on yoke 45. With the end portions being so supported, a rotational movement of drive arm can be achieved by sequential extensions of rams 32A, 33A.
Each ram 32A, 33A attaches at its end to drive arm 35 at provided openings 37, 38 of drive arm 35. Pinned connections 32c, 33c are preferable as shown in FIGS. 1 and 5.
Support for operator 30 is achieved by bracing cylinders 32, 33 at their upper end portion and by supporting their lower end portion at drive arm 35 with, as aforementioned, drive arm 35 being supported by kelly cock 20 and at its other end by yoke 45. The end portions of yoke 45 are supported by a plurality of brackets which themselves attach to the cylindrical member formed by the connection of upper sub 24, kelly cock 20, and lower sub 26. The construction of the supporting brackets will now be discussed more fully.
In FIGS. 4 and 5 there can be seen the inner bore 11 of kelly cock 20 and in these sectional views also the support of operator 30. Note in FIG. 4 a pair of upper support brackets 80, 81 which are connected together by structural bolts 83, 84. A pair of recesses 85 are formed on each side of support bracket 81 with pin connections 86, 87 being formed at recesses 85 to hold the upper end portions of cylinders 32, 33 in a supported fashion at bracket 81. Retainers 89, 90 in the form of a bolt and washer, for example, will be provided if desired to keep the pinned connections 86, 87 from disassembly during operation.
Openings 91, 92 which are generally semi-circular can be seen on bracket 80. These allow hydraulic hoses (not shown) to pass through openings 91, 92 and attach to collector ring assembly 44. The opposite end portion of the hoses (not shown) would connect respectively to the provided ports 32b, 33b.
Bracket 80 provides an enlarged portion 95 which could be weighted to act as a counterweight to the entire operator assembly 30 thus providing for a dynamically balanced apparatus 10 which would not impart excess or undesireable vibration to the drill string during rotation of the kelly.
Also seen on bracket 80 are openings 93, 94 which could provide inner threads. These openings 93, 94 would align with openings provided in plate 51 through which openings and the corresponding threaded openings of plate 50, attachment bolts would be connected. This would effect a vertical connection between bracket 80 and plate 50 discouraging slippage of brackets 80, 81 downwardly on the assembly of sub 24, kelly cock 20, and sub 26. The connection of bracket 80 to bracket 81 by structural bolts 83, 84 would also be a tight connection which would be assembled using torque so that a clamping effect would be achieved against upper sub 24 which would also enhance in discouraging vertical movement of brackets 80, 81 along the upper sub 24.
FIG. 5 shows a pair of lower brackets 100, 101 which are affixed to the joint 14 between kelly cock 20 and lower sub 26. A pair of bolts, for example, 103, 104 are attached to brackets 100, 101 respectively and provide conical tips which anchor brackets 100, 101 into the shown recess provided at joint 14. A further assembly of brackets 100, 101 to the assembly of kelly cock 20 and lower sub 26 is provided by structural bolts 106, 107 which assemble brackets 100, 101 together forming a bolted connection which could be torqued to provide a clamping effect of brackets 100, 101 and the provided bolts 106, 107 to the assembly of kelly cock 20 and lower sub 26.
A pair of openings 109, 110 on lower bracket 100 could be provided with inner threads which would allow a bolted connection to be formed between bracket 100 and cover assembly bottom plate 122. Also provided on bottom plate 122 of cover assembly 120 would be a pair of attachment blocks 125, 126 which could be attached thereto by welding, for example. Yoke 45 would be attached by bolting, for example, to blocks 125, 126 with the bolts shown in FIGS. 1 and 5 as 127, 128 respectively.
A retainer bolt 120 and washer 131 are provided for retaining key 36 and drive arm 35 in their lateral position so that movement outwardly is not possible. Bolt 130 would be threadably anchored in yoke 45 with washer 131 overlapping the end of sleeve 39 at recess 40. Note from an inspection of FIG. 10A that a reduced diameter to sleeve 39 is indicated as shoulder 41 in FIG. 10A. This reduced diameter would be the position occupied by an opening of substantially the same diameter as shoulder 41 in yoke 45.
The construction of cover assembly 120 is best seen in FIGS. 1 and 5. Cover assembly 120 provides a pair of halves 140, 150, each of which is hingedly attached at a provided hinge 141, 151 which hinge is attached to by welding, for example, its respective strut support member 142, 152. Each of support struts 142, 152 is attached by bolting, for example, at its upper end portion to plate 51 and at its lower end portion to plate 122. These bolted connections are shown in FIGS. 1 and 2.
Each cover plate 140, 150 is attached opposite its hinge 141, 151 to the opposite provided strut support 142, 152 as shown in FIGS. 1 and 5 by a plurality of, for example, machine screws. These machine screws are indicated as 160 in FIG. 1. Disassembly of cover assembly 120 can be achieved by merely removing the aforementioned bolts, first from struts 142, 152 and thereafter from plates 51, 122.
An opening is provided in cover plate 150 adjacent recess 40 which allows an allen wrench or like hand tool to be inserted therethrough for operation of recess 40 as aforementioned. A dust cover 155 which could be, for example, of rubber or the like would insure a dust-free environment within the confines of cover assembly 120.
FIGS. 1, 6-9 and 11-12 show with particularity the construction of collector ring assembly 44.
In FIGS. 1-1A there can be seen with particularity the complete assembly of collector ring assembly 44.
Collector ring assembly 44 comprises generally a pair of collector seal holders 60, 61 carried between a collector ring upper housing 50, end cap 56 and an outer housing cylinder 70. Upper housing 50 comprises generally plate 51 and housing inner wall 53, the two of which can be integral (see FIGS. 7-9).
FIGS. 6-9 show with particularity the construction of collector ring upper housing 50 while FIG. 11 shows more particularly the construction of each collector seal holders 60, 61; with FIG. 12 showing more particularly the construction of upper housing cylinder 70.
The construction of collector ring upper housing 50 will now be discussed more fully with respect to FIGS. 6-9.
Collector ring upper housing 50 provides a lower substantially flat plate portion 51 which connects to a collector housing inner wall 53. A central bore is provided which allows upper sub 24 to pass therethrough.
Wall 53 provides a pair of conduits 54, 55 which communicate respectively between provided ports. In FIG. 7, conduit 54 is shown being connected between port 62 and port 63 while conduit 55 connects at its end portions between port 64 and port 65.
Three annular grooves 66-68 are shown in wall 53 which are occupied by thrust rings 69 as being seen in FIG. 1A.
Upper threaded openings 71 allow for a threaded attachment of a bolt, for example, or like connector thereinto which allows assembly of end cap 56 to wall 53 of collector ring upper housing 50.
During operation fluid will flow from port 64 downwardly through conduit 55 to port 65. In a like manner, fluid will flow in operation from port 62 through conduit 54 to port 63. Ports 63, 65 will be attached by way of hydraulic hoses (not shown) to the provided ports 32b, 33c respectively provided upon hydraulic cylinders 32, 33.
Threaded openings 72 provided on plate 51 have inner threads which allow a bolted connection to be formed of plate 51 to bracket 80. Similar openings 93, 94 as aforementioned are provided on bracket 80 which align with the threaded openings 72 of plate 51.
Fluid is supplied through hydraulic inlet ports 75, 76 of outer housing 70 to each collector seal holder 60, 61. This hydraulic connection can be seen best in FIG. 1A. The construction of each collector seal holder is seen best in FIG. 11. Each seal holder 60, 61 has a central bore 73 for passage of wall 53 therethrough and also provides three external annular grooves 77 with O-rings or like packing material normally occupying the upper and lowermost grooves. Four openings 79 are bored in the middle groove communicating with an inner chamber 160. Four inwardly projecting annular ribs 161-164 define therebetween three inner annular grooves 165-167. Packing material 78 would normally occupy grooves 165-167.
With respect to upper port 75, fluid flow would be provided thereto in the form of compressed hydraulic fluid which would be the operator fluid. Though hoses are not shown connected to ports 75, 76, it will be understood that hydraulic hoses would be attached thereto and extend to a remote location where the source of hydraulic fluid would be contained. These hoses would prevent rotation of outer housing cylinder 70. A backup such as a chain, for example, (not shown) could be attached to outer housing cylinder 70 at one end, and at its other end anchored to the drilling rig structure to further insure non-rotation of outer housing cylinder 70. Otherwise, the entire remaining assembly would rotate with bearings "B" within a provided bearing race providing an interface between housing cylinder 70 and collector ring upper housing 50.
The flow of hydraulic fluid from port 75 to its respective cylinder 32, 33 would be from port 75 through collector ring outer groove 77 through opening 79 to inner groove 166 and thence to port 64 of collector ring upper housing 50, through conduit 55 and then to port 65. From port 65, a flexible hydraulic hose (not shown) would convey fluid to the port 32b or 33b of the cylinder 32 or 33 which was desired to be operated from the hose connected to port 75.
A similar flow of operator fluid would be seen with regard to port 76. A provided hydraulic hose (not shown) would convey hydraulic fluid from a desired source under pressure to port 76 and thence through to outer groove 77 of collector seal holder 60, 61 thence through opening 79 (four of which are preferably provided), thence to inner groove 166, thence to port 62 of collector ring upper housing 50 and then through conduit 54 to port 63. In similar fashion, a hydraulic hose would connect to port 63 and then be connected at its opposite end to either cylinder 32 or 33 at its provided port 32b, 33b. In this fashion, one skilled in the art will recognize that fluid dispensed at port 75 would operate one cylinder while fluid dispensed at port 76 would operate the other cylinder and a rotational movement of drive arm 35 effected which would respectively open or close kelly cock 20. It will follow that such opening and closing of kelly cock 20 would be effected in either a static or spinning condition of the assembly of kelly cock 20, upper sub 24, and lower sub 26.
If desired, seals could be provided at points 180 between outer housing cylinder 70 and end cap 56. Seals 182 could also be provided between outer housing cylinder 70 and plate 51.
FIG. 12 shows more particularly the construction of outer housing cylinder 70 having ports 75, 76 which would preferably be threaded and allow the attachment of hydraulic hoses thereto. A central bore 73 allows the passage of upper sub 24 therethrough and further allows for sufficient thickness to accommodate between collector seal holders 60, 61 and collector ring upper housing 50. Enlarged recess portions of bore 73 are seen at 70A and 70B which allow for placement of bearing races housing bearings B between collector ring upper housing wall 53 and outer housing cylinder 70.
FIGS. 13 and 14 illustrate another alternate embodiment of the apparatus of the present invention designated generally by the numeral 210.
Kelly valving apparatus 210 comprises generally valve body 212 attached to a conventional kelly 220 within which body 212 operator 230 is movably mounted. Attached to the upper portion of valve body 212 is collector ring 270 to which can be attached hydraulic fluid supply lines 214, 216.
Collector ring 270 comprises generally upper ring 272 and lower ring 274. It will be appreciated that upper ring 272 is movably mounted with respect to body 212 while lower ring 274 is attached rigidly to body 212 and moves therewith. A plurality of ball bearings 280 can be provided between upper and lower rings 272 and 274 with upper rings 272 being attached by means of brackets 29 through which suitable fasteners such as bolts 292 can be threadably affixed.
In FIG. 14 an overall schematic view of the kelly valve operator 210 of the present invention shows valve body 212 to which are attached fluid supply lines 214, 216 which cooperate with control panel 218 for valving the well kelly 220. Pressurized hydraulic fluid will be supplied to operate kelly valving apparatus 210 through control panel 218, lines 214, 216 and collector ring 270. Hoses 214, 216 as well as chain "C" prevent rotation of upper ring 272.
Provided at the inner portion of valve body 212 is valve member 225 which in the preferred embodiment is a spherical ball valve 225 having a flow opening (not shown) provided therethrough. It will be appreciated by one skilled in the art that operation of operator 230, a rack and pinion-type or similarly a Scotch yolk-type will rotate ball valve 225 between open flow and closed flow positions to achieve an open flow or closed flow status as is desired. In this manner, flow of drilling mud and the like can be valved at kelly.
Operator 230 as best seen in FIGS. 13 and 15-16 is hydraulic comprising a pair of drive pistons 232, 234 connected by rod 250. Rod 250 is provided with a plurality of teeth 252 and is operated by addition of pressurized hydraulic fluid into either inlet port 260 or inlet port 262 as the case may be.
Hydraulic fluid supply lines 214 will supply fluid through conduit 265 of upper rings 272 thence through outermost collector ring 203 formed by annular grooves 201, 203 into discharge ports 260 and into piston shaft 240.
In a like manner, inner fluid supply lines 216 will supply fluid through upper ring conduit 265 into innermost collector ring 204 formed by annular grooves 205 and 206 and thence into discharge port 262 into piston shaft 242.
The alternate introduction of hydraulic fluid in this manner to piston chamber 240 or to piston chamber 242 will move rod 250 in a slidable reciprocal fashion as illustrated by the arrow 254 in FIG. 13.
Rod 250 can be threaded with pistons 232, 234 being threadably mounted thereto, thus providing an adjustment of relative position of each piston 232, 234 upon rod 250. With such an adjustment, the volume of chambers 240, 242 can be changed.
FIGS. 17-19 illustrate another alternative construction of the preferred embodiment of the apparatus of the present invention designated generally by the numeral 310. The apparatus of FIGS. 17-19 provides a removable kelly valving apparatus 310 which can be added to existing manually operable kelly cocks or kelly valves which are existing on operating kellys on operating oil and gas rigs. Removable valving apparatus 310 comprises generally valve body 312 which is a two-part valve body, having valve body halves 313, 314 as best seen in FIG. 17.
In FIG. 17 axis x--x shows a schematic line of division between halves 313, 314 intersecting hinge pin 315.
Opposite hinge pin 315 is seen bolted connections 320, 322 which clamp together latches 313L, 314L.
As is the case with the preferred embodiment of FIGS. 1-12, a collector ring 370 is provided at the uppermost portion of valve body 312, to which could be supplied the necessary hydraulic supply lines as was taught with respect to the preferred embodiment.
Hydraulic conduits 360, 362 are likewise provided for discharging pressurized hydraulic fluid into drive chambers 340, 342.
It should be understood that a rack and pinion operator 230 is shown in FIGS. 17-19. However, a Scotch yolk operator could also be utilized if so desired.
Pistons 332, 334 are sealably mounted at the end portions of rack 350 with rack 350 providing a plurality of teeth (not shown) with the pinion gear 256 engaging with rack 250. A similar arrangement is seen in FIG. 15 with respect to the preferred embodiment.
Seals 335, 336 can be provided respectively to pistons 332, 334 for forming a sealable connection of each piston 332, 334 with the inner walls respectively of drive chambers 340, 342.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | A kelly valving apparatus for controlling flow of fluid through a kelly and drill string comprises a rotatable tubular section having a fluid conveying bore adapted to be attached to the drill string at the kelly with a valve associated valve body valving the flow of fluids through the bore. A remotely operable operator is rotatable with the rotatable tubular section, operably engaging the valve for moving the valve between positions which open and close the bore, the operator including at least one hydraulic cylinder having an extensible ram actuated by hydraulic fluid, and linkage is connected to the valve and the hydraulic cylinder so that extension/contraction of the ram effects an opening or closure of the bore. A liquid interface fluid collector ring is positioned adjacent the rotatable tubular section for transmitting pressurized hydraulic fluid to the hydraulic cylinder, even during spinning of the cylinder with the tubular section. A source of controllable pressurized hydraulic fluid is connectable to the fluid collector ring for supplying pressurized hydraulic fluid thereto. | 4 |
This invention was made with Government support under Contract DE-AC04-94DP85000 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND
The present invention relates to a new class of materials possessing a substructure of oriented aggregates of suspended magnetic particles. This substructure self-assembles under the influence of an external magnetic field, and induces a wide range of mechanical, dielectric, magnetic, and optical properties. In a particularly useful subclass of these materials, the magnetic particles are electrically conducting or are coated with a conducting layer, and the columnar concentrations are just dense enough to form a continuously conducting path through the material. These new materials enable a broad range of sensor devices and other applications.
The conduction of electricity in materials comprising a particulate conducting phase dispersed in a nonconducting medium have been of scientific and practical interest for some time. Such materials as conductive inks, some forms of conducting polymers, and static elimination materials have long used such dispersions to provide conductivity to conventionally non-conducting elements.
Prior art primarily considers applications of a composite mixture of conducting particles essentially uniformly distributed in a nonconducting medium. Roughly speaking, one expects the conductivity of a composite mixture to increase as the volume fraction of the dispersed conducting phase increases (i.e., as more conductive particles are introduced into the mixture). This is true, but the bulk conductivity of the composite is not simply proportional to the volume fraction of the dispersed phase.
If the volume fraction of conducting particles is small, then on average each particle will be surrounded by a layer of the nonconducting medium, so that the individual particles do not touch each other. In this case, the total conductivity of the composite remains very small. Alternatively, if the volume fraction of conducting particles is large, then on average each conducting particle will make effective electrical contact with a sufficient number of neighboring particles that the bulk conductivity of the composite will be large.
There is a volume fraction, whose exact value depends on the shape and size distribution of the conducting particles, near which the bulk conductivity of the composite rapidly increases by many orders of magnitude. Below this critical volume fraction, conductive paths within the composite extend only short, microscopic distances, being interrupted by particles in poor electrical contact. The result is low bulk conductivity. Above this critical volume fraction, bulk electrical conduction is dominated by conducting particles which are essentially in direct physical contact, giving the composite high bulk conductivity.
Near the critical volume fraction for bulk conduction, there are many conducting paths that are only interrupted by a few instances where current conduction must go through particles which are nearly, but not quite in contact. Small changes in the particle volume fraction can complete many of the paths, making the conductivity of these materials very sensitive to such changes.
Applications exist for such essentially uniform composite materials. An example appears in U.S. Pat. 5,574,377, in which a chemical sensor is implemented by measuring the electrical resistance of a composite material formed of a gel-like polymer containing dispersed conducting particles with volume fraction near the critical volume fraction. The sensor material has large conductivity in the absence of external chemicals. However, the sensor material (more particularly the nonconducting polymer) swells when in the presence of certain organic solvents. Such swelling increases the gaps between particles, thereby driving a large reduction in the bulk conductivity of the sensor material. Such chemical sensors can be quite sensitive if the proper volume fraction is achieved in the sensor material.
Despite the clear potential for using such near-critical composite materials for a variety of functions, practical applications are limited by prior art fabrication technology. It is very difficult to disperse conducting particles uniformly in a nonconducting medium. Exceedingly small changes in process conditions, or simply random variations in the local volume fraction of the conducting particles, can reduce or destroy the desired material response.
Thus, near-critical composite materials made using conventional technology cannot be routinely applied to most applications unless a great deal of effort is taken to control and then characterize the composite. Numerous samples must be typically made under slightly varying conditions, and the samples then individually characterized in a search for individual pieces having the proper bulk properties. When such composites can be used, the device or mechanism thereby enabled usually requires individual calibration.
There is thus a longstanding need for composite materials comprising conducting particles which can be reliably manufactured to exhibit precise and predefined conducting properties.
SUMMARY
The present application is directed to a new class of composite materials, called field-structured composite (FSC) materials, comprising magnetic particles (generally electrically conducting), wherein the distribution of the magnetic particles within the composite is not uniform, but form oriented rod-like or sheet-like aggregations within the composite, and to a new class of processes for their manufacture.
In an implementation of one such process, a field-structured composite can be made beginning with a nominally uniform dispersion of magnetic particles in a fluid that can be solidified. This initial dispersion typically has a volume fraction well below the critical volume fraction for a uniform distribution. To form a uniaxial field-structured composite, an external magnetic field is applied to this initial dispersion. This magnetic field aligns the particles into thin rod-like aggregations of particles which form an interconnecting network within the fluid. This network of particles will conduct, even though the sample is beneath the critical volume fraction for a uniformly dispersed material.
As the network evolves in the magnetic field, the electrical conductivity of the composite along the direction of the applied magnetic field will progressively increase by many orders of magnitude. Likewise, the electrical conductivity perpendicular to the field progressively increases, but remains generally smaller. This is because the density of bridges that link rods in such a network is typically smaller than the density of rods.
The conductivity of the FSC can be brought to a desired target value by controlling the time the dispersion is subjected to the structuring magnetic field. When the desired conductivity has been attained, the fluid can be solidified (e.g., by freezing or polymerizing). By causing the material in which the particles are suspended to solidify when the measured properties of the composite conform to the targeted values, the rodlike aggregates of magnetic particles are fixed in position. The ability to tailor the properties of such materials makes them well suited to a wide range of applications.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
FIG. 1. A schematic diagram of a field-structured composite material whose aggregate structure evolved under the influence of a magnetic field whose relative orientation to the material was fixed. The result is a dense matrix of rodlike aggregates of conducting particles linked in the perpendicular direction by bridges between neighboring rods.
FIG. 2. A schematic diagram of a field-structured composite material whose aggregate structure evolved under the influence of a magnetic field whose relative orientation to the material was rotating in a plane. The result is a stack of thin sheet-like aggregates of conducting particles. These sheet-like aggregates are only rarely bridged together, resulting in strongly anisotropic bulk conductivity in the final composite.
FIG. 3. A flow diagram of a process to prepare a solid field-structured composite material having a particular electrical conductivity perpendicular to the applied magnetic field. This process can produce field-structured composite materials with an arbitrary degree of percolation.
DETAILED DESCRIPTION
The present invention comprises a new class of structured composite materials called field-structured composite (FSC) materials. In one implementation, field-structured composite materials are produced by first forming a dispersion of magnetic particles in a nonmagnetic fluid medium. (Here the term nonmagnetic implies the relative absence of collective magnetic properties, such as ferromagnetism.) Typically, the magnetic particles will be electrically conducting, and the fluid medium will not, but this is not required. When electrically conducting magnetic particles are to be included, they may comprise electrically conducting magnetic material, or nonconducting magnetic material coated with a conducting layer, typically metallic in nature. For simplicity of discussion, the magnetic particles can be chosen to be small enough that the dispersion will not sediment during the fabrication process, but this is not required for controlled production of FSC materials.
The dispersion is then subjected to a magnetic field. This magnetic field causes particles to chain along the field direction, creating oriented aggregates of magnetic particles. If the field direction is fixed, and the sample is stationary, the rod-like structures in FIG. 1 emerge. If the field direction is fixed, and the sample is rotated, the sheet-like structures in FIG. 2 emerge. The latter structures can also be formed in a stationary sample subjected to a rotating field. It is important to note that both of these structures can produce high bulk electrical conductivity at very small particle volume fractions.
“The process of synthesizing a field-structured composite material includes varying the relative orientation of the composite and external magnetic field during the process of creating the field structured composite material. Additionally, the relative orientation of the composite material and the external magnetic field can be restricted so that the magnetic field vector remains in a single plane.”
The conductivity of such oriented aggregates of magnetic particles depends on both the length of time that the magnetic field is applied and on the strength of the applied magnetic field. In the synthetic process tested, a field of several hundred Gauss was found to be more than sufficient to produce bulk conductivity.
The rate of aggregate formation can be slowed, or even reversed, by reducing the applied magnetic field, so that the magnetic particles can diffuse or sediment. For example, assume that the goal is to create a FSC material with a preselected bulk conductivity. If the evolution of aggregates accidentally proceeds too far, so that the bulk conductivity is larger than desired, an appropriate aggregate structure can be regained by reducing the applied magnetic field. The bulk conductivity can even be used as a control parameter in a feedback control FSC fabrication system. As a result, the final conductivity of such field-structured composites can be precisely controlled. This ability to precisely control the properties of the final composite is why field-structured composites enable numerous applications suggested for, but not easily realized using conventional conducting composite materials.
Any material whose structure results from the magnetic field-induced formation of aggregates in a distribution of magnetic particles in a fluid medium are field-structured composite materials. At times an FSC material which remains in the fluid state may be well-suited to an application, e.g., a shear stress sensor to measure onset of slip across a coupling between rotating members. There are, however, applications in which a solid FSC material is more appropriate. Solid field-structured composite materials can be formed by choosing a fluid medium which can be solidified without disrupting the particle aggregates existing in the dispersion. Suitable modes of solidification include freezing, gel formation, and polymerization, e.g., through the action of temperature increase or optical illumination.
A particularly useful class of field-structured composite materials are those solid FSC materials in which the nonconducting medium responds to the presence of various chemicals in the surrounding environment by alteration of volume and/or shape. Examples include instances where the solid medium containing the dispersion of magnetic particles is a polymer or gel which expands in the presence of, e.g., acetone or water. If the FSC material is near the critical volume fraction for bulk conductivity, that conductivity will undergo a large change as the medium changes shape. Such materials can be used as sensitive chemical sensors.
In a related set of applications, FSC materials can be used as the basis for mechanical stress/strain sensors. As long as the medium and the magnetic particles have different elastic properties, an applied stress or strain will change the electrical conductivity as outlined above. Strains less than 10 −9 should be easily detectable in such sensors.
It is well known that the distribution of dispersed microparticles in composite materials can have dramatic effects on the strength of such materials. For example, in metals and ceramics having micron to submicron dispersed particles, the flow of dislocations which control plastic flow at high temperatures varies dramatically on the separation of such particles. A significant source of strengthening in brittle materials is the major increase in fracture energy which can be caused by the interface between that material and a distribution of particles bonded thereto. The strength, toughness, or abrasive properties of materials can be altered by introducing particulates or by changing the distribution of particulates therein. In the same manner, the strength of solid FSC materials is a function of extent of evolution of the oriented aggregate structure. The precise effect depends in well-understood ways on the bonding process between the magnetic particles and the medium, and on the mode of yielding normally exhibited by the medium.
A typical process for making FSC materials is shown schematically in FIG. 3 . This flow diagram shows the steps common to one subclass of processes useful for making FSC materials. The process details are not to be considered limiting or necessary, but simply as illustrative of one such process.
The first step is to prepare the materials which will combine to form the FSC material. In this example electrically conductive magnetic particles and an electrically nonconducting fluid medium are used, but this choice is not vital to the formation of an FSC material.
The conducting magnetic particles and the fluid medium are then combined so as to form a mixture comprising a uniform dispersion of conducting magnetic particles in the fluid medium. Other materials may also be included in the mixture. Here the term uniform means that the density of conducting magnetic particles as dispersed in the fluid medium is approximately constant on all length scales and in all locations. It does not indicate a precisely constant volume fraction. Thorough mechanical mixing is found to be sufficient for this process step.
Once the above mixture is formed, a magnetic field is applied to form the desired texture in the dispersion of conducting magnetic particles. If the magnetic field is fixed in orientation relative to the incipient composite, the spatial distribution of the initially-uniform dispersion of conducting magnetic particles evolves toward an interconnecting network of conducting rod-like concentrations as shown in FIG. 1 .
For the purposes of the current process this evolution can be monitored by measuring the conductivity of the mixture perpendicular to the applied magnetic field. This conductivity monitors the formation of the interconnecting network and is used as a feedback parameter to control the applied magnetic field—in this case supplied by a coil. If this conductivity is smaller than a preselected target value, the process is allowed to continue. If it is greater, the field is reduced to the point that the aggregation process reverses. Once the conductivity reaches the target value, the feedback control system maintains the desired structure while the continuous phase is solidified.
Other parameters can also be used to control the aging process. Most simply, the time spent aging the material can be controlled, although this does not provide the most precise control over the properties of the resulting FSC material. This time control technique was used to make various samples for study as described below.
Both magnetically soft and hard particles were used in these studies. The soft magnetic particles were a 3-5 μm carbonyl iron powder used to make samples with concentrations in the range of 2.0-30.0 vol. %. The magnetically hard particles were made of SmCo 5 , and were used at a concentration of 2.5 vol. %. Finally, stainless steel fibers nominally 1.0 μm in diameter and 1 mm in length were used at a concentration of 1.55 vol. %.
The examples above, combined with known principles of magnetic interaction, demonstrate that a wide range of magnetic particle shapes are compatible with the present invention, ranging from substantially spherical in shape to shapes substantially extended or contracted along one or more axes.
These particles were suspended in an epoxy resin 828 containing a small amount of a dispersing agent. A dispersing agent alters surface tension between the resin and the magnetic particles, and thereby discourages clumping of particles. These suspensions were placed in an ultrasonic bath for 1 hr to make them more uniform, at which point an epoxy catalyst was stirred into the suspension. The suspensions were then placed in 1 cm square polystyrene cuvets and degassed in a vacuum oven at 50° C. for 10 minutes.
The samples were then ready for exposure to the magnetic field which would cause the desired oriented aggregation structure to evolve. In this process, this exposure takes place simultaneously with a slow curing of the epoxy resin.
A 150 G magnetic field was supplied by two large plate magnets oriented such that the magnetic field was vertical, to prevent the sedimentation of evolving aggregates of magnetic particles. In those samples for which a rodlike aggregate structure is desired, the sample is placed in a fixed location and orientation between the magnets. When a sheetlike aggregate structure is desired, the sample holder was rotated around an axis perpendicular to the magnetic field at a speed of 100 rpm.
The initial curing of the epoxy takes some 20 hours, during which period the sample remains exposed to the magnetic field. This gels the resin so that the particles remain essentially fixed in place, but does not fully cure the epoxy. To fully cure the epoxy, a post-curing bake, consisting of ramping the temperature from 50° C. to 100° C. over 3 hrs, and then curing at 100° C. for at least 3 more hrs, was applied. These samples were then sectioned with a diamond saw for susceptibility measurements parallel and orthogonal to the direction of the structuring field.
A subclass of field-structured composite which can exhibit unusual optical properties occurs when the magnetic particles conduct electricity freely and the nonmagnetic medium is a semiconductor. For the proper type of oriented aggregate structures, such a field-structured composite exhibits a bulk conductivity which is a strong function of the amount of light falling on it, provided that the light has energy greater than the bandgap of the semiconducting medium.
Two effects join together to produce this extreme sensitivity. First is that the weak portions of conducting paths which are nearly complete require conduction through very short distances in the semiconducting medium. When the incoming light is absorbed by the semiconducting medium, electron-hole pairs are generated, which then enable electrical conduction in the semiconductor. Because the distances that the electrons must travel in the semiconductor are so short, any significant creation of carriers can result in a large increase in bulk conductivity.
The second effect adding to the sensitivity of such composites to incident light is that the substructure improves the portion of the incident light that is absorbed by the semiconducting medium. Essentially, the light bounces back and forth between the conducting magnetic particles (highly conducting particles are generally also highly reflective) until it is absorbed by the semiconducting medium. This effect allows a thin layer of such a composite to efficiently absorb incident light, resulting in larger concentrations of photons in the semiconducting medium between the conducting particles - precisely where the carriers will be most effective in increasing the bulk conductivity of the composite.
The above descriptions of field-structured composites and processes for their synthesis are intended to illuminate the essential nature of the present invention through discussion of specific implementations, and are not intended to limit the scope of the invention. | The present application is directed to a new class of composite materials, called field-structured composite (FSC) materials, which comprise a oriented aggregate structure made of magnetic particles suspended in a nonmagnetic medium, and to a new class of processes for their manufacture. FSC materials have much potential for application, including use in chemical, optical, environmental, and mechanical sensors. | 8 |
BACKGROUND OF THE INVENTION
The invention relates generally to an improved strand fabricating machine.
More specifically, the invention relates to an apparatus for rotation of sets of front and rear carriers for strand supply bobbins, in opposite directions around a central axis stationary shaft, by an improved drive mechanism connected to a power input shaft.
A fair description of a strand fabricating machine, also known in the prior art as a braiding machine, is found in U.S. Pat. No. 1,493,782, 1924, Klein. Reference is made "to that type of machine in which two oppositely rotating tables or turrets are provided, each turret or table carrying a series of spools or bobbins, the threads from all of said spools converging at a braiding point above the machine and means being provided whereby the threads from one series of bobbins will be interlaced with the threads from the other series of bobbins. The purpose of machines of this type is to produce a tubular braided fabric with or without a core." (Col. 1, 11. 9-21)
The prior art braiding machines with mechanisms for rotating two tables in opposite directions have generally used differential bevel gear or sun gear-planet gear systems. Such power transmission systems are inherently complex with precisely machined components and similarly complex machine bases, frames or support structures. The Klein patent shows a base 1 mounting a horizontal drive shaft 3 carrying a pulley 4 at its outer end adapted to be engaged by a suitable clutch 5 to connect the driving pulley to the drive shaft. A bevelled driving pinion 6 is mounted on the inner end of the drive shaft and engages two bevelled gears 7 and 8 for rotating the bobbin carrying plates in opposite directions.
Other prior art patents showing the use of differential bevel gear power transmission systems are: U.S. Pat. No. 1,707,718, 1929, Frederickson; U.S. Pat. No. 1,747,720, 1930, Krissiep; and, U.S. Pat. No. 3,362,238, 1968, Dergachev, et al. Prior art patents showing the use of sun gear-planet gear systems are: U.S. Pat. No. 3,756,117, 1973, DeYoung; and, U.S. Pat. No. 4,034,642, 1977, Iannucci, et al. These and other prior art patents relating to braiding machines with two oppositely rotating tables are to be found in Patent Office Class 87.
So far as is known to the inventor, the art relating to braiding machines having two oppositely rotating tables mounted on a central axis stationary shaft has not had a relatively uncomplex drive mechanism connected to a power input shaft for rotating the two tables in opposite directions.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved strand fabricating machine.
It is a further object of the invention to provide an improved apparatus for rotation of sets of front and rear carriers for strand supply bobbins, in opposite directions around a central axis stationary shaft, by an improved drive mechanism connected to a power input shaft.
Still further, it is an object to provide a drive mechanism connected to a braiding machine power input shaft which is relatively uncomplex; leading to lower costs of fabrication and efficiencies in operation and maintenance.
These and other objects of the invention, as well as the advantages thereof, will become apparent in view of the drawings and the detailed description.
The invention is used with a braiding machine having a set of rear carriers for a strand supply bobbin mounted on the rear side of a first table for rotation in one direction. The braiding machine also has a set of front carriers for a strand supply bobbin movable around the front side of the first table for rotation by a second table in the opposite direction. The braiding machine has a central axis stationary shaft for rotatable mounting of the first and second tables thereon. The braiding machine also has a drive mechanism power input shaft extending substantially parallel to the stationary shaft and toward the rear side of the first table. The braiding machine also has a frame base carrying a vertically oriented frame stanchion for mounting the stationary shaft and the power input shaft.
A drive mechanism according to the invention, for rotating the first and second tables in opposite directions, has a first sprocket mounted on the forward end of the power input shaft and behind the rear side of the first table. A second sprocket is positioned coaxially around the central axis stationary shaft and aligned with the first sprocket and coupled to the first table. A first chain means connects the first sprocket with the second sprocket so that a rotation of the power input shaft will rotate the first table in one direction. A post shaft extends from the front side of the first table substantially parallel to the stationary shaft and toward the second table. A third sprocket is positioned around the post shaft on the medial portion thereof and rotatable thereon. A fourth sprocket is positioned around the post shaft on the end thereof, and coupled to the third sprocket for rotation therewith. A fifth sprocket is positioned around the stationary shaft and coupled thereto and aligned with the third sprocket. A second chain means connects the third sprocket with the fifth sprocket so that the third sprocket is rotated in a second direction during rotation of the first table in the opposite direction. A sixth sprocket is positioned around the stationary shaft and aligned with the fourth sprocket and coupled to the second table. A third chain means connects the fourth sprocket with the sixth sprocket so that the fourth sprocket, coupled to the third sprocket and the second table, are rotated in a second direction during rotation of the first table in the opposite direction.
IN THE DRAWINGS
FIG. 1 is a side view of a braiding machine showing the table drive mechanism according to the invention in full lines, other components of the braiding machine being shown in chain lines;
FIG. 2 is an enlarged side view, in section, showing details of a table drive mechanism according to the invention;
FIG. 3 is a fragmentary rear section, looking toward the first table, taken substantially as indicated on line 3--3 of FIG. 2;
FIG. 4 is a full rear section taken substantially as indicated on line 4--4 of FIG. 2; and
FIG. 5 is still another full rear section, looking toward the second table, taken substantially as indicated on line 5--5 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
A horizontal braiding machine, embodying the present invention, is referred to generally by the numeral 120. The braiding machine 120 will have a set of rear carriers 20R for a strand supply bobbin mounted on the rear side of a first table 121 for rotation in one direction. The strands from bobbins on the rear carriers 20R pass through peripheral and radially arcuate slots 327 in the first table 121. The braiding machine 120 will further have a set of front carriers 20F for a strand supply bobbin movable around the front side of the first table 121 for rotation by a second table 122 in the opposite direction. A stationary shaft 123 on the central axis of the braiding machine rotatably mounts the first table 121 and second table 122 thereon. A drive mechanism power input shaft 124 extends substantially parallel to the stationary shaft 123 and toward the rear side of the first table 121.
A drive mechanism according to the invention, for selectively rotating the first table 121 and the second table 122 in opposite directions around the central axis stationary shaft 123, is referred to generally by the numeral 225. The table drive mechanism 225 is operable above a frame base 126 carrying a vertically oriented frame stanchion 127 for mounting the stationary shaft 123 and the power input shaft 124.
Each set of carriers for a strand supply bobbin, 20R and 20F, are shown only by chain lines. A carrier 20 particularly suited for use on a braiding machine 120 may be as disclosed in (Case No. 1795) U.S. patent appln. Ser. No. 648,064, filed Sept. 7, 1984, Bull et al, Carrier For A Strand Supply Bobbin. Reference is made to said patent application for such further details as may be required to more fully understand the nature of the invention.
A mounting assembly for the stationary shaft 123 and the power input shaft 124 is shown only by chain lines. A mounting assembly (125) particularly suited for use on a braiding machine 120 may be as disclosed in (Case No. 1794) U.S. patent appln. Ser. No. 673,382, filed Nov. 20, 1984, Bull, et al, Apparatus For Mounting Of Components For Rotation of Carriers for a Strand Supply Bobbin and for Timing Strand Movement Relative to Rotation. Reference is made to said patent application for such further details as may be required to more fully understand the nature of the invention.
A drive assembly for moving each front carrier 20F during rotation of the second table 122 is shown only by chain lines. A front strand carrier mounting and drive assembly (425) particularly suited for use on a braiding machine 120 may be as disclosed in (Case No. 1798) U.S. patent appln. Ser. No. 673,385, filed Nov. 20, 1984, Bull, et al, Apparatus For Rotating A Set Of Carriers For A Strand Supply Bobbin Relative To Moving Strands From A Set Of Contra-Rotating Carriers For A Strand Supply Bobbin. Reference is made to said patent application for such further details as may be required to more fully understand the nature of the invention.
The table drive mechanism 225 has a first sprocket 226 securely mounted on the forward end of the power input shaft 124 and behind the rear side of the first table 121. A second sprocket 227 is positioned coaxially around the central axis stationary shaft 123 and aligned with the first sprocket 226 and coupled to the first table 121, as by bolts 228. A first chain means 229 connects the first sprocket 226 with the second sprocket 227 so that a rotation of the power input shaft 124 will rotate the first table 121 in one direction.
As shown, a first journal sleeve 230 is positioned around the central axis stationary shaft 123. The journal sleeve 230 freely rotates on roller bearing assemblies 231. The front face of the journal sleeve 230 has an annular shoulder flange 232 for secure connection thereto of the first table 121 and the second sprocket 227, as by passthrough attachment of the bolts 228.
As shown, the rear face of the journal sleeve 230 carries a control element 328 which is securely connected, as indicated at 138, to the front end of a mounting assembly drive torque tube 136. The control element 328 is mounted on roller bearing assemblies 233 positioned within a circumferential bearing race 234 and is secured by an annular end retainer 235, attached to the journal sleeve 230 as by bolts 236.
Control element 328, positioned coaxially around the central axis stationary shaft 123 behind the rear side of the first table 121 and radially inwardly of the rear carriers 20R, is used with of a set of mechanisms (326) for guiding strands from bobbins on the rear carriers 20R through an arc segment relative to the central axis of the braiding machine 120 and inwardly and outwardly relative to moving strands (24F) from bobbins on the front carriers 20F. An embodiment of control element 328 and strand guiding components functioning in combination therewith may be as disclosed in (Case No. 1792) U.S. patent appln. Ser. No. 673,384, filed Nov. 20, 1984, Bull et al, Apparatus for Control of Moving Strands From Rotating Strand Supply Bobbins. Reference is made to said patent application for such further details as may be required to more fully understand the nature of the invention.
The drive mechanism 225 further has a post shaft 237 extending from the front side of the first table 121 and substantially parallel to the central axis stationary shaft 123 and toward the second table 122. A third sprocket 238 is positioned around the post shaft 237 on the medial portion thereof and rotatable thereon. A fourth sprocket 239 is positioned around the post shaft 237 on the end thereof and rotatable thereon. The third sprocket 238 and the fourth sprocket 239 are coupled together, as by mounting on a journal bushing 240 carried by the post shaft 237.
The drive mechanism 225 further has a fifth or "sun" sprocket 241 positioned around the central axis stationary shaft 123 and coupled or keyed thereto and aligned with the third sprocket 238. As shown, a coupler sleeve 242 in front of the journal sleeve 230 is secured to the stationary shaft 123 and the sun sprocket 241 is mounted thereon. A second chain means 243 connects the third sprocket 238 and the sun sprocket 241 so that the third sprocket 238 is rotated in a second direction during rotation of the first table 121 in the opposite direction.
The drive mechanism 225 further has a sixth sprocket 244 positioned around the central axis stationary shaft 123 and aligned with the fourth sprocket 239 and coupled to the second table 122, as by bolts 245. A third chain means 246 connects the fourth sprocket 239 with the sixth sprockets 244 so that the fourth sprocket 239, coupled to the third sprocket 238, and the second table 122 are rotated in a second direction during rotation of the first table 121 in the opposite direction.
As shown, a second journal sleeve 247 is positioned around the central axis stationary shaft 123 in front of the coupler sleeve 242. The journal sleeve 247 freely rotates on roller bearing assemblies 248. The face of the journal sleeve 247 has an annular shoulder flange 249 for secure connection thereto of the second table 122 and a ring flange 250 carrying the sixth sprocket 244, as by passthrough attachment of the bolts 245. The journal sleeve 247 is secured around the stationary shaft 123 by a bearing nut 251 having internal threads for mating engagement with external threads 252 on the stationary shaft 123. | A drive mechanism for rotating two tables around the central axis stationary shaft of a braiding machine having a set of strand carriers mounted on the rear side of a first table and another set of strand carriers movable around the front side of the first table for rotation by a second table. The drive mechanism is connected to a power input shaft extending substantially parallel to the stationary shaft and toward the rear side of the first table and includes a series of six sprockets, a postshaft and three chains so that the two tables are rotated in opposite directions in response to rotation of the power input shaft. | 3 |
INCORPORATION BY REFERENCE
This application is related to co-pending application entitled, "Removable Door Cassette For a Vehicle And Method of Assembly", Ser. No. 08/729,092, which is commonly owned, filed Oct. 15, 1996 and incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to a door for an automotive vehicle, and, more specifically, to an improved door cassette assembly allowing easy manufacturability and a method therefor.
Traditionally, doors for automotive vehicles are assembled on the assembly line simultaneously with the rest of the vehicle. During the assembly process, components such as the regulator that controls the movement of the window are tested for operability. The manufacturing personnel and time required to perform the installation and testing of the individual components are significant. If a component is not adjusted properly, the improperly adjusted component must be adjusted adding further delay into the assembly process.
On the assembly line, the fit of the door to the vehicle is tested. The vehicle door is typically a singularly stamped unit. An adjustment of the entire door may be made, but adjusting only a portion of the door relative to another portion is either difficult or impossible to make. Commonly, the door frame is manually bent to conform to the desired shape. This process is highly inaccurate and may lead to wind noise and water leaks. Also, achieving the desired adjustment is difficult since a door is not made to be adjusted in the manner in which they are adjusted. Since very small misadjustments may lead to water leaks or wind noise, the conventional method for adjusting a door is highly inconsistent.
Recently, several methods have been described for assembling a portion of the vehicle door off the assembly line that contain, for example, the window regulator and other hardware. The preassembled portion is brought to the assembly line for installation as a preformed unit.
In one modular door construction, the door cassette is removable from the door when desired by the vehicle operator. A frame member extends up from the door to which the cassette attaches. One drawback to the system is that an adjustment of the cassette inward to the vehicle body to prevent wind noise and water leaks is not possible since the cassette connects to the unadjustable frame member having limited adjustability.
Another configuration of a preassembled unit, includes only the window and its movement hardware that is inserted into a rigid door frame. No adjustment in the alignment of the door frame to the vehicle body is possible. Also, no adjustment of the window to the door frame is possible, and may result in water leaks and wind noise.
In yet another configuration a door frame is also preformed. The window track assembly is modularized for installation. The window track pivots relative to the door frame during installation. In such a configuration the window closing efforts may not be tested off line prior to assembly. Another disadvantage is that the door frame is not adjustable to the vehicle body, which may result in wind noise and water leaks.
In still another configuration, a door cartridge is fixed into place by a vertical member extending to the bottom sill of the door. The assembler must reach under the door to secure the cartridge to the door. This is inconvenient for the assembler. Easy adjustability for small adjustments in alignment are not provided.
It would therefore be desirable to provide a vehicle door having the mechanical portion assembled offline as well as provide for a method for convenient assembly and which is readily adjustable.
SUMMARY OF THE INVENTION
Briefly, the present invention provides a cross member onto which a door frame is connected. The cross member and door frame are pivotally connected to a door housing on the vehicle. The door frame has a lower door frame that extends into the door housing. A connection adjustably fastens the lower door frame in relation to the door housing.
In a further embodiment of the invention, the connection has a first adjuster to fasten a door frame into a first position and a second adjuster to adjust the frame about its pivot to secure the frame into a final position.
In one configuration the second adjuster has a screw that moves the cassette closer to or away from the vehicle frame. The screw preferably adjusts the door a small metered amount for each rotation so that the door cassette may be easily and precisely aligned.
An advantage of the invention is that the door frame may be easily adjusted to eliminate water leaks or wind noise.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become apparent from the following detailed description which should be read in conjunction with the drawings in which,
FIG. 1 is a perspective view of an automobile vehicle having a vehicle door according to the present invention;
FIG. 2 is an exploded view of an automotive door;
FIG. 3 is an interior view of an automotive door having its interior trim paneled removed;
FIG. 4 is a partial cutaway view of an end of automobile door looking forward;
FIG. 5 is a side view of a pivot point of the lower door;
FIG. 6 is a cross-sectional view of a pivot point of the assembled vehicle door;
FIG. 7 is a cross-sectional view vertically and longitudinally through the adjuster of the vehicle door;
FIG. 8 is a cross-sectional view laterally through the vehicle door at the adjuster;
FIG. 9 is a cross-sectional view of an alternative adjuster embodiment;
FIG. 10 is a partial cutaway end view of an automotive door from the front of the vehicle;
FIG. 11 is a partial cutaway view of an adjuster on the front of vehicle door looking rearward; and
FIG. 12 is a perspective view of an automotive vehicle door on an adjustment fixture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, like reference numerals are used to identify identical components in the various views. Although the invention will be illustrated in the context of a framed vehicle door, it will be appreciated that this invention may be used in conjunction with other applications requiring an adjustable vehicle door such as a frameless window application.
Referring now to FIG. 1, an automotive vehicle 20 is shown having a vehicle body 21 and an automotive vehicle door assembly 22 for closing an opening 23 in vehicle body 21. The terms, interior, exterior, rearward and forward, as used in this description, are related to door assembly as installed in vehicle body 21. The door assembly 22 described hereinafter is a driver side door. A passenger side door would be essentially the mirror image of the driver side door.
Referring now to FIG. 2, door assembly 22 is shown in an exploded view having door cassette 24 separated from lower door 26. Pivot bolts 28, coarse adjust bolts 30 and fine adjust bolts 32 are used to mount door cassette 24 to lower door 26. Pivot bolts 28 pivotally connect door cassette 24 to lower door 26 when door cassette 24 is housed by lower door 26. Coarse adjust bolts 30 fix door cassette 24 into a predetermined position with respect to the vehicle body. Fine adjust bolts 32 are used to finely adjust door cassette 24 with respect to lower door 26.
Door cassette 24 includes a door frame having an upper door frame 34 and lower door frame 38, a window 36 and its associated hardware, a plate member 40 and a cross member 46. A seal 48 may also be included as part of door cassette 24.
Upper door frame 34 defines an opening to enclose window 36. Upper door frame 34 is preferably roll formed but may also be stamped from steel. Of course, light weight material may be used in door cassette 24 such as plastic or aluminum if structural integrity is maintained. Upper door frame 34 may be eliminated in a frameless window application for applications such as a convertible.
Lower door frame 38 extends into lower door 26 when assembled. Lower door frame 38 may be used as means to secure door cassette 24 to lower door 26. As shown, lower door frame 38 comprises two members, one on the forward most end and rearward most end of door cassette 24. Each member of lower door frame 38 extends from upper door frame 34 near pivot bolt 28. Lower door frame 38 and upper door frame 34 may be separate pieces but are preferably formed as a single continuous piece with upper door frame 34. When formed as a continuous piece the transition between upper door frame 34 and lower door frame 38 is roughly at pivot bolts 28.
Plate member 40 is preferably an individual stamped piece that extends across door cassette 24 and is rigidly connected to the two members of lower door frame 38. Plate member 40 is shaped to provide attachment points for window and door movement hardware such as a window regulator 42 and glass guides 44. Plate member 40 may also provide some structural rigidity to door cassette by acting as a cross support.
Cross member 46 extends across door cassette 24 between the two members of lower door frame 38 and provides rigidity for door cassette 24. Because lower door frame 38 is used to secure door cassette 24, cross member 46 preferably connects to lower door frame 38 near where lower door frame 38 secures to lower door 26. Cross member 46 also provides rigidity to door cassette when shipped since door cassette 24 is built off line and transported before assembly.
Seal 48 extends around upper door frame 34 for sealing upper door frame 34 against the vehicle body. When supplied to the vehicle manufacturer door cassette 24 may contain seal 48 pre-installed on upper door frame 34. Seal 48 may also extend beyond door cassette 24 to provide an endless seal between the vehicle body and lower door 26. If a long seal is provided with door cassette 24, seal 48 may be fastened to lower door 26 after door cassette 24 is installed and adjusted. Seal 48 may also be used to cover connecting hardware such as pivot bolts 28.
Lower door 26 is preferably assembled by the vehicle manufacturer and has the necessary structure to connect to door cassette 24. Lower door 26 is shaped generally to define a cavity to receive door cassette 24. Lower door 26 has an outer door panel 50 contoured to meet the styling for the desired vehicle application. Outer door panel 50 has an opening 52 for receiving a door handle and lock.
Lower door 26 may also have a side impact beam 54 to meet government mandates. Side impact beam 54 extends across lower door 26. Side impact beam 54 is used to provide structural rigidity to lower door 26 in the event of a side impact.
A latch 56 may also be included in lower door 26. Latch 26 is preferably a conventional type latch. Including latch 56 on lower door 26 provides a means to keep the door assembly closed if desired during positioning of door cassette 24.
Referring now to FIG. 3, door cassette 24 is installed within lower door 26. Pivot bolts 28, coarse adjust bolts 28 and fine adjust bolts 32 are used to position door cassette 24 within lower door 26 and with respect to the vehicle body. Pivot bolts 30 define an axis 55 around which door cassette 24 rotates.
Although not shown, a finished trim panel is fastened to lower door 26 to complete assembly. The trim panel contains the buttons and levers to provide a vehicle operator interface to control the functions provided by the door assembly such as moving the window and locking the door.
Referring now to FIG. 4, when door cassette 24 is first placed into lower door 26, the initial position secured is governed by coarse adjust bolt 30 and its associated hardware. Coarse adjust bolt 30 is secured to lower door through a slot 58. The pivot movement of door cassette 24 is shown around pivot bolt 28. The maximum distance for movement is governed by slot 58. An opening 60 in lower door 26 allows access to coarse adjust bolt 30. During assembly coarse adjust bolt 30 is lightly tightened to correspond to some nominal position of door cassette 24 relative to the vehicle body.
To set the final position, fine adjust bolt 32 may be used to precisely move door cassette 24 into a final position. Another opening 62 in lower door 26 allows access to fine adjust bolt 32 from the interior side of lower door 26. A bracket 64 is preferably used to hold bolt 32 relative to lower door 26 to provide movement of fine adjust bolt 32 with respect to bracket 64. Bracket 64 may be threaded or a nut 66 may be fixedly attached to bracket 64 so that fine adjust bolt 32 may rotate relative to bracket 64. The end of fine adjust bolt 32 contacts lower door frame 38 so that a fine adjustment may be made in the position of upper door frame 34 with respect to the vehicle body. With the position of fine adjust 32 as shown, as fine adjust bolt is rotated into lower door 26, door cassette 24 is rotated about pivot bolts 28 so that upper door frame 34 is moved closer to vehicle body. Preferably, each rotation of fine adjust bolt 32 corresponds to a known value such as one millimeter of adjustment of upper door frame 34 toward or away from vehicle body. Thus, the desired adjustment may be precisely made.
Referring now to FIG. 5, a portion of lower door 26 is shown with its pivot means. As shown, the pivot means is a U-shaped channel 68 on which the pivot bolts 28 rest. Of course, other means for pivoting would be known to those skilled in the art such as providing merely a hole through which fine adjust bolts could be received or providing a pin on either door cassette 24 or lower door 26 that cooperate to provide a pivoting motion.
Referring now to FIG. 6, a cross sectional view through pivot bolt 28 is shown. As can be seen, pivot bolt 28 extends through lower door 26 and into upper door frame 34.
Referring now to FIG. 7, coarse adjust bolt 30 is shown with respect to lower door frame 38. A bracket 69 mounted to lower door 26 is used to secure coarse adjust bolt 30 to lower door 26. Also, fine adjust bolt 32 is shown with respect to lower door frame 38. Lower door frame 38 has a notch 70 or other means to engage fine adjust bolt 32 so that fine adjust bolt may adjust lower door frame 38. As shown, lower door frame 38 moves into and out of the page while coarse adjust bolt 30 moves within slot 58.
Referring now to FIG. 8, a cross sectional view of fine adjust bolt 32 with respect to notch 70 is shown. One method for finely adjusting the position of lower door frame 38 is to provide a groove 72 in fine adjust bolt 32. As fine adjust bolt 32 rotates with respect to bracket 64 and nut 66, the notch 70 of lower door frame 38 and groove 72 remain engaged. Lower door frame 38 moves as fine adjust bolt 32 and, as a result, notch 70 moves. Lower door frame 38 may be moved so that upper door frame 34 moves closer to or away from the vehicle body to achieve precisely the desired fit.
Referring now to FIG. 9, an alternative method for finely adjusting lower door frame 38 is shown. In this embodiment only the end of fine adjust bolt 32 presses against a portion of frame 38 to move lower door frame 38 about the pivot point. Door cassette 24 may be weighted so that fine adjust bolt 32 forces movement in one direction to counteract the weight of door cassette 24. Since if travel in the other direction is required, for example backing the bolt away, door cassette 24 will naturally move in that direction due to its weight.
Referring now to FIG. 10, a side cutaway view is shown of the forward most end of door assembly 22. It is preferred that both the front and rear portions of door assembly 22 have similar adjustment means. Front end of door has a pivot bolt 28, coarse adjust 30 and a fine adjust bolt 32 that operate in the same manner as that of the rearward most end of the door. Their vertical positions, however, may be slightly altered. The position of the adjustment means may be moved due to the design requirements of the vehicle including location of latches, hinges and passthroughs for wires to connect the electrical components within the door to the rest of the vehicle.
Referring now to FIG. 11, a side cross sectional view through coarse adjust bolt 30 and fine adjust bolt 32 is shown. Instead of connecting to a notch in the end of lower door frame 38 as in the rearward most connection, a bracket 73 may be connected to lower door frame 38 to provide the same function.
In operation, lower door 26 may be manufactured and installed on the vehicle so that lower door may be painted along with the rest of the vehicle or painted prior to installation. The lower door is preferably made by the vehicle manufacturer.
The door cassette structure is assembled off the assembly line and tested. To assemble the door cassette, upper door frame 34, lower door frame 38, plate member 40 and cross member 46 are preferably welded together to form the door cassette structure. This assembly is preferably dipped in a common rust preventative such as "E-coat" before further assembly. Also, this structure may be painted a finish color depending on the vehicle application.
Glass guides 44 are installed on the cassette structure and the window 36 is inserted. Window regulator 42 is then connected to the window and mounted to the structure. Any other mechanism may then be installed onto the door structure. Any seals may also, be preinstalled. The operation of the mechanisms are then tested for operability. This assembly is then moved to the assembly line for installation to complete a door assembly 22.
During the assembly process door cassette 24 is placed into lower door 26. Pivot bolts 28 are inserted so that door cassette pivots in lower door 26. Coarse adjust bolts 30 are tightened lightly to hold door assembly 22 into a position that has been predetermined to provide roughly the proper fit for the vehicle. The fine adjust bolts 32 may then be inserted and placed into a nominal position. The door of the vehicle may then be closed and any adjustment made from within the vehicle by fine adjust bolts 32. Fine adjust bolts 32 pivot upper door frame 34 about pivot bolts 28. Once fine adjust bolts 32 are adjusted, coarse adjust bolts 30 may be fully tightened.
Referring now to FIG. 12, a fixture 74 may also be used in the assembly process as an alternative to installing the door in a vertical fashion. Lower door 26 may be connected to door cassette 24 in a horizontal fashion, then installed onto the vehicle. Fixture 74 preferably has an adjustment 76 to allow the door cassette 24 to be set at a predetermined angle with respect to lower door 26. If the vehicle body being manufactured has a known tolerance variability, adjustment 76 may be set to match that tolerance. If any further adjustments are required, fine adjust bolts 32 may be adjusted once door assembly 22 has been placed upon the vehicle.
While the best mode for carrying out the present invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. For example in a frameless window application the upper door frame and seal may be eliminated. the seal may placed on the vehicle body. | A vehicle door has a door housing and a door cassette that may be assembled off the manufacturing line and tested prior to assembling on the door housing. The door cassette has a cross member onto which a door frame is connected. The cross member and door frame assembly is pivotally connected to the door housing. The door frame has a lower door frame that is inserted into the door housing. A connection adjustably fastens the lower door frame in relation to the housing so that the frame may be easily adjusted to fit to the vehicle body. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a method for recovering the sensible heat of slag, in particular of blast furnace slag, wherein the liquid slag is allowed to solidify on the surface of a hollow cooling body provided with a liquid internal cooling and preferably designed as a cooling drum, and is indirectly cooled by the liquid internal cooling, the liquid cooling medium of the liquid internal cooling being guided in a thermodynamic cyclic process, as well as to an arrangement for carrying out the method.
A method of the initially defined kind is known from German Offenlegungsschrift No. 31 22 059 in which the slag is poured between two drums provided with internal cooling, the drum surfaces moving upwardly with the slag in the region of contact so that the slag is in contact with the drums over a long period of time and is cooled to a low temperature. The slag, which adheres to the drums over more than 3/4 of the drum surfaces, is removeable from the drums only with difficulty and by the formation of relatively large pieces of slag. The drums are heated to a relatively high temperature by the slag covering them. As cooling is started, the temperature gradient is very low, rising only after a certain period of time, whereby the desired glassy solidification of the slag is not guaranteed.
A further method for recovering the sensible heat of slag is known from German Offenlegungsschrift No. 27 59 205. With this method, the slag is poured onto what is called a centrifugal wheel, which centrifugal wheel mechanically atomizes the slag and throws it away. During the slag's travel through the air after having been thrown away, the slag cools down, with a thin, still soft skin forming on the slag particles. During the relatively short flight of the slag particles through the air, a solidification all through of the same is not guaranteed so that the slag particles tend to agglomerate when subsequently impinging on one another. Therefore, it is necessary to add a powdery separating agent, which separating agent, as it partially remains adhered to the slag particles, restricts the fields of application of the slag particles and cannot be guided in circulation entirely on account of its adhering to the slag particles; it must be renewed all the time.
According to German Offenlegungsschrift No. 27 59 205 the slag particles, together with the separating agent, reach a vessel, through which air is streaming from bottom to top, cooling the slag particles. The air heated by the slag particles, after having passed a cyclone separator, serves to heat a medium in a heat exchanger. In the fluidized bed formed within the vessel by the slag particles as a result of the passage of air, a heat exchanging tube is arranged, which is subjected to a great mechanical wear.
Apart from the fact that with this known method the glassy solidification of the slag is not ensured and a separating agent must be used, as described above, the heat recovery is also insufficient because of the cooling is predominantly effected by air.
The invention has as its object to eliminate these disadvantages and difficulties and has as its object to provide a method, as well as an arrangement for carrying out the method, which makes feasible as completely as possible a recovery of the sensible heat of the slag, wherein, however, a high percentage of glassy portions of the slag and a good grindability of the slag are ensured.
SUMMARY OF THE INVENTION
This object is achieved according to the invention in that the liquid slag on the surface of the cooling body is intensively cooled indirectly by means of the liquid cooling medium to a temperature of closely below the solidification temperature in a first cooling step and the solidified slag separated from the surface of the cooling body is directly cooled by means of a gas flow in a second cooling step, the heated gas flow also being guided in a thermodynamic cyclic process.
Suitably, the slag is cooled to about 1,100° C. by means of the liquid cooling medium and from about 1,100° C. to about 200° C. by means of the gaseous medium.
According to a preferred embodiment, with which a particularly high thermal yield is realized, the heat absorbed by the gas flow is supplied to the cooling medium heated by the slag, the liquid cooling medium suitably being guided in a closed cycle under an elevated pressure and the gas flow, furthermore, suitably being guided in a closed cycle.
An arrangement for carrying out the method, comprising a cooling body, preferably a cooling drum, defining a cavity, through which a liquid cooling medium flows, and at least one slag supply duct reaching to the surface of the cooling body, the cavity of the cooling body being connected in duct-like manner with a heat transformer of a thermodynamic cyclic process by means of a drainage for the liquid cooling medium entering into the cavity, is characterized in that a substantially vertical vessel passed through by the slag separated from the surface of the cooling body is provided, into which a cooling gas entrance duct enters near its lower end and a cooling gas exit duct enters near its upper end, the cooling gas exit duct being connected to a further heat transformer of a thermodynamic cyclic process.
For the purpose of a particularly efficient recovery of the sensible heat, the heat transformer of the thermodynamic cyclic process of the cooling gas is penetrated by the drainage for the liquid medium.
According to a preferred embodiment, the cooling body is formed by two counterwise-driven casting rolls and, furthermore, is arranged in the interior of the vessel near its upper end.
Suitably, the drainage for the liquid cooling medium is connected in a closed cycle with a cooling-liquid supply conduit entering into the cavity of the cooling body and, furthermore, the cooling gas entrance duct is connected in a closed cycle with the cooling gas exit duct via the heat exchanger.
A particularly favorable solidification of the slag is ensured if the cooling body is provided with elevations and recesses extending in the peripheral direction, the recesses suitably being designed as grooves extending over the periphery of the cooling body and having a cross section that widens towards the surface.
To form slag bodies of defined sizes, the surfaces of the casting rolls suitably are provided with opposite recesses complementing each other to form a mold cavity closed on all sides, which recesses advantageously are semi-spherically designed.
In order to ensure perfectly the penetration of gas through the slag present in the vessel, the vessel, on its lower end, advantageously is provided with a cooling gas entrance chamber widening with regard to the vessel in terms of cross section.
In order to prevent losses of hot gas via a slag discharge means, a secondary-gas duct enters below the slag discharge means, through which gas may be injected at a higher pressure than into the cooling gas entrance chamber.
In order to ensure an efficient cooling of the cooling body, the cooling body is covered by a liquid-cooled radiation protection screen relative to the vessel interior, the radiation protection screen being connected with the cavity of the cooling body in a duct-like manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in more detail by way of several embodiments and with reference to the accompanying drawings, wherein:
FIG. 1 illustrates an arrangement according to a first embodiment of the present invention in section;
FIG. 2 shows a detail of FIG. 1 on an enlarged scale (taken along the line II--II of FIG. 3);
FIG. 3 is an illustration of a section taken along the line III--III of FIG. 2;
FIGS. 4 and 5 represent further embodiments of the present invention in illutrations analogous to FIG. 2;
FIG. 6 shows a detail VI of FIG. 5 on an enlarged scale; and
FIG. 7 illustrates a view of the surface of the cooling bodies represented in FIGS. 5 and 6, taken in the direction of the arrow VII of FIG. 6.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Near the upper end 1 of a vessel 2 closed on all sides (also referred to as a cooling tower), having a substantially cylindrical shape and a vertical axis 3, a cooling body 4 designed as a cooling drum is rotatably mounted. Through the lid 6 of the vessel 2, a slag supply channel 7 is directed to the surface 5 of this cooling body 4. The cooling body 4 is provided with an internal cooling for a liquid medium. A piping 9 (drainage) draining the cooling liquid enters into its cavity 8, leading to a heat exchanger 11, in the flow direction 10 of the cooling liquid, and from there is guided to a heat consumer 12 and further on to a condenser 13 and a pump 14. From this pump 14, a cooling liquid supply conduit 15 enters into a cavity 16 of a radiation protection screen 17, through which the cooling liquid flows, the cooling liquid, after having flown through the same, being supplied to the cavity 8 of the cooling body 4 via the cooling liquid supply conduit 18.
The cooling tower 2, which optionally is provided with a wall cooling, on its lower end 19 passes over into a cooling gas entrance chamber 20 that is widened in the cross section perpendicular to the axis 3 and comprises downwardly conically narrowed funnels 21. To the funnels 21 slag discharge means 22 are connected, which, in the embodiment illustrated, are designed as spike rollers and also serve to break the slag. Below the spike rollers, bucket wheels 23 are provided, by which a dosed discharge of the slag particles is possible. Closely below the spike rollers 22, a gas duct 24 enters into the funnels 21, through which cooling gas, such as cooling air, is injectable into the funnels 21 by means of a fan 25.
A cooling gas entrance duct 26 enters into the cooling gas entrance chamber 20, which is widened relative to the cooling tower 20 in terms of cross section. Closely below the cooling body 4, the cooling tower is surrounded by an annular duct 27, which serves as a collection duct for the cooling gas flowing through the cooling tower 2 from bottom to top. This cooling gas leaves the cooling tower through openings 28.
From the annular duct 27 a cooling gas exit duct 29 is led to a cyclone dust separator 30, from which the gas duct 29 is led to one end 31 of the heat exchanger 11, through which the liquid cooling medium flows counter the gas. On the opposite end of the heat exchanger 11, the cooling gas leaves the same and is supplied back to the chamber 20 by a ventilator 32 so that the cooling gas, like the cooling liquid, is guided in a closed cycle to cool the cooling body.
As is apparent from FIG. 3, the surface 5 of the cooling body 4 is provided with peripheral grooves 33. These peripheral grooves widen radially outwardly at an angle 34 of about 2° with respect to the radial direction. Driving of the cooling body 4 is effected via a toothed ring 35. As can also be seen from FIG. 3, the cooling body 4, which is designed as a cooling drum, is rotatably mounted on a tubular axle 36 by means of a bearing 37, the cooling liquid supplied through the cooling medium supply conduit 15 flowing into the annular cavity 8 formed by the axle 36 and the drum. Seals 38 are provided between the axle 36 and the cooling drum.
The arrangement functions in the following manner:
The slag supplied to the surface 5 of the cooling body 4 via the slag channel 7 and having a temperature of about 1,550° C., is cooled to about 1,100° C. by the cooling body 4, i.e., the slag solidifies on the surface of the cooling body 4. The cooling body 4 is set in rotation by a rotary drive (not illustrated). After the slag has completely solidified, the slag chips off the cooling body 4.
The chipped off slag 39 is collected in the cooling tower 2 and in the funnels 21 and is further cooled by the cooling gas flow, preferably by an air flow, from 1,100° C. to about 200° C. The additional cooling air coming in below the spike rollers 22 cools the slag by further 100° C. to about 100° C., after it has been disintegrated by the spike rollers.
The cooling air rising through the cooling tower 2 and heated by the slag reaches the heat exchanger 11 through the annular duct 27 and the cyclone dust separator 30, where it gives off its heat to the cooling liquid passing the heat exchanger 11 in counterflow.
Thus, the cooling liquid is heated not only by the heat given off to it by the slag via the cooling body and the radiation protection screen 17, but the heat that has been absorbed from the slag by the cooling gas is additionally supplied to it. Since the cooling body 4, in addition to the internal cooling, is provided also with an external cooling at least over 180° of its periphery, by means of a radiation protection screen 17 the cooling body is most effectively cooled so that a glassy solidification of the slag after contacting the surface 5 of the cooling body 4 is ensured and an agglomeration of the slag chipping off the surface 5 of the cooling body is prevented. The slag that has not automatically chipped off is scratched off by the radiation protection screen, which is moved to the surface 5 of the cooling body 4, by claws adapting to the shape of the drum.
The cooling water is supplied to the radiation protection screen 17 by means of the pump 14 at about 30° C., enters the cooling body at about 70° C. after having flown through the radiation protection screen 17 and leaves the cooling body at about 180° C. and a pressure of 10 bars. By the elevated pressure, the formation of bubbles within the cooling body 4 is prevented and an effective heat transfer to the cooling liquid is ensured, so that the slag will have completely solidified already at about 1/10 of the drum circumference of the cooling body 4.
The cooling air enters the chamber 20 at about 200° C. and is heated by the slag to about 600° C., at which temperature the cooling gas leaves the cooling tower 2. The ventilator 32 urges the cooling gas into the cooling gas entrance chamber 20 at about 1.5 bars and takes it in from the heat exchanger 11 at a slight negative pressure of about 0.5 bars. The additional cooling gas, which is supplied below the spike rollers 22, is injected at a pressure slightly larger than 1.5 bars in order to ensure a sealing of the funnels 21 downwardly and to replace the air escaping from the system.
The heat exchanger 11 operates according to the counterflow principle, with the water introduced into the heat exchanger 11 at about 180° C. evaporating. The steam leaves the heat exchanger 11 at about 600° C. and is supplied to the consumer at this temperature. The cooling gas leaves the heat exchanger 11 at about 200° C. The steam worked off by the heat consumer 12 is cooled to about 30° C. and liquefied in the optionally required condenser 13.
The particularity of the method according to the invention is to be seen in the fact that the slag is cooled in two steps. The first cooling step takes place by indirect liquid cooling over the well cooled surface 5 of the cooling body 4 to closely below the solidification temperature, wherein it is important that the slag solidifies all through in a glassy manner. The second cooling step takes place from about 1,100° C. downward by direct gas cooling. By the first step, a harsh cooling is effected, thus ensuring the glassy solidification and the complete solidification. In the second step, an almost overall heat transmission from the slag to the cooling gas is effected.
The immediate contact of the slag jet with the cooled surface 5 of the cooling body 4 enables the extremely rapid cooling of the slag on account of the heat accumulating ability of the material of the cooling body 4 and on account of the ratio of cooling body weight to slag to be cooled of about 2:1. It is of importance that the surface 5 is free of slag over 3/4 of its periphery and is also cooled from outside over half of its periphery by means of a radiation protection screen 17.
In FIG. 4 an exemplary embodiment is illustrated, in which two counterwisely driven cooling drums 40, 41 acting as casting rolls are provided as cooling body, the slag supply channel 7 being provided with two mouths 42, 43. The cooling drums 40, 41, with their surfaces 5, rotate towards each other, seen from above (in the direction of the arrows 44). Between the cooling drums 40, 41 a gap 45 having a certain width 46 is provided; this gap 45 enables the passage of the slag. The mouths 42, 43 of the slag channel 7 each lie close to the highest elevation of the cooling drums 40, 41, in the moving direction 44, so that the slag reliably is carried in the direction to the respective oppositely arranged cooling drum and an overflow of the slag towards outside is prevented.
It is possible to provide the cooling drums 40, 41 with smooth surfaces 5, as illustrated in FIG. 4, or to provide the two cooling drums with circumferential grooves 33, according to FIG. 3, an elevation of the opposite cooling drum projecting into one groove 33 each.
According to the embodiment illustrated in FIGS. 5 and 6, the surfaces 5 of the cooling drums 40, 41 contact each other. They are provided with recesses 47 which are designed approximately semi-spherical, the recesses 47 of the two oppositely arranged cooling drums complementing each other so as to form spherical hollows at the line of contact so that slag particles 48 are formed that have the dimensions of these spherical hollows. The slag supply is kept so large that the height 49 of the slag sump 50 forming between the cooling drums 40, 41 is as slight as possible. | To recover the sensible heat of slag the slag is allowed to solidify on the surface of a hollow cooling body provided with a liquid internal cooling and is indirectly cooled by the liquid internal cooling. The liquid cooling medium of the liquid internal cooling is guided in a thermodynamic cyclic process. In order to ensure as completely a recovery of the sensible heat of the slag as possible and a high percentage of glassy portions of the slag as well as a good grindability of the slag, the liquid slag on the surface of the cooling body is intensively cooled indirectly by the liquid cooling medium to a temperature of closely below the solidification temperature in a first cooling step. The solidified slag separated from the surface of the cooling body is then directly cooled by a gas flow in a second cooling step. The heated gas flow also is guided in a thermodynamic cyclic process. | 8 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to a method for laser-induced metallization on polymeric substrates.
While it is possible to produce high resolution patterns by deposition techniques wherein masking is employed to delineate the pattern, such plating processes require multiple steps. It is necessary to employ a photoresist to mask the surface, to selectively expose the photoresist mask, to plate the surface and finally, to strip the mask. This process is a multistep process.
It is known to expose an electroless plating solution to a high intensity light source to enhance the plating rate. While this technique increases the plating rate, it is not well suited for preferentially plating patterns since there will be a mixing of the activated solution with the nonactivated solution. This mixing will reduce the resolution of any resulting pattern.
It is also known to coat a surface to be plated with a sensitizing solution. The coated surface is exposed to light to form a catalytic layer capable of catalyzing the deposition of metal thereon from an electroless metal deposition solution. Again, this technique suffers from the limitation of being a multistep process and requires a light activated catalytic layer.
Ridenour et al, in U.S. Pat. No. 3,762,938, describes a process for depositing elemental metallic coatings on solid substrates which comprises forming a hydride of the metal to be deposited in situ on a substrate and subjecting the metal hydride to sufficient energy to deposit the elemental form of the metal on the substrate. The source of energy may be heat, actinic light ot high energy radiation, such as electron bombardment. This technique suffers from being a multistep process.
Beauchamp et al, U.S. Pat. No. 4,324,854, describe a process for depositing a thin film of material such as a metal onto a substrate through photodissociation of a gaseous compound capable of electron capture dissociation, such as metal carbonyl. Deutsch et al, U.S. Pat. No. 4,340,617, describe a process for depositing a thin film of material such as metal onto a substrate through laser induced photolytic decomposition of a gaseous compound, such as organo-metallics, metal carbonyls, metal halides and the like. These techniques suffer from the relative complexity of the apparatus required.
Blum et al, U.S. Pat. No. 4,239,789, describe a process for depositing a metal onto a workpiece comprising a thin layer of metal or an active layer of solution such as palladium chloride which comprises contacting the surface with an electroless plating solution and directing an energy beam onto the workpiece to locally heat the surface to promote enhanced plating. Kulynych et al, U.S. Pat. No. 4,349,583, describe a similar process wherein the plating solution does not contain a reducing agent. These patents do not address the plating of metals onto non-metallic surfaces.
Accordingly, it is an object of the present invention to provide a method for selectively plating onto the surface of a non-metallic workpiece.
Other objects and advantages of the present invention will be apparent to those skilled in the art from a reading of the following description of the invention.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method for selectively plating onto a polymeric workpiece without application of an electrical potential source which comprises the steps of contacting the workpiece with an electroplating solution and directing a coherent energy beam onto the workpiece to locally promote plating thereon.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, FIG. 1 shows a schematic of an energy source directed through a lens onto a workpiece located in a container holding an electroplating solution;
FIG. 2 shows an alternative focusing arrangement; and
FIG. 3 shows an alternative plating vessel.
DESCRIPTION OF THE INVENTION
Referring to the drawing, there is shown in FIG. 1 a vessel 10 which contains an electroplating solution 12. The polymeric workpiece 14 is immersed in plating solution 12 so as to cause the surface 16 where plating is desired, to be contacted by plating solution 12. A laser energy source 18 is focused by a lens system 20 to concentrate the energy and focus a beam 22 which passes through the plating solution 12 and impinges on the surface 16. A pattern 24 can be generated by moving the beam 22 or the workpiece using an xy table 26. A filter holder 28 for holding one or more absorbing filters 30 may be interposed in the light path between energy source 18 and lens system 20.
The beam 22 emitted from the energy source 18 may be modulated by a modulator 32 which may, if desired, be placed between the energy source 18 and the lens system 20, or alternatively between the lens system 20 and the workpiece 14. The modulator 32 may be a mechanical light chopper when the modulation rate is low or an optical modulator can be employed when more rapid modulation is desired. Optical modulation allows frequencies up to the gigahertz range.
The laser energy source 18 may be any known laser source which provides light in the range of visible to far infrared, preferably in the near infrared, and has an intensity sufficient to provide a beam 22 with an intensity in the approximate range of 0.05 to 5.0 joule/cm 2 , preferably about 0.1 to 2.0 joule/cm 2 . Thus, the laser energy source 18 may be an argon laser, tuned to about 0.5 μm, or preferably, a pulsed radiation beam, typically a Q-switched neodymium yttrium aluminum garnet (Nd:YAG) laser, is used. As used herein, the terms "pulsed radiation" and "pulsed laser" refer to radiant energy sources that produce discrete energy pulses as a function of time. These terms are not descriptive of , or limiting to, the method for achieving such energy pulses. For example, "pulsed laser" includes capacitor-switched lasers, Q-switched lasers, and the like.
Laser energy density upon the workpiece can be easily controlled and changed by inserting absorbing optical filters 30 between the source 18 and the lens system 20. Such filters are available commercially from a variety of sources.
The plating solution 12 may be any commercially available plating solution commonly used for the electroplating of metals onto a conductive substrate. Non-limiting examples of electroplating solutions include potassium-gold-cyanide solution, nickel-palladium solution, and the like. Periodic replenishment of the metal ions is necessary.
The polymeric material may be any polymeric material known in the art which is normally solid at room temperature. The polymeric material may be of the thermosetting or the thermoplastic type. Examples of suitable polymeric materials include phenolics, epoxies, polyethylene, polypropylene, acrylics, methacrylates, styrenic polymers, acrylonitrile butadienestyrene, polyamides, polyimides, and the like.
The xy table 26, and the laser energy source 18 or the modulator 32 may be controlled by a controller 34, which may be a microprocessor computer controller, a mechanical controller or other controlling means.
Deposition of the desired metal from solution onto the polymeric workpiece is carried out by immersing the workpiece 14 in the plating solution 12 in container 10 so that there is about 1-2 mm of liquid over the surface 16. The solution 12 is maintained at room temperature and no external power is applied. The laser beam 22 is focused upon surface 16 to obtain a spot diameter of about 20.25 to 2 mm, preferably about 0.5 to 0.75 mm. The xy table is set up to step in the x and/or y direction with about 95 to 50 percent spot overlap at the lineal rate of about 15-25 cm/min. Alternatively, the xy table may be set up to move in continuous fashion.
Greater definition of the plated pattern may be achieved using the apparatus shown in FIG. 2, in which the reference numeral 36 indicates an auxiliary focusing lens held in a lensholder 38 and positioned in the path of the beam 22 at a distance substantially equal to the focal length of the lens 36 away from the surface 16 of workpiece 14. The lensholder 38 is demountably attached via the struts 40 to the mount, not shown, holding the lens system 20. The auxiliary lens 36 can be positioned in or out of the plating solution 12.
For certain applications, it may be desirable to plate two or more different metals onto the same substrate. Using the apparatus shown in FIG. 1, the plating solution 12 can be syphoned or pumped out of the vessel 10, and a new solution then added to the vessel and the plating continued. Alternatively, the apparatus shown in FIG. 3 may be used, in which the reference numeral 42 indicates a closed workpiece holder positioned upon xy table 26. The closed holder 46 comprises a transparent cover 44, inlet means 46 for introducing plating solution and outlet means 48 for withdrawing plating solution.
The method of the present invention may be used in the manufacture of flexible printed circuits, chip carriers, and the like.
The following examples illustrate the invention.
EXPERIMENTAL SET-UP
The system used was similar to that shown schematically in FIG. 1. The laser system was a Q-switched Nd:YAG laser having a wavelength of 0.53 μm, pulse duration of 15ns and a repetition rate of 1.0 Hz. Laser energy density ranged from 0.164 to 2.0 joule/cm 2 with energy densities below 1.0 being provided by the use of absorbing filters.
A computer was employed to control the traverse of the xy table. The table was run at 20 cm/min and a delay was inserted in the computer program so as to make the table step at intervals of 5 to 50% of the diameter of the laser beam and stop until the next laser pulse. This method provided 95 to 50% overlapped spots.
MATERIALS
Specimens 20×30 mm were prepared from Kapton H-500 polyimide sheet, available from the DuPont Company, Wilmington, Del.
The electroplating solutions were a commercially available potassium-gold-cyanide solutions and a commercially available nickel-palladium solution.
PLATING PROCEDURE
The polymer specimens were immersed in the gold plating solution with about 1 mm of solution over the top surface of the specimen. The solution was at room temperature and no external power was used. The specimen surfaces were irradiated under various conditions and at various locations according to a desired preplanned program.
The plating conditions are shown on the following table:
______________________________________Laser energy density (joule/cm.sup.2) 0.2-22Pulse Overlap 50-95%Laser Beam Diameter (mm) 0.5-1.5Pulse Duration (ns) 15______________________________________
DEPOSITE MORPHOLOGY AND COMPOSITION
A scanning electron microscope (SEM) was used to examine the deposits of metal on the polyimide. It was found that laserinduced metal deposition resulted in uniform continuous and well defined plated areas (lines) of metal. In general, the metal deposit was proportional to the laser energy applied. Further, it was found that the metal deposition occurred without substantial damage to the polymeric workpiece when the laser energy density was 0.3 joule/cm 2 or below.
Various modifications may be made without departing from the spirit of the invention or the scope of the appended claims. | A method for high resolution maskless deposition of metals onto a polymer without application of an electrical potential by contacting a polymeric workpiece with an electroplating solution and directing a laser beam through the solution onto the polymer to locally achieve plating. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to gas turbine engines, more particularly to combustors used with gas turbine engines.
[0002] Known turbine engines include a compressor for compressing air which is suitably mixed with a fuel and channeled to a combustor wherein the mixture is ignited within a combustion chamber for generating hot combustion gases. More specifically, at least some known combustors include a dome assembly, a cowling, and liners to channel the combustion gases to a turbine, which extracts energy from the combustion gases for powering the compressor, as well as producing useful work to propel an aircraft in flight or to power a load, such as an electrical generator. Moreover, at least some known combustors include ignition devices, such as ignitors, primer nozzles, and/or pilot fuel nozzles, which are used during pre-selected engine operations to facilitate igniting the mixture within the combustion gases.
[0003] At least some known fuel injectors are dual fuel injectors capable of supplying a liquid fuel, a gaseous fuel, or a mixture of liquid and gaseous fuels to the combustor. To facilitate reducing emissions within such combustors, at least some known combustors include water injection systems to facilitate nitrous oxide emission abatement. Within such systems, the water is premixed with the fuel during liquid fuel operation and is injected into the combustor through the fuel injector. Combining the water with liquid fuel in a single fuel circuit provides a design compromise, as the fuel/water mixture is optimized for flow and atomization, rather than requiring the liquid fuel and water to be individually optimized. However, within known fuel injectors, the water injection may provide only limited benefits, as the combined fuel/water mixture may become unmanageable at higher fuel flows.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect, a method for assembling a gas turbine engine is provided. The method comprises coupling a fuel nozzle within the engine to inject fuel into the engine, wherein the fuel nozzle includes three independent injection circuits arranged such that the second injection circuit is between the first and third injection circuits, coupling a liquid fuel source to a first injection circuit defined within the nozzle and including an annular discharge opening, and coupling a water source to one of the second injection circuit and the third injection circuits such that the water is coupled in flow communication to an annular discharge opening.
[0005] In another aspect, a fuel nozzle for a gas turbine engine is provided. The fuel nozzle includes three injection circuits. A first injection circuit includes an annular discharge opening and is for injecting liquid fuel downstream from the nozzle into the gas turbine engine, The second injection circuit is aligned substantially concentrically with respect to the first injection circuit. The third injection circuit is aligned substantially concentrically with respect to the first injection circuit, such that the second injection circuit is between the second and third injection circuits. One of the second and third injection circuits is for injecting water downstream from the nozzle into the gas turbine engine. One of the second injection circuit and the third injection circuit includes an annular discharge opening.
[0006] In a further aspect a gas turbine engine includes a combustor including a combustion chamber and at least one fuel nozzle. The at least one fuel nozzle includes three injection circuits. The first injection circuit includes an annular discharge opening and is for injecting only liquid fuel into the combustion chamber. The second injection circuit is aligned substantially concentrically with respect to the first and third injection circuits, such that the second injection circuit extends between the first and third injection circuits. One of the second and third injection circuits includes an annular discharge. One of the second and third injection circuits is for only injecting water into the combustion chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic of an exemplary gas turbine engine.
[0008] FIG. 2 is a cross-sectional illustration of an exemplary combustor that may be used with the gas turbine engine shown in FIG. 1
[0009] FIG. 3 is an enlarged cross-sectional view of a portion of the fuel nozzle shown in FIG. 2 ; and
[0010] FIG. 4 is an end view of the fuel nozzle shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 is a schematic illustration of a gas turbine engine 10 including a low pressure compressor 12 , a high pressure compressor 14 , and a combustor 16 . Engine 10 also includes a high pressure turbine 18 and a low pressure turbine 20 . Compressor 12 and turbine 20 are coupled by a first shaft 22 , and compressor 14 and turbine 18 are coupled by a second shaft 21 .
[0012] In operation, air flows through low pressure compressor 12 and compressed air is supplied from low pressure compressor 12 to high pressure compressor 14 . The highly compressed air is delivered to combustor 16 . Airflow from combustor 16 exits combustor 16 and drives turbines 18 and 20 , and then exits gas turbine engine 10 .
[0013] FIG. 2 is a cross-sectional illustration of a portion of an exemplary combustor 16 that may be used with gas turbine engine 10 . Combustor 16 includes an annular outer liner 40 , an annular inner liner 42 , and a domed end 44 that extends between outer and inner liners 40 and 42 , respectively. Outer liner 40 and inner liner 42 are spaced radially inward from a combustor casing 46 and define a combustion chamber 48 therebetween. Combustor casing 46 is generally annular and extends around combustor 16 . Combustion chamber 48 is generally annular in shape and is defined between from liners 40 and 42 .
[0014] A fuel nozzle 50 extends through domed end 44 for discharging fuel into combustion chamber 48 , as described in more detail below. In one embodiment, fuel nozzle 50 is aligned substantially concentrically with respect to combustor 16 . In the exemplary embodiment, fuel nozzle 50 includes an inlet 54 , an injection or discharge tip 56 , and a body 58 extending therebetween.
[0015] FIG. 3 is an enlarged side view of a portion of fuel nozzle 50 , and FIG. 4 is an end view of fuel nozzle 50 . Fuel nozzle 50 is a quad-annular fuel nozzle that includes a plurality of injection circuits 80 and a center axis of symmetry 81 extending therethrough. Specifically, injection circuits 80 are each routed independently through fuel nozzle 50 such that none of the injection circuits 80 are in flow communication with each other within nozzle 50 .
[0016] Fuel nozzle 50 includes a liquid fuel injection circuit 82 , a gaseous fuel injection circuit 84 , and a water injection circuit 86 . Liquid fuel injection circuit 82 includes a primary fuel injection circuit 88 and a secondary fuel injection circuit 90 that are each coupled in flow communication to a liquid fuel source for injecting only liquid fuel downstream therefrom into combustion chamber 48 . Primary fuel injection circuit 88 includes an annular fuel passageway 92 that extends substantially concentrically through nozzle 50 to an annular discharge opening 94 . In the exemplary embodiment, fuel passageway 92 and discharge opening 94 are each toroidal.
[0017] In the exemplary embodiment, fuel passageway 92 extends substantially co-axially through nozzle 50 with respect to axis of symmetry 81 such that passageway 92 is a radial distance D pf from axis of symmetry 81 such that fuel flowing therein flows substantially parallel to axis of symmetry 81 until flowing through an elbow 100 . Elbow 100 is positioned upstream from, and in close proximity to, discharge opening 94 and directs liquid fuel into a convergent portion 102 of passageway 92 such that liquid fuel is discharged inwardly from passageway 92 towards axis of symmetry 81 .
[0018] Secondary fuel injection circuit 90 includes an annular fuel passageway 110 that extends substantially concentrically through nozzle 50 to annular discharge opening 94 . In the exemplary embodiment, fuel passageway 110 is toroidal and is radially outward from fuel passageway 92 . More specifically, in the exemplary embodiment, fuel passageway 110 is substantially concentrically aligned with respect to fuel passageway 92 , and with respect to axis of symmetry 81 . Accordingly, liquid fuel flowing within passageway 110 flows substantially parallel to axis of symmetry 81 until flowing through an elbow 114 . Elbow 114 is positioned upstream from, and in close proximity to, discharge opening 94 and directs liquid fuel into a convergent portion 116 of passageway 110 such that liquid fuel is discharged inwardly from passageway 110 towards axis of symmetry 81 .
[0019] Nozzle discharge tip 56 includes a nozzle portion 120 that extends divergently downstream from, and in flow communication with, opening 94 . Accordingly, the combination of passageway convergent portions 102 and 116 , opening 94 , and divergent nozzle portion 120 creates a venturi that facilitates enhancing control of flow discharged from nozzle discharge tip 56 . More specifically, the relative location of opening 94 within discharge tip 56 and with respect to nozzle portion 120 facilitates reducing dwell time for fuel within nozzle discharge tip 56 , such that coking potential within nozzle discharge tip 56 is also facilitated to be reduced.
[0020] Water injection circuit 86 is used to supply only water to combustion chamber 48 and includes an annular water injection passageway 130 that extends substantially concentrically through nozzle 50 to an annular discharge opening 132 . In the exemplary embodiment, fuel passageway 130 is toroidal and is positioned radially outward from fuel passageway 110 . More specifically, in the exemplary embodiment, water injection passageway 130 is coupled to a water source and is substantially concentrically aligned with respect to fuel passageways 92 and 110 , and with respect to axis of symmetry 81 . Accordingly, water flowing within passageway 130 flows substantially parallel to axis of symmetry 81 until being discharged through annular discharge opening 132 . In the exemplary embodiment, opening 132 is a distance downstream from opening 94 . Accordingly, the orientation of discharge opening 132 with respect to opening 94 , ensures that water is discharged from opening 132 at a wider spray angle than that of the liquid fuel discharged from opening 94 , thus facilitating nitrous oxide abatement. Moreover, the narrower spray angle of the liquid fuel facilitates positioning the liquid fuel towards an aft end of the venturi, thus reducing dwell time and coking potential.
[0021] Gaseous fuel injection circuit 84 is coupled to a gaseous fuel circuit such that only gaseous fuel is supplied to combustion chamber 48 during pre-determined engine operating conditions by circuit 84 . Gaseous fuel injection circuit 84 includes an annular fuel passageway 140 that extends substantially concentrically through nozzle 50 to a plurality of circumferentially-spaced discharge openings 142 . In the exemplary embodiment, fuel passageway 140 is toroidal and is positioned radially outward from water injection passageway 130 . In an alternative embodiment, water injection passageway 130 is positioned radially between primary fuel injection circuit fuel passageway 92 and gaseous fuel injection fuel passageway 140 . Within such an embodiment, secondary fuel injection circuit fuel passageway 110 is positioned radially outward from gaseous fuel injection passageway 140 . More specifically, in the exemplary embodiment, gaseous fuel injection passageway 140 is substantially concentrically aligned with respect to fuel passageways 92 and 110 , and with respect to axis of symmetry 81 . Accordingly, gaseous fuel flowing within passageway 140 flows substantially parallel to axis of symmetry 81 until being discharged through discharge openings 142 .
[0022] In the exemplary embodiment, gaseous fuel injection openings 142 are oriented obliquely with respect to axis of symmetry 81 . Accordingly, gaseous fuel discharged from openings 142 is expelled outwardly away from axis of symmetry 81 .
[0023] During initial engine operation, and through engine idle operation, only primary fuel injection circuit 88 is used to supply fuel to combustion chamber 48 . More specifically, primary fuel injection circuit 88 provides atomization of low fuel flows required for engine starting and transition to engine idle operation.
[0024] During higher power operations, the remaining liquid fuel required for operation is injected through secondary fuel injection circuit 90 , and gaseous fuel may be injected through gaseous fuel injection circuit 84 . In one embodiment, secondary fuel injection circuit 90 provides up to approximately 95% of total liquid fuel flow required for high power engine operations. During such operations, water is introduced to combustion chamber 48 through water injection circuit 86 . Water injection facilitates abating nitrous oxide generation within combustion chamber 48 . Moreover, in the exemplary embodiment, atomization is facilitated through a liquid water sheet formation induced by swirling the water flow within water injection circuit 86 . In an alternative embodiment, bleed air from a compressor discharge is used to facilitate atomization of the water flow. In a further alternative embodiment, natural gas flow is used to facilitate atomization of the water flow.
[0025] Because fuel is injected through independent injection circuits, the plurality of independent injection circuits 80 facilitates the independent optimization of each circuit for each mode of operation, including a liquid fuel dry mode, in which no water is injected into chamber 48 , a liquid fuel+NO x water abatement mode of operation, and a gaseous fuel+NO x water abatement mode of operation. Accordingly, optimization of the circuits 80 is facilitated at all engine operational power settings.
[0026] The above-described fuel nozzle provides a cost-effective and reliable means for reducing nitrous oxide emissions generated within a combustor. The fuel nozzle includes a plurality of independent injection circuits that facilitate enhanced optimization of fluids to be injected into the combustion chamber. More specifically, because water and fuel are not mixed within, or upstream from the fuel nozzle, the flows of each may be independently optimized. As a result, injection schemes are provided which facilitate reducing nitrous oxide emissions at substantially all engine operating conditions.
[0027] An exemplary embodiment of a fuel nozzle is described above in detail. The fuel nozzle components illustrated are not limited to the specific embodiments described herein, but rather, components of each fuel nozzle may be utilized independently and separately from other components described herein. For example, the plurality of injection circuits may be used with other fuel nozzles or in combination with other engine combustion systems.
[0028] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | A method enables a gas turbine engine to be assembled. The method comprises coupling a fuel nozzle within the engine to inject fuel into the engine, wherein the fuel nozzle includes three independent injection circuits arranged such that the second injection circuit is between the first and third injection circuits, coupling a liquid fuel source to a first injection circuit defined within the nozzle and including an annular discharge opening, and coupling a water source to one of the second injection circuit and the third injection circuits such that the water source is coupled in flow communication to an annular discharge opening. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the field of urinal mats and screens. In some embodiments the mats and screens may be scented. Additional embodiments relate to compositions used in the formation of urinal mats and screens.
[0003] 2. Background of the Related Art
[0004] Urinals are commonly used in lavatories. Although flushing urinals have been ubiquitous in men's lavatories for some time, non-flushing (or “waterless”) urinals are growing increasingly popular for their savings in water and energy.
[0005] Unfortunately, urinals have a number of drawbacks. Deposit of materials into a urinal other than urine or water, such as chewing gum or cigarette butts may clog the drain or lead to an unsightly appearance until the urinal is able to be cleaned. This is particularly troublesome in a non-flushing urinal, where the drain may lead immediately to a holding and treatment area. Accumulation of non-urine waste in this area could impair the function of the urinal and require more frequent cleaning of the urinal, the holding and treatment area, and any associated plumbing.
[0006] Urinals also suffer from issues of potential “splashback” of urine on a user. This may have many causes, including the hard surface and angle of the urinal. The retention of water in the urinal drain at a level that is visible to a user may also contribute to splashback when the urine strikes the standing pool of water.
[0007] Many solutions for these and other issues have been proposed. The most common solution is the use of a “urinal screen,” also known as a “urinal mat” or simply a “screen.” In its most simple form a urinal screen in a flat polymer sheet, typically circular or approximately circular, that includes one or more holes large enough to allow the flow of urine through the screen and into the drain but small enough to block the passage of other waste. In some instances the sheet includes a central housing that includes a deodorant block. This deodorant block may include surfactants or chealating agents. The urinal screen extends over the drain area of most urinals, though normally it is placed next to the drain if the drain has a cover.
[0008] One example of a urinal screen is shown in U.S. Pat. No. 8,007,707. The '707 patent reports a flat polymer sheet of ethylvinyl acetate. The '707 patent further reports that the sheet has been loaded with a fragrance material. The screen of the '707 patent also includes a plurality of vertical protrusions from the screen. According to the '707 patent, these protrusions increase the surface area of the screen and break up a urinal stream, preventing or decreasing splashback. Unfortunately, as indicated in the '707 patent, these kinds of screens have tendency to float. These kinds of screens are therefore unsatisfactory for use in urinals in which there is a standing water, because the screen may be lifted or washed out of position, allowing debris to enter the drain. Furthermore, the alleged benefits offered by the protrusions are not conclusively proven, and given the large, flat surface area splashback remains a significant possibility.
[0009] Screens shown in the '707 patent and screens like them are also typically unsatisfactory because they do not shed urine. To the contrary, urine may reside on the flat surface between the holes in the screen, or it may be retained in a meniscus created by the holes. The slowly-evaporating urine generates an offensive odor and may leave deposits that gradually build up and clog the holes, interfering with proper urine flow and further exacerbating the problem. Bacterial and fungal growth may also be encouraged by the urine remaining in the meniscus or on the screen. This issue is particularly troublesome with waterless urinals, because the lack of a flushing action means that any urine that is retained remains indefinitely until evaporation.
[0010] Another example of a urinal screen is shown in U.S. Pat. No. 6,920,648. The '648 patent reports a screen that includes a flexible segmented supporting base with a central opening and a central raised housing including a deodorant block. This screen includes a number of slots that also retain urine in a meniscus. Furthermore, the flat top surface of the '648 patent's screen may contribute to rather than discourage splashback.
[0011] It would be desirable to provide an economical urinal screen without one or more of the above-discussed disadvantages. Of course, the ability to eliminate one or more of the above disadvantages is not a requirement for a device to be within the scope of the claims.
BRIEF SUMMARY OF THE INVENTION
[0012] Embodiments of the invention provide urinal screens. In a preferred embodiment the screen is a dome-shaped screen including a central hub, a plurality of spokes radiating out and down from the central hub, and a plurality of concentric rings supported by the spokes. It should be noted that although the common term that will be used herein is “dome,” typical urinal screens of the invention lack a flat bottom surface and are therefore more precisely referred to in a mathematical sense as a “spherical cap.”
[0013] In some embodiments the top surface of the spokes and/or rings may be flat. In other embodiments the top surface may be contoured. In still further embodiments the spokes and/or rings may come to an angular point.
[0014] Further embodiments of the invention provide compositions that are useful for making urinal screens of the design disclosed herein as well as other designs. These compositions include materials that increase the hydrophobicity of the polymer screen, thereby reducing the retention of urine by the screen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
[0016] FIG. 1 shows top, bottom, angled top, and angled bottom views of a first embodiment of the invention.
[0017] FIG. 2 shows top, angled top, and side views of a preferred embodiment of the invention. This embodiment includes serrated rings, curved but continuous spokes with concave undersides extending beyond the outer ring, and a rounded hub.
[0018] FIG. 3 shows side, bottom, and top views of another embodiment of the invention. In this embodiment the spokes are discontinuous, and the central hub is smaller than that shown in the embodiment of FIG. 2 .
[0019] FIG. 4 shows top, angled, and side views of three similar embodiments that differ in the ratio of height to diameter. The measurements given in FIG. 4 are exemplary only and are not meant to limit the invention. In each case the diameter of the screen is about 150 mm, though this is also exemplary only.
[0020] FIG. 5 shows top and angled side views of three different embodiments. Each of the embodiments in FIG. 5 have different hub designs. They also have spokes that end at the outer ring.
[0021] FIG. 6 shows a detail of a drip line at the bottom center of a rib.
[0022] FIG. 7 shows a number of embodiments of the invention, each with a different addition to the outermost ring to assist in the flow of urine from the screen. These include, from left to right, multiple separate protrusions arrayed about the outside and bottom of the outermost ring, an outermost ring with a contoured, irregular bottom, and large, regular serrations on the bottom of the outermost ring.
[0023] FIG. 8 shows an angled top view of a preferred embodiment of the invention.
[0024] FIG. 9 shows a bottom view of the embodiment shown in FIG. 8 .
[0025] FIG. 10 shows a side view of the embodiment shown in FIG. 8 .
[0026] FIGS. 11-13 show additional embodiments and features.
[0027] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Embodiments of the invention provide a urinal screen. The urinal screen may have one or more beneficial aspects relating to shape and/or composition, as set forth more fully below.
[0029] I. Composition
[0030] Embodiments of the invention are typically made from a polymer or polymers, including but not limited to high density polyethylene, low density polyethylene, polystyrene, acrylic polymers, polycarbonates, polyurethanes, nylons, ethylvinyl acetate (EVA), polyvinyl chloride (PVC), and mixtures or copolymers of the foregoing. In a preferred embodiment a urinal screen is made from EVA, which is a copolymer of ethylene and vinyl acetate.
[0031] EVA used in the invention may have a molecular weight in the range of, for example, 10,000 Daltons to 100,000 Daltons, more preferably 22,000 to 87,000 Daltons. This provides durability as well as the potential for the screen to be loaded with a fragrance that will be released over time. EVA screens are typically formed by press molding, though the method of formation of the screen is typically not material to the properties of the final screen.
[0032] In some embodiments the EVA is infused with a fragrance. This is accomplished, for example, by heating EVA beads with a quantity of fragrance, then allowing the beads and fragrance to cool. The beads, fragrance, and other additives are combined through agitation via a rotary drum mixer, with the application of heat. Fragrance may be introduced into the polymer at weight percents varying from 5 to 40%, from 20 to 40% from 30 to 40%, from 5 to 10%, from 5 to 20%, from 5 to 30%, and from 5 to 35%. In further embodiments, fragrance is introduced into the polymer at a weight percent of about 1%, about 10%, about 20%, about 25%, about 30%, about 35%, or about 40%.
[0033] Those skilled in the art will recognize that one or more fragrances may be used in embodiments of the invention; however, given the other advancements that are discussed herein, some embodiments of the invention do not need to include any fragrance. If addition of fragrance is desired, suitable fragrances may be selected from those compiled by the U.S. Food and Drug Administration in Title 21 of the Code of Federal Regulations, Sections 172.510 and 172.515, incorporated by reference herein. Fragrance components selected from benzaldehydes, phenols, cinnamic aldehydes and esters, octadienes, dienes, cyclohexadienes, and terpenes may be used in the invention. Fragrance oils are also suitable for use alone or in combination with other fragrance chemicals. Suitable fragrance oils are, for example spice oil, flower oil, and fruit oil.
[0034] Other suitable fragrances include but are not limited to benzyl alcohol, ethyl maltol, furaneol, 1-hexanol, cis-3-hexen-1-ol, menthol, benzaldehyde, hexanal, cinnamaldehyde, citral, cis-3-hexenal, furfural, neral, vanillin, ethyl acetate, ethyl butanoate, ethyl decanoate, ethyl hexanoate, ethyl octanoate, hexyl acetate, isoamyl acetate, methyl butanoate, methyl salicylate, pentyl butanoate, pentyl pentanoate, sotolon, strawberry aldehyde, fructone, anethole, anisole, eugenol, dihydrojasmone, 2-acetyl-1-pyrroline, 6-acetyl-2,3,4,5-tetrahydropyridine, gamma-decalactone, gamma-nonalactone, delta-octalactone, jasmine lactone, massoia lactone, camphor, citronellol, linalool, nerol, nerolidol, alpha-terpineol, thujone, and thymol.
[0035] Embodiments may also include ingredients directed to odor neutralization. These may be intended to mask, neutralize, and/or prevent the perception of malodors. Examples of suitable odor-neutralizing additives include, for example, but are not limited to activated carbon, activated anthracite, zeolite, silica gel, and baking soda.
[0036] Embodiments of the invention may include additional non-fragrance additives. For example, in preferred embodiments of the invention the screen includes one or more additives that are designed to reduce hydrophilicity and increase hydrophobicity of the screen. Altering these properties increases the tendency of urine to move away from and off of the screen, because the urine forms “beads” that reduce the amount of urine retained and allow the urine to run off more easily when the surface of the screen is sloping or angled. Although this is beneficial when applied to a typical flush urinal, it is especially helpful when a screen is used with a waterless urinal because the urine will flow off of the screen and into the drain without further action. Decrease in urine residence decreases the unpleasant odors and other effects associated with urine retention.
[0037] We have found that a number of additives are suitable for reducing the hydrophilicity of the EVA or other polymer used in the screen. These include, for example, but are not limited to silicone, silicon waxes, alkylmethylsiloxane, and dimethicone. Inclusion of these additives in the body of the screen itself is superior to surfactant-containing blocks for a number of reasons. For example, they have a greater expected useful lifespan, as the incorporated hydrophilicity-reducing agent is unlikely to be consumed and exhausted as one would expect from a disposable urinal block or cake. Second, the screen is able to shed water (and therefore urine) without the need to release potentially troublesome surfactants or chealating agents into the environment, which is done with a conventional block or cake.
[0038] Various other additives such as color additives may be added in different embodiments depending on desired characteristics of a particular screen. Plasticizers may also be added to polymeric materials that are used in embodiments of the invention. These may include, for example, diethyl phthalate and tri-acetic acid ester of glycerin.
[0039] II. Shape
[0040] Embodiments of the invention may be shaped in one or more ways that offer many beneficial aspects. A particularly preferred embodiment of the invention may be appreciated with reference to FIG. 1 . Although FIG. 1 includes multiple beneficial aspects in a single screen, those of skill in the art are likely to recognize that many of the advances disclosed herein will be useful alone or in combination with less than all of the other aspects.
[0041] FIG. 1 shows a urinal screen including a central hub 1 from which a plurality of spokes 3 depend. The spokes support a plurality of concentric rings 5 . Because the spokes shown in this embodiment curve downward from the hub, the rings are at different elevations relative to the hub. The combination of rings and spokes forms a plurality of voids through which urine may travel. This is done without the formation of a meniscus, substantially aiding in flow of the urine to the drain.
[0042] The domed shape of the urinal screen shown in FIG. 1 offers a number of advantages. First, elevation of a substantial portion of the screen helps prevent the screen from floating on the surface of any water retained in the urinal drain. This is different from other screens, particularly other EVA screens, which may float on the surface of water retained in the drain if it is high enough. This can allow debris to flow under the screen and into the drain.
[0043] The ability of the screen to resist floating is also assisted by the weight provided by the polymer in the hub. Furthermore, the tendency of the hub to stay above all but the deepest standing drain water (which would likely result only through a malfunction of the urinal) provides a consistent evaporative route for any fragrance that has been included in the screen.
[0044] The domed screen offers other significant advantages. For example, the domed shape provides space for the screen to be placed over a urinal drain that has a protruding drain cover. This is significantly different from a conventional flat screen, which is usually placed haphazardly in the urinal and fails to function in any but an ornamental sense.
[0045] We have surprisingly found that when the screen is constructed of EVA the screen is able to maintain the domed shape despite the relative flexibility of the EVA. This allows the screen to have a relatively rigid shape that prevents deformation that would allow debris to enter the urinal drain. Although the screen may be deformable, it typically returns to its pre-deformed shape with little effort. This may be referred to as “semi-rigid” and is in marked contrast to existing conventional screens, which typically freely bend to roughly adopt the shape of the bottom of the urinal into which they are placed, and which are unable to maintain a domed shape.
[0046] The domed screen also significantly deters splashback. This is the result of a number of elements working in unexpectedly beneficial combination. First, the dome creates a significant void into which urine may flow before striking a standing urine pool. This creates more open area than a conventional screen without compromising the ability of the screen to protect the drain. If by chance the stream is reflected, it is most likely to hit a component of the dome and be retained rather than splashing back. Second, the curved dome is markedly different from a conventional screen, which creates a flat, reflective surface normal to the typical urine flow and encourages splashback. Flat screens sometimes use a multitude of hair- or pin-like elements to suppress the splashback; unfortunately, these collect debris, making them look dirty. They also significantly collect urine, adding to the odor issue.
[0047] The height and curvature of the dome may vary. Typically the ratio of the height of the dome to the diameter of the dome is about 1:4, though significant variations in that range are possible. For example, in some embodiments the ratio of the height of the dome to the diameter of the dome is between 1:2-1:8, 1:2-1:6, 1:2-1:4, 1:4-1:6, 1:4-1:8, or 1:6-1:8. FIG. 4 shows three different embodiments of the invention, each varying from the other in ratio of height to diameter. These may have different applications depending, for example, on the size of the urinal or the presence of a metal urinal drain.
[0048] The spoke and ring design of the screen also offers significant advantages in avoiding the formation of a meniscus. The varying height of the concentric rings creates voids that are angled and that do not tend toward meniscus formation. To the extent that any meniscus may be present, the angled voids render it short-lived.
[0049] The formation of a meniscus is further deterred by the use of angles or curvature on the spokes and the rings. In some embodiments the spokes have a peaked top. In other embodiments the rings have peaked or contoured tops, either in addition to or in the alternative to the peaks or contours of the spokes. Both the top and bottom of the spokes and rings may be peaked or contoured.
[0050] When the top of a spoke or ring is peaked, the more narrow peak angles tend to be more effective at shedding urine; however, too great of an angle decreases the anti-splashback advantages of the screen. A more acute angle encourages more efficient flow of urine through the screen; typically the angle is balanced between draining and presenting a flat surface which will splash-back.
[0051] In addition to a top angle or curvature, spokes may have one or more ridges on the bottom of the spoke, running parallel or approximately parallel to the direct of the spoke. These ridges help direct urine away from the bottom of the screen and into the drain. Edges of the spokes and/or rings, preferably the terminal edges, may be scalloped or serrated. This may further decrease the amount of urine that is retained on the screen. These serrations are not required to extend any particular length into each spoke or ring, though having them extend between 1% to 25% into the ring is typical. They may be locations on one or both sides of each ring or spoke. Sample serrations are shown in FIG. 2 . As shown, for example, in FIG. 1 , the underside of each spoke may be concave, either along the entire length or along part of the length of the spoke.
[0052] Spokes may end on the outermost ring, as shown in embodiments of FIG. 5 . In some embodiments, and as shown for example in FIGS. 1 and 2 and elsewhere, the spokes may also extend beyond the circumference of the outermost ring. This may aid in urine flow and prevent the bottom ring from resting directly on the bottom of the urinal, potentially managing urine flow between the bottom of the screen and the urinal surface.
[0053] Additional features may be included on the underside of one or more of the rings to enhance flow. Typically these are on the underside of the last ring. FIG. 7 shows multiple additional options for the ring bottoms. The leftmost column in FIG. 7 shows multiple separate protrusions arrayed about the outside and bottom of the outermost ring. The central column in FIG. 7 shows an outermost ring with a contoured, irregular bottom. The rightmost column in FIG. 7 shows large, regular serrations on the bottom of the outermost ring.
[0054] Spokes may include further features that enhance the removal of urine from the screen and hasten its deposit in a drain. For example, the bottom of one or more of the spokes may include a “drip line.” This line, typically located in the bottom center of each rib, helps guide urine away from the center of the screen. A detail showing such an element is in FIG. 6 .
[0055] Although shown and described as a “central hub” in FIG. 1 , this is not the only possible structure for the central element of embodiments of the invention. Alternatives are shown in FIG. 5 , including a central hub with a hole for urine flow, a rounded central hub, and a flat central hub.
[0056] The many advancements provided by the inventive screens allow a significant decrease in the amount of urine that is retained on the screen, offering a significant advantage to both flushing and non-flushing urinals. For example, embodiments of the invention may retain urine relative to their original weight in the amounts of 1-10%, 1-5%, 2-4%, or about 4%.
[0057] Although embodiments of the invention have been described as having a dome or spherical cap shape, it should be understood that the rings may be elliptical if the spokes do not have equal lengths. A cone shape may also be formed. Although some embodiments do form a right circular cone, there is no requirement that this be the only permitted shape. The rings need not be concentric in all embodiments of the invention. In some embodiments the rings are circular on one side and flat on the other, allowing the screen to be properly seated in a urinal that has a flat back and short drain area.
[0058] Although the spokes in FIG. 1 are linear and continuous from the central hub, it will be appreciated that in some embodiments the spokes are not linear. In some they are not continuous. In some embodiments they are neither. For example, FIG. 2 shows spokes that are continuous but that, at their ends, are not linear.
[0059] FIG. 3 shows an embodiment in which the spokes do not continuously radiate from the central hub to the end of the final ring. Instead, each ring is connected by a series of smaller spokes to the next ring. In this embodiment the ability to stagger the spokes relative to each other prevents the alignment of the voids between the rings, allowing increased urine flow and further decreasing the likelihood of urine retention.
EXAMPLES
[0060] The following example is given to help those skilled in the art appreciate the invention. It should not be construed to limit the scope of the claims.
[0061] A preferred embodiment of a screen of the invention is shown in FIGS. 8-10 . FIG. 8 shows an angled top view of a screen having a central hub, rounded rings, and discontinuous spokes. The width of each ring varies along the ring, allowing creation of non-uniformly-shaped voids between the rings and the spokes. As shown in FIG. 9 , the underside of each ring is concave. FIG. 10 , which is a side view, shows that the outermost ring includes long, regular serrations at its bottom edge, assisting with the transport and removal of urine. After trials, we found that the prior art urinal screens lacking the components and shape of the inventive screen retained an average of 24% of their original weight in fluid, while the inventive screens retained only 4%.
[0062] Of course, those skilled in the art will, with the advantage of this disclosure, recognize variations and alternatives to the subject matter that is disclosed herein. To the extent possible the claims encompass material within the scope and spirit of the claims. | Embodiments of the invention provide domed urinal screens. In preferred embodiments the screens include a hub, a plurality of spokes radiating downward from the hub, and a plurality of concentric rings supported by the spokes. Compositions deterring accumulation of fluids on urinal screens are also disclosed. | 4 |
RELATED APPLICATION
[0001] This application is a Continuation-in-Part of U.S. application Ser. No. 11/645,109 entitled “SYSTEM AND METHOD FOR CREATING A NETWORKED INFRASTRUCTURE DISTRIBUTION PLATFORM OF FIXED AND MOBILE SOLAR AND WIND GATHERING DEVICES” filed on Dec. 22, 2006. The entire teachings of the above application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] A wind-powered turbine, or simply wind turbine, generates electrical power, which can be delivered to an existing electricity grid system via an interconnection or which may be used to directly power an individual home, business or utility. Wind turbines used to gather large amounts of power (e.g., in the megawatt range) are large structures, typically 100 feet high or higher.
SUMMARY OF THE INVENTION
[0003] Currently, installations of large-sized wind turbines, on the order of 100 feet or more, dot the landscape of the planet. These large-sized wind turbines are often located in remote fields, out to sea, or on private property away from public infrastructure.
[0004] Installations of small-sized wind turbines and other wind energy gathering devices, in the 5 to 30 foot range, are typically utilized in one of three deployments. The first deployment features clusters of small to mid-sized wind turbines set up in remote windy areas, such as, the desert environment near Palm Desert in California. The second deployment features isolated powering of homes and small businesses, such as those in remote artic or extreme cold climates where heating and cooling infrastructures do not exist. In another example, such isolated powering augments at the micro-use level power consumption by homes and small businesses. The third deployment features isolated powering of entities for government utilities, such as isolated powering of single light stands at the Hanauma Bay National Park public parking lot in Oahu, Hi.
[0005] Conventional deployments address power plant and isolated use models for generating and distributing wind generated energy or power. Large-sized wind turbines generate megawatt quantities of power for local use or for interconnecting back to an electricity or utility grid system. Small-sized wind energy generation systems, on the other hand, are typically used to solve local power issues, such as street lights, home power needs or business power needs. Some small-sized wind energy generation systems have the ability to be interconnected to a utility grid system for the purpose of selling wind generated energy generated by the wind energy gathering system to a public or private utility.
[0006] Unfortunately, existing conventional uses have certain limitations in distribution and deployment. Acceptance of large-sized wind turbines is faced with several challenges. For example, environmentalists fear that the noise and size of wind turbines will disrupt both scenic and habitat conditions. Also of environmental concern is the threat to the well being of birds that may be caught in the blades of large wind turbines. The United States Department of Defense too has voiced its concern that large-sized wind turbines interfere with radar signals and tracking.
[0007] Large-sized wind turbines or turbine systems which are placed far away from existing infrastructures are expensive. Large expenses are incurred not only in transporting such systems to remote locations, but also building the necessary infrastructure to carry wind generated energy from these locations to where the energy is consumed.
[0008] Finally, a large-sized wind turbine represents a single, large volatile investment. If wind is not present or wind currents change, a large-sized wind turbine is a poor investment because the wind turbine will not generate enough power to recover the investment. Also, because a large-sized wind turbine is a large, single entity, if the wind turbine breaks for any reason, no wind generated energy can be generated. Large-sized turbines also require labor intensive maintenance and monitoring. The lifespan for a large-sized wind turbine is 20 years. The waste associated with manufacturing, installation and decommissioning of a large-sized wind turbine is another environmental issue to contend with.
[0009] In contrast, small-sized wind turbines used in isolated areas for private homes, businesses, and individuals are a great way to introduce clean energy on a unit-by-unit grass roots level. Furthermore, small-sized wind turbines can be easily connected to multiple direct sources or various grid interconnection points for distribution.
[0010] In some applications, components for small-sized wind turbines, such as tiny wiring forming a wiring grid on the micrometer scale, have been shown to have super conductive properties which may help increase the energy gathering efficiency of small-sized wind turbines.
[0011] Small-sized wind turbines on the order of an eighth of an inch and greater may be made using standard molding and forming processes. Small-sized wind turbines in range of 50 micrometers may be made using advanced lithography and laser tools.
[0012] Because of its small size, small-sized wind turbines may allow for deployment of billions of wind turbines in spaces where larger-sized wind turbines can not fit, such as curved guardrails along roadways, on top of vehicles, or mounted vertically or horizontally in positions which would not be functional for larger-sized wind turbines.
[0013] The functions of small-sized wind turbines may be wide ranging. For example, wind generated energy generated by small-sized wind turbines affixed to winter jackets and gloves may be used to generate heat. In another example, large strips of installable sheets of small-sized turbines may be rolled out or otherwise deployed along public and private highways to form wind generation systems. Installed on medians or outside of breakdown lanes, such a wind generation system of small-sized wind turbines offers numerous advantages.
[0014] For example, private highways and municipalities have existing maintenance crews as well as existing relationships with contracted infrastructure building providers who can be trained to install the wind generation systems along specified parts of roadways.
[0015] Second, the wind power generation systems can be small and noiseless, small enough to fit millions or billions of small-sized wind turbines on a median between opposite sides of a divided highway with existing medians.
[0016] Third, the energy generated (wind generated energy) by the devices may be distributed directly to homes or businesses along the highway route, or to hydrogen conversion plants distributing directly to homes or businesses for powering the same. Distribution to hydrogen conversion plants for clean power from the electrolysis of hydrogen for filling stations along a highway, either utilizing hydrogen conversion at individual filling stations or at a conveniently located hydrogen conversion plant adjacent to the highway or roadway.
[0017] Fourth, other clean energy sources such as solar, geothermal and other heat conversion technologies may be used to create a multi-source clean energy ‘power grid’. Such a multi-source clean energy power grid may be along with or in tandem with the ‘grid’ in place via potential for the connection of miles of wind power gathering, storage and transfer of generated power.
[0018] Fifth, these infrastructures benefit the wind power generator companies and benefit; the roadway owners via lease or easement revenue. Various products of manufacturer can benefit from an easily installed ‘skin’ or sheet of the small-sized wind turbines energy gathering material. Also these infrastructures provide a stable and consistent infrastructure project generating a service provider economy for clean energy production as well as the environment.
[0019] Sixth, roadways are a consistent source of wind and by having small wind energy capture devices close to the ground the wind energy capture devices, such as small noiseless spiral or helix-style turbines, enable the devices to capture wind energy generated by passing vehicles as well as atmospheric currents.
[0020] Seventh, the power generated by this system may also be connected to a grid system at many different and convenient points located very close to the existing grid infrastructure.
[0021] Embodiments of the present invention relate to creating a configuration of wind turbines. The configuration of wind turbines may be installed in a location for the purpose of gathering wind energy or power. The configuration of wind turbines may be installed in a manner which maximizes the number of functioning wind turbines installed within an area suitable for implementation. In addition, the configuration may also be installed in a manner which maximizes the wind energy gathering potential for a given area.
[0022] A method for installing, implementing or otherwise configuring a plurality of wind turbines of different sizes for maximizing a number of wind turbine installed in a given area or for maximizing the wind generated energy potential of a given area is hereinafter referred to as a “stratum implementation method.” A corresponding apparatus is hereinafter referred to as a “stratum implementation of wind turbines” or “stratum configuration of wind turbines.” The abbreviated forms “stratum implementation” and “stratum configuration,” are also used hereinafter.
[0023] In general, a stratum implementation of wind turbines finds an implementation of different sized wind turbines in close proximity to each other. By varying the size of wind turbines and forming a slope of wind turbines in the implementation and installation process regarding the wind turbines in relation to each other, the wind turbines are not impinging on each other in terms of the areas to be swept by the wind turbines and the possible swept area between the turbines is maximized.
[0024] Conceptually, think of the stratum implementation of wind turbines as a stratum of rock where one layer resides on an independent plane from another layer. In addition to the slope of wind turbine, there may also be an accretive gain in wind turbine installation configuration. By this it is meant that wind turbines and micro-sized wind turbines which stand gradually larger may be installed throughout most of an installation space, similar to a grass lawn that is cut in ascending to descending angles, where a sweeping element of a wind turbine sits on an independent plane for the proper spacing between a next turbine of substantially identical sweep height.
[0025] For example, rather than having two 20 foot wind turbines, which must be 40 feet apart, using the stratum implementation method, a ten foot wind turbine may be located within the horizontal and vertical sweeping clearance space or area between the two 20 foot turbines. In other words, using the stratum implementation method, an intermediate wind turbine is sized to horizontally and vertically clear immediately adjacent wind turbines. Again using the stratum implementation method, in between the 20 foot and 10 foot wind turbines, a series of smaller wind turbines may be installed with vertical and horizontal clearances of the sweeping areas in relation to other adjacent wind turbines.
[0026] In addition to straight line implementations, the stratum implementation may be used for horizontal and vertical row implementations, resembling corn rows if the corn were cut at ascending and descending levels. In this way, in a stratum implementation where more than a straight line or arrangement of wind turbines is possible, horizontal and vertical rows would take on the appearance of a series of gradual pyramids as the slope of the wind turbine came to points from horizontal and vertical directions at once.
[0027] As the wind turbines get smaller in size, more and more small-sized wind turbines can be fitted into the stratum implementation, until finally one more sheet of micro wind turbines can be laid across an entire stratum configuration, interrupted only by implementation of larger-sized turbines. In such a stratum implementation, one or more sheets of micro-sized wind turbines may be produced with openings which allow larger-sized wind turbines to fit through the sheets and around the micro-sized wind turbines. For example, during production, openings for larger-sized wind turbines may be stamped through a sheet or pre-molded into a sheet. Where such openings are stamped or pre-molded may be specified using a computer aided design (CAD) implementation design program.
[0028] A CAD implementation design program or other computer implemented design process may also be used to determine a stratum implementation of wind turbines. For example, given a particular physical location and the location of existing large-sized wind turbines, the computer implemented design process configures small-sized wind turbines into a stratum implementation suitable for installing with the existing large-sized wind turbines. The small-sized wind turbines are then installed around the previously installed large-sized wind turbines in accordance with the stratum implementation as determined by the design process. Because the small-sized wind turbines are installed after installing the large-sized wind turbine, this type of stratum configuration implementation may be referred to as post-installation.
[0029] Alternatively, one or more sheets of small-sized wind turbines may be manufactured in accordance with a stratum implementation as determined by the computer implemented design process. The manufactured sheets of small-sized wind turbines may then be installed around the previously installed large-sized wind turbines, much like laying tile around a pipe or other protrusion. In either example, the net result is a stratum implementation of wind turbines.
[0030] Accordingly, a method and corresponding apparatus for maximizing the wind energy gathering potential of a plurality of wind turbines for a given location, each wind turbine having a sweep height, includes sizing the sweep heights of substantially all wind turbines of the plurality of wind turbines to intersect at least one horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0031] Alternatively, a method and corresponding apparatus for harnessing wind energy with a plurality of wind turbines, each wind turbine having a sweep height, includes sizing the sweep heights of substantially all wind turbines of the plurality of wind turbines to differ from a sweep height of immediately adjacent wind turbines.
[0032] In yet another alternative, a method and corresponding apparatus for harnessing wind energy with a plurality of wind turbines, each wind turbine having a sweep height, includes sizing sweep heights of a first wind turbine and at least one second wind turbine with substantially same sweep heights according to a horizontal spacing between the first wind turbine and the at least one second wind turbine, reducing the horizontal spacing, and repeating the sizing and the reducing at least until each wind turbine of the plurality of wind turbines is sized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views.
[0034] The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
[0035] FIG. 1A is a view of an environment where example embodiments of the present invention may be deployed;
[0036] FIG. 1B is a block diagram of an example roadway system in which embodiments of the present invention may be an element;
[0037] FIG. 2 is a diagram of an example stratum configuration, in accordance with an embodiment of the present invention;
[0038] FIGS. 3A-F are diagrams of example stratum configurations with sweep heights sized with respect to horizontal planes intersected by a sweep height of an immediately adjacent wind turbine, in accordance with embodiments of the present invention;
[0039] FIGS. 4A-C are diagrams of example stratum configurations with sweep heights sized with respect to a sweep height of an immediately adjacent wind turbine, in accordance with embodiments of the present invention;
[0040] FIG. 5 is a diagram of a stratum configuration with sweep heights of a first wind turbine and at least one second wind turbine sized according to a horizontal spacing between the first wind turbine and the second wind turbine, in accordance with an embodiment of the present invention;
[0041] FIGS. 6A-B are diagrams of stratum configurations with accretive gain and loss, in accordance with embodiments of the present invention;
[0042] FIGS. 7A-B are diagrams of a stratum configuration having two axes of implementation, in accordance with an embodiment of the present invention; and
[0043] FIGS. 8A-B are flow diagrams of example processes for implementing a stratum configuration, in accordance with embodiments of the present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0044] A description of example embodiments of the invention follows.
[0045] In FIG. 1A , in an example roadway system 100 for wind energy generation and distribution, vehicles 10 a and 1051 (e.g., an automobile, truck, etc.) travel along a roadway 110 (e.g., a road, highway, etc.). Situated or otherwise located alongside the roadway 110 are a plurality of wind turbines 115 a , 115 b , . . . 115 n (generally 115 ). The plurality of wind turbines 115 gather wind energy from or created by a variety of sources.
[0046] For example, being situated alongside the roadway 110 , the plurality of wind turbines 115 gather wind energy created by the vehicles 105 a and 105 b moving by the plurality of wind turbines 115 and causing air to move (so called, “dirty wind”).
[0047] In another example, the plurality of wind turbines 115 gathers naturally occurring wind energy (e.g., atmospheric wind). In this way, wind energy is gathered (and thus wind generated energy is generated) even when there are no vehicles traveling along the roadway 110 .
[0048] Furthermore the plurality of wind turbines 115 gathers wind energy from incident wind, i.e., air movement or current falling or striking the plurality of wind turbines 115 or some portion of the plurality of wind turbines 115 . For example, wind energy may be gathered from a main current of air, such as air moving along the line of travel of the vehicles 105 a and 105 b , striking the plurality of wind turbines 115 or some portion of the plurality of wind turbines 115 . In another example, wind energy may be gathered from a current of air moving contrary to a main current of air (i.e., an eddy) striking the plurality of wind turbines 115 or some portion of the plurality of wind turbines 115 .
[0049] Wind or more precisely a current of air may be infinitely divided into smaller currents of air. Furthermore, each individual current of air may be characterized with a directional vector, velocity and other physical characteristics. As such, one skilled the art will readily recognize principles of the present invention contemplate such individual currents of air and characteristics. For example, while it may be perceived at the human scale that air is not moving, at the granularity of an individual air current, air may nevertheless be moving from which wind energy may be gathered.
[0050] Accordingly, wind energy gathered from any combination of sources, such as atmospheric wind, and air movement caused by other vehicles or objects, as well as wind energy gathered from incident wind striking a plurality of wind turbines or some portion of a plurality of wind turbines is suitable for the present invention.
[0051] Because the plurality of wind turbines 115 is situated or otherwise positioned on part of a road or near to one or more roads, the potential installation footprint is hundreds of thousands of miles of available roadways. Compared to wind turbines located in remote areas, such as a hilltops, situating the plurality of wind turbines 115 on part of a road or near to one or more of roads allows for easier access for maintenance crews. Furthermore, there is greater access to a utility grid and additional direct powering opportunities to homes and businesses.
[0052] Additionally, by situating or otherwise locating the plurality of wind turbines 115 on part of a road or near to one or more roads to gather wind energy and generated wind generated energy, it may be said that a roadway network or system of wind generated energy is formed.
[0053] FIG. 1B illustrates, in greater detail, the roadway system 100 of FIG. 1A . The plurality of wind turbines 115 are electrically connected, in parallel, to a roadway system electricity grid 125 by a power line 130 . Alternatively, the plurality of wind turbines 115 is electrically connected to the roadway system electricity grid 125 by a battery pack system 135 . Furthermore, the plurality of wind turbines 115 may be electrically connected to the roadway system electricity grid 125 in such a manner as to form a parallel circuit, a series circuit or a combination parallel and series circuit.
[0054] Wind generated energy is power conditioned by inverters 140 a and 1401 b Electricity meters 145 a and 145 b measure an amount of wind generated energy which is gathered and generated by the plurality of wind turbines 115 . As such, the roadway system electricity grid 125 measures an amount of conditioned wind generated energy provided by the plurality of wind turbines 115 .
[0055] Wind generated energy generated by the plurality of wind turbines 115 and provided to the roadway system electricity grid 125 is distributed by the roadway system electricity grid 125 through distribution points 150 a . . . e , generally 150 . The distribution points 150 are configured to distribute wind generated energy to, for example, a utility grid 15 , a vehicle 152 , directly to a business or a home 153 or a hydrogen electrolysis and storage facility or a battery storage facility 154 . As such, the roadway system electricity grid 125 is configured for mass distribution of electricity.
[0056] In contrast, a plurality of wind turbines located on private land (e.g., a field abutting farm land) is configured to provide wind generated energy for private consumption. That is, it is the intention of an entity, such as homeowner or a farmer to use such a plurality of wind turbines to produce wind generated energy for the entity's own use. For example, a homeowner installs a plurality of wind turbines next to the homeowner's house to reduce the cost of providing energy to the house. In another example, a farmer installs a plurality of wind turbines in a field to provide power for a well pump to irrigate an isolated parcel of farmland which has no access to utilities.
[0057] Consequently, with such situated plurality of wind turbines there is a neither a need nor desire to distribute the wind generated energy to others, i.e., to mass distribute the wind generated energy. Moreover, with such situated plurality of wind turbines there is neither a need nor desire for a roadway system electricity grid configured to mass distribute the wind generated energy, which is in stark contrast with the roadway system electricity grid 125 of the present invention.
[0058] Electricity meters 155 a . . . d , generally 155 measure an amount of wind generated energy distributed to, for example, a direct power user, such as a home. As such, the roadway system electricity grid 125 measures an amount of conditioned wind generated energy provided by the roadway system electricity grid 125 .
[0059] The roadway system electricity grid 125 may include, for example, a battery backup 160 to store wind generated energy in an event the roadway system electricity grid 125 fails or is otherwise inoperable. In this way, wind generated energy generated by the plurality of wind turbines 115 can be stored without substantial loss despite an inability to distribute such generated energy. The wind generated energy stored by the battery backup 160 may then be distributed once the roadway system electricity grid 125 is operable.
[0060] The roadway system electricity grid 125 may also include, for example, a switch 165 to pass, in an automated manner, wind generated energy from a first plurality of wind turbines to a second plurality of wind turbines based on use or distribution demand. For example, wind generated energy generated by a first plurality of wind turbines (e.g., 115 a of FIG. 1A ) may be distributed by the roadway system electricity grid 125 to a direct power load or user, such as a business or home. The amount of wind generated energy distributed to the direct power load may be insufficient to meet the present demands of the direct power load, e.g., an increase use of air conditioning. The roadway system electricity grid 125 , sensing the increase demand from the direct power load, passes or reroutes wind generated energy generated by a plurality of wind turbines (e.g., 115 b of FIG. 1A ) to add or otherwise augment energy already being distributed to the direct power load. In this way, the roadway system electricity grid 125 is responsive to distribution demands. Alternatively, the roadway system electricity grid 125 may be programmed to distribute wind generated energy according to a projected or otherwise anticipated distribution demand. For example, during business hours, a demand for wind generated energy by businesses is higher than a demand for wind generated energy by homes. During non-business hours or weekends, however, the demand by homes is higher than the demand by businesses. As such, the roadway system electricity grid 125 may pass wind generated energy from a plurality of wind turbines near homes and distribute such power to businesses during business hours, and vice versa during non-business hours or weekends.
[0061] The roadway system electricity grid 125 may also include, for example, an energy distribution depot 170 to store, channel and recondition wind generated energy.
[0062] While the roadway system 100 illustrated in FIG. 1B gathers and distributes wind energy, other forms of energy may be gathered and distributed in addition to wind energy. For example, solar generated energy may be gathered and distributed, as described in a U.S. patent application Ser. No. 11/624,987 entitled “SYSTEM AND METHOD FOR CREATING A NETWORKED INFRASTRUCTURE DISTRIBUTION PLATFORM OF SOLAR ENERGY GATHERING DEVICES” filed Jan. 19, 2007 and assigned to Genedics LLC.
[0063] The plurality of wind turbines 115 are configured (arranged or otherwise positioned) in a configuration hereinafter referred to as a “stratum configuration.” In general, a stratum configuration involves the sizing of sweep heights of a plurality of wind turbines. More specifically, in a first alternative, sweep heights are sized with respect to horizontal planes intersected by a sweep height of an immediately adjacent wind turbine, described in reference to FIGS. 2 and 3 A- 3 F. In a second alternative, sweep heights are sized with respect to a sweep height of an immediately adjacent wind turbine, discussed in reference to FIGS. 4A-4C . In a third alternative, sweep heights are sized with respect to a horizontal spacing between a first wind turbine and a second wind turbine, described in reference to FIG. 5 . As such, a stratum configuration is not the mere following of an underlying topology or support, such as land or a building. For example, deploying wind turbines with substantially similar sweep heights along a hillside slope, while producing a “layering effect,” is not the same as a stratum configuration according to embodiments now being described.
[0064] In FIG. 2 , an example stratum configuration 205 of a plurality of wind turbines includes a first wind turbine 210 a , a second wind turbine 210 b , and a third wind turbine 210 c (generally, 210 ). Each of the wind turbines 210 has a respective sweep height 215 a , 215 b , and 215 c (generally, 215 ). The sweep height 215 of each wind turbine 210 intersects an infinite number of planes which are all oriented perpendicular to the sweep height 215 , hereinafter referred to as “horizontal planes.” In the stratum configuration 205 , the sweep heights 215 of each wind turbine 210 are sized to intersect at least one horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0065] For example, immediately adjacent to the first wind turbine 210 a with the first sweep height 215 a is the second wind turbine 210 b with the second sweep height 215 b . The first sweep height 215 a intersects a horizontal plane 220 . In contrast, the second sweep height 215 b , the sweep height of the immediately adjacent second wind turbine 210 b , does not intersect the horizontal plane 220 . As such, the horizontal plane 220 is a horizontal plane which differs or is otherwise unique from horizontal planes intersected by the second sweep height 215 b . Furthermore, in the stratum configuration 205 , the first sweep height 215 a (and hence first wind turbine 210 a ) is sized to intersect this unique horizontal plane.
[0066] Note that the third sweep height 215 c also intersects the horizontal plane 220 . However, unlike the second wind turbine 210 b , the third wind turbine 210 c is not immediately adjacent to the first wind turbine 210 a . As such, the horizontal plane 220 is a horizontal plane which is the same or is otherwise non-unique from horizontal planes intersected by the third sweep height 215 c , the sweep height of a wind turbine not immediately adjacent to the first wind turbine 210 a.
[0067] Returning to the first sweep height 215 a , the first sweep height 215 a further intersects a horizontal plane 225 . The second sweep height 215 b also intersects the horizontal plane 225 . As such, between the first wind turbine 210 a and the second wind turbine 210 b , the horizontal plane 225 is not a horizontal plane unique from horizontal planes intersected by the first sweep height 215 a or the second sweep height 215 b . However, between the second wind turbine 210 b and the third wind turbine 210 c , also an immediately adjacent wind turbine to the second wind turbine 210 b , the horizontal plane 225 is a horizontal plane unique from horizontal planes intersected by the third sweep height 215 c.
[0068] In this way, in a stratum configuration, such as the stratum configuration 205 of FIG. 2 , sweep heights of substantially all wind turbines of the configuration are each sized to intersect at least one horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine. Variations of this principle are described below.
[0069] In FIG. 3A , a stratum configuration 304 includes a first wind turbine 306 a , a second wind turbines 306 b , a third wind turbine 306 c . The first wind turbine 306 a is immediately adjacent to the second wind turbine 306 b . The second wind turbine 306 b is immediately adjacent to the first wind turbine 306 a and the third wind turbine 306 c . The third wind turbine 306 c is immediately adjacent to the second wind turbine 306 b.
[0070] The first wind turbine 306 a has a first sweep height 308 a which intersects horizontal planes “A” through “E” ( 310 a - 310 e ). The second wind turbine 306 b has a second sweep height 308 b which intersects the horizontal planes “B” through “D” ( 310 b - 310 d ). The third wind turbine 306 c has a third sweep height 308 c which intersects the horizontal plane “C” 310 c.
[0071] Between the first wind turbine 306 a and the second wind turbine 306 b (a wind turbine immediately adjacent to the first wind turbine 306 a ) both the first sweep height 308 a and the second sweep height 308 b intersect the horizontal planes “B” through “D” ( 310 b - 310 d ). In other words, between the two wind turbines, the horizontal planes “B” through “D” ( 310 b - 310 d ) are not unique, but are common or otherwise shared.
[0072] The horizontal plane “A” 310 a and the horizontal plane “E” 310 e , however, are not shared between the first wind turbine 306 a and the second wind turbine 306 b , but are uniquely intersected by the first sweep height 308 a . As such, in the stratum configuration 304 , illustrated in FIG. 3A , the first sweep height 308 a (and hence first wind turbine 306 a ) is sized to intersect at least two unique horizontal planes—the horizontal plane “A” 310 a and the horizontal plane “E” 310 e.
[0073] Between the second wind turbine 306 b and the first wind turbine 306 a both the first sweep height 308 a and the second sweep height 308 b intersect the horizontal planes “B” through “D” ( 310 b - 310 d ), as described above.
[0074] Between the second wind turbine 306 b and the third wind turbine 306 c , the second sweep height 308 b and the third sweep height 308 c both intersect the horizontal plane “C” 310 C. The horizontal plane “B” 310 b and the horizontal plane “D” 310 d , however, are not shared between the second wind turbine 306 b and the third wind turbine 306 c , but are uniquely intersected by the second sweep height 308 b . As such, in the stratum configuration 304 , illustrated in FIG. 3A , the second sweep height 308 b (an hence second wind turbine 306 b ) is sized to intersect at least two unique horizontal planes—the horizontal plane “B” 310 b and the horizontal plane “D” 310 d.
[0075] Between the second wind turbine 306 b and the third wind turbine 306 c both the second sweep height 308 b and the third sweep height 306 c intersect the horizontal plane “C” 310 c , as described above. In fact, the third sweep height 308 c intersects no horizontal plane which is unique from horizontal planes intersected by the first sweep height 308 a and second sweep height 308 b . As such, the third sweep height 308 c (third wind turbine 306 C) is sized not to intersect a horizontal plane unique from horizontal planes intersected by an immediately adjacent wind turbine the second wind turbine 306 b.
[0076] In this way, sweep height of substantially all wind turbines of a stratum configuration, such as the stratum configuration 304 of FIG. 3A , are sized to intersect at least two horizontal planes unique from horizontal planes intersected by a sweep height of at least one immediate adjacent wind turbine.
[0077] In FIG. 3B , a stratum configuration 314 includes a first wind turbine 316 a , a second wind turbine 316 b , and a third wind turbine 316 c . The first wind turbine 316 a is immediately adjacent to the second wind turbine 316 b . The second wind turbine 316 b is immediately adjacent to the first wind turbine 16 a and the third wind turbine 316 c . The third wind turbine 316 c is immediately adjacent to the second wind turbine 316 b.
[0078] The first wind turbine 316 a has a first sweep height 318 a which intersects a horizontal plane “A” 320 a . The second wind turbine 316 b has a second sweep height 318 b which intersects a horizontal plane “B” 320 b . The third wind turbine 316 c has a third sweep height 318 c which intersects a horizontal plane “C” 320 c.
[0079] Between the first wind turbine 316 a and the second wind turbine 316 b (a wind turbine immediately adjacent to the first wind turbine 316 a ) neither the first sweep height 318 a nor the second sweep height 318 b intersect a common horizontal plane. All horizontal planes intersected by the first sweep height 318 a are unique from horizontal planes intersected by the second sweep height 318 b . In the example illustrated in FIG. 3B , the first sweep height 318 a intersects the horizontal plane “A” 320 a . No other sweep height intersects the horizontal plane “A” 320 a.
[0080] Similarly, between the second wind turbine 316 b and the third wind turbine 316 c (a wind turbine immediately adjacent to the second wind turbine 316 b ) neither the second sweep height 318 b nor the third sweep height 318 c intersect a common horizontal plane. All horizontal planes intersected by the second sweep height 318 b are unique from horizontal planes intersected by the third sweep height 318 c . In the example illustrated in FIG. 3B , the second sweep height 318 b intersects the horizontal plane “B” 320 b . No other sweep height intersects the horizontal plane “B” 320 b.
[0081] In this way, in a stratum configuration, such as the stratum configuration 314 of FIG. 3B , sweep heights of substantially all wind turbines of a stratum configuration are sized to intersect horizontal planes unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0082] In FIG. 3C , a stratum configuration 324 includes a first wind turbine 326 a , a second wind turbine 326 b , and a third wind turbine 326 c . The first wind turbine 326 a is immediately adjacent to the second wind turbine 326 b . The second wind turbine 326 b is immediately adjacent to the first wind turbine 326 a and the third wind turbine 326 c.
[0083] The third wind turbine 326 c is immediately adjacent to the second wind turbine 326 b . The first wind turbine 326 a has a first sweep height 328 a which intersects a horizontal plane “A” 330 a . The second wind turbine 326 b has a second sweep height 328 b which intersects a horizontal plane “B” 330 b . The third wind turbine 326 c has a third sweep height 328 c which intersects a horizontal plane “C” 330 c.
[0084] Between the first wind turbine 326 a and the second wind turbine 326 b (a wind turbine immediately adjacent to the first wind turbine 326 a ) both the first sweep height 328 a and the second sweep height 328 b intersect the horizontal plane “B” 330 b and the horizontal plane “C” 330 c . The first sweep height 328 a intersects the horizontal plane “A” 320 a . The second sweep height 328 b , however, does not intersect the horizontal plane “A” 330 a . Additionally, the horizontal plane “A” 330 a is above horizontal planes intersected by both third sweep height 328 c and the second sweep height 328 b (e.g., the horizontal plane “B” 330 b and the horizontal plane “C” 330 c ). As such, the horizontal plane “A” 330 a is a horizontal plane which is both unique from and above horizontal planes intersected by the second sweep height 328 b of the immediately adjacent second wind turbine 326 b . Furthermore as FIG. 3C illustrates, the first sweep height 328 a (and hence first wind turbine 326 a ) is sized to intersect the horizontal plane “A” 330 a.
[0085] Similarly, the horizontal plane “B” 330 b is a horizontal plane which is both unique from and above the horizontal planes intersected by the third sweep height 328 c of the immediately adjacent third wind turbine 326 c . Furthermore as FIG. 3C illustrates, the second sweep height 328 b is sized to intersect the horizontal plane “B” 330 b.
[0086] Unlike the previously described first and second sweep heights ( 328 a and 328 b ), the third sweep height 328 c does not intersect a horizontal plane which is both unique from and above the horizontal planes intersected by the second sweep height 328 b of the immediately adjacent second wind turbine 326 b . All horizontal planes intersected by the third sweep height 328 c are also intersected by the second sweep height 328 b . As such, as FIG. 3C illustrates, the third sweep height 328 c (third wind turbine 326 c ) is not sized to intersect a horizontal plane which is both unique from and above the horizontal planes intersected by the second sweep height 328 b of the immediately adjacent second wind turbine 326 b.
[0087] In this way, in a stratum configuration, such as the stratum configuration 324 of FIG. 3C , sweep heights of substantially all wind turbines of the configuration are sized to intersect at least one horizontal plane unique from and above horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0088] In an alternative stratum configuration, sweep heights of substantially all wind turbines of the configuration are sized to intersect at least one horizontal plane unique from and below horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0089] In FIG. 3D , a stratum configuration 334 includes a first wind turbine 336 a , a second wind turbine 356 b , a third wind turbine 336 c , and a fourth wind turbine 336 d . The first wind turbine 336 a has a first sweep height 338 a which intersects a horizontal plane “A” 340 a . The second wind turbine 336 b has a second sweep height 338 b which intersects a horizontal plane “B” 340 b.
[0090] The first sweep height 338 a does not however intersect the horizontal plane “B” 340 b . As such, the horizontal plane “B” 340 b is unique from a horizontal plane intersected by a sweep height of an immediately adjacent wind turbine (viz., the first sweep height 338 a of the first wind turbine 336 a ). Furthermore, the second sweep height 338 b is sized to intersect the horizontal plane “B” 340 b.
[0091] Similarly, the second sweep height 338 b does not intersect the horizontal plane “A” 340 a . As such, the horizontal plane “A” 340 a is unique from a horizontal plane intersected by a sweep height of an immediately adjacent wind turbine (viz., the second sweep height 338 b of the second wind turbine 336 b ). Furthermore, the first sweep height 338 a is sized to intersect the horizontal plane “A” 340 a.
[0092] In the stratum configuration 334 , the third wind turbine 336 c has a third sweep height 338 c which is sized substantially the same as the first sweep height 338 a . The fourth wind turbine 326 d has a fourth sweep height 338 d which is sized substantially the same as the second sweep height 338 b . In other words, in the stratum configuration 334 , a sweep height is sized either like the first sweep height 338 a or the second sweep height 338 b —a first “size” and a second “size”. Consequently, in such a configuration, the stratum configuration 334 resembles a “picket fence” in appearance.
[0093] The stratum configuration 334 illustrated in FIG. 3D is merely illustrative and one skilled in the art will readily recognize that sweep heights may be sized according to additional “sizes” (e.g., a third size). In this way, in a stratum configuration, such as the stratum configuration 334 illustrated in FIG. 3D , sweep heights of at least two wind turbines of the configuration are sized to intersect at least one horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0094] In FIG. 3E , a stratum configuration 344 includes a first wind turbine 346 a , a second wind turbine 346 b , and a third wind turbine 346 c . The second wind turbine 346 b is immediately adjacent to the first wind turbine 346 a and the third wind turbine 346 c . Presented differently, the second wind turbine 346 b is an intermediate wind turbine between two terminal wind turbines, namely the first wind turbine 346 a and the third wind turbine 346 c.
[0095] The second wind turbine 346 b has a second sweep height 348 b which intersects a horizontal plane “A” 350 a . The first wind turbine 346 a has a first sweep height 348 a , and the third wind turbine 346 c has a third sweep height 348 c . The first sweep height 348 a and the third sweep height 348 c intersect a horizontal plane “B” 350 b . The first sweep height 348 a and the third sweep height 348 c do not however intersect the horizontal plane “A” 350 a . As such, the horizontal plane “A” 350 a is a horizontal plane unique from the horizontal planes, such as the horizontal plane “B” 350 b , intersected by the first sweep height 348 a and the third sweep height 348 c . Furthermore, the horizontal plane “A” 350 a is above the horizontal plane “B” 350 b.
[0096] As FIG. 3E illustrates, the second sweep height 348 b , the sweep height of an intermediate wind turbine, is sized to intersect the horizontal plane “A” 350 a , a horizontal plane which is both unique and above horizontal planes intersected by the first and third sweep heights ( 348 a and 348 c ), the sweep heights of two terminal wind turbines.
[0097] In this way, in a stratum configuration, such as the stratum configuration 344 illustrated in FIG. 3E , sweep heights of substantially all wind turbines between two wind turbines of the configuration are sized to intersect a horizontal plane above the horizontal planes intersected by the two wind turbines.
[0098] In FIG. 3F , a stratum configuration 354 includes a first wind turbine 356 a , a second wind turbine 356 b , and a third wind turbine 356 c . The second wind turbine 356 b is immediately adjacent to the first wind turbine 356 a and the third wind turbine 356 c . Presented differently, the second wind turbine 356 b is in between two wind turbines, namely the first wind turbine 356 a and third wind turbine 356 c.
[0099] The second wind turbine 356 b has a second sweep height 358 b which intersects a horizontal plane “B” 360 b . The first wind turbine 356 a has a first sweep height 358 a , and the third wind turbine 356 c has a third sweep height 358 c . The first sweep height 358 a and the third sweep height 358 c intersect a horizontal plane “A” 360 a . The first sweep height 358 a and the third sweep height 358 c do not however intersect the horizontal plane “B” 360 b . As such, the horizontal plane “B” 360 b is a horizontal plane unique from the horizontal planes, such as the horizontal plane “A” 360 a , intersected by the first sweep height 358 a and the third sweep height 358 c . Furthermore, the horizontal plane “B” 360 b is below the horizontal plane “A” 360 a.
[0100] As FIG. 3F illustrates, the second sweep height 358 b (second wind turbine 356 b ) is sized to intersect the horizontal plane “B” 360 b , a horizontal plane which is both unique from horizontal planes intersected by the sweep heights of the first and third sweep heights ( 358 a and 358 c ) and below such horizontal planes. In this way, in a stratum configuration, such as the stratum configuration 354 illustrated in FIG. 3F , sweep heights of substantially all wind turbines between two wind turbines of the stratum configuration are sized to intersect a horizontal plane below the horizontal planes intersected by the two wind turbines.
[0101] The above description in reference to FIGS. 3E and 3F is not intended to limit embodiments of the present invention to a single intermediate wind turbine between or otherwise bordered by two terminal wind turbines. Rather, the principles of the present invention are readily applicable to any number of intermediate wind turbines between the two terminal wind turbines. As before, in such instances, sweep heights of substantially all wind turbines between two wind turbines of the stratum configuration are sized to intersect a horizontal plane above (or below) horizontal planes intersected by the two wind turbines.
[0102] In reference to FIGS. 3A-3F , a stratum configuration is described as a configuration of a plurality of wind turbines whose sweep heights are sized to intersect one or more horizontal planes unique from horizontal planes intersected by a sweep height of a least one immediately adjacent wind turbine. That is, in the example embodiments described in reference to FIGS. 3A-3F , the sizing of a sweep height depends on a horizontal plane and how the subject horizontal plane relates to other horizontal planes. Alternatively, a sweep height of a wind turbine may be sized so that the sweep height differs from another sweep height of another wind turbine. That is, rather than depending on a horizontal plane, the sizing of a sweep height for a given wind turbine depends on a sweep height of one or more immediately adjacent wind turbines.
[0103] In FIG. 4A , a stratum configuration 404 includes a first wind turbine 406 a , a second wind turbine 406 b , and a third wind turbine 406 c . In the stratum configuration 404 , the first wind turbine 406 a is immediately adjacent to the second wind turbine 406 b , the second wind turbine 406 b is immediately adjacent to the first wind turbine 406 a and the third wind turbine 406 c , and the third wind turbine 406 c is immediately adjacent to the second wind turbine 406 b . The first wind turbine 406 a is not immediately adjacent to the third wind turbine 406 c.
[0104] The first wind turbine 406 a has a first sweep height 408 a , the second wind turbine 406 b has a second sweep height 408 b , and the third wind turbine 406 c has a third sweep height 408 c . The first sweep height 408 a differs from (i.e., is not equal to) the second sweep height 408 b . In this example, the first sweep height 408 a is less than the second sweep height 408 b . The second sweep height 408 b differs from both the first sweep height 408 a and the third sweep height 408 c . In this example, the second sweep height 408 b is greater than both the first sweep height 408 a and the third sweep height 408 c . The first sweep height 408 a is substantially the same or otherwise equal to the third sweep height 408 c . However, the first wind turbine 406 a is not immediately adjacent to the third wind turbine 406 c . In this way, in a stratum configuration, such as the stratum configuration 404 of FIG. 4A , sweep heights of substantially all wind turbines of the configuration are sized to differ from a sweep height of an immediately adjacent wind turbine.
[0105] In FIG. 4B , a stratum configuration 414 includes a first wind turbine 416 a , a second wind turbine 416 b , and a third wind turbine 416 c . In the stratum configuration 414 , the first wind turbine 416 a is immediately adjacent to the second wind turbine 416 b , the second wind turbine 416 b is immediately adjacent to the first wind turbine 416 a and the third wind turbine 416 c , and the third wind turbine 416 c is immediately adjacent to the second wind turbine 416 b . The first wind turbine 416 a is not immediately adjacent to the third wind turbine 416 c . The first wind turbine 416 a has a first sweep height 418 a , the second wind turbine 416 b has a second sweep height 418 b , and the third wind turbine 416 c has a third sweep height 418 c.
[0106] In the stratum configuration 414 , the first wind turbine 416 a and the third wind turbine 416 c are “terminal” wind turbines. That is to say, the first wind turbine 416 a and the third wind turbine 416 c are positioned at the “ends” of the stratum configuration 414 . In the example illustrated in FIG. 4B , the sweep heights ( 418 a and 418 c ) of the terminal wind turbines are substantially equal to one another. Alternatively, sweep heights of terminal wind turbines may differ from one another (e.g., one is greater than the other).
[0107] Continuing with FIG. 4B , the second wind turbine 416 b is an “intermediate” wind turbine, i.e., the second wind turbine 416 b is located in between or in the “middle” of the ends of the stratum configuration 414 . In the example illustrated in FIG. 4B , the second sweep height ( 418 b ) of the intermediate wind turbine is less than the first and third sweep heights ( 418 a and 418 c ) of the terminal wind turbines. Alternatively, a sweep height of an intermediate wind turbine may be greater than sweep heights of terminal wind turbines.
[0108] While FIG. 4B illustrates a single intermediate wind turbine, the principles of the present invention are also applicable to instances where there are more than one intermediate wind turbine between terminal wind turbines. In this way, in a stratum configuration, such as the stratum configuration 414 of FIG. 4B , sweep heights of substantially all wind turbines between a first wind turbine and at least one second wind turbine are sized to differ from a first sweep height of the first wind turbine and a second sweep height of the second wind turbine.
[0109] In FIG. 4C , a stratum configuration 424 includes a first wind turbine 426 a , a second wind turbine 426 b , a third wind turbine 426 c , and a fourth wind turbine 426 d . The first wind turbine 426 a has a first sweep height 428 a , the second wind turbine 426 b has a second sweep height 428 b , the third wind turbine 426 c has a third sweep height 4298 , and the fourth wind turbine 426 d has a fourth sweep height 428 d . The sweep heights of the second wind turbine 426 b and the fourth wind turbine 426 d (viz., 428 b and 428 d ) are substantially the same or otherwise equal. As such, the second wind turbine 426 b and the fourth wind turbine 426 d are a pair of wind turbines having substantially equal sweep heights.
[0110] In the stratum configuration 424 , the third wind turbine 426 c is between the pair of wind turbines 426 b and 426 d . The third sweep height 428 c of the third wind turbine 426 c differs from (i.e., is not equal to) the second sweep height 428 b and the fourth sweep height 428 d . In this way, in a stratum configuration, such as the stratum configuration 424 , sweep heights of substantially all wind turbines between any pair of wind turbines having substantially the same sweep heights are sized to differ from the sweep heights of the pair of wind turbines.
[0111] So far, in one embodiment described in reference to FIGS. 2 and 3 A- 3 F, sweep heights are sized with respect to horizontal planes intersected by a sweep height of an immediately adjacent wind turbine. In an alternative embodiment described in reference to FIGS. 4A-4C , sweep heights are sized with respect to a sweep height of an immediately adjacent wind turbine. Now, in yet another embodiment, sweep heights are sized with respect to a horizontal spacing between a first wind turbine and a second wind turbine.
[0112] In FIG. 5 , in a stratum configuration 500 , a first wind turbine 505 a and a second wind turbine 505 b , each with substantially similar sweep height 510 , are located a distance from one another, hereinafter referred to as a horizontal spacing 515 . The horizontal spacing 515 may be defined as a multiple of the sweep height 510 . To illustrate, horizontal spacing 515 is equal to two and half times the sweep height 510 . Accordingly, with a sweep height of 50 feet, the first and second wind turbines ( 505 a 505 b ) are spaced 125 feet apart from one another.
[0113] A particular or “recommended” horizontal spacing between wind turbines may account or otherwise be influence by aerodynamic considerations or constraints. For example, improper spacing between wind turbines of similar sweep heights may result in turbulence, interfering with wind energy gathering capabilities, and thus efficiency of such wind turbines.
[0114] Continuing with FIG. 5 , within the horizontal spacing 515 , a second set of wind turbines 520 a and 520 b , each with a substantially similar sweep height 525 , are located. The second set of wind turbines 520 a and 520 b are located a second horizontal spacing 530 from each other. As FIG. 5 illustrates, the second horizontal spacing 530 is a smaller division of the horizontal spacing 515 . As such, the sweep heights 525 are sized less than the sweep height 510 .
[0115] Similarly, within the second horizontal spacing 530 , a third set of wind turbines 535 a - d , each with a substantially similar sweep height 540 , are located. The third set of wind turbines 535 a - d is located a third horizontal spacing 545 from each other. The third horizontal spacing 545 is a smaller division of the second horizontal spacing 530 and an even smaller division of the horizontal spacing 515 . As such, the sweep height 540 is sized smaller than the sweep height 525 and sized even smaller than the sweep height 510 .
[0116] It should be readily apparent that a horizontal spacing may be divided or otherwise reduced into ever smaller divisions or horizontal spacings. That is to say, a horizontal spacing is infinitely divisible. Equally apparent, with each smaller division of the horizontal spacing, a respective sweep height is sized even smaller. For example, the stratum configuration 500 includes a sheet of micro-sized wind turbines 550 . One skilled in the art will readily recognize that even smaller sized wind turbines, such as nano-sized wind turbines, are also applicable.
[0117] In this way, in a stratum configuration, such as the stratum configuration 500 of FIG. 5 , sweep heights of a first wind turbine and at least one second wind turbine are sized according to a horizontal spacing between the first wind turbine and the second wind turbine.
[0118] In FIG. 6A , in a stratum configuration 605 , starting from a first terminal wind turbine 610 a and a second terminal wind turbine 610 b , sweep heights 612 of each successive intermediate wind turbine 615 are sized greater than a sweep height of a previous wind turbine until a maximum sweep height 617 is reached or is otherwise attained. In the stratum configuration 605 , the maximum sweep height 617 height belongs to a maximum intermediate wind turbine 620 .
[0119] An overall increase in sweep height size from a first wind turbine to at least one second wind turbine may be said to describe a stratum configuration with a positive sweep height slope. Similarly, an overall decrease in sweep height size from a first wind turbine to at least one second wind turbine may be said to describe a stratum configuration with a negative sweep height slope.
[0120] Returning to FIG. 6A , in the stratum configuration 605 , sweep heights 612 of intermediate wind turbines 615 are successively increasing from both the first terminal wind turbine 610 a and the second terminal wind turbine 610 b to the maximum intermediate wind turbine 620 . The stratum configuration 605 resembles a “pyramid” in appearance. As such, the stratum configuration 605 may be characterized as having a first positive sweep height slope 625 a and a second positive sweep height slope 625 b . Presented differently, the stratum configuration 605 may be said to be a stratum configuration with an “accretive gain.”
[0121] In FIG. 6B , in a stratum configuration 655 , starting from a first terminal wind turbine 660 a and a second terminal wind turbine 660 b , sweep heights 662 of each successive intermediate wind turbine 665 are sized less than a sweep height of a previous wind turbine until a minimum sweep height 667 is reached or is otherwise attained. In the stratum configuration 655 , the minimum sweep height 667 belongs to a minimum intermediate wind turbine 670 .
[0122] In the stratum configuration 655 , sweep heights are successively decreasing from both the first terminal wind turbine 660 a and the second terminal wind turbine 660 b to the minimum intermediate wind turbine 670 . The stratum configuration 655 resembles a “suspension bridge” in appearance. As such, the stratum configuration 655 may be characterized as having a first negative sweep height slope 675 a and a second negative sweep height slope 675 b . Presented differently, the stratum configuration 655 may be said to be a stratum configuration with an “accretive loss.”
[0123] The stratum configurations 605 and 655 illustrated in FIGS. 6A and 6B are merely illustrative of the above-mentioned principles. For example, one skilled in the art will readily recognize that the “patterns” underlying the stratum configurations 605 and 655 may be repeated indefinitely in a stratum configuration.
[0124] In the above description, example stratum configurations are illustrated as having a plurality of wind turbines arranged in a single line (e.g., arranged side to side when viewed from the front of a stratum configuration). Such examples are merely illustrative and are not intended to limit the principles of the present invention. One skilled in the art will readily recognize that in a stratum configuration embodying the aforementioned principles, a plurality of wind turbines may be arranged or otherwise implemented along one or more lines or axes. Consider the following example.
[0125] FIG. 7 is a top down view of an example stratum configuration 705 having a First implementation axis 710 a and a second implementation axis 710 b . The first implementation axis 710 a and second implementation axis 710 b are substantially perpendicular to each other.
[0126] Running parallel to the first implementation axis 710 a , a first wind turbine 715 a , second wind turbine 715 b , third wind turbine 715 c , and a fourth wind turbine 715 d (generally 715 ) are arranged or otherwise located in a first “row” 720 a and a second “row” 720 b (generally 720 ). Additionally, running parallel to the second implementation axis 710 b , the wind turbines 715 are arranged in a first “column” 725 a and a second “column” 725 b (generally 725 ).
[0127] The terms “row” and “column” are merely used as a convenient way of differentiating an arrangement of wind turbines aligned with one implementation axis from an another arrangement of wind turbines aligned with another implementation axis. As such, the terms are not intended to be limiting or suggest a preferred orientation.
[0128] In the stratum configuration 705 , for each wind turbine 7115 in the rows 720 and columns 725 , a sweep height is sized according to example embodiments previously described. To illustrate, consider the following example illustrated in FIG. 7B .
[0129] FIG. 7B illustrates the stratum configuration 705 of FIG. 7A , but in a perspective view. For the sake of readability, the location of each wind turbine is described as an ordered pair, i.e., (row number, column number). The first wind turbine 715 a , located at (1, 1), has a first sweep height 730 a . The second wind turbine 715 b , located at (1, 2), has a second sweep height 730 b . The third wind turbine 715 c , located at (2, 1), has a third sweep height 730 c . The fourth wind turbine 715 d , located at (2, 2) has a fourth sweep height 730 d . In the stratum configuration 705 , the wind turbines 715 are immediately adjacent to each other.
[0130] A horizontal plane “A” 735 a is intersected by the first sweep height 730 a , but not by the second, third or fourth sweep heights ( 730 b - d ). As such, the first sweep height 730 a is sized to intersect a horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine, e.g., the second sweep height 730 b , the third sweep height 730 c or the fourth sweep height 730 d.
[0131] Similarly, a horizontal plane “C” 735 c is intersected by the fourth sweep height 730 d , but not by the first, second or third sweep heights ( 730 a - c ). As such, the fourth sweep height 730 d is sized to intersect a horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbines, e.g., the first sweep height 730 a , the second sweep height 730 b or the third sweep height 730 c.
[0132] A horizontal plane “B” 735 b is intersected by both the second sweep height 730 b and the third sweep height 730 c . However, because the second wind turbine 715 b is immediately adjacent to the first wind turbine 715 a and the first sweep height 730 a does not intersect the horizontal plane “B” 735 b , the second sweep height 730 b is sized to intersect a horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine. Similarly, because the third wind turbine 715 c is immediately adjacent to the fourth wind turbine 715 d and the fourth sweep height 730 d does not intersect the horizontal plane “B” 735 b , the third sweep height 730 c is sized to intersect a horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine.
[0133] In this way, in a stratum configuration having more than one implementation axis, such as the stratum configuration 705 of FIGS. 7A and 7B , sweep heights of substantially all wind turbines in the configuration are sized to intersect at least one horizontal plane unique from horizontal planes intersected by at least one immediately adjacent wind turbine.
[0134] In FIG. 8A , an example process 800 starts ( 801 ) maximizing wind energy gathering potential of a plurality of wind turbines for a given location. The process 800 sizes ( 805 ) sweep heights of substantially all wind turbines of the plurality to intersect horizontal planes unique from horizontal planes intersected by a sweep height of an immediately adjacent wind turbine. The process 800 ends ( 806 ) with the wind energy gathering potential of the plurality of wind turbines maximized for the given location.
[0135] In FIG. 5B , an example process 850 starts ( 851 ) sizing sweep heights of wind turbines between a first wind turbine and second wind turbine. The process 850 determines ( 855 ) whether a sweep height of a wind turbine intersects a horizontal plane unique from horizontal planes intersected by an immediately adjacent wind turbine. If the process 850 determines ( 855 ) the sweep height does not intersect a horizontal plane unique from horizontal planes intersected by an immediately adjacent wind turbine, the process 850 sizes ( 860 ) the sweep height to intersect a horizontal plane which is unique from horizontal planes intersected by the immediately adjacent wind turbine.
[0136] The process 850 determines ( 865 ) whether the sweep height intersects a horizontal plane below horizontal planes intersected by the first and second wind turbines. If the process 850 determines ( 865 ) the sweep height does not intersect a horizontal plane below the horizontal planes intersected by the first and second wind turbines, the process 850 sizes ( 870 ) the sweep height to intersect a horizontal plane below the horizontal planes intersected by the first and second wind turbines.
[0137] The process 850 determines ( 875 ) whether there are more wind turbines between the first and second wind turbines. If the process 850 determines ( 875 ) there are more wind turbines between the first wind turbine and second wind turbine, the process 800 continues (loops back) to determine ( 855 ) whether a sweep height of another wind turbine intersects a horizontal plane unique from horizontal planes intersected by an immediately adjacent wind turbine. If, however, the process 850 determines ( 875 ) there are no more wind turbines between the first and second wind turbines, the process 850 ends ( 876 ) with the sweep heights of the wind turbines between the first and second wind turbines sized.
[0138] Returning to the process 850 determining ( 855 ), in an event the process 850 determines ( 855 ) that the sweep height does intersect a horizontal plane unique from horizontal planes intersected by an immediately adjacent wind turbine, the process 850 then determines ( 865 ) whether the sweep height intersects a horizontal plane below horizontal planes intersected by the first and second wind turbines.
[0139] Returning to the process 850 determining ( 865 ), in an event the process 850 determines ( 865 ) that the sweep height does intersect a horizontal plane below horizontal planes intersected by the first and second wind turbines, the process 850 then determines ( 875 ) whether there are more wind turbines between the first and second wind turbines.
[0140] While this invention has been particularly shown and described with references to example embodiments thereof, it will b understood by those skilled in the art that various changes in form and details may b made therein without departing from the scope of the invention encompassed by the appended claims.
[0141] For example, while example embodiments of the present invention are described in reference to one “type” of wind turbine, one skilled in the art will readily recognize that the principles of the present invention are also applicable to other types of wind turbines.
[0142] A wind turbine (or “wind turbine generator”) is a device that includes a turbine and a generator, wherein the turbine gathers or captures wind by conversion of some of the wind energy into rotational energy of the turbine, and the generator generates electrical energy from the rotational energy of the turbine. These wind turbine generators can employ a turbine rotating around an axis oriented in any direction.
[0143] For example, in a “horizontal axis turbine,” the turbine rotates around a horizontal axis, which is oriented, typically, more or less parallel to the ground (or other form of underlying support). Furthermore, in a “vertical axis turbine,” the turbine rotates around a vertical axis, which is oriented, typically, more or less perpendicular to the ground (or other form of underlying support).
[0144] For example, a vertical axis turbine can be a Darrieus wind turbine, a Giromill-type Darrieus wind turbine, a Savonius wind turbine, a “helix-style turbine” and the like. In a “helix-style turbine,” the turbine is helically shaped and rotates around a vertical axis. A helix-style turbine can have a single-helix design or multi-helix design, for example, double-helix, triple-helix or quad-helix design.
[0145] A “roadway” or “road,” as used in this application refers to any identifiable route or path between two or more places on which vehicles can drive or otherwise use to move from one place to another. A roadway is typically smoothed, paved, or otherwise prepared to allow easy travel by the vehicles. Also, typically, a roadway may include one or more lanes, one or more breakdown lanes, one or more medians or center dividers, and one or more guardrails. For example, a roadway may be: a highway; turnpike; pike; toll road; state highway; freeway; clearway; expressway; parkway; causeway; throughway; interstate; speedway; autobahn; superhighway; street; track for railroad, monorail, magnetic levitation trains; track for subterranean, ground level, and elevated forms of public transmit or mass transmit; car race track; airplane runway; and the like.
[0146] It should be understood that the flow diagrams ( FIGS. 8A-B ) may include more or fewer elements, be arranged differently, or be represented differently. It should be understood that implementation may dictate the flow diagrams and the number of flow diagrams illustrating the execution of embodiments of the invention. Processes 800 and 850 of FIGS. 8A-B may be computer implemented. | Installing large-sized wind turbines creates numerous challenges and limitations, hindering acceptance of wind generated energy. With small-sized wind turbines, such hindrances are omitted or minimized. Sized ever smaller, more small-sized wind turbines may be installed per installation. Accordingly, a method and corresponding apparatus for maximizing wind energy gathering potential of a plurality of wind turbines, each wind turbine having a sweep height, for a given location is provided. The present invention includes sizing sweep heights of substantially all wind turbines of the plurality of wind turbines to intersect at least one horizontal plane unique from horizontal planes intersected by a sweep height of at least one immediately adjacent wind turbine. Because the sweep height of each wind turbine of the plurality is individually sized in a prescribed manner, the present invention maximizes the wind energy gathering potential of the plurality of wind turbines especially for deployment of small-sized wind turbines. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS, IF ANY NONE
BACKGROUND OF THE INVENTION AND PRIOR ART
The art of golf putters has been extremely well developed since the Scots first began playing the game centuries ago. Various materials have been used for golf club shafts, ranging from hickory and willow to metals and space-age technology graphite reinforced resin composites. At the present time, most golf club shafts are made of steel which is then chrome plated and a rubber or composition grip is then glued to the shaft. Steel shafts are usually continuously tapered or step-tapered from a thin tip end to the handle or butt end and are designed with flexibility characteristics for wood or iron head clubs intended to be swung for full or partial shots rather than for putters. These same steel shafts are then cut down to a length appropriate for putter shafts. Although the shortening increases the stiffness of the shaft, cut down steel shafts are generally less stiff than desired for putters. The butt end is of suitable diameter to receive a wound or sleeve type grip which increases the grip size to accommodate the hands of the golfer.
Ingenious golf putter developments in the past have resulted in various configurations including those having single and double bend steel shafts; straight steel shafts with or without fluting over a portion of their length; and straight shafts made of other materials such as fiberglass or graphite composites and alloys. Apart from special bends or fluting, most shafts used in prior art putters are ordinary steel shafts not specially constructed for putter use. The butt or handle ends of these shafts are of circular cross-section having a typical diameter in the range of from 0.580-0.600 inches for receiving a grip of rubber or leather or other non-slip generally soft material. The exterior grip configuration may vary within the Official Rules of Golf.
In direct contrast with golf club shafts intended for woods and irons where achieving maximum distance is one of the major objectives accomplished by cocking of the wrists on the backswing and uncocking or release of the wrists on the downswing to generate high club head speed, putters should have stiff shafts and the golfer's wrists preferably should not break when executing a putting stroke. Clubhead speed is generated best when the weight of the club is concentrated in the head. A good putting stroke is quite the opposite in that it is accepted wisdom in teaching circles that the golfer should not cock or break his wrists during the putting stroke. Instead, the triangle formed by the golfer's shoulders and arms is generally kept in a constant configuration to control speed and direction of the putt. This suggests that the ideal putter should have characteristics which assist the golfer in keeping his wrists stiff or firmly locked when putting. Accordingly, the handle should be configured (in conformity with the Official Rules of Golf) to assist the golfer in keeping his wrists firm during the putting stroke. Also, it is thought that the putter weight distribution need not emphasize weight of the club head but could and perhaps should instead place greater weight toward the handle end of the club such that the balance point is more toward the mid-point of the club shaft rather than only a few inches from the blade as is conventional.
SUMMARY OF THE INVENTION
The present invention provides a hollow shaft for a golf putter comprising:
a tip section;
a handle section having a substantially flat side; and
a tapered section interconnecting said tip section and said handle section, said sections being integrally formed from a single piece of metal, said substantially flat side of said handle section having a width, measured in a plane generally perpendicular to the plane of a putter blade when affixed to the shaft, of not less than 0.930 inches.
The present invention further provides a golf putter comprising:
a putter blade having a ball striking face generally lying in a striking plane; and
a hollow shaft having:
a tip section to which said putter blade is affixed;
a handle section having a substantially flat side; and
a tapered section interconnecting said tip section and said handle section, said sections being integrally formed from a single piece of metal, said substantially flat side of said handle section having a width, measured in a plane generally perpendicular to the plane of said putter blade, of not less than 0.930 inches.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a golf putter employing the putter shaft of the present invention.
FIG. 2 is a front elevation of the golf putter shaft of the present invention.
FIG. 3 is a longitudinal cross-section of the golf putter shaft of the present invention looking from the front of the shaft as seen in FIG. 2 drawn to an exaggerated scale for clarity.
FIG. 4 is a longitudinal cross-section of the golf putter shaft of the present invention looking from the side of the shaft as seen in FIG. 2 drawn to an exaggerated scale for clarity.
FIG. 5 is a cross-section looking in the direction of line 5--5 of FIG. 3.
FIG. 6 is a tip or bottom end view.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The perspective view of a putter incorporating the teachings of the present invention as seen in FIG. 1 comprises an elongated putter shaft 10 having a putter blade B shown in phantom, suitably affixed to the tip end and having a generally circular cross-section including an integrally formed handle section 12 with a flattened side 14 facing perpendicular to the intended line of the putt. This flattened portion 14 conveniently provides a resting surface for the thumbs of the golfer and assists in preventing rotation of the putter handle in the golfer's hands during the putting stroke. The construction of the putter shaft is best understood with reference to the cross-sectional views of the invention seen in FIGS. 3-5. The putter shaft 10 is formed from a single stiff hollow tube, preferably aluminum, which is worked with common drawing, swaging or extrusion techniques to reform the originally cylindrical tube into an integral shaft comprised of the handle section 12, a tip section 16 and a tapered section 18 between the tip section and handle section. In the preferred embodiment shown in FIGS. 3 and 4, the tapered section 18 includes a first taper 20 and a second taper 22 although only one taper is necessary. The shaft is thus comprised of at least three sections 12, 16 and 18 integrally formed from a single piece of metal, preferably aluminum alloy, although other metals or alloys are also contemplated for future putter shaft constructions. The wall thickness of the putter shaft of the present invention varies along the length of the shaft from relatively thick at the tip end to relatively thin at the butt end unlike conventional shafts which have a substantially constant wall thickness.
Contrary to conventional putter shafts which have a handle receiving end with a maximum handle diameter of about 0.600 inches, the handle section of the present putter shaft does not have a circular cross section but has a width W, measured in a plane generally perpendicular to the plane of a putter blade when affixed to the shaft, of not less than 0.930 inches as seen in FIG. 6. This handle width is thus over 150% larger than the handle diameter of conventional putters. Although it is anticipated that various golfers, for whatever reasons, will wish to employ a soft grip cover on the handle section 12 of the putter shaft of the present invention, the putter shaft of the present invention is designed and intended for use without a soft cover. To that end, the curved side of handle section 12 of the putter shaft 10 is preferably shot peened to a roughened non-shiny appearance. Direct contact between the golfer's hands and the putter handle section 12 improves the golfer's feel for the putting stroke and the flattened handle side 14 provides a firm thumb rest which, with the roughened curved portion of the handle, assists the golfer in keeping his wrists locked and prevents the putter shaft from rotating in the golfer's hands during the putting stroke.
Specific Example
A putter was constructed by affixing a standard putter head weighing about 300 grams to a shaft formed from a single tube of aluminum and cut to a shaft length of 35 inches and weighing about 135 grams. The total weight of the putter, which included a thin grip on the handle section was about 470 grams. It will be appreciated that shafts can be of varying lengths in the range of approximately 32 inches through 38 inches depending on the height and preference of the golfer.
The tip section had a length of 10 inches with an outside diameter of 0.370 inches. The wall thickness of the aluminum tube at the tip end was 0.100 inches. The range of acceptable wall thicknesses for the tip section of the shaft is approximately from 0.065 inches through 0.105 inches.
The first taper 20 had an axial length of 12 inches and the second taper 22 had an axial length of 3 inches for a total length of tapered section 18 of 15 inches through which the wall thickness diminished as the diameter of the shaft increased toward the butt or handle section 12 which, in the manufactured embodiment, had an outside diameter or width W (FIG. 6) of 0.940 inches before flattening. It is contemplated that the outside diameter of the curved portion of the handle section 12 will be within the range of 0.930 inches through 0.950 inches for average golfers. The wall thickness of the tube in the handle section 12 was 0.034 inches but it is contemplated that the generally acceptable range of wall thickness in this section can very from approximately 0.030 inches through 0.045 inches. In the manufactured embodiment, the flattened side 14 of the handle extended for the full 10 inch length of the handle section and slightly into the tapered section 18. The width WF (FIG. 6) of the flattened section 14 was approximately 0.75 inches.
Supplementary weight may be provided in the handle section 12 of the shaft such that the balance point of a putter having a typical blade attached to the shaft is approximately in the mid-point of the shaft. More specifically, the balance point of the putter should be located a distance D measured from the tip end of the shaft in the range of from 40% to 60% of the length L of the shaft. In comparison, prior art putters typically have a balance point which is only 5 or 6 inches from the blade rather than near the mid-point of the putter. The amount of supplementary weight added in the handle section as well as its specific location together determine the desired position of the balance point which can easily be adjusted to accommodate the golfer's preference. Supplementary weighting of from 15% -40% of the total weight of the putter is contemplated. For example, 115 grams of added weight (about 20%) would be used in the putter mentioned above which, in absence of a grip, weighed 435 grams. In order to eliminate the pinging sound made when a ball is struck with a putter having a hollow metal shaft of the present invention, vibration dampening filler can be placed into the shaft at selected locations following which the open butt end of the shaft is plugged to prevent entry of dirt and act as an end cap.
Persons skilled in the art will readily appreciate that various modifications can be made from the preferred embodiment thus the scope of protection is intended to be defined only by the limitations of the appended claims. | A golf putter shaft having an integrally formed handle intended for use without a soft grip overwrapping having a handle section preferably of D shaped cross-section sized to assist the golfer to keep his wrists from breaking during putting. The putter shaft is preferably made from aluminum alloy of increased stiffness compared to ordinary golf club shafts. Supplementary weighting may be provided in the handle section to result in a putter having its balance point located near the mid-length of the shaft. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a control apparatus for controlling a rotor supported by a magnetic bearing to be stable up to high speed rotation, and particularly to a magnetic bearing control method and apparatus suitable for use in processing the amount of feedback in a frequency region in order that the rotor can be controlled to undergo a damping effect up to a high speed region.
In the magnetic bearing, it is difficult to make the axis of inertia of the rotor completely coincident with a predetermined axis set in the bearing. In general, the rotor has a natural frequency dependent on the shape and material of the rotor. Thus, upon rotation the rotor has a dangerous speed at which the vibration of the shaft increases. If the bearing has no damping effect, the vibration increases at the dangerous speed, so that the rotor cannot rotate. So far, in order to prevent this shaft vibration, a control apparatus has been used which detects the positional deviation of the rotating shaft from a predetermined axis, and controls the current in the electromagnetic coil for the magnetic bearing so that this deviation is suppressed, or that the damping effect can be brought about. Since the vibration of the rotor shaft has great energy in the frequency components synchronized with the rotation frequency of the rotor, the control system should greatly suppress only the vibration at such frequencies. Therefore, the control apparatus disclosed in Japanese Patent Laid-open Gazette No. 52-93853 includes a filter of analog circuits for tuning to the frequency equal to the rotation speed of the rotor so that the phase-controlled signal is supplied to the servo circuit, making great damping to the vibration frequencies. Thus, a complicated circuit is used which is formed of a differentiator, an integrator, an adder and so on.
The value of the detected deviation of the rotating shaft is subjected to Fourier transform in real time, to a signal processing in a vibration control law which is a frequency region and to reverse Fourier transform so as to produce a control signal. This control signal is used to control the current in the electromagnetic coil. Thus, an arbitrary control characteristic can be achieved with ease and satisfaction. The frequency analyzer(hereinafter, abbreviated "FFT analyzer") using the principle of discrete Fourier transform (hereinafter, abbreviated "DFT") will be described briefly with reference to FIGS. 1 and 2.
As shown in FIG. 1, an input waveform x(t) is sampled at each specified sampling period Δt, and N samples are sequentially stored in a memory (N=8). This storing process is shown at step 401 of the flowchart shown in FIG. 2. The stored values are, as illustrated, x0, x1, . . . x7. At step 402, complex amplitude values Ak, k=0-7 are found from the formula of DFT given by ##EQU1##
In this equation, j is the imaginary unit, and the following equation is given. ##EQU2## The complex amplitude values A k at each frequency ω k show that the larger the values, the greater the vibration at the frequency. At step 403, the absolute value of the calculated result A k (k=0-7) is displayed as a bar graph.
The FFT analyzer fast executes a sequence of operations of data storing→DFT processing→displaying indicated at steps 401 to 403 in FIG. 2. The timing of this sequence of operations is shown in FIG. 1. N (N=8) samples are stored at each sampling period T=(N-1)Δt of the input vibration waveform, and then the calculation of DFT and displaying are performed. During the calculation and displaying the data is stopped from being stored. Therefore, DFT calculation is not made over all the interval of the input waveform, and thus a certain interval of the vibration waveform is inevitably overlooked. This DFT calculation is based on the fact that the values of stored data x 1 ˜x 7 are a periodical function which is periodically repeated even out of the sampling period T. Therefore, in practice the input waveform is normally multiplied by the window function for picking up the waveform only during the sampling interval before the sampling operation.
The algorithm for the complex amplitude values. Ak of the equation (1) is a very-high speed one called the butterfly computation. As described above, the actual Fourier transform device is constructed to have various functions for its purpose. A conventional example thereof is disclosed in, for example, Japanese Patent Laid-open Gazette No. 61-196370.
The main object of the above common FFT analyzer is to display and monitor the result of having analyzed the frequencies of the vibration waveform even during the data reading stop period. The FFT analyzer is widely used because very useful information for analyzing the source of an abnormal vibration can be obtained by monitoring the complex amplitude values of the frequency components displayed as the output so as to detect the abnormal vibration. However, when it is used as the controller, the presence of the pause period prevents sufficient control. The formula of calculation for the DFT processing and finding the complex amplitude at each operation of reading the waveform data without pause period is described in, for example, "HOW TO USE FFT" written by Ankyo Intake and Masayuki Nakashima, pp.132 to 133 in Electronics science series 91 published by Sanpo shuppan, February, 1982. That is, as shown in FIG. 3, the sample values x 1 to x 7 at time points 0 to 7 (N=7) on the input waveform x(t) are read and stored in a memory and the complex amplitude values A k , k=0 to 7 are calculated. Then, when the value x8 at time point 8 on the input waveform x(t) is sampled, the oldest data x out x 0 is discarded, the stored samples of data each are shifted left within the memory, and the read sample x in =x 8 is stored in the rightmost vacancy of the memory. The complex amplitude A k at this time is given by
A.sub.k1 =(A.sub.ko +(x.sub.in -x.sub.out)/N.sup.-1/2)exp(jω.sub.k), K=0-7 (3)
This equation can be easily derived. According to the equation (3), if the complex amplitude values A k0 , k=0 to 7 previously sampled are held, these complex amplitude values A k1 , k=0 to 7 can be obtained by making once each of the addition, subtraction, multiplication and division of complex numbers for each k. This equation, as compared with the equation (1), is executed in much less time in real time with ease.
According to the DFT algorithm in the FFT analyzer, if the regions other than the sampling interval of the input waveform are a periodical function and coincide in its period with the sampling period of the input waveform as shown in FIG. 4A, the input waveform is subjected to Fourier transform, and the obtained complex amplitude values are shifted in phase ahead by with 90 degrees, and subjected to reverse Fourier transform so as to be a real-time waveform. Thus, at this time the waveform (which occurs during the sampling pause period) with 90 degrees ahead of the input waveform can be known. However, when as shown in FIG. 4B the period of the periodical function does not coincide with the sampling period, the above waveform cannot be obtained. In addition, if the input wave is shifted from the periodical function, correct processing cannot be performed. The control apparatus for the magnetic bearing using the DFT algorithm without the pause period is also not realized yet.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a magnetic bearing control method and apparatus using Fourier transform which can effectively suppress the vibration synchronized with the rotation speed of a rotor even when the vibration of the rotor rotating shaft is not a complete periodic function.
According to this invention, there is provided a magnetic bearing control method having the steps of sampling a vibration waveform at pulses which are synchronized with the rotation of a rotor, averaging vibration waveform values at each revolution, extracting only the frequency components synchronized with the rotation frequency of the rotor from the vibration waveform, subjecting the extracted components to Fourier transform, processing the frequency regions of the Fourier-transformed components, subjecting the processed components to Fourier reverse transform, and controlling a magnetic bearing by a signal obtained by a sequence of the signal processes given above so that vibration components can be suppressed.
According to another aspect of the invention, there is provided a magnetic bearing control method having the steps of generating N sampling pulses of first to N-th pulse (N is an integer) at each revolution of a rotor on a magnetic bearing, detecting deviations of a rotating shaft of the rotor from predetermined positions in two directions within a plane perpendicular to the shaft, sampling the detected deviations in two directions by the first to N th sampling pulses to produce first to N th sampled values, averaging the i-th sampled values obtained after start of operation so as to produce an i th average value each time the i-th sampled values (i=1-N) in two directions are produced, obtaining i-th average values up to that time point from the i-th average value, obtaining complex amplitude values by discrete Fourier transform of the first to N-th average values in two directions and calculating a control signal by discrete Fourier reverse transform of the complex amplitude values after signal processing, and controlling the shaft of the rotor on a magnetic bearing by the control signal.
According to this invention, there is further provided a magnetic bearing control apparatus having pulse generating means for generating N sampling pulses of first to N-th sampling pulses (N is an integer) at each revolution of a rotor on a magnetic bearing, detection means for detecting deviations of a rotating shaft of the rotor from predetermined positions in two directions within a plane perpendicular to the shaft, sampling means for producing first to N sampled values by sampling the detected deviations in two directions at the first to N-th sampling pulses, averaging means for obtaining an i-th average value from the i-th average values of the i-th sampled values produced after start of operation up to that time point each time the i-th sampled values (i=1N) in two directions are produced from the sampling means, signal processing means for obtaining complex amplitude values by discrete Fourier transform of the first to N th average values in two directions obtained by the averaging means and for calculating a control signal by discrete Fourier reverse transform of the complex amplitude values after signal processing, and control means for controlling the rotating shaft of the rotor on the magnetic bearing by the control signal.
Since the vibration waveform is sampled at pulses synchronized with the rotation of the rotor and since the sampled waveform values at each revolution of the rotor are averaged by the averaging means, only the frequency components synchronized with the rotation frequency of the rotor are extracted from the vibration waveform. Since the components are main components of the deviations of the rotor, the magnetic bearing is controlled so that these deviations can be suppressed by the signal processing of the frequency region into which they are subjected to Fourier transform. Thus, desired control can be realized. In addition, since this Fourier transform processing can be performed at a high speed, the real time processing becomes easy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a timing chart showing the operation of a conventional FFT analyzer;
FIG. 2 is a flowchart for the Fourier transform processing in the FFT analyzer shown in FIG. 1;
FIG. 3 is a diagram useful for explaining the continuous Fourier transform processing in another conventional example;
FIGS. 4A and 4B are diagrams showing the relations between the period of the periodic function and the sampling period;
FIG. 5 is a block diagram of one embodiment of a control apparatus of the invention;
FIG. 6 is a flowchart for the operation of the control apparatus shown in FIG. 5; and
FIG. 7 is a diagram useful for explaining the average processing shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of the invention will be described with reference to FIGS. 5 and 6. FIG. 5 is a block diagram of one embodiment of a control apparatus of the invention. The vibration displacement x in a vertical plane, of the rotating shaft of a rotor 1 on a magnetic bearing is detected by a position detector 2X and sampled by a sampling circuit 3. At this time, the sampling trigger pulses are N pulses per revolution which are produced from a PLL circuit 5 to which the output from a detector 4 is supplied after detecting the rotation of the rotor 1. The PLL circuit 5 and the detector 4 may be replaced by a pulse encoder which produces N pulses per revolution. The sampled values are supplied to an average processing circuit 6. The vibration of the rotating shaft of the rotor is two-dimensionally caused in a vertical plane relative to the rotating shaft. The control system shown in FIG. 1 is only for one-axis component. In practice, another control system is required for the output y from a position detector 2Y for detecting the component perpendicular to the vibration displacement X.
The average processing circuit 6 receives the sampled values Xi from the sampling circuit 3 and the N pulses from the PLL circuit 5 and produces an average value e i of the sampled values per revolution of the rotor 1. This output is subjected to Fourier transform by a Fourier transform circuit 7. The Fourier transform output is subjected to C k processing by a signal processing circuit 8. The sampled values, V i in time regions from a Fourier reverse transform circuit 9 are supplied to an adder 13.
The average value e i is also subtracted from the sampled values X i by a subtracter 12, and the fluctuation, or vibration portion Δx i from the subtracter is supplied to a PID processing circuit 10. The PID processed output is supplied to the adder 13 where it is added to the sampled value V i . The added output is supplied to an X-direction magnetic bearing coil 11. The same signal processing is made for the vibration displacement Y detected by the position detector 2Y. The Y-processed output is supplied to a magnetic bearing coil 11', though not shown because the signal processing is exactly the same as that for X direction.
The important circuit elements of the embodiment after the average processing circuit 6 inclusive will be described in detail.
FIG. 6 is a flowchart for the processing after the circuit 6. The average processing circuit 6 includes N data storing areas for storing average values e 0 ˜e N-1 which will be described later, associated with the N sampled values, 2N data storing areas (N storing areas for each of the real part and the imaginary part) for storing complex amplitude values C 0 ˜C N-1 of the calculated result, and 2N data storing areas (N storing areas for each of the real part and the imaginary part) for storing complex amplitude values B 0 ˜B N-1 the processed result. Upon start of operation, at step 201, the above data storing areas are all cleared, and then at step 202 parameters M for average processing are set to 0. At step 203, another parameter i is set to zero and at step 204 one sampled data is stored and designated as X. At step 205 the value determined as the average value e i is substituted into x out , and a new average value is obtained using the input X from the following equation:
x.sub.in =(2.sup.M ei+X)/(1+2.sup.M) (4)
and this average value is substituted into e i . These operations are performed by the average processing circuit 6 shown in FIG. 5. The meaning of the operations will be described with reference to FIG. 7.
It is assumed that as shown in FIG. 7 sampled values x 0 0 ˜x 7 0 are obtained by 8 pulses from the input waveform x during the time T corresponding to one revolution of the rotor from time point t 0 . The lower subscripts 0 to 7 of the sampled values correspond to i (step 203) in FIG. 6. The value x in obtained from the equation (4) at step 205 is stored as e 0 to e 7 in this order in the average storing areas. At the next revolution of the rotor, the same processing is performed for the sampled values of x 0 1 , x 0 2 . . . Therefore, at each revolution of the rotor, a new average value e 0 can be obtained from the equation (4) by using the average value of the sampled value at the first rotation pulse and the sampled value at the first previous rotation pulse. Similarly, for the second and the following pulses, e 1 , e 2 . . . are updated. Thus, the values e 0 ˜e 7 at step 205 in FIG. 6 are the average values of the vibration waveforms at every revolutions of the rotor. Only the vibration components synchronized with the rotation frequency of the rotor can be derived by this processing.
At next step 206 in FIG. 6, the Fourier transform circuit 7 shown in FIG. 5 executes that processing. In other words, the complex amplitude C k is updated by substituting the values of x in and xout obtained at step 205 and the previously obtained complex amplitude Ck into the following equation called the continuous real time FFT:
C.sub.k +C.sub.k +N.sup.-1/2 (x.sub.in -x.sub.out)exp(-ijω.sub.k), k=0-7 (5)
where ω k is the value shown at equation (2), and the equation (5) is given in Japanese Patent Laid-open Gazette No. 2-244205. The Fourier transform processing can be fast executed by this algorithm.
At step 207, the signal processing circuit 8 makes the processing based on the control of the complex amplitude C k , thus calculating the complex amplitude B k . For example, in order to obtain the Fourier transform of the signal indicating the speed from the vibration displacement waveform x, the following equation is used:
B.sub.k =jω.sub.k C.sub.k, k=0-N-1 (6)
In addition, if the B k is given by
B.sub.k =jC.sub.k, k=0-7 (7)
the complex amplitude value 90 degrees ahead can be obtained without changing the gain. In either case, the complex amplitude value B k of the control signal is obtained in accordance with the object. This processing can be written as the following equation (8) using a certain constant α k as generally shown by the equations (6) and (7):
B.sub.k =α.sub.k C.sub.k, k=0-N-1 (8)
At step 208, the Fourier reverse transform circuit 9 shown in FIG. 5 executes that processing, or makes Fourier reverse transform from B k and calculates the sampled values v i of time region from the following equation: ##EQU3##
After the end of the above processing, at step 209, i is incremented by 1, and then the processing after step 204 is repeated. When i=N indicating that the rotor has made one full revolution, M is incremented by 1. Then, the program returns to step 203, and the processing for the next revolution is started. The parameter M thus indicates the number of revolutions so far made.
As described above, the vibration components corresponding to the rotation frequency of the rotor and the harmonics are taken out by average processing, converted into a frequency region and then processed back to a time region for the control of the magnetic bearing. Thus, particularly only the vibration at the frequency (the rotation frequency of the rotor) at which the vibration is great, and at the harmonics can be suppressed. The frequencies at which no vibration occurs are not suppressed. Accordingly, it is possible to make the control with less energy loss, or with high efficiency.
Moreover, as shown in FIG. 5, the value, Δx i is obtained by subtracting the average value e i from the sampled value x i and the PID processing (10) is made. This value Δx i corresponds to the fluctuation other than the components synchronized with the rotation frequency of the rotor. Therefore, if the magnetic bearing is controlled by the signal after the PID processing (proportion, integration, differentiation), since the harmonics are already removed from the value Δx i the PID processing is easy and the control for suppressing the fluctuation can be accurately performed. | A control method and apparatus for suppressing the vibration components of a magnetic bearing. According to this invention, a vibration wave is sampled at pulses synchronized with the rotation of a rotor, the vibration waveform sampled values at each revolution are averaged, and only the frequency components synchronized with the rotation frequency of the rotor are extracted from the vibration waveform. In addition, the extracted components are subjected to Fourier transform, processed in a frequency region and subjected to Fourier reverse transform. The sequence of these signal processes produces a signal, and the vibration components are suppressed by this signal. | 5 |
CROSS-REFERENCES AND RELATED APPLICATIONS
[0001] This application claims the benefit of priority to Chinese Application No. 201410666089.5, entitled “Methods for enhancing alpha-ketoglutarata production in Yarrowia lipolytica ”, filed Nov. 19, 2014, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of metabolic engineering, which relates to methods for enhancing alpha-ketoglutarata production in Yarrowia lipolytica , and more particularly relates to enhance alpha-ketoglutarata production in Yarrowia lipolytica by the regulation of intracellular amino acid metabolism.
[0004] 2. Description of the Related Art
[0005] α-ketoglutarata(α-KG) is involved in many metabolic activities as one of the important intermediates of Krebs cycle (TCA) pathway in microbial cells. It is one of the key nodes in the citric acid cycle which involves in the synthesis of amino acids, proteins, vitamins and energy metabolism, and its accumulation in microbial cells is regulated by more factors compared with other intermediates of TCA. Therefore, to reveal the accumulation and regulation mechanism of α-KG in microbial cells has important significance, which would also guide the enhancement of accumulation of other products of TCA. α-KG is also an important chemical synthesis intermediates of the synthesis of amino acids, vitamins and other small molecules, which has important applications in the fields of pharmaceutical, organic synthesis, nutritional supplements, and so on. However, traditional chemical synthesis of α-KG has the following disadvantages: multiple steps, complex reaction process, the use of toxic compounds to human body such as cyanide. These prevent the applications of chemically synthesized α-KG in high value-added products, such as pharmaceutical and food. Microbial fermentation of α-KG production reduces the dependence on fossil energy supply, and the use of renewable biomass materials has many advantages, such as environmentally friendly and economically sustainable.
[0006] However, microbial production of α-KG also has shortcomings, such as low concentrations and low production intensity. The present invention provides a method to increase the production and accumulation of α-KG by modulating the synthesis of amino acids from α-KG.
DETAILED DESCRIPTION
[0007] The goal of the present invention is to provide a recombinant Yarrowia lipolytica ( Y. Lipolytica ) enhancing the production of α-KG, which is constructed by overexpressing the glutamate dehydrogenase (GDH) in the starting strain Y. lipolytica to strengthen the enzyme activity of GDH and the supply of glutamate and accordingly enhance the accumulation of α-KG.
[0008] The gene encoding the GDH was from Saccharomyces cerevisiae ( S. cerevisiae ) in one of the embodiments of the present invention.
[0009] The nucleotide sequence of the gene encoding the GDH was SEQ ID NO.2 in one of the embodiments of the present invention.
[0010] Y. lipolytica is the starting strain of the recombinant Y. lipolytica and integrative expression vector p0 is the expression vector which containing a gene hph encoding a hygromycin phosphotransferase as screening marker in one of the embodiments of the present invention.
[0011] The starting strain was Y. lipolytica WSH-Z06 which preservation number is CCTCC NO: M20714 in one of the embodiments of the present invention.
[0012] The construction of plasmid P0 refers to: Swennen D, Paul MF, Vernis L, Beckerich JM, Fournier A, Gaillardin C. Secretion of active anti-Ras single-chain Fv antibody by the yeasts Y. lipolytica and Kluyveromyces lactis . Microbiology-Sgm, 2002. 148: 41-50.
[0013] The present invention also provides a method for enhancing the synthesis of α-KG in Y. lipolytica through the regulation of nitrogen metabolism in cells. Overexpressing of the GDH in the starting Y. lipolytica strengthened the activity of GDH and the supply of glutamate and accordingly enhanced the accumulation of α-KG.
[0014] L-methionine imine as glutamine synthetase inhibitor was added to reduce the metabolic breakdown of intracellular glutamate and enhance intracellular glutamate supply and α-KG accumulation in one of the embodiments of the present invention.
[0015] The present invention also provides a method for constructing the recombinant Y. lipolytica . The method comprises the following steps:
(1) Construction of integrative expression plasmid for target gene: the hph gene which encodes a hygromycin phosphotransferase was amplified and the nucleotide sequence of the hph gene is SEQ ID NO.1. The PCR products were digested with Stu I/Hind III and ligated into Stu I/Hind III-digested integrative expression vector p0 to create p0(hph) which containing a hygromycin phosphotransferase as screening marker. (2) Construction of recombinant plasmid: the whole sequence of the open reading frame of GDH2 encoding an GDH was synthesized according to the sequences published on NCBI. The pruducts were digested with Sfi I/Not I and ligated into the plasmid p0(hph) to create a recombinant plasmid p0(hph)-GDH2. (3) Transformation of p0(hph)-GDH2 into Y. lipolytica WSH-Z06: The recombinant plasmid p0(hph)-GDH2 was linearised with Avr II and then transformed into Y. lipolytica WSH-Z06 by electroporation. The genomes of transformants were extracted and verification primers VBF/V-GDH2 were used to screen the positive transformants to obtain recombinant Y. lipolytica strains named the Y. lipolytica -GDH2.
[0019] The present invention also provides a method for producing α-KG in recombinant Y. lipolytica . The activated recombinant Y. lipolytica strains were inoculated into the fermentation medium and incubated at 28-30° C. and 200-220 rpm for 144-168 hours.
[0020] In one of the embodiments of the present invention, the fermentation medium contained 100 g·L −1 glycerol, 3 g·L −1 (NH 4 ) 2 SO 4 , 3 g·L −1 KH 2 PO 4 , 1.2 g·L −1 MgSO 4 ·7H 2 O, 0.5 g·L −1 NaCl, 0.1 g·L −1 K 2 HPO 4 , 2×10 −7 g·L −1 thiamine hydrochloride, and then adjusted to pH 5.0 and CaCO3 was added to it to 20 g·L −1 .
[0021] L-methionine imine was added into the fermentation medium in one of the embodiments of the present invention.
[0022] In one of the embodiments of the present invention, the fermentation medium contained 36.1 mg·L −1 L-methionine imine, 100 g·L −1 glycerol, 3 g·L −1 (NH 4 ) 2 SO 4 , 3 g·L −1 KH 2 PO 4 , 1.2 g·L −1 MgSO 4 ·7H 2 O, 0.5 g·L −1 NaCl, 0.1 g·L −1 K 2 HPO 4 , 2×10 −7 g·L −1 thiamine hydrochloride, and then adjusted to pH 5.0 and CaCO 3 was added to it to 20 g·L −1 .
[0023] In one of the embodiments of the present invention, the recombinant Y. lipolytica strain was incubated in seed medium at 28° C., 200 rpm for 16-18 hours and then inoculated into a 500 ml flask containing 50 ml fermentation medium with a inoculation volume of 10%, and incubated at 28° C. with a stirred revolutions of 200 rpm for 144-168 hours.
[0024] The GDH catalytic activity of the recombinant Y. lipolytica overexpressing the GDH rises to 8.62 U per mg protein, which is 7.2 times of the starting strain.
[0025] Adding of 0.2 mM glutamine synthetase inhibitor L-methionine imide during the fermentation of the recombinant strains reduces the breakdown of glutamate. The content of glutamate intracellular increases to 0.99 μmol per mg dry cells weight (DCW) with an increase of 86.3% and the accumulation of α-KG extracellular increases to 19.2 g·L −1 with an increase of 32.4%.
[0026] The present invention enhances the metabolic flux from glutamate to α-KG by overexpression of GDH, and then strengthens the supply of intracellular glutamate by adding L-methionine imine in the fermentation process which significantly increases the extracellular accumulation of α-KG. Through the regulation of amino acid metabolism, the present invention reduces the synthesis of amino acids from α-KG in microbial cells, weakens the catabolism of α-KG and then enhances the accumulation of α-KG extracellular.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1 . Overexpression of GDH to increase intracellular catalytic activity of GDH; WSH-Z06 is the starting strain and GDH2 is the recombinant strain.
[0028] FIG. 2 . Overexpression of GDH to enhance the synthesis of α-KG; WSH-Z06 is the starting strain and GDH2 is the recombinant strain.
[0029] FIG. 3 . Adding of L-methionine imide to strengthen the supply of intracellular glutamate; WSH-Z06 is the starting strain and GDH2 is the recombinant strain.
[0030] FIG. 4 . Changes of the content of extracellular external α-KG; WSH-Z06 is the starting strain and GDH2 is the recombinant strain.
EXAMPLES
Materials and Methods
[0031] YPD medium: 10 g·L −1 yeast extract, 20 g·L −1 peptone, 20 g·L −1 dextrose.
[0032] Solid YPD medium: YPD medium with 20 g·L −1 agar. Hygromycin B was added to a final concentration of 400 mg·L −1 when screening the positive recombinant strain.
[0033] Seed medium: 20 g·L −1 glucose, 10 g·L −1 peptone, 0.5 g·L −1 MgSO 4 ·7H 2 O, 1.0 g·L −1 KH 2 PO 4 , the pH was adjusted to 5.5 with dilute hydrochloric acid and then sterilized at 115° C. for 15 min. 20 g·L −1 agar was added in solid medium.
[0034] Fermentation medium: 36.1 mg·L −1 L-methionine imine, 100 g·L −1 glycerol, 3 g·L −1 (NH 4 ) 2 SO 4 , 3 g·L −1 KH 2 PO 4 , 1.2 g·L −1 MgSO 4 ·7H 2 O, 0.5 g·L −1 NaCl, 0.1 g·L −1 K 2 HPO 4 , 2×10 −7 g·L −1 thiamine hydrochloride, pH 4.5, and then sterilized at 115° C. for 15 min. CaCO 3 sterilized at 121° C. for 30 min was added to 20 g·L −1 before inoculation.
[0035] Y. lipolytica WSH-Z06 was obtained from China Center for Type Culture Collection with a preservation number CCTCC NO: M20714.
[0036] Determination of GDH catalytic activity and intracellular amino acid content: cells were collected by centrifugation in the exponential growth phase and washed by 0.9% saline, then suspended by 10 mL buffer (0.1 M KH 2 PO 4 -K 2 HPO 4 , 1 mM EDTA, 0.01 mM DTT, pH 7.5). Pickling glass beads was added for grinding for 5 min at 4° C., and then centrifuged at 13000×g for 10 min. The supernatant was used for the determination of catalytic activity of GDH and the intracellular amino acid content.
[0037] Quantification of the catalytic activity of GDH: A reaction mixture (6 mM NAD + , 100 mM glutamic acid, 160 mM glycine, 1.8 mM NaCl, 1.8 mM NaCl, pH=9.0) was added to 1.5 ml cell disruption supernatant to a total volume of 3 mL. The content of NADH was detected at 340 nm, 30° C. One unit of catalytic activity was defined as the amount of enzyme required for the generating of 1 μmol NADH per unit time.
[0038] Intracellular glutamate and glutamine was determinated by the following steps: 200 μl cell disruption supernatant and 800 μL 5% trichloroacetic acid was sequentially added to an 1 mL EP tube and standed for 5 min. 1 mL sample was filtered by 0.22 μm aqueous filter head and then centrifuged at 10000 rpm for 10 min. The amino acid content of the treated sample was measured by HPLC.
[0039] The HPLC conditions were as follows: pre-column derivatization of sample was carried out by o-xylene (OPA) and 9-Fluorenylmethyl Chloroformate. Mobile phase A was made by the following steps: 1000 mL water was added to 5.0 g sodium acetateanhydrous in a 1000 mL beaker and stirred until fully dissolved; Then 200 μL triethylaminewas add, and 5% acetic acid was dropwised to pH 7.20±0.05 while stirring; 5 mL tetrahydrofuran was added and mixed for later use. Mobile phase B was made by the following steps: 400 mL acetonitrile, 400 mL methanol was sequentially added to 5.0 g anhydrous sodium acetate in 1000 mL beaker and then ultra-pure water was added to dilute to 1000 mL. Stired until fully dissolved and adjusted the pH to 7.20±0.05. Mixed for later use. The column was ODS-2 Hypersil (250 mm×4.6 mm×5 μm), column temperature was 40° C. and the excitation wavelength was 338 nm of the UV detector. The elution procedure was shown in Table 1.
[0000]
TABLE 1
The gradient elution of amino acid analysis
Time (min)
A %
B %
Velocity of flow (ml/min)
0
92
8
1
27.5
40
60
1
31.5
0
100
1.5
32
0
100
1.5
34
0
100
1
35.5
92
8
1
[0040] Extracellular α-KG was quantified by HPLC. Appropriate supernatant of fermentation broth centrifuged at 13000×g was diluted 50-fold with ultrapure water and filtrated by 0.22 μm filter for HPLC analysis. The column was Aminex HPX-87H ion exchange column and 5 mmol·L −1 sulfuric acid solution (550 μL concentrated sulfuric acid volumed to 2 L) filtrated by 0.22 μm filter and degassed was used as mobile phase. The velocity of flow was 0.6 mL·min −1 with a column temperature at 35° C. and a injection volume of 10 μL. The wavelength of UV detector was 210 nm.
[0041] The transformation of p0(hph)-GDH2 into Y. lipolytica WSH-Z06 was achieved by electroporation. Fresh Y. lipolytica WSH-Z06 single colony on YPD medium was transferred to YPD liquid medium and incubated at 28° C., 200 rpm overnight. Then the seeds were transferred to fresh YPD liquid medium with 10% inoculation and incubated at the same conditions to OD 600 1.2. The cells were collected by centrifugation and treated with pH 7.5 buffer (8 mL 100 mmol·L −1 LiAc, 10 mmol·L −1 DTT, 0.6 mol·L −1 sorbitol 10 mmol·L −1 Tris-HCL) at 30° C. Then the cells were collected by centrifugation and washed by 5 mL ice-cold sorbitol for three times and suspended with 1 mol·L −1 sorbitol to 10 10 cells per mL. 1 μg pre-linearized integrative vector was added to the cell suspension and placed on ice for 5 min. The mixture was transferred to a prechilled 0.2 cm electroporation cuvette and shocked at 2.5 KV, 25 μF, 200 Ω. 1 mL ice-cold 1 mol·L −1 sorbitol was added immediately and standed at room temperature for 1 hour. The 0.2 mL electric shocked products were applied to screening plates containing 400 mg·L −1 hygromycin B and cultured at 28° C. for 48-72 hours.
[0000]
TABLE 1
Verification primers for positive recombinant
strain.
Primers
Sequences (from 5′ to 3′)
VBF
CGTTTGCCAGCCACAGATT
V-GDH2
TTCAACCTGTTTCAATGCTGC
Example 1 Influence of Overexpression of GDH on the Growth of Cells
[0042] Construction of the recombinant strain Y. lipolytica -GDH2 was carried out by the following steps:
(1) Construction of integrative expression plasmid for target gene: the hph gene which encoded a hygromycin phosphotransferase was amplified and the nucleotide sequence of the hph gene is SEQ ID NO.1. The PCR products were digested with Stu I/Hind III and ligated into Stu I/Hind III-digested integrative expression vector p0 to create p0(hph) which containing a hygromycin phosphotransferase as screening marker. (2) Construction of recombinant plasmid: the whole sequence of the open reading frame of GDH2 encoding an GDH was synthesized according to the sequence published on NCBI which was from S. cerevisiae with the GeneID:851311. The pruducts were digested with Sfi I/Not I and ligated into the plasmid p0(hph) to create a recombinant plasmid p0(hph)-GDH2. (3) Transformation of p0(hph)-GDH2 into Y. lipolytica WSH-Z06: The recombinant plasmid p0(hph)-GDH2 was linearised with Avr II and then transformed into Y. lipolytica WSH-Z06 by electroporation. Transformants was selected on the screening plate which containing 400 mg·L −1 hygromycin B. The genome of transformants was extracted and validated by primers VBF/V-GDH2 (As shown in Table 1) to screen the positive transformants to obtain recombinant Y. lipolytica strains named the Y. lipolytica -GDH2.
[0046] The construction of plasmid P0 refers to: Swennen D, Paul MF, Vernis L, Beckerich JM, Fournier A, Gaillardin C. Secretion of active anti-Ras single-chain Fv antibody by the yeasts Y. lipolytica and Kluyveromyces lactis . Microbiology-Sgm, 2002. 148: 41-50.
[0047] The wild type Y. lipolytica WSH-Z06 and the recombinant strain Y. lipolytica -GDH2 were incubated in 250 mL flasks with 20 mL YPD medium at 28° C., 200 rpm to exponential growth phase (about 20 hours) at the same time. Cells were centrifugated and washed by physiological saline for two times. The intracellar catalytic activities of GDH, the contents of glutamate and glutamine contents were quantified by the methods described above.
[0048] Compared to the wild type strain, the intracellar catalytic activity of GDH of the recombinant strain Y. lipolytica -GDH2 rose to 8.62±1.02 U per mg protein, which was 7.2 times of the wild type as shown in FIG. 1 . And the α-KG content accumulated extracellular increased to 17.4 g·L −1 from 14.5 g·L −1 as shown in FIG. 2 .
Example 2 Enhancement of Glutamate Supply by Adding L-Methionine Imide
[0049] The wild type Y. lipolytica WSH-Z06 and the recombinant strain Y. lipolytica -GDH2 were incubated in 500 mL flasks with 50 mL fermentation medium at 28° C., 200 rpm for 96 hours at the same time. The fermentation broths were centrifugated to collect the cells. The glutamate contents were quantified by the methods described above.
[0050] Compared to the wild type strain, the intracellar glutamate contents increased to 0.99 μmol per mg DCW from 0.53 μmol per mg DCW as shown in FIG. 3 .
Example 3 Enhancement of the Accumulation of α-KG by the Regulation of Intracellular Amino Acid Metabolism
[0051] α-KG was produced as the method described above. The wild type Y. lipolytica WSH-Z06 and the recombinant strain Y. lipolytica -GDH2 were incubated in 500 mL flasks with 50 mL fermentation medium containing L-methionine imide at 28° C., 200 rpm for 144 hours at the same time to accumulate α-KG extracellular. Comparison indicated that enhancement of glutamate supplying and glutamate metabolized to α-KG significantly increased the catalytic activity of GDH of the recombinant strain Y. lipolytica -GDH2 and the α-KG accumulated extracellular increased to 19.2 g·L −1 from 14.5 g·L −1 as shown in FIG. 4 .
[0052] While the present invention has been described in some detail for purposes of clarity and understanding, one skilled in the art will appreciate that various changes in form and detail can be made without departing from the true scope of the invention. All figures, tables, appendices, patents, patent applications and publications, referred to above, are hereby incorporated by reference. | The present invention provides methods for enhancing α-KG production in Yarrowia lipolytica , relates to the field of metabolic engineering. This invention successfully overexpresses the glutamate dehydrogenase in wild type strain Y. lipolytica WSH-Z06 to construct the recombinant Y. lipolytica WSH-Z06 which regulates the glutamate catabolism to synthesis α-KG. L-methionine imine is added into the fermentation medium during the process to strengthen the supply of intracellular glutamate and inhibite the intracellular glutamine synthesis from glutamate metabolism and then enhance the accumunation of α-KG. Therefor, the present invention provides an effective method for enhancing the accumunation of α-KG through regulation of intracellular amino acid metabolism. | 2 |
PRIORITY CLAIM
The present application is a Continuation of U.S. patent application Ser. No. 11/940,367 filed on Nov. 15, 2007 (now U.S. Pat. No. 8,062,318) which is a Continuation of U.S. patent application Ser. No. 10/453,367 filed Jun. 3, 2003, (now U.S. Pat. No. 7,300,445) which is a Continuation of U.S. patent application Ser. No. 09/994,518 filed Nov. 26, 2001 (now U.S. Pat. No. 6,605,078). These patents are expressly incorporated herein, in their entirety, by reference.
FIELD OF THE INVENTION
The present invention relates to full thickness resection devices for performing localized resections of lesions.
BACKGROUND OF THE INVENTION
Resection procedures involve excising a portion of an organ, approximating the surrounding tissue together to close up the hole created by the excision, and removing excess tissue. Various conventional devices and procedures are available for resectioning lesions in organs.
For example, several known resection devices and procedures require at least one incision in an area near the portion of the organ to be excised for access to the lesion or treatment site (because, for example, these resectioning devices may lack steering and/or viewing capabilities). Thus, an incision is required to allow a physician to access the organ section to be excised and guide the device to that section. Alternatively, when the organ section to be excised is beyond the reach of the surgical device, or if the surgical device is not flexible enough to wind through the organ to the site to be excised, an incision is required to position the device for the procedure. Of course, these incisions are painful and may involve a partial or entire loss of mobility while recuperating from the incision, in addition to the discomfort associated with the resectioning procedure itself. In addition, these incisions may add significantly to the recovery time required for the procedure.
One type of conventional resection procedure utilizes a circular stapling instrument in which a tubular section of a substantially tubular organ is excised, resulting in the organ being separated into first and second segments. The open ends of these first and second segments are then tied in a purse-string fashion, approximated toward one another and stapled together. The tissue radially inside the stapled areas (i.e., the “purse-stringed” end sections) is then cut off to open the interiors of the two segments to one another. In this full circle resectioning procedure, at least one incision must be made near the section to be excised in order to cut and “purse string” the end sections of the first and second segments. Also, a second incision is necessary to place one part of the resectioning device in the first segment and a corresponding second part of the device in the second segment. Thus, this type of resectioning procedure involves the drawbacks mentioned above in regard to procedures requiring invasive incisions. In addition, the separation of the organ into two segments creates the risk of spillage of non-sterile organ contents into the sterile body cavity, which may cause severe infection and possibly death.
An alternative resectioning device includes a stapling and cutting assembly on a shaft which may be bent or formed into a desired shape and then inserted into a patient's body cavity. Once the shaft has been bent into the desired shape, the rigidity of the shaft ensures that the shape is maintained throughout the operation. This arrangement limits the effective operating range of the device as the bending of the shaft into the desired shape before insertion and the rigidity of the shaft once bent require the physician to ascertain the location of the organ section to be removed before insertion, and deform the shaft accordingly. Furthermore, the rigidity of the shaft makes it difficult to reach remote areas in the organ—particularly those areas which must be reached by a winding and/or circuitous route (e.g., sigmoid colon). Thus, an incision may be required near the organ section to be excised in order to position such a device at the organ section to be excised.
A full-thickness resection system has been disclosed by the present Applicant along with others in U.S. Pat. No. 6,126,058, the disclosure of which is expressly incorporated herein by reference in its entirety. The system utilizes a flexible endoscope slidably received through at least a portion of a stapling mechanism.
SUMMARY OF THE INVENTION
The present invention is directed to an operating head for a full thickness resection device, comprising a first optical device disposed on a distal portion thereof, the first optical device having a viewing area extending distally of the distal portion and a second optical device mounted within a working chamber extending within an exterior wall of the operating head, wherein a first portion of the exterior wall is moveable with respect to a second portion thereof to selectively open the working chamber to an exterior of the operating head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a full thickness resection device according to one embodiment of the present invention;
FIG. 2 shows a front view of the full thickness resection device shown in FIG. 1 ;
FIG. 3 shows a side view, in partial cross section, of the full thickness resection device shown in FIG. 1 , where the device is in the open position;
FIG. 4 shows a side view, of the full thickness resection device as shown in FIG. 3 , where a lesion has been pulled into the device;
FIG. 5 a shows a schematic cross-sectional view of a full thickness resection device having a movable door, according to another embodiment of the invention;
FIG. 5 b shows a schematic cross-sectional view of a full thickness resection device as shown in FIG. 5 a where the movable door is in the open position;
FIG. 6 a shows a side view of a device according to a further embodiment of the invention moving through a body organ along a guide wire;
FIG. 6 b shows a cross-sectional front view of the device according to FIG. 6 a;
FIG. 7 shows a cross-sectional view of an insertion sheath including an integral custom endoscope according to one embodiment of the present invention; and
FIG. 8 shows a cross-sectional view of an insertion sheath including an endoscope receiving lumen according to a further embodiment of the present invention.
DETAILED DESCRIPTION
As shown in FIGS. 1 and 2 , an optical full thickness resection device 10 according to one embodiment of the present invention includes an openable instrument head 14 which is preferably formed from a front portion 14 a and a rear portion 14 b . The head 14 may be egg-shaped as shown in FIG. 1 . Such a shape allows for the head 14 to be smoothly inserted into and removed from an organ 50 . However, it is understood that many other shapes of the head 14 may be employed to ease insertion and removal from the organ 50 . For example, the head 14 may be bullet-shaped or, alternatively, may be relatively more spherical. In the illustrated embodiment, the head 14 may preferably have a diameter in the range of 10 to 35 mm.
Those skilled in the art will recognize that the organ 50 may include the colon, the small bowel, the esophagus, or a variety of other organs in which endoscopic procedures have been conducted.
Conventional endoscopes employed with prior endoscopic full thickness resection devices incorporated certain functional limitations which frustrated attempts to reduce their size. These devices were employed in a wide variety of procedures and included features which were not utilized in the full thickness resection procedure. For example, these endoscopes included one or more working channels through which an operator might perform therapeutic and/or diagnostic tasks. Furthermore, these endoscopes may also incorporate an insertion tube shaft to enable the operator to push the endoscope through a body lumen. These working channels and the insertion tube add significantly to the diameter of the endoscope. As discussed below, the present invention proposes an endoscope-like device in which these elements are eliminated as unnecessary to the full thickness resectioning procedure.
FIG. 2 shows a cross-sectional view of the front end of a front portion 14 a , including additional features of the device 10 . In one embodiment, a movable optic device 12 and an irrigation source 13 are provided on the front portion 14 a with the optic device 12 providing an interior view of the organ 50 to an operator of the device 10 . The irrigation source 13 allows a solution such as saline to be introduced into the organ 50 in order to clear debris therefrom improve the operator's view. Additionally provided are light sources 22 for illuminating the organ 50 so that the optic device 12 captures a satisfactory image for the operator. In one embodiment, the optic device 12 may include a vision chip which may include, for example, both photosensors and parallel processing elements. According to an exemplary embodiment of the device 10 , an infusion port 24 allows the operator to inject air or an inert gas into the organ 50 to insufflate the organ. This insufflation of the organ 50 may further improve the operator's view by distending the walls of organ 50 .
In the illustrated embodiment, an insertion sheath 40 serves to propel the head 14 through tubular organ 50 . In this instance, the insertion sheath 40 which may be formed of a flexible polymeric material such as, for example, polypropylene, is part of an insertion sheath propulsion system and constructed, for example, as described in U.S. Pat. Nos. 5,259,364 and 5,586,968 to Bob et al., the entire disclosures of which are hereby incorporated by reference. The insertion sheath 40 is slidably received around an insertion tube 18 which is of reduced diameter relative to the head 14 .
As described more fully below in regard to FIG. 7 , the insertion tube 18 ′ may preferably be constructed substantially similarly to known endoscopes including similar steering and other operating mechanisms but with a reduced diameter with respect to these known endoscopes as no insertion tube is required. Those skilled in the art will understand that the diameter of the insertion tube 18 ′ may be further reduced if no working channels are required therein. That is, although FIG. 7 shows a single working channel 72 , for certain operations this working channel 72 may be unnecessary. Thus, an insertion tube 18 ′ for use in such operations may include an integral endoscope 100 with no such working channel 72 and the diameter of the endoscope 100 (and, consequently, that of the insertion tube 18 ′, may be further reduced.
If a propulsion system is to be used, the column strength of the insertion tube 18 may be substantially reduced as the column strength necessary to allow a standard endoscope to be pushed through an organ is no longer necessary. Furthermore, as the insertion tube 18 is received within the insertion sheath 40 , no separate insertion tube shaft is incorporated therein as would be the case in a standard endoscope, thereby enabling the diameter of the insertion tube 18 to be further reduced with respect to conventional endoscopes. Thus, the diameter of the insertion tube 18 may preferably be in the range of 5 to 25 mm with an outer diameter of the insertion sheath 40 being between 10 and 30 mm. Of course, those skilled in the art will understand that these values may be made larger or smaller as desired so long as the flexibility and steering capacity of the insertion tube 18 in conjunction with the insertion sheath 40 substantially matches that of conventional endoscopes.
The insertion sheath 40 is longitudinally flexible so as not to impair the flexibility of the insertion tube 18 and the steerability of the device 10 generally. Thus, when a distal end of the insertion sheath 40 abuts against a proximal end of the head 14 and an operator engages the insertion sheath 40 distally into the organ 50 , the head 14 is advanced further into the organ 50 .
However, it is understood that other propulsion arrangements may be used with the device 10 . For example, a crawler system (not shown) may be used to move head 14 . Such a crawler system may be constructed, for example, as described in U.S. Pat. No. 5,398,670 to Ortiz et al., and U.S. Pat. No. 5,906,591 to Dario et al. the entire specifications of which are hereby incorporated by reference. In yet another embodiment as shown in FIGS. 6 a and 6 b , a guidewire 60 is placed in the organ 50 using a conventional endoscope as is known in the art. The guidewire 60 is then strung through the device 10 via a guidewire opening 62 at the front portion 14 a of head 14 and the device 10 is pushed along the guidewire 60 to the desired location within the organ 50 . In order to accommodate the force exerted on the device 10 as it is pushed into the organ 50 , the insertion tube of the device 10 according to this embodiment is formed with an increased column strength relative to embodiments in which a propulsion system is employed.
As shown in FIGS. 3 and 4 , in one embodiment, fins 16 are disposed at a proximal end of rear portion 14 b . Preferably two or more fins 16 are provided on opposing sides (180° degrees apart) of the rear portion 14 b . Alternatively, one fin 16 may be used. The fins 16 provide a solid surface against which the insertion sheath 40 may abut to push device 10 through the organ 50 . Also, the fins 16 serve to prevent portions of the tubular organ 50 from becoming entangled with the insertion sheath 40 .
Now turning to FIG. 3 , the head 14 is shown in an open position in which the front portion 14 a is slid forward to expose an interior work area 15 . A main optic device 32 is provided at the rear of the rear portion 14 b . Preferably, the device 32 points in a generally forward direction as shown in FIG. 3 . A base portion 25 of the interior work area 15 may include an auxiliary optic device 26 that points in a direction generally perpendicular to the direction of main device 32 . The optic devices 32 and 26 may be illuminated by illumination sources 34 and 28 , respectively, to help provide a satisfactory image for the operator. As with the exterior optic device 12 , the optic devices 32 and 26 may preferably include vision chips. As will be discussed in connection to the operation of the device 10 , the multiple viewing angles provided by the optic devices 32 and 26 allow for an improved method of resectioning tissue. In a preferred embodiment, a suction lumen 36 extends from the proximal end of the device 10 to a port 35 that opens into the work area 15 so that, when suction is drawn therethrough, tissue adjacent to the head 14 is drawn into the work area 15 . An anvil 64 is positioned in the work area 15 to work in conjunction with a stapler 62 for stapling tissue received therein. Furthermore, a knife 66 is movably mounted within the work area 15 to cut tissue received therein radially inward with respect to a perimeter of staples delivered by the stapler 62 .
A controller 21 is also provided for controlling each of the components discussed above. The controller 21 , which may be used by the operator as a handle, may include a plurality of actuators coupled to the head 14 and, in turn, to the various components thereof by a one or more wires or flexible drive cables 19 as would be understood by those of skill in the art. The cables 19 may pass through the insertion tube 18 and into the head 14 . Alternatively, the actuators of the controller 21 may be coupled to these components by electric cables and/or by means of remote control (e.g., radio transmission) to actuate electric motors, as would be understood by those of skill in the art, to drive the components as desired by the operator. By manipulating the actuators of the controller 21 , the operator may, for example, adjust the optic devices 26 and 32 , the illumination sources 28 and 34 as well as any other components of the head 14 .
In an alternative embodiment of the invention shown in schematic views in FIGS. 5 a and 5 b , the head 14 includes a door 70 instead of the separable front and rear portions 14 a and 14 b of the previously described embodiment. The door 70 is movable between open and closed positions so that, in the open position, the interior of the organ 50 is accessible to the interior work area 15 , as described in the previously described embodiment. With the exception of this difference the apparatus according to this embodiment may function substantially similarly to the other embodiments.
In operation, the head 14 is maintained in the closed position, as shown in FIG. 1 , while the device 10 is being maneuvered to the desired location within the organ 50 . When the desired location has been found using the exterior optic device 12 , with the aid of illumination from light source 22 , to view the interior of the organ 50 . As described above, to further aid in locating the site, an operator may wash debris away from areas being viewed using the irrigation source 13 and/or by insufflating the organ 50 . As described above, resectioning at this desired location may be necessary due to, for example, the presence of a lesion 52 as shown on the wall of the organ 50 in FIGS. 3 and 4 .
Once the head 14 has been positioned as required, the interior work area 15 may be exposed by sliding the front portion 14 a away from the rear portion 14 b of the head 14 using the controller 21 . In this position, the optic device 26 on the base portion 25 may be used to view the lesion 52 . Moreover, the light source 28 provides the portion of organ 50 with the necessary illumination to provide a satisfactory image to the operator. The operator then draws a partial vacuum in the work area 15 through the use of the suction device 35 to draw the lesion 52 into the work area 15 under visual control of the operator via the optic device 32 and the light source 34 . Based on this observation, the operator may also reposition or reorient the head 14 , as required. However, once the lesion 52 has been sufficiently drawn into the resectioning chamber 31 , the view from the optic device 32 may be obscured by the lesion 52 itself. At this time, the optic device 26 may be used to provide continuing observation of the lesion 52 and its geometry with respect to the organ 50 .
The tissue surrounding the lesion 52 may now be stapled using the stapler 62 in conjunction with the anvil 64 and, after the stapling operation has been completed, the knife 66 may be actuated to cut the lesion 52 from the organ 50 . The operator then utilizes the controller 21 to slide the front portion 14 a toward the rear portion 14 b of the head 14 until the head 14 is sealed in the closed position. The lesion 52 is then retained within the work area 15 until the head 14 has been removed from the patient's body, at which time it may be further studied to aid in the patient's diagnosis and/or treatment.
As shown in FIG. 7 , an insertion tube 18 ′ according to a first embodiment of the invention may include an integral endoscope 100 . The custom endoscope 100 includes a steering mechanism which include control wire guides 80 (in this case 4 guides 80 ) which are coupled to a distal tip of the integral endoscope 100 as is known in the art. In addition, the integral endoscope 100 includes a single, optional working channel 82 , an optic member 84 , an irrigation channel 86 , one or more light source members 88 (in this case 2 light source members 88 ) and a suction/insufflation lumen 90 . As would be understood by those of skill in the art, the optic member 84 may be either a fiber optic cable or an electric cable depending on the type of optic system employed. Similarly, the light source members 88 may be fiber optic light cables or electric cables if, for example, one or more LED light source members are employed at the distal tip of the integral endoscope 100 to illuminate a viewing area of the optic member 84 . Those skilled in the art will understand that the irrigation channel may be employed to supply irrigation fluid to a distal end of the optic member 84 (e.g., a lens) to clean the distal end to maintain the field of vision for an operator of the device.
FIG. 8 shows an alternate embodiment of an insertion tube 18 ″. The insertion tube 18 ″ includes a central endoscope receiving lumen 92 , optional working channels 94 and a suction/insufflation lumen 96 . Thus, this insertion tube 18 ″ may be employed with a custom endoscope (not shown) constructed substantially as shown in FIG. 7 including an optic member, an irrigation channel and light source members. As the insertion tube 18 ″ includes working channels 94 and the suction/insufflation lumen 96 , these items may be eliminated from the custom endoscope for use with this insertion tube 18 ″ thereby reducing the diameter of the endoscope. The use of this insertion tube 18 ″ allows the custom endoscope inserted through the endoscope receiving lumen 92 to be reused, as would be understood by those of skill in the art.
Those skilled in the art will further appreciate that while the apparatus of the present invention has been described with reference to a full thickness resection of the colon, the apparatus may be utilized in other digestive tract transluminal procedures, and may be introduced transorally as well as transanally. Also, while certain embodiments have been described with reference to custom endoscopes, it will be appreciated that the specific configurations of the custom endoscopes/stapler embodiments may be varied. For example, different arrangements of lumena and control wires, and different coupling means for coupling the control wires to the driving gears may be provided with similar results obtained. Also, the control wires may be replaced, for example with flexible cables or hydraulic fluid channels. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed. | A system for treating a target tissue includes (a) an instrument head sized and shaped for insertion into a hollow organ of a living body, the instrument head including a working chamber movable between an open position in which the working chamber is exposed to an exterior of the head and a closed position in which the working chamber is substantially sealed with respect to an exterior of the instrument head, the instrument head including a first imaging device having a field of view extending distally of a distal end thereof and a second imaging device having a field of view within the working chamber; (b) a handle which, during use, remains outside the living body, the handle including an actuator; (c) a steering mechanism coupled to the actuator for steering the instrument head within the hollow organ based on actuation of the actuator; and (d) a controller coupled to the first and second imaging devices for processing the image data received from the first and second imaging devices and providing images to an operator. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present system relates to the field of the U.S. Navy's weapon systems. Specifically, it relates to a surface-to-air defense weapon system. This system will be used primarily to protect the Navy's aircraft carriers. It would have the ability to destroy all of many incoming ballistic missiles and bombs, and their fragmentation over a wide area.
[0003] 2. Description of the Related Art
[0004] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
[0005] The monthly magazine Seapower is about the Navy, Marine Corps, Coast Guard and Merchant Marine. It is a sea services directory that gives the latest information on all weapons and many other things as well. It will be the subject of ships' surface-to-air weapons that I am concerned with for this system, the defense against ballistic missiles in particular.
[0006] The phalanx CIWS, a Gatling gun, is a last-ditch defense system against aircraft and anti-ship missiles and surface craft, not ballistic missiles that comes down from the edge of space. This system fills a gap. The Navy needs a last-ditch defense system against many incoming ballistic missiles and bombs and their fragmentation over a wide area.
BRIEF SUMMARY OF THE INVENTION
[0007] This is primarily a last-ditch defense weapon system for the Navy's aircraft carriers and the Marine Corps' amphibious landings. This system would have the ability to destroy all of many incoming ballistic missiles and bombs and their fragmentation over a wide area.
[0008] The ships are out at sea and are moving; falling debris is only a minor problem compared to getting hit by a bomb or a missile. The advantages and object of this system will be described in the specification and shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a ship and a rotating circular platform combination.
[0010] FIG. 2 is a side view of the platform assembly on the ship's deck.
[0011] FIG. 3 is a schematic diagram of the pattern the fired projectiles will make over a given defended area.
[0012] FIG. 4 is a top view of the rotating platform assembly on the ship's deck.
[0013] FIG. 5 is a partial section view of the platform and deck combination.
[0014] FIG. 6 is a block diagram of the entire system.
[0015] FIG. 7 is a block diagram of a modified gun.
[0016] FIG. 8 is a block diagram of a power source.
[0017] FIG. 9 is a block diagram of a cooling system.
[0018] FIG. 10 is a top view of three guns mounted on the platform.
[0019] FIG. 11 is a top view of two guns mounted on the platform.
DETAILED DESCRIPTION
[0020] FIG. 1 shows a good place to place this system. The rotating circular platform 40 is placed on a ship's forward deck 60 , or on a land based structure. The ship can be modified existing one or a new one. The ship can have its own ballistic missiles detection ability or rely on other ships of a Navy battle group for detection of incoming ballistic missiles.
[0021] FIG. 2 shows a powerful electric motor 45 and its electrical connection 49 under the deck 60 , the platform 40 is rotated with the motor's shaft 47 . On the platform 40 is mounted four modified guns. Many types of modified guns can be used from a single barrel to a multiple barrel. Each of these guns 20 A, 20 B, 20 C and 20 D comprises an inner regulated power supply section, equipment protection section fire-control mechanisms and outer multiple barrels 22 and an ammunition drum 24 ; gun 20 B is omitted for clarity. The equipment support column 55 and electrical connections are omitted for clarity.
[0022] The stationary guns 20 A and 20 C lean to the right approximately five degrees C., and guns 20 B and 20 D lean to the left approximately 5 degrees C.; degrees of other amounts can be used. Each gun's line-of-fire B points substantially upward; each line-of-fire B makes an angle C with the vertical. The guns 20 A, 20 B, 20 C and 20 D are approximately ninety degrees apart around the outer portion of the platform 40 . Each gun has no search or tracking radar; they are not needed. The guns 20 A, 20 B, 20 C and 20 D are fired simultaneously.
[0023] FIG. 3 shows how the projectiles from the guns are dispersed. They form a slightly exaggerated point A on the rotating platform 40 on the deck 60 . The two sets of guns create a nearly cone-shaped line-of-fire B and an angle C around the vertical axis of the platform 40 . The angle C is approximately five degrees. The maximum effective range D is a minimum of two miles; it can be much, much higher. A nearly umbrella-shaped pattern E of projectiles will be produced when three guns are fired simultaneously while rotating. This umbrella pattern E will have a minimum diameter of 1,848 feet or more.
[0024] FIG. 4 shows the approximately ninety degree angle between the guns 20 A, 20 B, 20 C and 20 D. The motor 45 and an equipment support column 55 are in the center of the platform 40 on the ship's deck 60 . Electrical connections are omitted for clarity. An outer multiple barrel 22 and an ammunition drum 24 are shown on 20 A. 81 , 82 , 83 and 84 are power sources; 81 A, 82 A, 83 A and 84 A are cooling systems.
[0025] FIG. 5 is a partial sectional view. The equipment support column 55 is connected to the platform 40 . The motor's shaft 47 rotates the platform 40 and the motor 45 is powered through an electrical line 49 under the ship's deck 60 .
[0026] FIG. 6 shows the entire ROTATING RAPID-FIRING DEFENSE WEAPON SYSTEM 10 . The control cables W, X, Y and Z are between the remote receivers RR 1 , RR 2 , RR 3 and RR 4 and the modified guns 20 A, 20 B, 20 C and 20 D and the antennas. The remote receivers RR 1 , RR 2 , RR 3 and RR 4 control cables W, X, Y and Z and the antennas are mounted on the equipment support column 55 .
[0027] The stationary remote control transmitters RT 1 , RT 2 , RT 3 , and RT 4 are mounted on the ship facing the rotating remote receivers RR 1 , RR 2 , RR 3 and RR 4 on the rotating platform 40 . A stationary structure on land or sea can be a good mounting place for stationary objects of the system 10 . The ship's structure is an example.
[0028] Each gun 20 A, 20 B, 20 C and 20 D has a power source 81 , 82 , 83 and 84 and a cooling system 81 A, 82 A, 83 A and 84 A adjacent to it. The central control room 75 will house the control panels/video screens 85 that are physically and electronically connected to the remote control transmitters RT 1 , RT 2 , RT 3 and RT 4 and outer antennas. There is an electric line 49 to the motor 45 . An independent electric power source 65 will supply all the power needed by the control room 75 .
[0029] A land-based system will have a central control room. There should be a means for supplying electric power for all versions of this system 10 .
[0030] FIG. 7 shows the output electrical power OEP into each gun 20 A, 20 B, 20 C, and 20 D. Each control cable W, X, Y, and Z makes electrical connections inside each gun. Each gun 20 A, 20 B, 20 C, and 20 D comprises a regulated power supply section, equipment protection section and fire control mechanism; and each gun has multiple barrels 22 and an ammunition drum 24 (see FIG. 2 ). There is a cooling connection CC to each gun.
[0031] FIG. 8 shows the output electrical power OEP out of each power source 81 , 82 , 83 , and 84 . For this means for power source 81 , 82 , 83 , and 84 , there is a small fossil fuel engine that power an electrical generator. Each engine is controlled through a cable W, X, Y, and Z.
[0032] The regulated power supply takes place within each gun 20 A, 20 B, 20 C, and 20 D as shown in FIG. 7 . Another option is to change the output electrical power OEP to a regulated power supply before going into each gun. The output electrical power OEP will be 440 volts (v) at 60 cycles (Hz) in both cases.
[0033] FIG. 9 shows the cooling connection CC out of each cooling system 81 A, 82 A, 83 A, and 84 A. For this means for cooling 81 A, 82 A, 83 A, and 84 A, there is a water reserve and auxiliary units. The auxiliary units are controlled through a cable W, X, Y, and Z. One auxiliary unit would be a water pump.
[0034] FIG. 10 shows an assembly of three guns A 1 B 1 and C 1 the rotating platform 41 . They are approximately 120 degrees apart; 46 is the electric motor and 56 is the support column. FIG. 11 shows an assembly of two guns N and O on the rotating platform 42 and opposite one another. The number of guns used could increase or decrease the effectiveness of this system. A substantial number of guns would be best; 48 is the motor and 58 is the column.
[0035] This system would be relatively economical to design and manufacture. This is due to the technology needed for such a system has already been developed. And there is ongoing progress in the improvement of this technology.
[0036] The ships are out at sea and are moving; falling debris is only a minor problem compared to getting hit by a bomb or missile. A land or port version of this system may be of some interest.
[0037] There has been a lot of talk about how to defend against a swarm of unmanned aerial vehicles. The above system is one way; any type of gun can be used. This system has the ability to shoot down anything that comes in range of its projectiles. | Guns are fired simultaneously from a rotating platform. This is primarily a last-ditch, defense weapon system to protect the Navy's aircraft carriers and the Marine Corps amphibious landings: This system would have the ability to destroy all of many incoming ballistic missiles and bombs, and their fragmentation over a wide area. The ships are out at sea and are moving; falling debris is only a minor problem compared to getting hit by a bomb or missile. A land or port version of this system may be of some interest; such as a system on a mobile water platform or vehicle. The system could certainly knock down a swarm of hostile unmanned aerial vehicles. | 5 |
FIELD OF THE INVENTION
The present invention relates to a color processing apparatus for performing the masking process of a color image.
BACKGROUND OF THE INVENTION
Hitherto, a color processing apparatus of a color image in which color image information is input and subjected to the color correcting process and then output to a color printer has been used.
In such a kind of color processing apparatus, since the printing ink or toner is not completely cyan, magenta, and yellow, the color correcting process is generally performed by way of a linear masking method.
FIG. 3 shows a conventional color processing apparatus using the linear masking method. A color image to be read is color separated and read out by a readout unit 1 and converted into density signals Y, M, and C of yellow, magenta, and cyan from densities Dr, Dg, and Db of the red, green, and blue light. These density signals are sent to a color processing apparatus 11. In the color processing apparatus 11, the input color signals Y, M, and C are converted into the desired color signals Y', M', and C' according to the characteristics of the printing ink or toner on the basis of the following density expressions called linear masking equations and sent to various color printers (output unit) 13 such as ink jet color printer, thermal transfer copying color printer, electrophotographic color printer, and the like.
Y'=a .sub.1 Y-a.sub.2 M-a.sub.3 C (1)
M'=-a.sub.4 Y+a.sub.5 M-a.sub.6 C (2)
C'=-a.sub.7 Y-a.sub.8 M+a.sub.9 C (3)
The output unit 13 prints color inks in yellow, magenta, and cyan in accordance with the signals (signals which were subjected to the masking process) Y', M', and C' after they were subjected to the color correcting process, respectively, thereby reproducing a color image on a recording medium.
The color component of each printing ink or toner of yellow, magenta, and cyan actually includes the other color components. Therefore, the correction coefficients a 1 to a 9 of the expressions (1) to (3) are set to the proper values in accordance with the characteristics of the ink or toner and the color component is corrected.
For example, a 2 in the expression (1) is the coefficient to correct the yellow component contained in the magenta ink or toner and a 3 is the coefficient to correct the yellow component contained in the cyan ink or toner.
Such a linear masking method can be realized by a simple circuit arrangement and the coefficients can be easily optimized by the computer simulation; therefore, this method is widely used.
However, in general, the output characteristics in the actual color printers such as ink jet color printer, thermal transfer copying color printer, electrophotographic color printer, and the like are not linear and the characteristics in the case of mixed colors are further complicated nonlinear characteristics.
Therefore, according to the linear masking method, the color correcting processes which can sufficiently correct the color characteristics of the printing ink or toner of the printer cannot be realized. This causes the problem that the color difference between the original image and the output reproduced image is small with respect to certain colors but is large with respect to other colors.
To avoid such problems, a nonlinear masking method whereby the color processes are executed by quadratic masking equations is also proposed. However, the circuit constitution and simulation are complicated even with this masking method, and it is difficult to completely correct the complicated color characteristics of the printer.
On the other hand, as a method of perfectly correcting the color characteristics of the printer, a color correcting method whereby one set of outputs of Y', M', and C' are made to correspond to each combination of the densities of the input data of three colors of Y, M, and C is known.
FIG. 4 shows a color conversion memory according to the above method. The digital color density signals Y, M, and C of three colors of yellow, magenta, and cyan which are input from the readout unit 1 are input as the address data of a color conversion memory 15. The conversion data Y', M', and C' of three colors which have been preliminarily stored in a table in the memory 15 are read out on the basis of the address data and output to the output unit 13. The output unit 13 prints the color images of yellow, magenta, and cyan on the recording medium in correspondence to the conversion data Y', M', and C'.
According to this conversion data storing method, since the input data and output data are made to perfectly correspond in a one-to-one correspondence manner, the color processes which can completely correct the printer characteristics can be theoretically realized.
However, the above conversion data storing method has a serious drawback such that the necessary memory capacity is extremely large. Namely, assuming that each of the input digital signals Y, M, and C of the respective colors consists of m bits, only 2 m states are provided for each color, so that the number of states which can be expressed by synthesizing three colors will be 2 3m . On the other hand, assuming that each of the output signals Y', M', and C' of the respective colors also consists of m bits, 2 3m bits are necessary as addresses and 3 m bits are needed as data for the color conversion memory 15. Therefore, 23 m ×3 m bits are necessary as the whole memory capacity.
For example, when m=6, (2 3m ×3 m=2 18 ×18=) 4,718,592 bits are needed. When m=8, (2 3m ×3m=2 24 ×24=) 402,653,184 bits are needed. Accordingly, the manufacturing cost of the apparatus becomes very expensive. There is also a problem such that a very large amount of work is required to calculate the data to be stored in the color conversion memory 15 by the simulation.
The ink jet color printer will be further explained in detail as an example.
FIG. 5 shows a method of scanning ink jet heads for obtaining color images by overlapping the inks of three colors; yellow, magenta, and cyan.
In the diagram, reference numerals 101a to 101c denote multi nozzle heads which are arranged with a distance d held, respectively. Each head is scanned on a recording paper 103 in the direction indicated by an arrow 104 at a speed of v while emitting the ink from an orifice 102. The head 101a is used for the yellow ink. The head 101b is used for the magenta ink. The head 101c is used for the cyan ink. The yellow, magenta, and cyan inks are printed on the recording paper 103 in accordance with this order.
FIG. 6 is a block diagram for the image signal processed by such an ink jet recording apparatus. Input signals 105a to 105c indicative of the image densities of yellow, magenta, and cyan are input to a color processing unit 106 and subjected to the color processes such as a masking process and the like. Thereafter, the processed signals are input to a gradation correcting unit 107 and are γ corrected. The yellow signal among the three corrected color signals is directly sent to a recording head 109a. However, the magenta and cyan signals are temporarily stored into buffers 108a and 108b, respectively, and thereafter, they are delayed by the times corresponding to the distance d in the scanning direction of the recording head, namely, by the time of d/v in the case of the magenta signal and by the time of 2d/v in the case of the cyan signal and sent to heads 109b and 109c. Thus, the respective color inks of yellow, magenta, and cyan are printed at the same position on the recording paper 103 and the color image is reproduced.
The γ correction in the gradation correcting unit 107 is performed so as to obtain the linear relation between the input image density signal and the density of the printed image with respect to each color of yellow, magenta, and cyan. The γ characteristics after the correction become as shown in FIG. 7 with regard to yellow, magenta, and cyan.
However, these γ characteristics are obtained when the image is printed in single color of each of yellow, magenta, and cyan. The γ characteristics differ in the case of the mixture of two or three colors.
In the case of the mixture, the γ characteristic of each color component depends on an amount of ink printed previously.
FIG. 8 shows a change in γ characteristic of magenta by the amount of yellow ink printed previously.
In FIG. 8, numeral 110a denotes γ characteristic of magenta in the case where no yellow image is printed but the magenta image was first printed. With an increase in yellow print amount, the γ characteristic of magenta changes as shown at 11Ob to 11Od.
FIG. 8 shows the relationship between a driving signal and image density in a situation where one is printed prior to the printing of another color. The driving signal performs the printing of the other color, and the image density is of an image actually reproduced on the paper.
IN this situation, the second color that is printed could be of any color ink (yellow, magenta or cyan). If the printing order of the other color is the second of thereafter (i.e., the other color is printed over the same area where printing of first color occurred), the characteristics of the other color are expressed in FIG. 8.
It is considered that such a phenomenon is caused by the nonlinear mechanism when the ink is absorbed by the paper. However, there is the nonlinear relation between the output image density signal and the color component of the output image because of this phenomenon. Therefore, there is a drawback, that sufficient color reproduction cannot be derived by the linear color correcting processes such as a linear masking method or the like. For example, in the ordinary linear masking method, assuming that the input yellow, magenta, and cyan signals are respectively Y, M, and C, the following conversion is performed. ##EQU1## However, according to this method, since there is the linear relation between the input signals and the output signals, it is impossible to correct the printer characteristics which nonlinearly change in accordance with an amount of ink printed previously.
To solve this problem, a method whereby the nonlinear color correction is performed using the masking equations of two or higher order is also proposed. This method, however, has the inconvenience such that the circuit constitution is complicated and expensive.
On the other hand, in the case of using a method whereby tables in the memory are referred to with respect to all of the color correcting processes, there is the inconvenience that a very large amount of memory capacity is necessary as mentioned above.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a color processing apparatus which can eliminate the above-mentioned drawbacks and can properly correct the color output characteristics of a printer by a simple circuit constitution.
According to one aspect of the present invention, in a color image processing apparatus which receives color component signals of a plurality of colors and performs the color correction using the masking equations in order to form a color image, it is an object to provide a color image processing apparatus in which the values of the coefficients of the masking equations are changed in accordance with the values of the color signals to be multiplied with those coefficients.
According to another aspect of the invention, there is provided dividing means for dividing each of a plurality of input color component signals into a plurality of regions in accordance with the level of each signal and for outputting the data indicative of the region to which each of the input color component signals belongs; coefficient selecting means for outputting a coefficient selection signal in accordance with the combination with respect to respective colors of the data indicative of the region which is output from the dividing means; switching means for switching coefficient values of the linear masking in response to the coefficient selection signal; and linear masking processing means for performing the linear masking processes of the input color component signals using the coefficient values switched by the switching means.
According to still another aspect of the invention, each of the input color component signals is divided into a plurality of regions, the coefficients of the linear masking which has been prepared are selected in accordance with the combination of the regions of each color after the division, and the linear masking arithmetic operations are executed using the selected coefficients, thereby performing the color correction of each color signal. In this manner, since the nonlinear portion is properly finely divided and linearly approximated in each of the divided space, the color characteristics of the printer can be inexpensively and accurately corrected.
Namely, according to the conventional method whereby the linear masking is performed by use of one kind of coefficient with respect to the whole color space as mentioned above, the nonlinear color characteristics of the printer cannot be accurately corrected. However, the present invention is made on the basis of the principle such that by dividing the color space into small spaces, accurate approximation can be accomplished by the linear masking method in each of the divided color spaces, so that the color characteristics of the printer can be practically and sufficiently corrected.
The above and other features of the present invention will become apparent from the following detailed description and the appended claims with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a fundamental constitution of the first embodiment of the present invention;
FIG. 2 is a block diagram showing a circuit constitution of the first embodiment of the invention;
FIGS. 3 and 4 are block diagrams showing constitutions of conventional apparatuses, respectively;
FIG. 5 is a diagram showing an arrangement of recording heads and a scanning direction;
FIG. 6 is an image processing block diagram of a conventional image recording apparatus;
FIG. 7 is a γ characteristic graph in the case of a single color;
FIG. 8 is a γ characteristic graph in the case of mixed colors in a conventional example;
FIG. 9 is an image processing block diagram of an image recording apparatus of the second embodiment of the invention;
FIG. 10 is a characteristic graph of masking coefficients in the second embodiment;
FIGS. 11A and 11B are characteristic graphs of the masking coefficients in the second embodiment;
FIG. 12 is a circuit diagram for changing the masking coefficients;
FIG. 13 is a diagram showing the memory content of an ROM in FIG. 12;
FIG. 14 is a characteristic diagram of the masking coefficients which are derived by an ROM having such a memory content as shown in FIG. 13; and
FIGS. 15A to 15C are characteristic graphs of respective color masking coefficients in other embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described in detail herein below with reference to the drawings.
FIG. 1 shows a fundamental constitution of the first embodiment of the invention. In FIG. 1, a denotes division means for dividing each of the color density input signals Y, M, and C of three colors into a plurality of density regions and for outputting the data indicative of the density region to which the input signal belongs.
b represents coefficient selection means for outputting a coefficient selection signal in accordance with the combination of respective colors of the data indicative of the density region which was output from the division means a.
c indicates switching means for switching the coefficient values of the linear masking in response to the above coefficient selection signal.
d denotes linear masking processing means for performing the linear masking processes of the color density input signals using the foregoing coefficient values switched by the switching means c and for outputting the masked color density signals Y', M', and C'.
FIG. 2 shows a constitution of a Y signal correction processing circuit in a color processing apparatus of the first embodiment of the invention. Since the correction processing circuits of the other M and C signals are constituted in substantially the same manner as the circuit of FIG. 2, their detailed descriptions are omitted.
In FIG. 2, reference numerals 3A, 3B, and 3C denote division ROMs (read only memories with the arithmetic operating function, the same shall apply hereinafter). The division ROMs divide a corresponding one of the 8-bit digital data (color density data) Y, M, and C of the colors yellow, magenta, and cyan which are respectively supplied from the readout unit 1 into sixteen parts and output four-bit division data 4A, 4B, and 4C indicative of the corresponding density regions. In this case, when it is assumed that each of these digital data is divided into sixteen equal parts, the input data of Y, M, and C is used as the address data, and the upper four bits of the input data are previously stored into each address in the internal memories in the division ROMs 3A to 3C. The upper 4-bit data of the addresses corresponding to the 8-bit input digital data Y, M, and C is read out of the memory areas in the division ROMs and output as the division data 4A, 4B, and 4C.
Numerals 5A, 5B, and 5C denote selector ROMs. The three kinds of division data 4A to 4C are respectively input as the address data to the selector ROMs in parallel. Four-bit coefficient selection signals 6A, 6B, and 6C in accordance with the combination of those address data are read out of the memory areas and output.
Numerals 7A, 7B, and 7C denote coefficient ROMs. A combination of a corresponding one of the coefficient selection signals 6A, 6B, and 6C and one of the 8-bit digital data Y, M, and C is input as address data to each of the coefficient ROMs 7A to 7C. One of the 8-bit digital data a 1 Y, -a 2 M, and -a 3 C as the multiplication values of the optimum linear masking coefficients a 1 , -a 2 , and -a 3 corresponding to the address data and Y, M, and C is read out of the memory areas and output.
An adder 9 adds the 8-bit digital data of a 1 Y, -a 2 M and -a 3 C which are supplied from the coefficient ROMs 7A to 7C and outputs the resultant data to the output unit 13 (refer to FIG. 3) as a yellow output signal Y' which was subjected to the masking process.
The operation of the embodiment will now be described further in detail.
The color image to be read is color separated and read out by the readout unit 1. In the readout unit 1, the color separation signals are converted from the density signals Dr, Dg, and Db of red, green, and blue into the color density signals Y, M, and C of yellow, magenta, and cyan of the 8-bit digital data and sent to the division ROM 3C and coefficient ROM 7C in FIG. 2.
The 8-bit digital data Y, M, and C are stored as the address data into the division ROMs 3A, 3B, and 3C. The 4-bit division data 4A, 4B, and 4C corresponding to those addresses are read out of the memory areas in the division ROMs and transferred to the selector ROMs 5A to 5C.
The division data 4A to 4C of the respective colors are input as the address data into the selector ROMs 5A to 5C in parallel, respectively. The 4-bit coefficient selection signals 6A to 6C corresponding to the combination of the address data are read out of the memory areas in the selector ROMs and output to the coefficient ROMs 7A to 7C.
The operation of the coefficient ROMs will now be explained with respect to the ROM 7A as an example. The yellow input Y is input as the address data and the value a 1 Y of which the data Y was multiplied with the coefficient a 1 selected by the coefficient selection signal 6A is read out of the memory area and output as the 8-bit data. Sixteen kinds of values are prepared for the coefficient a 1 . The optimum coefficient a 1 corresponding to the combination of the inputs Y, M, and C is selected and read out by the 4-bit coefficient selection signal 6A.
Similarly, the optimum coefficients a 2 and a 3 are selected and a 1 Y, -a 2 M, and -a 3 C are output from the respective coefficient ROMs to the adder 9. The yellow output Y' (=a 1 Y-a 2 M-a 3 C) after the color process is output from the adder 9 to the output unit.
The foregoing masking processes are also similarly executed for the 8-bit input digital signals M and C. The resultant magenta output M' (=-a 4 Y+a 5 M-a 6 C) and cyan output C' (=-a 7 Y-a 8 M+a 9 C) are output to the output unit. In the output unit (not shown), the color inks of yellow, magenta, and cyan corresponding to the color density signals Y', M' and C' after the masking processes are printed, thereby obtaining a color image.
As described above, according to this embodiment, the input signals Y, M, and C which are supplied from the readout unit 1 are respectively divided into sixteen parts, thereby dividing the density spaces (gradation regions) of Y, M, and C into the 16 3 (=4096) regions. Then, by selecting the optimum masking coefficients in the respective spaces by the selector ROMs 5A, 5B, and 5C, the optimum color correcting processes are executed.
In the 4096 small divided spaces, the color characteristics of the printer can be also linearly approximated and the color correction can be accurately performed by the linear masking method.
Therefore, according to the embodiment, the color processes which can properly correct the printer characteristics with regard to the whole color space can be accomplished.
The necessary memory capacities of the various ROMs in the embodiment are as follows.
(1) Division ROMs 3A, 3B, 3C
2 8 ×4=1024 bits for each ROM since the input consists of eight bits and the output consists of four bits
(2) Selector ROMs 5A, 5B, 5C
2 12 ×4=16384 bits for each ROM since the input consists of twelve bits and the output consists of four bits
(3) Coefficient ROMs 7A, 7B, 7C
2 12 ×8=32768 bits for each ROM since the input consists of twelve bits and the output consists of eight bits
Since the division ROMs can be commonly used for each color, one division ROM, three selector ROMs and three coefficient ROMs are necessary with respect to the correction of each color signal of Y, M, and C. Thus, the memory capacity of total 445,440 (=1024 ×3+16384×9+32768×9) bits is needed.
As in the foregoing conventional apparatus of FIG. 4, according to the masking method whereby each combination of the input data Y, M, and C of three colors is made to correspond to the outputs of one set of Y', M', and C', if the input data consists of eight bits, the memory capacity of 402,653,184 (=2 8 ×2 8 ×2 8 ×8×3) bits is necessary. However, according to the subject embodiment, only a memory capacity of 445,440 bits is necessary. Thus, as compared with the foregoing conventional method, the embodiment has an advantage that sufficient color processes can be performed by the small memory capacity of merely 0.11 % (i.e., 445440÷402,653,184≈0.0011).
In the foregoing embodiment of the invention, the ROMs 3A, 3B, and 3C have been used to divide the input data. However, if the input data is divided into equal parts, the upper four bits of the input data are equal to the output of the division ROM. Therefore, for example, the upper four bits of the input data may be also directly supplied as the input address signal into the selector ROM by use of a register without using the ROM. In this case, the necessary memory capacity can be saved by 3072 bits. On the other hand, the method of dividing the input data is not necessarily limited to the method whereby it is divided into equal parts. For example, if data, such as the input data is finely divided in the region where the human sense of sight is sensitive and it is roughly divided in the other regions is previously stored into the ROM, the more natural output image can be derived.
As explained above, if the division ROMs 3A, 3B, and 3C in the embodiment have the function to divide the input data into a plurality of regions, an arbitrary dividing method may be used.
On the other hand, the selector ROMs 5A, 5B, and 5C in the embodiment are not necessarily limited to memory elements but may be encoders which are constituted by logic circuits such as AND (logical product) circuits, OR (logical sum) circuits, and the like. In this case, the necessary memory capacity can be remarkably saved. In brief, it is possible to use the selector ROMs having the function to generate a predetermined selection signal in accordance with the combination of the input signals of three colors.
The coefficient ROMs 7A, 7B, and 7C in the embodiment are not always limited to the memory elements but may be the devices such as to convert the input data Y, M, and C into the analog signals and these analog signals are amplified by operational amplifiers and the amplification factors thereof are switched by the selection signals from the selector ROMs. In this case, the necessary memory capacity can be partially saved. In brief, the devices having the function of switching the coefficients of the linear masking equations in accordance with the selection signal may be used.
On the other hand, the division of the signals, the generation of the selection signals, and the switching of the masking coefficients in the embodiment may be also realized by a constitution using a microcomputer in a software manner.
In addition, although each of the input signals of the respective colors has been divided into sixteen parts in the embodiment, the invention is not limited to this method. Other methods whereby each input signal is divided into a plurality of regions of two or more are incorporated in the scope of the invention. The number of division regions of each color is not necessarily limited to the same number. The number of division regions of each color may be also different. For example, in the case of the linear masking equations of the output yellow signal Y', the input yellow signal is divided into sixteen parts. The input magenta signal M and input cyan signal C are divided into eight parts, respectively.
Further, in this embodiment, each of the coefficient selection signals which are output from the selector ROMs 5A, 5B, and 5C has been set to four bits and sixteen kinds of coefficients have been switched in each of the coefficient ROMs 7A, 7B, and 7C. However, the invention is not limited to these signals. Other coefficient selection signals which can switch two or more coefficients may be used and incorporated in the scope of the invention. Also, the kinds of coefficients of each color are not necessarily limited to the same kind but may be different. For instance, in the case of the linear masking equation (1) of the output yellow signal Y', sixteen kinds of values are provided for the coefficient a 1 . Eight kinds of values are provided for the coefficients a 2 and a 3 , respectively.
On the other hand, the recording method of the output apparatus of the image data processed by the invention is not particularly limited if the output apparatus is the printer which can print a color image such as an ink jet printer, thermal transfer copying printer, electrophotographic printer, or the like.
As described above, according to the first embodiment of the invention, each of the input signals of three colors is divided into a plurality of density regions, the coefficient selection signal is generated in accordance with the combination of the respective division signals indicative of the density regions, and the respective coefficients of the linear masking equation are selected and switched in accordance with the selection signal. Therefore, it is possible to provide a color processing apparatus in which the nonlinear printer color characteristics can be accurately corrected by a simple circuit constitution and good color reproducibility is obtained.
In addition, the first embodiment of the invention has an excellent advantage in that the necessary memory capacity is significantly reduced to, e.g., 0.11 % of that of the conventional apparatus.
The second embodiment of the invention will now be described with reference to FIG. 9 and the subsequent drawings.
FIG. 9 is an image signal processing block diagram of an image forming apparatus of the second embodiment. In this embodiment, ink jet heads are arranged and scanned as shown in FIG. 5. Namely, the print is performed in accordance with the order of yellow, magenta, and cyan.
In FIG. 9, reference numerals 113a, 113b, and 113c denote 6-bit digital input signals Y, M, and C of yellow, magenta, and cyan. These signals are input to a masking circuit 114 from an image reading apparatus, an image data storing apparatus, and the like (not shown).
The masking circuit 114 executes the following color correcting processes.
Y'=a.sub.11 Y-a.sub.12 M-a.sub.13 C (1)'
M'=-f.sub.21 (Y)·Y+a.sub.22 M-a.sub.23 C (2)'
C'=-f.sub.31 (Y)·Y-f.sub.32 (M)·M+a.sub.33 C (3)'
In this embodiment, the magnitudes cf coefficients are changed in accordance with the input levels.
First, since the yellow ink is first printed, the γ characteristic does not change by the print of the other color inks. Therefore, a 11 , a 12 , and a 13 are set to constants similarly to the conventional example.
Since the magenta ink is printed after the yellow ink the γ characteristic charges in dependence on a printing amount of yellow ink. Namely, as the printing amount of yellow ink increases, the γcharacteristic of magenta becomes gentle as shown in FIG. 8. To correct this, a larger quantity of magenta ink needs to be printed.
For this purpose, the magnitude of f 21 (Y) is reduced as the value of Y increases as shown in FIG. 10. After the value of Y was converted by the expression (1)', it is further transmitted to the γ correcting circuit and becomes the printing signal. Therefore, the value of Y does not always correspond to the printing amount of yellow ink which has previously been printed in a one-to-one correspondence manner. However, as will be obvious from the expression (1)', the printing signal of yellow also increases with an increase in Y. Therefore, by changing the value of f 21 (Y) as shown in FIG. 10, when the amount of yellow ink previously printed is large, the printing amount of magenta ink is increased over that in the case of masking by use of the constant. Thus, the change of the γ characteristic can be corrected.
In the expression (2)', the Y characteristic of magenta is not influenced by the printing amount of cyan ink which is subsequently printed. Therefore, a 23 is set to a constant and a 22 is also set to a constant.
In the next expression (3)', the Y characteristic of cyan is influenced by both the printing amounts of yellow and magenta inks which have previously been printed. Therefore, only a 33 is set to a constant and f 31 (Y) and f 32 (M) are set to values which vary in accordance with the input signals as shown in FIGS. 11A and 11B. Thus, as the printing amounts of yellow and magenta inks previously printed are large, the printing amount of cyan ink increases as compared with that in the case of masking by use of the constant, so that the change in γ characteristic can be corrected.
A method as shown in, e.g., FIG. 12 is used to change the values of the coefficients in accordance with the input signals as mentioned above.
The input data Y is input as the address data of a coefficient ROM 20. The value of which the address was multiplied with f is preliminarily stored into each address in the ROM 20 and this value is output. Thus, the f·Y is output for the input Y. If the data f·Y to be stored into this ROM is set as shown in FIG. 13, the value of f for the input Y changes as shown in FIG. 14. By providing such an arithmetic operating ROM for each term of the masking equations and by adding the results of the outputs, the masking processes in the invention can be accomplished.
After the color correction by such masking processes was executed, the gradations of respective corrected signals 115a, 115b, and 115c of yellow, magenta, and cyan are corrected by gradation correcting circuits 116a, 116b, and 116c in FIG. 9, respectively. A yellow signal 117a is directly sent to a yellow head 119a. A magenta signal 117b and a cyan signal 117c are sent to buffers 118a and 118b and delayed by the times corresponding to the distances between the heads. Thereafter, the delayed signals are transmitted to heads 119b and 119c. The inks of the respective colors are printed and a color image is reproduced.
In this manner, by changing the masking coefficients in accordance with the magnitudes of the input data, the change in γ characteristic and a change in color balance by the ink previously printed are corrected, so that the gradations and color reproducibility can be remarkably improved.
In the foregoing embodiment, the coefficients of the equation to calculate the color component to be printed later among the masking equations have been changed in accordance with the input. However, the invention is not limited to this but may be also similarly embodied by changing the coefficients of the equation to calculate the color component to be printed first in accordance with the inputs. In this case, the masking equations are set as follows.
Y'=a.sub.11 Y-f'.sub.12 (M)·M-f'.sub.13 (C)·C (4)'
M'=-a.sub.21 Y+a.sub.22 M-f'.sub.23 (C)·C (5)'
C'=-a.sub.31 Y-a.sub.32 M+a.sub.33 C (6)'
Then, f' 12 (M), f' 13 (C), and f' 23 (C) are changed as shown in FIGS. 15A, 15B, and 15C. By doing this, if there is an ink to be printed later, the amount of ink which is printed first is reduced from that in the case of masking by use of the constant and the change in color balance in the case of the mixed colors shown in FIG. 8 is corrected, so that the stable color reproducibility can be derived.
In the foregoing embodiment the γ characteristic of the color ink to be printed first is not influenced by the printing amount of ink which will be printed later. However, if the distance between the respective heads is narrow or if the absorbing rate of the ink into the paper is slow in dependence on the characteristics of the ink and recording paper, or the like, there is the case where before the ink printed first is sufficiently absorbed into the recording paper, the next ink is printed, so that the γ characteristic of the color ink printed first is influenced by the amount of ink printed later. In such a case, it is sufficient to change the values of a 12 and a 13 in the expression (1)' and the value of a 23 in the expression (2)' in accordance with the input.
Namely, in the case, the values of the coefficients other than the diagonal components of the coefficient matrix change in accordance with the input when it is assumed that ##EQU2## The degree of changes in the respective coefficients for the inputs are different in dependence on the inks, recording paper, distance between the respective color heads, head scanning speeds, and the like. Therefore, the relation as shown in FIG. 8 is obtained by the experiments of every combination of the respective colors and the optimum degree of change may be determined on the basis of the resultant data.
In the foregoing embodiment, a 11 in the expression (1)', a 22 in the expression (2)', and a 33 in the expression (3)' have been set to the constants. However, the invention is not limited to those constants. If the γ characteristics of the printer are not linear even in the case of the printing in single color, or the like, the γ characteristics may be also corrected by changing the values of a 11 , a 22 , and a 33 in accordance with the inputs.
Although the embodiment has been described with respect to the case of printing the inks of three colors of yellow, magenta and cyan, the invention is not limited to this case. A color image may be also reproduced by overlapping four color inks by adding the black ink to those three color inks.
On the other hand, in the case of reproducing a color image by overlapping four color inks including the black ink, assuming that the color inks are printed in accordance with the order of yellow, magenta, cyan, and black, if the invention is embodied by setting the masking equations as follows
Y'=a'.sub.11 Y-a'.sub.12 M-a'.sub.13 C-a'.sub.14 Bk
M'=-f'.sub.21 (Y) Y+a'.sub.22 M-a'.sub.23 C-a'.sub.24 Bk
C'=-f'.sub.31 (Y) Y-f'.sub.32 (M) M+a'.sub.33 C-a'.sub.34 Bk
Bk'=-f'.sub.41 (Y) Y-f'.sub.42 (M) M-f'.sub.43 (C) C+a'.sub.44 Bk
the γ characteristic of the black component can be also corrected. Thus, the gray balance is further stabilized.
The invention is not limited to the ink jet printer but may be also applied to other color printers of various types.
As described above, according to the second embodiment of the invention, the coefficients of the masking equations to obtain a color image by sequentially printing the coloring agents of a plurality of colors are changed in accordance with the inputs. Thus, the Y characteristic by the coloring agent printed first can be corrected and good gradations and good color reproducibility can be always obtained by the circuit scale which is almost equivalent to that in the conventional linear masking processes.
Fundamentally, the invention uses the linear masking equations, so that the simulation by the computer can be fairly easily performed. Therefore, there is an advantage such that even if the number of divided density regions is large, the optimization can be easily executed.
The present invention is not limited to the foregoing embodiments but many modifications and variations are possible within the spirit and scope of the appended claims of the invention. | A color processing apparatus performs the masking process of a color image by receiving a plurality of color component signals, and has a masking circuit for performing a linear masking process for the plurality of color component signals. The masking process utilizes a plurality of coefficients each of which has a particular value. The value of at least one of the coefficients of the masking circuit is varied in accordance with levels of the plurality of color component signals. A signal indicative of an amount of one kind of colorant which is to be recorded prior to the recording of other kinds of colorants can be discriminated, and a signal level which indicates the amount of the other kinds of colorants to be recorded on the same area after the recording of the one kind of colorant is corrected in accordance with the discrimination result. | 7 |
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to printing. Specifically, the present invention relates to power savings.
2. Description of the Related Art
In modern computing environments computers are networked to share resources. For example, several computers may be networked to share the same server. The server may house resources used by each computer, such as a database or specific programs.
Sharing these resources provides for efficiencies in the network. For example, if a database is stored on one server there is no need to replicate the database information on each machine that uses the information. As a result, the amount of hardware required in the network is greatly reduced. With less hardware, tangential savings are also achieved such as power savings, since an end-user has to run fewer machines. Running fewer machines ultimately results in financial savings.
In addition to computing devices, peripheral devices in the network are also shared. For example, conventional printers are often networked and shared by several end-users. As with computing devices, using a network printer results in end-user efficiencies, since several end-user stations share the same printer. Ultimately, this results in a savings in hardware, power and space resources required to run and house the printer. Across a large organization, this savings can be substantial.
Although sharing network printers provide efficiencies, in many ways conventional network printers still function in an inefficient manner. For example, conventional network printers operate in a power save mode when they are not in operation. In power save mode the printer runs on less power, when the printer is not printing or processing a job. When a network printer receives a print job, the printer comes out of power save mode and begins to print the job. When several jobs arrive at a network printer the jobs are printed as they are received by the printer.
If the printer is in power save mode, the printer will begin to print the first job. The printer will then place each additional job that arrives in a print queue and sequentially print the jobs from the queue. In other words a first in—first out (FIFO) algorithm is used. There is no prioritization of the jobs. With the random arrival of jobs, a conventional network printer is often cycling between operating mode and power save mode. Cycling back and forth, stops the printer from maximizing the full benefit of the power save mode. In addition, without any prioritization of jobs, end-users have limited control over how or when their jobs are printed.
There is a need in the art for a more efficient system or method for sharing a printing resource. For example, there is a need for a shared printer resource that will maximize the use of the power save mode feature. There is a need for a shared printer resource that enables the prioritization of jobs. Lastly, there is a need in the art, for shared printer resource that gives an end-user more control over how and when a print job is processed.
SUMMARY OF THE INVENTION
The need in the art is addressed by the method and apparatus for strategic printing of the present invention. In accordance with present teachings, a shared printer in power save mode receives a job for printing and switches from power save mode to a ready state. In the ready state, the printer prints jobs based on the length of the job and a priority code associated with the job. The priority code is used to look up the delay time before the printer prints the job. The delay time in conjunction with the length of the job information is then used to compute the printing time for the job. When the delay time is less than the printing time the job is printed.
In an alternate embodiment of the present invention a printer in the power save mode receives a first print job that includes information on the length of the job information and priority code information. The printer once again calculates the printing time and if it is not time for printing, stores the print job in memory. When the printer receives a second print job with higher priority code information, the printer prints all the jobs stored in memory when it is time to print the second print job with the higher priority code information. In a third embodiment, if there are several print jobs in memory, the printer will print all of the jobs in memory regardless of their priority code when the first print job stored in the memory is ready for printing. Finally, in a fourth embodiment of the present invention, the printer is in the ready state, so the job is printed irrespective of the priority code.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram of the present invention.
FIG. 2 is a conceptual drawing of a network implementing the method and apparatus of the present invention.
FIG. 3 is a graphical user interface of a print control screen.
FIG. 4 is a conceptual drawing of the system setup of the present invention.
FIG. 5 is a priority code table implemented utilized in the method and apparatus of the present invention.
FIG. 6 is a flow diagram of the method of the present invention.
DESCRIPTION OF THE INVENTION
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
FIG. 1 is a block diagram of an illustrative embodiment of a system implemented in accordance with the teachings of the present invention. As shown in FIG. 1 , the system 100 includes a central processing unit (CPU) 102 . Internal memory 104 is included which provides random access memory 106 for staging information and a read only memory 108 for storing computer instructions. The CPU 102 accesses information in the RAM 106 and the ROM 108 through a standardized communication pathway or a bus 110 . Input devices such as a keyboard, a mouse, a joy stick, a scanner and a light pen are also shown as 112 . Communication between the input device 112 and other parts of the system, is accomplished through an input interface 114 and the bus 110 . Output devices such as a monitor and a printer are also shown. Communication between an output device and other parts of the system, is accomplished through the bus 110 and an output interface 118 . External memory 120 is also shown. External memory 120 may include a floppy disk drive, a hard disk drive, a CD ROM or a magnetic tape.
In accordance with an illustrative embodiment of the method of the invention, a number of print jobs may arrive at the printer and be stored in a queue, in internal memory 104 or external memory 120 . Computer instructions for processing the print jobs in accordance with the present invention are stored in internal memory 104 (e.g. ROM 108 ). As print jobs come into the memory ( 104 , 120 ), the CPU 102 processes the print jobs in accordance with the computer instructions (software) stored in ROM 108 .
In the method of the present invention several print jobs may arrive and be stored in the memory ( 104 , 120 ). The CPU 102 processes the print jobs under control of the software. In accordance with the present teachings, the CPU 102 executes the computer instructions and reorganizes the priority or order of the print jobs.
FIG. 2 shows a Local Area Network 200 adapted to utilize the teachings of the present invention. It should be appreciated that a printer implementing the teachings of the present invention may be a shared printer of any type regardless of whether the printer is shared across a network (e.g. Local Area Network or internet) or if the printer is shared as a result of a direct connection to several end-users.
In FIG. 2 computers 202 , 204 and 206 communicate across a shared communications path 108 with a shared printer 210 . The computers 202 , 204 , 206 are each independent devices. Each of the computers is capable of sending a print job at any time. The shared printer 210 operates in both an operating mode and a power save mode. In the operating mode the printer is fully functional and power is supplied to the full printer circuitry and apparatus. In operating mode the printer receives print jobs and processes these jobs immediately if there are no print jobs pending. If print jobs are pending the printer stores the print job in memory until the received print job can be printed by the printer apparatus. Placing incoming jobs in memory until printer resources are available for printing creates a queue of print jobs in the memory.
When the printer is in power save mode, the full functionality of the printer is not being utilized. For example, power is applied to a subset of the printer circuitry and apparatus to save energy. When a printer receives a job in power save mode, the printer first powers up the printer circuitry and apparatus that maintained in a standby or ‘sleep’ state. This places the printer in operational mode. After the printer is in operational mode, the printer prints the job as mentioned above.
FIG. 3 displays a modified graphical user interface 300 used to print documents in accordance with the inventive method. In FIG. 3 a printer type field is shown as 302 . The printer type field enables an end-user to select a specific printer and change details about how the document should be printed. For example, the landscape or portrait option may be selected. A copies field is also shown as 304 . The copies field 304 enables an end-user to specify or request a number of copies. A zoom field is shown as 306 . The zoom field 306 enables an end-user to scale the size of the print job. A page range field 308 is shown. The page range field 308 enables an end-user to print the current page, selected pages or all the pages of a print job.
A “print when” field is shown at 310 . In accordance with the present teachings, the “print when” field 310 enables the end-users to put a time requirement on the print job. For example, the end-user may be given a choice of zero seconds before printing, fifteen seconds before printing or thirty seconds before printing. In accordance with the present invention, once the user selects a “print when” designation, the print job is assigned a priority code at the end-user location and sent out to the printer. Selecting a “print when” option attaches a set of printer commands to the print job. The printer commands are sent with the print job to the printer. When the printer receives the print job, the printer interprets and processes the printer commands with the other printer command (e.g. number of copies) and processes the job accordingly.
A “print what” field 312 and a print field 314 are also shown. These two fields enable the end-user to print specific documents. An option field 316 enables an end-user to specify specific printing options. Once all the print selections have been made an OK field 318 and a cancel field 320 may be utilized. These fields enable an end-user to print the job or cancel the printing of the job.
FIG. 4 displays a conceptual drawing 400 of the components of the presenting invention. In FIG. 4 additional instructions 402 are added to the firmware and the memory of a printer, represented by 404 . The firmware includes the logic that the printer uses to process print jobs as the jobs come into the printer.
In accordance with the present teachings, additional firmware for reading and processing a priority code attached to each print job is provided. In addition, a priority code lookup table is stored in the printer memory and used in conjunction with the firmware instructions. For example, a job may arrive at the printer with priority code 2 . The firmware will read-in the priority code ‘ 2 ’ and then access the priority code table stored in the printer memory. Based on where the priority code of 2 is located in the priority code table, the firmware instructions will then process the job based on the predefined instructions stored in the firmware.
In accordance with the method of the present invention, the printer may follow a series of firmware logic steps and perform a number of activities to process a print job. For example, the printing priority may be based on the number of pages required to be printed. The logic may be established so that pages with a smaller number of pages are always printed first. Alternatively, the printing priority may be based on the time that the print job is required by the end-user. Therefore, the print jobs may be prioritized and printed based on when the end-user plans to pick up the print job from the printer. The priority may also be based on a combination of the two, such that the jobs are printed based on both the number of sheets in the print job and the time that the print job is required. It should be appreciated that a number of priority schemes may be implemented. For example, priority schemes may be based on individual users or class of users or priority schemes may be based on the type of job being printed.
FIG. 5 displays a priority code table 500 adapted for use in accordance with an illustrative implementation of the teachings of the present invention. In the present invention, the priority code table is stored in the printer memory and accessed based on the logic that is hard coded into the printer firmware. However, it should be appreciated that the priority code table or the firmware instructions may be stored in another memory, may be hard coded, soft coded or downloadable software that can be updated.
The priority code table 500 includes a priority code column 502 and a delay column 504 . The priority code column includes a predefined set of priority codes. The predefined set of priority codes may be any codes defined by the user. The delay column includes the time delay before printing. The time delay values may be values based on any time scheme and separated by predefined intervals. For example, the delay may be in seconds, minutes or hours.
Each priority code is associated with a delay. For example, priority code zero as shown in 506 is associated with a delay of more than three hundred minutes as shown at 508 . Priority code 1 as shown at 510 is associated with a time delay of between sixty and three hundred minutes as shown at 512 . Priority code 2 as shown at 414 is associated with a time delay that is less than sixty as shown at 516 .
In the method of the present invention, the time delay 508 , 512 and 516 is selected by the end-user. The print job is then coded with a priority code and sent to the printer. At the printer, the firmware instructions are followed to process the priority code by reading the corresponding time delay in the priority code lookup table 500 . The print job is then processed consistent with the method of the present invention.
FIG. 6 displays the methodology of the present invention. A job is sent to the printer with priority information coupled to it as shown at 600 . The printer then reads the length of the job (e.g. number of pages) and the priority code. The printer uses a lookup table, such as the lookup table 500 of FIG. 5 , to determine the amount of time that the job can be delayed before printing, as shown at 602 . The printer checks the current status (e.g. operational mode or power save mode) as shown at 604 . If the printer is in the ready state as shown at 606 the job is printed irrespective of the priority code as shown at 608 . If the printer is not in the ready state, but in power save mode as shown at 610 , the printer analyzes the length of job and priority code input, to determine when the job should be printed as shown at 612 .
In the methodology of the present invention, the printer computes the printing time based on the number of pages and waits until the delay time is less than the printing time to print the job. During this time the job is stored in the printer memory. If another print job with a higher priority code or any other job that is already in memory needs to be printed thereby bringing the printer to ready state, then all the to jobs are printed irrespective of the priority code. For example, if a job was already in memory and then a job with a higher priority is subsequently stored in the memory, all the jobs in the memory will be printed when the higher priority job is printed. In addition, if a job that was already in memory reaches a point where it is time to print that job, then all of the jobs are printed irrespective of the priority code.
As an alternative to printing all the jobs in memory when one job reaches its printing time, it is possible with the method of the present invention, to reorder the printing of jobs and only print the specific job that has reached its printing time.
Furthermore, when prioritizing jobs based on classes or categories, with the method of the present invention, it is possible to reorder and print certain classes or categories of jobs before others.
Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.
It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention. | The present invention discloses a method and apparatus for saving power in a printing system, by prioritizing printer jobs. Using a graphical user interface an end-user assigns a print time to a first job. The print time designation is attached to the first job and the first job is transmitted from the end-user station to a printer. Based on whether the printer is in ready state or in power save mode the first job is printed immediately or stored in memory. When the first job is stored in memory, computations are made to determine a printing time to initiate printing of the first job. The first job is then printed at the printing time or at an earlier printing time if a second job with an earlier printing time is stored in the memory. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to a method for controlling power consumption during a rock drilling process of the kind defined in the preamble of claim 1 .
[0002] The invention further relates to a system and a rock drilling apparatus of the kind defined in the preamble of claims 11 and 21 , respectively.
BACKGROUND OF THE INVENTION
[0003] Rock drilling apparatuses may be used in a number of fields. For example, rock drilling apparatuses may be used in tunnelling, underground mining, rock reinforcement, raise boring, and for drilling of blast holes, grout holes and holes for installing rock bolts.
[0004] Rock drilling is often performed by percussion rock drilling, in which a drill tool mounted at one end of a drill rod is provided with impact pulses by a hammer piston, arranged on the opposite side of the drill rod, and arranged to be powered to repeatedly impact upon the drill rod. At the outermost end of the drill tool there are drill bits that penetrate the rock and break it upon the impacts by the hammer piston.
[0005] The drill tool also may be pressed against the rock to maintain contact between the tool and the rock in order to make sure that as much impact energy as possible from the hammer piston is transmitted to the rock. To make the drilling process more efficient the drill tool may further be rotated somewhat between the impacts so that the drill bits hit a new location at every impact. The drill cuttings are flushed away from the hole with a suitable medium. This medium usually is air in surface drilling apparatuses, water in underground working apparatuses. Alternatively, watermist with or without a chemical additive may be used in both types of apparatuses.
[0006] The rock drilling apparatus further comprises main power supply means, such as a diesel engine that is used to produce power for power requiring functions of the rock drilling apparatus. These functions may include a compressor for producing flushing pressure/flow, percussion power, rotational power, feeding power, feeding rate, hydraulic pumps, cooling fans.
[0007] Rock drilling may further be carried out by apparatuses utilising only rotation and applied pressure to break the rock, or apparatuses only utilising rotation to break the rock.
[0008] The main power supply means is dimensioned such that all functions may be used using their maximum output power rate simultaneously at all times to ensure proper function.
[0009] A problem with existing rock drilling equipment, however, is that they often consume more power than necessary during a drilling process, which results in excessive fuel consumption, and heat and noise generation.
[0010] Accordingly, there is a need for an improved rock drilling method that solves the above mentioned problem.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a method for controlling power consumption during a rock drilling process that solves the above mentioned problem. This object is achieved by a method for controlling power consumption during a rock drilling process according to the characterising portion of claim 1 .
[0012] Another object of the present invention is to provide a system for controlling power consumption during a rock drilling process, which solves the above mentioned problem. This object is achieved by a system as defined in the characterising portion of claim 11 .
[0013] It is a further object of the present invention to provide a rock drilling apparatus that solves the above mentioned problem. This object is achieved by a rock drilling apparatus according to claim 21 .
[0014] The method for controlling power consumption during a rock drilling process with a rock drilling apparatus, includes adjusting the flush power at least partly as a function of hole depth, and controlling at least the percussion power and/or rotational power and the flush power such that the total power consumption of each sub-process is controlled such that the power output from the main power supply means is kept at or below a predetermined level.
[0015] This has the advantage that only the required amount of power at a certain hole depth is used for flushing, and that the remaining power may be used for other functions and/or for saving power, resulting in for example less fuel consumption, less noise and less heat.
[0016] The flush power may further be adjusted at least partly as a function of hole diameter and/or diameter of the drill rod.
[0017] The flow of the flush medium may be kept substantially constant throughout the drilling process, i.e. the flush power increases with increased hole depth. The hole depth may further be continuously measured. This has the advantage that the flow may be kept at precisely the flow level needed for managing to flush the drill hole, and thus the flush power may kept at lowest possible value throughout the drilling process, at all times.
[0018] The flow of the flush medium may be increased at least slightly with increasing hole depth. This has the advantage that as the hole depth increases, the flow may be increased somewhat in order to further compensate for the hole depth and/or drill rod joints and/or drill cuttings tending to get stuck on the wall of the drill hole.
[0019] The required flush power may be determined by computer means. The computer means may be connected to a memory in which is stored a table comprising one or more of lists of types of drill tools and/or types of drill rods, and preferably calculation parameters to be used with a selected combination. The flush power may be determined based on stored data concerning type of drill tool and/or type of drill rod and/or hole depth. This has the advantage that the flow of the flush medium may be kept at a desired value independent of for example which drill tool diameter and/or drill rod diameter that is used.
[0020] The invention may be used in conventional rock drilling apparatuses, for example in apparatuses utilising percussion or rotation or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows an exemplary embodiment of a rock drilling apparatus according to the present invention.
[0022] FIG. 2 shows a block diagram describing an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] FIG. 1 depicts an exemplary rock drilling apparatus according to the present invention. In the figure is shown a rock drilling apparatus 1 , in this exemplary a surface drill rig. The drill rig 1 is shown in use drilling a hole 2 , starting from a ground level, at present having reached a depth α and destined to result in a hole of depth β, for example 30 meters, the finished hole being indicated by interrupted lines. (The shown relation of drill rig height/hole depth is not intended to be exact. The total height γ of the drill might for example be 10 meters.)
[0024] The drill rig 1 is provided with a top hammer 11 mounted via a rock drill cradle 13 on a feed 5 . The feed 5 is attached to a boom 15 via a feed holder 12 . The top hammer 11 provides percussive action to a drill tool 3 with one or more drill bits 4 via a drill rod 6 supported by a rod support 14 . The top hammer 11 is power supplied from a hydraulic pump 10 , driven by a diesel engine 9 , via a conduit attached to the feed 5 (the hydraulic feed is not shown in the figure). The drill cuttings are flushed out of the hole 2 by compressed air that is fed through a tube, preferably in the center of the drill rod 6 , and is discharged near the drill tool 3 . The compressed air flushes the drill cuttings upwards through and out of the hole 2 , as indicated by the upwardly directed arrows in FIG. 1 . Instead of compressed air, other flushing media may be used as well, for example watermist with or without a chemical additive. The compressed air is fed to the drill rod 6 from a compressor 8 via a tube 7 . The compressor 8 , in turn is powered by the diesel engine 9 .
[0025] In current drill rigs the diesel engine 9 has to be large enough to be able to simultaneously drive both the compressor and the hydraulic pump at full rate as well as cooling fans and other appliances. The compressor is always driven at or near its maximum rate during drilling, and since the compressor may consume for example 120 hp of a diesels total output of for example 300 hp, the compressor consumes a large amount of fuel, which results in the generation of large amounts of exhaust gases and of noise and heat, which further results in even more noise and fuel consumption due to the fact that cooling fans need to be driven harder.
[0026] According to the present invention, however, these drawbacks may be reduced by driving the compressor at the power level that is currently required. For example, at the beginning of the drilling of a hole, the flush power that is required to produce a flow of the flush medium being sufficient to evacuate the drill cuttings is relatively small, and thus the compressor need not deliver more than this required power. This means that the diesel engine in turn can be driven with reduced power output, thus resulting in decreased fuel consumption, less generated heat and less generated noise. Alternatively, the power thus saved by driving the compressor with reduced input power may be used to allow more power to be allocated to the top hammer than otherwise is possible, which results in faster drilling in the first and/or most part of the hole.
[0027] The compressor power reduction may be accomplished in different ways depending on compressor type. In case of for example a displacement compressor, the power may be reduced by either reducing the R.P.M. or unloading the compressor by shutting the inlet.
[0028] The control of the compressor power will now be described with reference to FIG. 2 , showing a block diagram of a control system. The figure shows a drill rig 21 with a diesel engine 22 . The diesel engine is directly or indirectly connected to a compressor 23 , a hydraulic pump 29 , cooling fan(s) 24 , other appliance(s) 25 , a top hammer 26 and a controller 27 , such as a computer. The controller is further connected to the compressor 23 and/or the hydraulic pump and/or the cooling fans(s) 24 and/or of the appliances 25 .
[0029] In order to control the compressor power, a sensor 28 , for example mounted on the feed, provides the controller 27 with information regarding the current hole depth, and the controller 27 then transmits, for example via a CAN bus, control signals to the compressor 23 including information about which power/pressure it should deliver in order to produce a desired flow of the flush medium. The controller may further send control signals to the diesel engine and/or cooling fans(s) and/or other appliances as needed, for example desired power values. The controller 27 may include a memory 30 in or connected to it, in which is stored desired values for the compressor settings versus hole depths so that the compressor may be correctly adjusted. Alternatively or in addition, there may further be stored calculation parameters to be used with the hole depth to calculate a desired compressor power. These calculation parameters may be dependent on type of drill tool and/or type of drill rod. Preferably calculation parameters are stored for each possible combination of drill tool and/or drill rod. In an alternative embodiment there are listings stored in the memory, wherein each listing includes compressor settings versus depth for each combination. For example, there may be values stored for each cm or dm or m increased hole depth. It is also possible to store values resulting in an increasing flow as the hole depth increases in order to compensate for the factors mentioned above.
[0030] In a further exemplary embodiment (not shown), a sensor sensing the actual flow may be connected to the controller, which enables the controller to continuously send control signals to the compressor based on the flow values. The flow may for example be calculated as litres per revolution of the compressor*revolutions per minute (R.P.M)*working time/total time.
[0031] The desired flow may in an alternative exemplary embodiment be set by the operator by setting a value on a control or by inputting a desired value to the controller via a man machine interface such as a display and/or a keyboard.
[0032] The desired flow may in an alternative exemplary embodiment be The present invention has for example the advantage that when drilling narrow holes, the compressor need not be working at full power at all during the drilling process, thus resulting in a fuel save and/or extra power for the top hammer throughout the drilling process.
[0033] In the above description, the invention has been described in connection with a surface drill rig with a hydraulic top hammer drill rig. The present invention may, however, equally well be used with any other type of drilling apparatus with separately powered flushing and drilling. For example, the invention may be used with rock drilling apparatuses utilising both percussion and rotation to perform the rock drilling. The invention may also be used in rock drilling where only rotation and applied pressure is utilised to break the rock, or where only rotation is used, which for example might be the case in soft rock drilling, such as in coal mines. In the cases where rotation is used to break the rock, the power saved from reduced flushing may be utilised for faster rotation and thereby faster drilling.
[0034] It should further be understood that numerous other sensors, for example temperature sensors, may be connected to the controller in order to provide it with information useful in controlling the operation of the rock drilling apparatus. | Method for controlling power consumption during a rock drilling process with a rock drilling apparatus, wherein the rock drilling apparatus includes main power supply means for supplying power for the rock drilling process, which includes at least the sub-processes of percussion and/or rotation and flushing, the method comprising the steps of:—adjusting the flush power at least partly as a function of hole depth, and controlling at least the percussion power and/or rotational power and the flush power such that the total power consumption of each sub-process is controlled. | 4 |
FIELD OF THE INVENTION
The present invention relates to the field of fermented alcoholic beverages, and particularly to a fermented beverage and method for production thereof comprising use of animal extract.
BACKGROUND OF THE INVENTION
There are a number of beverages on the market produced by a fermentation process, including beer, sake (Japanese rice wine), shochu (Japanese distilled spirits), whiskey, brandy, and wine. These beverages are produced through a fermentation of different materials such as grains or fruit, and possible subsequent distillation, and limited options are available for altering the resulting alcohol content in the production process.
With the health food boom in recent years, the consumption of yogurt, produced through the fermentation of milk by lactic acid bacteria, is increasing sharply. Soymilk products fermented by lactic acid bacteria are also being sold on the market. In Taiwan and other Southeast Asian countries, concentrated meat extract (e.g. chicken extract) is marketed as a health drink. Additionally, in Europe and America, various processed meat products, for example fermented sausage, are consumed.
Particular problems in producing a meat-based bacterially modified product are spoilage and bacterial toxins. Therefore, meat aging typically employs a lactic acid fermentation of the meat, which for example is performed by bacterial cultures that produce lactic acid and thereby reduce pH, and possibly employ other means for suppressing growth of harmful strains. Fermented beverages based on animal extracts pose difficulties, and are generally considered to be unstable with respect to consistency in mass production and distribution.
Previously, no alcoholic beverages have been produced through lactic acid fermentation and yeast fermentation of various broths or stocks.
SUMMARY AND OBJECTS OF THE INVENTION
Heretofore, there has not been any beverage product such as that according to the present invention made from animal extracts, for example meat extract, meat stock and/or bone extract, fermented with lactic acid bacteria and by yeast. The resulting product has a distinctive flavor, is storage stable, and is nutritious. The product generally contains alcohol, although processes may be implemented to reduce or eliminate alcohol in the product.
It is therefore an object of the present invention to provide a beverage comprising a liquid meat-based stock subjected to lactic acid fermentation and subsequently subjected to yeast fermentation, resulting in an alcoholic product.
It is a further object of the present invention to provide a method for producing a beverage comprising the steps of preparing a stock from animal sources, lactic acid fermenting the stock, and subjecting the lactic acid fermented stock to yeast fermentation.
It is a still further object of the invention to provide a unit packed alcoholic beverage for human consumption, comprising a lactic acid fermented stock derived from meat which is subsequently yeast fermented.
It should be apparent that the animal sources need not be the sole, or even principal origin of the beverage. For example, plant derived materials may be included in the lactic acid fermentation, added prior to the yeast fermentation, or added during both intervals. These added plant derived materials may be relatively simple carbohydrates or more complex compositions. The resulting alcoholic fermented beverage may also be blended with other products.
It should also be apparent that, by controlling the starting conditions, i.e., fermentable sugar and amino acid components leading into the yeast fermentation, as well as the fermentations conditions themselves, the alcohol content and other properties of the resulting product may be controlled.
It is further understood that, during or after lactic acid fermentation, the pH or other parameters of the broth may be altered or controlled, for example by the addition of a base or buffer. Likewise, the lactic acid fermented broth may be sterilized by heat and/or filtering. A low pH is generally preferred during lactic acid fermentation in order to suppress growth of organisms competing with the lactic acid producing bacteria.
Various techniques are well known in the art for the preparation of yeast-fermented beverages such as wine, beer, ale, sake, and the like, which may be applied to the yeast fermentation phases of the production process according to the present invention. Likewise, various techniques are also known for lactic acid fermentation of both liquids and meats, which may also be applied in conjunction with the lactic acid fermentation phase of the process according to the present invention.
Further objects will become apparent from a review of the detailed description of the preferred embodiments.
This invention is intended to offer new fermented alcoholic beverages produced through lactic acid fermentation and yeast fermentation of broth or stock from meat and/or bone extract, that are of high-quality with a wide variety of uses, stable and safe for manufacturing and commercial distribution through retail channels, and economically feasible for industrial production.
Alcoholic beverages according to the present invention may be made from various extracts of meat and/or bone, for example from beef, pork, mutton, chickens, ducks, turkeys, etc. Fermentation conditions may be advantageously altered through the addition of fruit juice, vegetables, and/or saccharides prior to lactic acid fermentation and/or yeast fermentation.
In addition, the lactic acid and yeast fermented alcoholic beverages may be aged, either naturally or in an artificially accelerated manner, as known in the art.
The production methods include lactic acid fermentation, usually involving the inoculation with food grade liquid cultures and/or frozen or freeze-dried concentrated cultures of lactic acid bacteria, cultivated at appropriate temperature and time conditions, and yeast fermentation, usually involving the inoculation with liquid cultures and/or dried yeast, cultivated at appropriate temperature and time conditions.
Carbonated water and flavoring materials such as fruit juice and honey may be added to the resulting fermented beverage according to an aspect of the invention. The alcoholic beverage may also be used in subsequent processes to produce composite beverages (e.g., cocktails), or as an ingredient in other foods or sauces.
The process according to the present invention has far fewer process control limitations to achieve a wider range of alcohol content, than other alcoholic beverages on the market made from grain or fruit such as beer, sake (Japanese rice wine), shochu (Japanese distilled spirits), whiskey, brandy, and wine.
The present invention provides fermented alcoholic beverages with a rich aroma, flavor, and alcohol content. Their flavor, color (red, white, rose, etc.), and alcohol content can be readily adjusted by changing the combination of materials, amount of fruit juice (blueberry, raspberry, grape, apple, orange, etc.), malt and/or grains, types of vegetables, and fermentation conditions. That is, the flavor, aroma, color, and/or alcohol content of the product are adjusted by altering fermentation conditions through the addition of fruit juice, vegetables and/or saccharides prior to lactic acid fermentation and/or yeast fermentation. In the manner of a beer or ale, hops may be added during fermentation.
It has been confirmed that different flavored fermented products can be produced, for example, by adding grape juice, apple juice, orange juice or strawberry juice prior to lactic acid fermentation. It has also been confirmed that the same can be said about the effects of adding these ingredients prior to or during yeast fermentation. In regard to aroma, its strength can be adjusted, as shown in FIG. 3 , depending on the concentration of saccharide added at the beginning of yeast fermentation. Also, as shown in FIG. 4 , the aroma can be adjusted by changing the period of yeast fermentation. As for color, beets cooked together in the extracting process for making meat extract and/or bone extract produces a color similar to red wine. To produce color with vegetables, other vegetables beside beets, such as red cabbage or purple onions can also be used. Cranberries can also be used for this purpose by adding them at the beginning or prior to yeast fermentation. A preferred colorant is beet root powder which may be obtained from a variety of commercial sources. Likewise, other vegetable powder extracts may also advantageously be employed. By adding various vegetables and different type of fruit juice to the meat and/or bone extract for fermentation, beverages with a range of flavor, color, or alcohol content can be offered to meet a wide range of personal preferences.
In order to provide a suitable industrial process, the pH and titratable acidity may be monitored, especially during lactic acid fermentation, in order to assure that fermentation is complete, and that fermentation proceeds as expected. Likewise, a control system may be implemented to achieve desired process conditions, for example monitoring and/or controlling temperature, fermentation time, saccharide levels, acidity, or other relevant properties.
A resulting beverage generally comprises organic amines (e.g. proteins and amino acids) representing greater than about 25% by weight of total soluble solids. For example, a preferred beverage comprises nitrogen expressed as protein according to the well-known so-called AOAC method (or AOAC approved method) of at least about 50% by weight of total soluble solids. Thus, one aspect of the present invention is that residual carbohydrates in the brewed product are (or may be maintained) quite low.
A preferred embodiment of the present invention has low sodium, and indeed the starting materials have inherently low sodium. This may be expressed in a number of ways, for example, less than about 0.5% by weight sodium or less than about 1% by weight sodium chloride. For example, the fermented alcoholic beverage has less than about 5,000 mg sodium per liter, more preferably less than about 1,250 mg sodium per liter, and most preferably less than about 250 mg per liter. A serving size is, for example, 375 ml, and a preferred product has a sodium concentration of less than about 250 mg per serving.
The alcohol content may be controlled during the process, for example by adjusting the fermentable carbohydrate prior to or during yeast fermentation. Preferably, the resulting product comprises at least 1.5% ethanol by volume, and may comprise at least 12% ethanol by volume. The full range of fermented alcohol concentration, about 0% to 20%, is theoretically available. Fortified and/or alcohol depleted formulations are also possible.
The beverages according to the present invention provide a smooth flavor and aroma. At the same time, the fermentation conditions may be readily altered to adjust the beverage's alcohol content as desired. The beverage includes amino acids and peptides from the meat and/or bone extract, that act to improve body functions, and also includes products of certain beneficial microorganisms resulting from lactic acid fermentation, that are recognized for their ability to assist in maintaining good health. In addition, the moderate amount of alcohol produced through yeast fermentation acts to increase appetite and has positive health effects. The anserine and carnosine peptides have been shown to lower stress, and in addition to their antioxidant properties for countering free radical damage inside the body, also have anti-cancer and anti-aging effects.
An extract with low solids and high water activity is generally susceptible to bacterial proliferation. However, during lactic acid fermentation, the pH drops. Thus, by inducing lactic acid fermentation, proliferation of other bacteria is controlled, to ensure a product that is stabilized by bio-preservation methods. In the past, when broth made from meat and/or bone materials were sought to be used in commercial beverage production for retail distribution, there were problems with bacterial proliferation.
While it is well known to preserve products by fermentation, for example lactic acid fermentation, typically a resulting product has a high moisture content and includes salt as a preservative to counteract its high water activity. Cured meat products such as sausage typically also include nitrates and nitrites as preservatives, which adds sodium and have a characteristic flavor. Thus, the product according to the present invention differs from previously known fermented meat products. See, U.S. Pat. Nos. 6,110,510, 6,103,282, 6,077,546, 5,486,367, 4,759,933, 4,587,127, 4,432,997, and 4,411,991, expressly incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained with reference to the figures, in which:
FIG. 1 shows the growth of yeast in chicken broth/stock with 20% sucrose added;
FIG. 2 shows the relationship between initial saccharide concentration and resulting alcohol concentration of the chicken broth/stock;
FIG. 3 shows results of Gas chromatograph-Mass spectroscopy (GC-MS) analysis on initial saccharide concentration and aroma component formation;
FIG. 4 shows results of GC-MS analysis of aroma components over an elapsed period of time with an initial saccharide concentration of 30%;
FIG. 5 shows aroma components and GC-MS results that show the aroma components formed over the passage of time include the same components detected in wine and sake;
FIG. 6 shows the relationship between fermentation temperature and alcohol production time;
FIG. 7 shows the fermentation temperature and formation of aroma components; and
FIG. 8 shows GC-MS analysis on the fermented product of two types of chicken broth/stocks fermented under the same conditions, but with one type of chicken broth/stock being extracted from a mixture with added aromatic vegetables and herbs and the other being extracted without the presence of any added aromatic vegetables or herbs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preparation of Stock
First, the broth/stock is made from meat and/or bones. Specifically, the meat and bones of chicken, beef, pork, mutton, or other livestock or wild game animals are extracted with hot water, just as is done with regular broth or stock, soup, Chinese broth or other extracts. The extraction may be conducted in industrial scale, or commercially available meat extracts may be used.
The broth and remaining meat and bones can be either separated or used together for fermentation. If the saccharide content is low, it may be supplemented. Added saccharides may include dextrose, mannose, galactose, fructose, xylose maltose, lactose, sucrose, honey, and starch hydrolysate. Yeast fermentation activity on these saccharides in chicken stock was examined, with the results shown in Table 1. The growth of yeast in the chicken stock with the added 20% saccharide is shown in FIG. 1 . The results confirmed a vigorous growth of yeast.
TABLE 1
Type of
Yeast
Dextrose
Mannose
Galactose
Fructose
Xylose
Maltose
Lactosa
Sucrose
Honey
Starch hydrosylate
BSJ
++
++
−
++
−
++
−
++
++
++
1118
+
++
++
++
−
++
−
++
++
++
253
++
++
+
++
−
++
−
++
++
++
W27
++
++
−
++
−
++
−
++
++
++
2323
++
++
++
++
−
++
−
++
++
++
71B
++
++
++
++
−
++
−
++
++
++
Shochu
++
++
+
++
−
++
−
++
++
++
Yeast
No growth: −
Weak growth: ±
Moderate growth: +
Vigorous growth: ++
Yeast strain used
BSJ #7 Brewing Society of Japan #7 yeast
1118 LALVIN EC-1118 Saccharomyces bayanus
253 IFO-0253 Saccharomyces cerevisiae
W27 LALVIN WADENSWIL27 Saccharomyces cerevisiae
2323 LALVIN Rhone L2323 Saccharomyces cerevisiae
71B LALVIN 71B Saccharomyces cerevisiae
Shochu yeast Kagoshima shochu yeast
Incubation
25° C.,
incubation
48
hours
temperature
time
Culture base
saccharide
20
g
Yeast extract
2
g
Bacto-peptone
5
g
Magnesium sulfate
0.5
g
heptahydrate
Potassium phosphate
1
g
Distilled water
1000
ml
Lactic Acid Fermentation
Lactic acid fermentation is initiated by inoculating liquid cultures and/or frozen or freeze-dried concentrated cultures of lactic acid bacteria, and cultivating them under proper temperature and time conditions. More specifically, the aforementioned lactic acid fermentation is normally conducted by adding food grade lactic acid bacteria. For example, 0.01–0.1% frozen or freeze-dried concentrated cultures or 1–10% liquid cultures are added and incubated under fermentation conditions between 10–40° C. for 12–48 hours.
Lactic acid fermentation normally involves the use of food grade lactic acid bacteria, which include Lactobacillus gasseri, Lactobacillus casei, Lactobacillus acidophilus, Lactobacillus sakei subsp. sakei, Lactobacillus curvatus, Lactobacillus rhamnosus, Lactobacillus pentosus, Lactobacillus paracasei subsp. paracasei, Lactobacillus plantarum, Lactobacillus jugurti, Lactococcus lactis subsp. lactis, Lactococcus lactis subsp. cremoris. Streptococcus thermophilus, Pediococcus pentosaceus, Enterococcus faecium, Bifidobacterium bifidum, Pediococcus pentacens, and Bifidobacterium longum.
The inoculum quantity of lactic acid bacteria that is added should be within the range of 0.01–0.1% for frozen or freeze-dried concentrated cultures and 1–10% for liquid cultures. However, the amount is not necessarily limited within this range. Depending on the materials used or the targeted fermented alcoholic beverage, the amount can be used in higher or lower concentration.
Dextrose, mannose, galactose, fructose, lactose, sucrose, etc. can be used as a saccharide source if necessary for the growth of lactic acid bacteria. In addition, acid content and pH at the end of fermentation can be controlled by adjusting the saccharide concentration for fermentation to the appropriate level.
The increase in saccharide concentration and acidity titratable as lactic acid in the whole chicken broth is shown in Table 2, and the changes in pH are shown in Table 3.
TABLE 2
Concentration of added saccharide
Increased acidity
0%
0.09
0.5%
0.38
1.0%
0.56
Bacteria used: Lactobacillus gasseri (JCM1131)
Incubation temperature: 37° C.
Saccharide: Sucrose
Acidity: Titratable (%) of Lactic Acid
TABLE 3
pH
Prior to
After
Concentration of added saccharide
Fermentation
Fermentation
0%
6.27
6.00
0.5%
6.27
5.07
1.0%
6.14
4.73
Bacteria used: Lactobacillus gasseri (JCM1131)
Incubation temperature: 37° C.
Saccharide: Sucrose
Lactic acid content and pH at the end of fermentation can be controlled by adjusting the lactic acid fermentation time. Besides the liquid culture of the aforementioned species of lactic acid bacteria, frozen or freeze-dried starters available commercially for the production of fermented milk, cheese, fermented sausage, etc. may be used.
Normally, lactic acid fermentation can take place under temperature ranges from 10–40° C., preferably at the optimum growth temperature for the starter. Generally, the time period for lactic acid fermentation is 12–48 hours. However, the growth phase becomes stationary after approximately 24 hours. Therefore, from an economical standpoint, fermentation time may be set between 12–24 hours.
The time needed for growth also varies according to the bacterial strain. The optimal time may also depend on the conditions of the materials, or preference in acidity, aroma, flavor, etc. The amount of lactic acid can be controlled by adjusting the concentration of substrate for fermentation.
Lactic acid bacteria may be killed by heat (e.g., Pasteurization) or removed by filtration. Of course, other sterilization techniques may be employed. Upon the completion of fermentation, to halt lactic acid generation, or if a clear liquid product is needed, bacteria and turbidity may be removed through centrifugation or filtration, etc. The lactic acid fermentation product produced through the aforementioned procedures is used as a starting material for alcoholic fermentation.
Alcohol Fermentation
For alcoholic fermentation, various yeast strains generally used for sake, shochu, and wine may be chosen. Specifically, these include Saccharomyces cerevisiae, Saccharomyces capensis, Saccharomyces chevalieri, Saccharomyces italicus, Saccharomyces bayanus, Saccharomyces heterogenius, Saccharomvces uvarum, etc.
The inoculum quantity of yeast that is added should be within the range of 0.01–0.1% for dried yeast and 0.5–5% for liquid cultures. However, the amount is not necessarily limited within this range. Depending on the materials used or the targeted fermented concentrated cultures beverage, the amount can be used in higher or lower concentration.
Alcohol concentration and formation of aroma components in the fermented final product can be controlled by adjusting the saccharide concentration during yeast fermentation. The relationship between the initial saccharide concentration in the chicken broth/stock and the generated alcohol concentration is shown in FIG. 2 . The results of Gas Chromatography-Mass Spectroscopy (GC-MS) analysis of the initial saccharide concentration and aroma component formation is shown in FIG. 3 .
These results confirm that more ethanol and abundant aroma components are generated when the initial saccharide concentration is high.
The results of GC-MS analysis of aroma components over an elapsed period of time with an initial saccharide concentration of 30% are shown in FIG. 4 .
These results confirm that aroma components are formed as time passes. It was also confirmed that this aroma component apparently included the same components detected in wine and sake. These components and the results of GC-MS analysis are shown in FIG. 5 .
The alcohol formation time and aroma component formation in the fermented final product can be controlled by adjusting the fermentation temperature during alcohol fermentation. The relationship between the fermentation temperature and alcohol formation time is shown in FIG. 6 , and that between fermentation temperature and aroma component formation is shown in FIG. 7 .
Normally, the optimum growth temperature for yeast is 25° C. For the formation of aroma components, the lowest possible temperature within the range of yeast growth temperatures is generally deemed to be preferred. The fermented product created through the above procedures is made clear through centrifugation, filtration, etc. If aging is needed, the fermented product can be put in a barrel or the like and aged at a low temperature, thereby enhancing the delicate flavor, the balanced taste, mellowness, and smoothness. Then, the product is packed and distributed. In particular, a preferred unit package is a glass bottle or aluminum can containing 0.3–0.5 liters. It is also possible to pack the beverage in a keg or multi-portion package, such as a 0.75–1.5 liter bottle. The beverage generally contains between about 0% to about 20% alcohol, and preferably between about 1.5–12.5% alcohol. Low alcohol levels may require a post-fermentation process to reduce alcohol, while high alcohol levels may require adjustments to the saccharide levels in the fermentation broth during the course of fermentation or fortification. The fermentation product may also be distilled.
As shown with the above examples, flavor, aroma, color and/or alcohol content can be adjusted as desired. They can be changed in various ways depending on personal preferences. These products contain peptides from the meat and/or bone extract including anserine and carnosine, which are believed to mitigate stress, act as antioxidants against harmful free radicals, and provide anti-cancer and anti-aging benefits. In addition to producing a mellow flavor, lactic acid fermentation lowers the pH level, thereby controlling the proliferation of contaminating bacteria as well as making the production process safe and facilitating commercial production.
EXAMPLE
6 kg whole chicken, 14 L water, 250 g carrots, 700 g onions, 300 g leek, 250 g celery, 1 bay leaf, 6 black peppercorns, and 20 g of tarragon were used to produce as a base to produce a beverage. The whole chicken was separated into leg meat and breast meat, its skin and bones removed, and it was steamed with high heat, then rinsed clean with cold water. The whole chicken was then put into a stock pot with water and brought to a boil. After scum and fat were removed, aromatic vegetables and spices were added, and the mixture was cooked for 2.5 hours at 95° C. Next, herbs were added for aroma and the mixture was cooked for one more hour. The chicken broth was made from the resulting filtrate.
The chicken broth was boiled with 0.01 kg sucrose per 1 kg of chicken broth for 30 minutes to kill bacteria. Following this sterilization process, the broth was cooled to 37° C. and inoculated with 1% of fresh culture of Lactobacillus gasseri. After the inoculation, the broth underwent lactic acid fermentation for 24 hours after which 0.2 kg sucrose was added to the solution, and boiled for 30 minutes for disinfection purposes.
After disinfection, the liquid was cooled to 15° C. and inoculated with previously cultivated wine yeast, Saccharomyces cerevisiae. Following the inoculation, the liquid underwent alcohol fermentation for 2 weeks at 15° C. Afterwards, the liquid was sterilized for 20 minutes at 70° C. and centrifuged at 4,000×g for 20 minutes, in order to obtain a clear, fermented beverage.
An experiment was conducted to test the effects of adding aromatic vegetables and herbs. Chicken broth was extracted using the same methods as above, and, for comparison, was also extracted without having added any vegetables or herbs. Both types of broth underwent the same fermentation procedures, and the GC-MS analytical results are shown in FIG. 8 .
These findings clearly confirmed the abundance of aroma components in large quantities in the fermented alcoholic beverages obtained from the fermented chicken broth with the addition of extract from aromatic vegetables and herbs.
While the above detailed description has shown, described and pointed out the fundamental novel features of the invention as applied to various embodiments, it will be understood that various omissions and substitutions and changes in the form and details of the system and method illustrated may be made by those skilled in the art, without departing from the spirit of the invention. Consequently, the full scope of the invention should be ascertained by the appended claims. | A method for producing a beverage, comprising the steps of providing an aqueous animal extract, fermenting said aqueous animal extract with lactic acid bacteria, and fermenting the product of lactic acid bacteria fermentation with yeast fermentation, to produce an alcoholic beverage. Additional ingredients may be added for flavor or to enhance the fermentation process. In particular, a saccharide source may be added to control resulting alcohol content. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a memory cell and a semiconductor memory device having thereof memory cell, and particularly to a single memory cell configured by a transfer transistor, a load transistor, and a drive transistor.
2. Description of the Related Art
An SRAM (Static Random Access Memory) is one of semiconductor memory devices. Here, an example of a circuit of an SRAM is shown in FIG. 5 . In an SRAM 100 shown in FIG. 5 , a plurality of memory cells F 1 to Fn are connected to a bit line pair configured by bit lines DT and DB. The memory cells F 1 to Fn each include drive transistors 110 , 111 , drive transistors 120 , 121 , and transfer transistors 130 , 131 . Data are stored in storage nodes of connection points at each of which the drive transistor and the drive transistor are connected to each other, and read out by transfer of the data to the bit lines DT and DB via the transfer transistors.
Here, a timing chart of operations for reading data stored in a memory cell F 1 is shown in FIG. 6 . In an example shown in FIG. 6 , storage nodes D 01 , D 0 n −1, D 0 n at the side of the bit line DT each are held at low level (for example, hold a ground voltage) while storage nodes E 01 , E 0 n −1, E 0 n at the side of the bit line DB each are held at a high level (for example, hold a power supply voltage), in the memory cells F 1 , Fn−1, Fn, respectively.
In the timing chart shown in FIG. 6 , the level of a word line WL 1 for selecting the memory cell F 1 becomes high in a period from timing T 11 to timing T 12 . Meanwhile, even in the period from timing T 11 to timing T 12 , word lines WLn−1 and WLn selecting memory cells Fn−1 and Fn are held at low level. Therefore, in the period from T 11 to T 12 , data is read from the storage nodes D 01 and E 01 of the memory cell F 1 to the bit lines DT and DB. As a result of reading the data, the bit line DT changes to low level, but the bit line DB is held at high level.
However, in the SRAM 100 , the storage nodes E 0 n −1 and E 0 n at the side of the bit line DB of the memory cells Fn−1 and Fn are held at low level, whereas the bit line DB changes to high level after the reading of data. Thus, a potential difference occurs between the source and drain of the respective transfer transistors 131 of the memory cells Fn−1 and Fn. Here, since the word lines WLn−1 and WLn are at low level, the transfer transistor 131 s are in a nonconductive state, but a potential difference between the bit line DB and the storage node of each of the memory cells Fn−1 and Fn lets leak currents Ileak flow between the source and the drain of the transfer transistor 131 of each of the memory cells Fn−1 and Fn. Further, since there is substantially no potential difference between the bit line DB and the storage node E 01 on the side of the bit line DB, the transfer transistor 131 is conductive, but is in a state equivalent to a nonconductive state. Thus, the bit line DB has a high impedance. Therefore, in the SRAM 100 , the potential of the bit line DB which has to be held at high level is reduced. In the timing chart shown in FIG. 6 as well, the potential of the bit line DB is reduced in the period of the timing T 11 to T 12 .
In recent semiconductor memory devices, an operating supply voltage is set low so as to reduce power consumption. Therefore, a potential difference between high level and low level in the bit lines DT and DB is small. Such a semiconductor memory device has a problem that, when a potential reduces in a bit line, a potential difference from another bit line cannot be detected correctly in a sense amplifier to which the bit lines are connected, so that a data read failure occurs.
Therefore, Japanese Patent Application Publication No. 2004-288306 (JP-A2004-288306) discloses a technique to prevent a potential reduction in a bit line from causing a data read failure. In JP-A2004-288306, the semiconductor memory device includes a leak detection line, a leak generation circuit, and a signal correction circuit in addition to memory cells and bit lines. The leak detection line is disposed in parallel to the bit lines. The leak generation circuit supplies a leak current to the leak detection line. The signal correction circuit detects a potential state of the leak detection line, and corrects a signal transferred via the bit line. That is, in JP-A2004-288306, the potential level of a signal transferred via the bit line is corrected based on the potential of the leak detection line having a potential reduction by a leak current, and on the potential of the bit line. In JP-A2004-288306, a data read failure is thus avoided even when the potential is reduced by a leak current in a bit line.
The following analyses are given by the present invention. In JP-A2004-288306, since the leak detection line, the leak generation circuit, and the signal correction circuit are added to the memory cells and bit lines, the circuit size is inevitably increased. Further, the leak generation circuit and memory cell are formed by use of different transistors, respectively. Therefore, it is likely that variation in transistors in manufacturing processes causes variation between a leak current amount generated in the leak generation circuit, and a leak current amount generated in the memory cell. That is, in JP-A2004-288306, the leak current amount of the memory cell may not necessarily correspond to the leak current amount of the leak generation circuit in some cases, which causes a problem of deteriorating a data read accuracy.
SUMMARY
An aspect of the present invention is provision of a semiconductor memory device in which a single memory cell is formed of a transfer transistor, a load transistor and a drive transistor. The semiconductor memory device includes a first transfer transistor which is connected to a connection point of the load transistor and the drive transistor; a second transfer transistor which is connected between the first transfer transistor and a bit line; and a compensation transistor which is connected between a constant voltage node and a connection point of the first and second transfer transistors, and which is switched to a conductive state exclusively from at least one of the first and second transfer transistors.
Another aspect of the present invention is provision of a semiconductor memory device in which a single memory cell is formed of a transfer transistor, a load transistor, and a drive transistor, a plurality of the memory cells are connected to a single bit line, and a read operation of data or a write operation thereof is performed on a single memory cell selected from among the plurality of memory cells. The memory cell includes a first transfer transistor which is connected to a connection point of the load transistor and the drive transistor; a second transfer transistor which is connected between the first transfer transistor and a bit line; and a compensation transistor which is connected between a constant voltage node and a connection point of the first and second transfer transistors, and which causes a voltage supplied to the constant voltage node to be supplied to a connection point of the first and second transfer transistor, while the read operation or the write operation is performed on other memory cell.
In the semiconductor memory device according to the present invention, the compensation transistor is switched to the conductive state exclusively from the first and second transfer transistors. Therefore, even when a potential difference occurs between a bit line and a storage node of a memory cell which is not selected, a voltage from the constant voltage node is supplied to the connection point of the first and second transfer transistors by the compensation transistor, so that no potential difference occurs between the source and the drain of the second transfer transistor. As a result, a leak current does not flow between the source and the drain of the second transfer transistor of the memory cell which is not selected. Hence, the semiconductor memory device of the present invention is capable of preventing a leak current from flowing into a memory cell via a bit line.
The semiconductor memory device in accordance with the present invention is capable of preventing a leak current from causing a data read failure.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages and the features of the present invention will be more apparent from the following description of certain preferred modes taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a circuit diagram of an SRAM according to Embodiment 1;
FIG. 2 is a timing chart of a read operation in the SRAM according to Embodiment 1;
FIG. 3 is a circuit diagram of an SRAM according to Embodiment 2;
FIG. 4 is a timing chart showing a relationship among control signals according to Embodiment 2;
FIG. 5 is a related art of a SRAM; and
FIG. 6 is a timing chart, made by the inventors, for explaining a problem in read operation of an SRAM.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be now described herein with reference to illustrative embodiments. Those skilled in the art will recognize that many alternative embodiments can be accomplished using the teachings of the present invention and that the invention is not limited to the embodiments illustrated for explanatory purposes.
Embodiment 1
This embodiment of the present invention is described below with reference to the accompanying drawings. In this embodiment, an SRAM is described as an example of a semiconductor memory device. In FIG. 1 , a circuit diagram of an SRAM 1 is shown. As shown in FIG. 1 , in the SRAM 1 , a plurality of memory cells are connected to a bit line pair composed of bit lines DT and DB. In this embodiment, memory cells C 1 to Cn are connected to a bit line pair. In the SRAM 1 , a potential difference between the bit lines DT and DB is detected by a sense amplifier (not shown) so that data stored in the memory cells is read.
The memory cells C 1 to Cn have the same configuration, so that memory cell C 1 is taken as an example for describing a memory cell. The memory cell C 1 includes drive transistors 10 , 11 ; drive transistors 20 , 21 ; first transfer transistors 30 , 31 ; and second transfer transistors 40 , 41 . In this embodiment, the drive transistors 10 , 11 , the first transfer transistors 30 , 31 and the second transfer transistors 40 , 41 are composed of NMOS transistors; and the second transfer transistors 40 , 41 and compensation transistors 50 , 51 are composed of PMOS transistors.
The drive transistor 10 and the load transistor 20 are connected in series between a power supply node VDD to supply a supply voltage and a ground node VSS to supply a ground voltage. Further, a gate of the drive transistor 10 and a gate of the load transistor 20 are connected in common. A connection point of a drain of the drive transistor 10 and a drain of the load transistor 20 forms a first storage node A 01 . The drive transistor 11 and the load transistor 21 are connected in series between the power supply node VDD and the ground node VSS. Further, a gate of the drive transistor 11 and a gate of the load transistor 21 are connected in common. A connection point of a drain of the drive transistor 11 and a drain of the load transistor 21 forms a second storage node B 01 . In addition, the first storage node A 01 is connected to the gate of the drive transistor 11 and the load transistor 21 . The second storage node B 01 is connected to the gate of the drive transistor 10 and the load transistor 20 .
The first transfer transistor 30 is connected to the first storage node A 01 . The second transfer transistor 40 is connected between the first transfer transistor 30 and the bit line DT. That is, the first transfer transistor 30 and the second transfer transistor 40 are connected in series between the first storage node A 01 and the bit line DT. A connection point of the first transfer transistor 30 and the second transfer transistor 40 is hereinafter referred to as a first compensation node A 11 . A gate of the first transfer transistor 30 and a gate of the second transfer transistor 40 are both connected to the word line WL 1 . The word line WL 1 transfers a control signal controlling a conductive state of the first and second transfer transistors 30 , 40 and the compensation transistor 50 . The SRAM 1 selects a memory cell to perform data writing and data reading according to this control signal. The compensation transistor 50 is connected between the first compensation node A 11 and a constant voltage node. A gate of the compensation transistor 50 is connected to the word line WL 1 . In the constant voltage node, the same voltage is supplied as a voltage in a bit line holding a logical value at high level. Therefore, in this embodiment, the power supply node VDD is used as the constant voltage node.
The first transfer transistor 31 is connected to the second storage node B 01 . The second transfer transistor 41 is connected between the first transfer transistor 31 and the bit line DB. That is, the first transfer transistor 31 and the second transfer transistor 41 are connected in series between the second storage node B 01 and the bit line DB. A connection point of the first transfer transistor 31 and the second transfer transistor 41 is hereinafter referred to as a second compensation node B 11 . A gate of the first transfer transistor 31 and a gate of the second transfer transistor 41 are each connected to the word line WL 1 . The compensation transistor 51 is connected between the second compensation node B 11 and a constant voltage node (for example, a power supply node VDD). A gate of the compensation transistor 51 is connected to the word line WL 1 .
Here, in the memory cell Cn−1, a node corresponding to the first storage node A 01 is referred to as a first storage node A 0 n −1; a node corresponding to the first compensation node A 11 is referred to as a first compensation node A 1 n −1; a node corresponding to the second storage node B 01 is referred to as a second storage node B 0 n −1; and a node corresponding to the second compensation node B 11 is referred to as a second compensation node B 1 n −1. In the memory cell Cn, a node corresponding to the first storage node A 01 is referred to as a first storage node A 0 n ; a node corresponding to the first compensation node A 11 is referred to as a first compensation node A 1 n ; a node corresponding to the second storage node B 01 is referred to as a second storage node B 0 n ; and a node corresponding to the second compensation node B 11 is referred to as a second compensation node B 1 n . Further, a word line of the memory cell Cn−1 is referred to as a word line WLn−1, and a word line of the memory cell Cn is referred to as a word line WLn.
Next, read operation of data of the SRAM of this embodiment is described. Here, a description is given of a case where multiple memory cells holding different logical values are connected to a single bit line pair, and where data is read from one of the memory cells. As logical values which memory cells hold, there are a first logical value and a second logical value. The first logical value shows that the first memory node is held at low level (for example, the same voltage as a ground voltage, and denoted by “L” in FIG. 1 ), and that the second memory node is held at high level (for example, the same voltage as a supply voltage, and denoted by “H” in FIG. 1 ). The second logical value shows that the first storage node is held at high level, and that the second storage node is held at low level. In the example shown in FIG. 1 , the memory cell C 1 holds the first logical value, and the memory cells Cn−1 and Cn have the second logical value.
In FIG. 2 , a timing chart of a read operation in the SRAM 1 is shown. FIG. 2 shows a timing chart in a case where data is read from the memory cell C 1 . The read operation is performed in the period of time ranging from timing T 1 to timing T 2 . In this period of time, the word line WL 1 is set at high level. In addition, the SRAM 1 performs a precharge operation in a period in which an access to a memory cell is not performed, and the bit line pair is set under the precharge voltage. The precharge voltage of this embodiment has the same voltage value as the supply voltage.
At timing T 1 , when the level of the word line WL 1 changes from low to high, the first transfer transistors 30 , 31 and the second transfer transistors 40 , 41 become conductive. Meanwhile, the compensation transistors 50 , 51 become nonconductive. This causes the bit line DT and the first storage node A 01 to be electrically connected to each other, and the bit line DT is set at low level based on data held in the first storage node A 01 (here, low level). Meanwhile, the bit line DB and the second storage node B 01 are also set to be electrically connected, but since data held in the second storage node B 01 is set at high level, the bit line DB is held at high level. At this time, since there is substantially no potential difference between the second storage node B 01 and the bit line DB, the first transfer transistor 31 and the second transfer transistor 41 are conductive, but are in a state equivalent to a nonconductive state. Thus, the bit line DB is turned into a high impedance state.
In contrast, since the word lines WLn−1 and WLn is held at low level, in the memory cells Cn−1 and Cn, the first transfer transistors 30 , 31 and the second transfer transistors 40 , 41 are in a nonconductive state, and the compensation transistors 50 , 51 are in a conductive state. Accordingly, in the memory cell Cn−1, the bit line DT and the first storage node A 0 n −1 are in a nonconductive state, and the bit line DB and the second storage node B 0 n −1 are in a nonconductive state. Further, a supply voltage is supplied to the first compensation node A 1 n −1 and the second compensation node B 1 n −1. Here, the memory cell Cn−1 and the second storage node B 0 n −1 are held at low level, while the bit line DB is held at high level.
Therefore, a potential difference occurs between the source and the drain of the first transfer transistor 31 , so that a leak current flows from the second compensation node B 1 n −1 into the second storage node B 0 n −1 via the first transfer transistor 31 . Meanwhile, a supply voltage is supplied to the second compensation node B 1 n −1 via the compensation transistor 51 , so that no potential difference occurs between the source and the drain of the second transfer transistor 41 and that a leak current does not flow between the source and the drain of the second transfer transistor 41 . That is, even when the bit line DB has a high impedance, a leak current flowing from the bit line DB into the memory cell Cn−1 does not occur, so that the potential of the bit line DB is not reduced.
In the memory cell Cn, the same logical value as in the memory cell Cn−1 is held, and a control signal for low level (a potential of the word line WLn) is supplied to the memory cell Cn. Therefore, also in the memory cell Cn, a leak current flowing from the bit line DB into the memory cell Cn does not occurs as in the memory cell Cn−1.
As described above, the SRAM 1 of this embodiment controls a compensation transistor so that the compensation transistor can be conductive exclusively from first and second transfer transistors in a data reading period. That is, when the first and second transfer transistors are in a nonconductive state, the compensation transistor causes a compensation node to have the same voltage value as a constant voltage node (for example, a voltage value at a time when a bit line is held at high level). Thus, there is substantially no potential difference between the source and the drain of the second transistor connected to the bit line held at high level. Accordingly, even when a storage node held at low level is connected to a bit line held in a high impedance state and at high level, via a transfer transistor held in a nonconductive state, it is possible to prevent a leak current from flowing between the source and the drain of the second transfer transistor. Specifically, since electric charges are not taken out from the bit line having a high impedance in the SRAM 1 , the potential of the bit line having a high impedance is not reduced.
Further, in the SRAM 1 of this embodiment, a compensation transistor of a memory cell, which is not a target of the read operation, is set to be in a conductive state, while a read operation of data is being performed in the target memory cell. Thus, even when a potential difference occurs between a storage node and a bit line of the memory cell which is not the target of the read operation, it is possible to prevent a leak current flowing between the source and the drain of the second transfer transistor. Accordingly, it is possible to prevent a leak current from flowing from a bit line having a high impedance into a memory cell not being a target of a read operation, and to prevent a potential reduction of the bit line. In other words, the SRAM 1 of this embodiment exerts a more remarkable effect, when multiple memory cells are connected to a single bit line.
As described above, stabilization of a voltage value of a bit line enables a potential difference between multiple bit lines to be stabilized and secured in the SRAM 1 . Therefore, even when a low operating supply voltage is used in the SRAM 1 , a data read failure can be prevented. Further, in a semiconductor memory device described in JP-A2004-288306, a leak generation circuit and a signal correction circuit are added, but the SRAM 1 of this embodiment requires only a pair of a compensation transistor and another pair of transfer transistors. Accordingly, it is also possible to check increase in the size of a circuit.
Incidentally, when a first transfer transistor and a compensation transistor both become conductive at the same time, there is a risk that data in a storage node is destroyed. Hence, in order to prevent the data from being destroyed, it is preferable that the compensation transistor be controlled so as to be conductive exclusively from the first transfer transistor.
Embodiment 2
A circuit diagram of an SRAM 2 of this embodiment is shown in FIG. 3 . As shown in FIG. 3 , the SRAM 2 includes control signal lines CNT 1 to CNTn which are different from the word lines WL 1 to WLn. The control signal lines CNT 1 to CNTn are connected to each gate of the compensation transistors 50 , 51 of the memory cells C 1 to Cn. In this embodiment, with control signals transferred via the word lines WL 1 to WLn, conductivity states of the first transfer transistors 30 , 31 and the second transfer transistors 40 , 41 are controlled, and with control signals transferred via the control signal lines CNT 1 to CNTn, conductivity states of the compensation transistors 50 , 51 are controlled.
Here, a relationship between the two kinds of control signals in the SRAM 2 is shown in FIG. 4 . Incidentally, in FIG. 4 , only control signals given to the memory cell C 1 are shown as an example. As shown in FIG. 4 , a control signal of the word line WL 1 is set at high level in a data reading period (timing T 4 to T 5 ). In contrast, a control signal of the control signal line CNT 1 is set at high level for a longer period (timing T 3 to T 6 ) than the data reading period. That is, in the SRAM 2 , the compensation transistor is in a nonconductive state for a longer period than the first and second transfer transistors are in a conductive state.
There is no problem, if the compensation transistor is in a conductive state exclusively from the first and second transfer transistors in a data reading period. However, the conductivity type of the first and second transfer transistors differs from that of the compensation transistor. Therefore, the threshold values of the first and second transistors and of the compensation transistor are different. In such a case, if the first and second transistors and the compensation transistor are controlled according to the same control signal, the first transfer transistor and the compensation transistor become conductive at the same time in some cases. In such a state, there is a risk that a supply voltage is applied to a storage node via the first transfer transistor so that data at low level held in the storage node is destroyed.
In contrast, in the SPAM 2 , the transfer transistors are set to be conductive after the compensation transistor is changed to be nonconductive. This can prevent a supply voltage from being applied to a storage node held at low level in the SRAM 2 . Further, in the SRAM 2 , the compensation transistor is set to be in a conductive state after reading of data from the storage node is completed. Thus, when the transfer transistors are conductive, the compensation transistor never becomes conductive.
According to the above description, the SRAM 2 of Embodiment 2 has a higher capability in preventing data from being destroyed than the SRAM 1 of Embodiment 1, and is capable of enhancing the reliability of data. Incidentally, it is preferable that a difference between a data reading period and a period when the compensation transistor stays in a nonconductive state, be set small so as to prevent increase in a leak current.
It is to be understood that the present invention is not limited to the above-described embodiments, and various changes may be made therein without departing from the spirit of the present invention. | Conventional semiconductor memory devices have a problem of a data read failure caused by a leak current. To address this problem, a semiconductor memory device of the present invention including memory cells each formed of a transfer transistor, a load transistor and a drive transistor. Each of the memory cells includes: a first transfer transistor connected to a connection point of the drive transistor and the load transistor; a second transfer transistor connected between the first transfer transistor and a bit line DB; and a compensation transistor connected between a constant voltage node and a connection point of the first transfer transistor and the second transfer transistor. The compensation transistor is switched to a conductive state exclusively from at least one of the first transfer transistor and the second transfer transistor. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field and Industrial Applicability of the Invention
[0002] The present invention relates to extended binder compositions which reduce the cost of the binder composition while simultaneously maintaining acceptable strength and binding performance and/or improving one or more binder parameters. The binder compositions of the present invention are particularly useful in the glass fiber industry in a wide range of products, for example, range insulation, duct board, pipe, ceiling board and commercial and residential insulation.
[0003] 2. Background of the Invention
[0004] Glass and other organic and inorganic fibers come in various forms and can be used for a variety of applications. During the preparation and use of glass fiber products, whether produced by blowing or continuous filament manufacturing processes, the included glass fibers are easily weakened by the self-abrasive effect caused by the relative motion of adjacent fibers at points of contact. This self-abrasive effect produces surface defects in the glass fiber filaments that tend to reduce the overall mechanical strength of the product. Furthermore, glass fiber products, particularly those products destined for use as building insulation and sound attenuation, are often shipped in a compressed form in order to lower shipping costs. However, when the compressed glass fiber products are utilized at a job site, it is imperative that the glass fiber product recover a substantial amount of its precompression thickness to improve its insulation and sound attenuation properties.
[0005] Manufacture of glass fiber thermal insulation typically utilizes a continuous process in which raw batch materials are fed into a melting furnace to produce molten glass. The molten glass is then ejected from the furnace through a number of trays or bushings having small openings to form glass filaments. The initial glass filaments are then typically pulled and attenuated to produce the final fiber dimensions and cooled to form the glass fibers. The cooled fibers are then collected on a conveyor belt or other receiving surface in a forming chamber to form a mat.
[0006] The glass fibers are typically bonded together to form an integral batt or layer structure by applying a binder composition to the fibers as they are being collected on the conveyor belt. The collection of binder-coated fibers is then cured, typically in a curing oven, to evaporate remaining solvent and set the binder composition. The fibers in the resulting fiber product thus remain partially coated with a thin layer of the binder material and may exhibit greater accumulation or agglomeration at junctions formed where adjacent fibers are in contact or the spacing between them is very small. As a result of the improved strength and resiliency, the resulting fiber products exhibit higher recovery and stiffness than fiber products that do not incorporate a binder.
[0007] The residual heat from the glass fibers and the flow of air through the fibrous mat during the forming operation are generally sufficient to volatilize a majority of the water from the binder, thereby leaving the remaining components of the binder on the fibers as a viscous or semi-viscous high-solids liquid. The coated fibrous mat, which is formed in a somewhat compressed state due to the tremendous flow of air typically passing through the mat in the forming chamber, is then transferred out of the forming chamber to a transfer zone. Once in the transfer zone, the mat tends to expand vertically due to the resiliency of the glass fibers. This vertical expansion is extremely important to the successful manufacture of commercially acceptable fibrous glass thermal or acoustical insulation products.
[0008] Fiberglass insulation products prepared in this manner can be provided in various forms including batt, board (a heated and compressed batt) and molding media (an alternative form of heated and compressed batt) for use in different applications. Most fiberglass batt insulation will have a density of less than 1 lb/ft 3 (16 kg/m 3 ) with about 4-5 wt % being binder. Fiberglass board typically has a density of between 1 and 10 lbs/ft 3 (16 and 160 kg/m 3 ) with about 7-12 wt % binder while fiberglass molding media will more typically have a density between 10 and 20 lbs/ft 3 (160 and 320 kg/m 3 ) with at least about 12 wt % binder. The glass fibers incorporated in these products typically have diameters from about 2 to about 9 microns and may range in length from about 0.25 inch (0.64 cm) to the extremely long fibers used in forming “continuous” filament products.
[0009] As the batt of binder-coated fibers emerges from the forming chamber, it will tend to expand as a result of the resiliency of the glass fibers. The expanded batt is then typically conveyed to and through a curing oven in which heated air is passed through the insulation product to cure the binder. In addition to curing the binder, within the curing oven the insulation product may be compressed with flights or rollers to produce the desired dimensions and surface finish on the resulting blanket, batt or board product. In the case of molding media, after partially curing the binder, the fiber product is fed into a molding press that will be used to produce the final product shape and to complete the curing process. Typically, for fiber products incorporating phenolic binders the curing ovens were operated at a temperature from about 200° C. to about 325° C. and preferably from about 250° C. to about 300° C. with curing processes taking between about 30 seconds and 3 minutes.
[0010] Generally, the goal is to identify a binder system that is relatively inexpensive, is water soluble (or at least water dispersible), and can be easily applied and readily cured. The binder composition should also be sufficiently stable to permit mixing and application at temperatures ordinarily encountered in fiber product manufacturing plants. Further, the cured binder product should result in a strong bond with sufficient elasticity and thickness recovery to permit reasonable deformation and recovery of the resulting fiber product. Thickness recovery is especially important in insulation applications for both conserving storage space and providing the maximum insulating value after installation.
[0011] Phenol-formaldehyde binders are generally characterized by relatively low viscosity when uncured and the formation of a rigid thermoset polymeric matrix with the fibers when cured. A low uncured viscosity simplifies binder application and allows the binder-coated batt to expand more easily when the forming chamber compression is removed. Similarly, the rigid matrix formed by curing the binder allows a finished fiber product to be compressed for packaging and shipping and then recover to substantially its full original dimension when unpacked for installation.
[0012] Phenol/formaldehyde binders utilized in the some prior art applications have been highly alkaline resole (also referred to as resol or A-stage) type that are relatively inexpensive and are water soluble. These binders are typically applied to the fibers as an aqueous solution shortly after the fibers are formed and then cured at elevated temperatures. The curing conditions are selected both to evaporate any remaining solvent and cure the binder to a thermoset state. The fibers in the resulting product tend to be partially coated with a thin layer of the thermoset resin and exhibit accumulations of the binder composition at points where fibers touch or are positioned closely adjacent to each other.
[0013] Typically, phenol-formaldehyde resole binders used in manufactured boards and fiber insulation products release formaldehyde during curing process. Various techniques have been used to reduce formaldehyde emission from phenol/formaldehyde resins during curing including various formaldehyde scavengers that may be added to the resin during or after its preparation. Urea is a commonly used formaldehyde scavenger that is effective both during and subsequent to the manufacture of the fiber product. Urea is typically added directly to the phenol/formaldehyde resin, to produce a urea-extended phenol/formaldehyde resole resin (also referred to as “premix” or “pre-react”). Further, urea, being less expensive than the alkaline phenol/formaldehyde resoles commonly used as binders, can provide substantial cost savings for fiber product manufacturers while simultaneously reducing formaldehyde emissions.
[0014] Alternative polymeric binder systems for fibrous glass products having low molecular weight, low viscosity binders designed to allow for maximum vertical expansion of the batt as it exits the forming stage also tend to form a non-rigid plastic matrix when cured, thus reducing the vertical height recovery properties of the final product after compression. Conversely, higher viscosity binders which tend to cure to form a rigid matrix interfere with the vertical expansion of the coated, but uncured, fiber batt as it exits the forming stage.
[0015] These problems were addressed with a variety of non-phenol/formaldehyde binders exhibiting low uncured viscosity and structural rigidity when cured. These binders are often referred to as formaldehyde-free, while it is accurate that the binder is free of formaldehyde when mixed, the cured fiberglass product does include measurable amounts of formaldehyde. One such binder composition was disclosed in U.S. Pat. No. 5,318,990, which is herein incorporated, in its entirety, by reference, and utilized a polycarboxy polymer, a monomeric trihydric alcohol and a catalyst comprising an alkali metal salt of a phosphorous containing organic acid. Other binder compositions have also been developed to provide reduced emissions during the coating and curing processes utilizing compounds such as polyacrylic acid as disclosed in U.S. Pat. Nos. 5,670,585 and 5,538,761, which are herein incorporated, in their entirety, by reference.
[0016] Another polyacrylic binder composition is disclosed in U.S. Pat. No. 5,661,213, which teaches an aqueous composition comprising a polyacid, a polyol and a phosphorous-containing accelerator, wherein the ratio of the number of equivalents of the polyacid to the number of equivalents of the polyol is from about 100:1 to about 1:3.
[0017] As disclosed in U.S. Pat. No. 6,399,694, another alternative to the phenol/formaldehyde binders utilizes polyacrylic glycol (PAG) as a binder. Although more expensive, PAG binders are relatively odorless, more uniformly coat each fiber and have a generally white or light color. Indeed, fiber board products utilizing PAG binders can be provided with decorative surfaces suitable for display.
[0018] There continues to exist a need for a method of inhibiting and reducing both the corrosion and volatile organic emission issues associated with these prior art binders. A previous binder composition formulated to address the corrosion problem is disclosed in Chen et al.'s U.S. Pat. No. 6,274,661, which disclosed the addition of corrosion inhibitors including, for example, tin oxalate and thiourea, and which is incorporated herein, in its entirety, by reference.
[0019] Traditional phenol/formaldehyde resole binders continue to be very attractive as a result of their significantly lower cost. In order to make the newer binder systems more economically competitive, therefore, the search continues for extenders that will provide less expensive binder compositions while at the same time enhancing or at least substantially preserving the desirable properties of the underlying binder systems.
SUMMARY OF THE INVENTION
[0020] The underlying polyacrylic acid based binder system addressed by the present invention comprises a low molecular weight polyacrylic acid (typically hypophosphite or sulfite terminated), a crosslinking agent (such as triethanolamine or glycerol) and, optionally, a catalytic cure accelerator. As noted above, these polyacrylic acid based binder compositions are more expensive than conventional phenol/formaldehyde based binder compositions. In order to reduce the cost of the binder composition, the present invention incorporates one or more water soluble materials, such as lignin, low molecular weight starch or soybean protein, into the binder composition.
[0021] Being less expensive than the basic binder system components, each of the extender additives will reduce the overall cost of polyacrylic acid composition. In addition to reducing the cost, the extenders may be selected to alter one or more characteristics of the basic binder composition, such as the binder wetting behavior, the compatibility between oil emulsions and the binder composition, dust generation and wash water flow properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a graph comparing the cure performance of a first embodiment of the present invention using a lignin extender with a comparative binder.
[0023] [0023]FIG. 2 is a graph reflecting the comparative rheologic performance of the lignin extended binder compositions and standard non-extended binder from FIG. 1.
[0024] [0024]FIG. 3 is a graph comparing the cure performance of a first embodiment of the present invention using a starch extender with a comparative binder.
[0025] [0025]FIG. 4 is a graph reflecting the comparative rheologic performance of the starch extended binder compositions and standard non-extended binder from FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The basic binder according to the present invention preferably comprises an aqueous solution of a polycarboxy polymer, a monomeric trihydric alcohol, a catalyst and a pH adjuster. The viscosity of the binder composition should be relatively low, due in part to the use of the monomeric trihydric alcohol crosslinking agent, to provide acceptable vertical expansion of the fibrous glass mat as it exits the forming chamber. Ideally, the binder composition should allow for a degree of vertical expansion generally similar to that exhibited by the traditional phenol-formaldehyde binders. Although the use of monomeric reactants in low viscosity curable resins has been associated with degraded strength of the cured thermoset structure, the addition of a cure catalyst allows the basic binder composition of the present invention to form an acceptably rigid thermoset. An example of such a binder composition is disclosed in U.S. Pat. No. 5,318,990.
[0027] The polycarboxy polymer of the present invention comprises an organic polymer or oligomer containing more than one pendant carboxy group. The polycarboxy polymer may be a homopolymer or copolymer prepared from unsaturated carboxylic acids including, but not limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α,β-methyleneglutaric acid, and the like. Alternatively, the polycarboxy polymer may be prepared from unsaturated anhydrides including, but not necessarily limited to, maleic anhydride, itaconic anhydride, acrylic anhydride, methacrylic anhydride, and the like, as well as mixtures thereof. The polymerization of these acids and anhydrides is considered to be within the abilities of one of ordinary skill in the art.
[0028] The polycarboxy polymer of the present invention may additionally comprise a copolymer of one or more of the aforementioned unsaturated carboxylic acids or anhydrides and one or more vinyl compounds including, but not necessarily limited to, styrene, .alpha.-methylstyrene, acrylonitrile, methacrylonitrile, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, methyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, glycidyl methacrylate, vinyl methyl ether, vinyl acetate, and the like. Methods for preparing these copolymers are well-known in the art.
[0029] Preferred polycarboxy polymers comprise homopolymers and copolymers of the polyacrylic acid. The preferred polyacrylic acid has a molecular weight ranging from about 100 to about 200,000; more preferably from about 1,000 to about 10,000 with about 2,000 to about 6,000 being the most preferred. In addition, the preferred polyacrylic acid has free carboxylic acid groups from greater than about 90% with greater than about 95% bring most preferred.
[0030] Contemplated equivalent trihydric alcohols according to the present invention having the same operability and utility include, but are not necessarily limited to, glycerol, trimethylolpropane, trimethylolethane, triethanolamine, 1,2,4-butanetriol, and the like, as well as mixtures thereof. In practice, the monomeric trihydric alcohols of the present invention may be mixed with other polyhydric alcohols for use in the inventive binder composition. Such other polyhydric alcohols include, but are not necessarily limited to, ethylene, glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, 2-butene-1, erythritol, pentaerythritol, sorbitol, and the like, as well as mixtures thereof. Preferred monomeric trihydric alcohols comprise glycerol and trimethylolpropane, as well as mixtures thereof. Examples of preferred trihydric alcohols include triethanolamine and glycerine.
[0031] The catalyst according to the present invention comprises an alkali metal salt of a phosphorous-containing organic acid; particularly alkali metal salts of phosphorous acid, hypophosphorous acid, and polyphosphoric acids. Examples of such catalysts include, but are not necessarily limited to, sodium, sodium phosphite, potassium phosphite, disodium pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, potassium phosphate, potassium polymetaphosphate, potassium polyphosphate, potassium tripolyphosphate, sodium trimetaphosphate, and sodium tetrametaphosphate, as well as mixtures thereof. Preferred catalysts include sodium hypophosphite and sodium phosphite, as well as mixtures thereof.
[0032] The binder composition according to the present invention may also include a corrosion inhibiting agent selected to reduce corrosive effects of the binder composition, particularly on metal surfaces. Corrosion inhibitors such as thiourea and other similar sulfur compounds such as allylthiourea have been found useful in this regard. Preferred inhibitors include compounds such as tin oxalate, tin sulfate, tin chloride and thiourea and, if present, are included in the binder composition in amounts ranging from about 100 to about 100,000 ppm and most preferably, from about 1,000 to about 5,000 ppm.
[0033] The polycarboxy polymer, monomeric trihydric alcohol, as well as the optional catalyst and/or corrosion inhibitor may be mixed with water in any conventional mixing device capable of providing sufficient agitation. The ratio of polycarboxy polymer to monomeric trihydric alcohol may be determined by comparing the ratio of moles of hydroxyl groups contained in the monomeric trihydric alcohol to the moles of carboxy groups contained in the polycarboxy polymer. Although this stoichiometric ratio may vary widely to include compositions having ratios of from about 0.5 to about 1.5, the more preferred binder compositions will have a ratio from about 0.7 to about 1.0.
[0034] One of ordinary skill in the art will appreciate that the amount of catalyst used may also vary quite widely depending upon the cure temperatures as well as duration of the curing period during which the binder is maintained at elevated curing temperatures. The quantity of catalyst is preferably sufficient to produce a substantially cured binder composition (i.e., at least about 75% of the stoichiometrically available carboxy and hydroxyl groups have reacted). Based upon the combined weight of the polycarboxy polymer, monomeric trihydric alcohol, and catalyst, the amount of catalyst required to achieve this desired level of performance may vary over wide limits from about 1% to about 15% by weight. It is anticipated, however, that in most instances a composition comprising between about 4% to about 8% by weight catalyst will provide sufficient performance.
[0035] The binder composition of the present invention also incorporates a functional quantity of one or more extenders to reduce the overall cost of the binder composition while maintaining acceptable thermoset binder performance. Depending on the extender or extenders selected, certain other properties of the binder composition may also be modified to adjust the binder performance for different applications. Preferred extenders include lignin, low molecular weight starch, soybean protein.
[0036] Water soluble polysaccharide extenders suitable for use in the present invention may be derived from a variety of natural products including plant, animal and microbial sources. Examples of such polysaccharides include starch, cellulose, gums, such as guar and xanthan, alginates, pectin and gellan. Suitable polysaccharide starches may include maize or corn, waxy maize, high amylose maize, potato, tapioca and wheat starch. In addition to the natural starches, genetically engineered starches such as high amylose potato and potato amylopectin starches may also be utilized as an extender in the present invention.
[0037] The preferred polysaccharides are characterized by adequate water solubility and a relatively low molecular weight, such as exhibited by certain etherized, esterified, acid hydrolyzed, dextrinized, oxidized, or enzyme modified polysaccharides. In particular, polysaccharides suitable for use in the present invention are expected to have a weight average molecular weight of not more than 10,000, and preferably less than 5,000.
[0038] Water soluble sulfonated lignins, either singly or as a mixture, are also useful as extenders in the present invention. Two such sulfonated lignins are sodium lignosulfonate and ammonium lignodulfonate, with sodium lignosulfonate being especially preferred.
[0039] Water, the primarily component of the binder composition, may be added to the mixture of polycarboxy polymer, monomeric trihydric alcohol, extender and catalyst in any amount that will produce an aqueous binder composition having the desired viscosity and flow rate for its intended application. The binder composition may be applied to the fibers in any convenient method, such as by spraying or immersion. Depending on the selection of the other components and the intended application, water may comprise up to about 95% by weight of the binder composition.
[0040] The binders of the present invention may optionally contain conventional additives such as coupling agents, dyes, oils, fillers, thermal stabilizers, flame retarding agents, lubricants, pH adjusters and the like, typically in amounts not exceeding 20% of the weight of the binder composition. In particular, pH adjusters such as ammonium hydroxide may be used to raise the pH. The preferred pH for application of the binder is from about 2.5 to about 5 with about 3 to about 4 being the most preferred.
[0041] During a typical manufacturing operation, the binder composition will be applied to glass fibers as they are being formed into a mat. The majority of the water will be evaporated from the binder composition to produce a mat coated with a binder composition having a relatively high solids content. The coated mat is then typically heated to evaporate the remaining solvent and to cure the remaining portion of the binder composition to produce a finished fibrous glass batt. Depending on its construction, the bound glass batt may be used as a thermal or acoustical insulation product, a reinforcement for a subsequently produced composite or in the production of some other fiber product.
[0042] The present invention will be further illustrated by way of the following examples:
COMPARATIVE EXAMPLE
Basic Polyacrylic Acid—Glycerol Binder
[0043] A hypophosphite terminated polyacrylic acid based resin, specifically QRXP 1629S, with glycerol as the crosslinking agent was obtained from Rohm and Haas Company. The resin was diluted with water to obtain an aqueous binder composition comprising a 30 weight percent solid aqueous solution. A Dynamic Mechanic Analysis (“DMA”) was conducted to establish a reference cure curve.
EXAMPLE 1
Binders with a Lignin Extender
[0044] The basic binder composition of the Comparative Example was prepared as described above. Sodium lignonsulfonate, specifically LIGNOSITE® 260 from the Georgia-Pacific Corporation, and water were added to the basic binder composition to obtain binder compositions comprising a 30 weight % solid aqueous solution in which the sodium lignonsulfonate:polyacrylic acid ratio was set at 1%, 5%, 15%, 30% and 45%. Additional DMA was then conducted to examine the cure performance of the extended binder compositions. The DMA data for the basic binder composition and the lignin extended binder compositions are illustrated in FIG. 1.
[0045] The rheology of the lignin extended binders prepared in Example 1 was further examined using 0.2 ml samples analyzed on an Advanced Rheometer 1000 from TA Instruments from 30-220° C. using a 5° C. per minute ramp rate, a 4 cm diameter sample plate, a 750 μm gap, an oscillation frequency of 1 Hz and a 5% strain. The results generated for each of the samples is plotted in FIG. 2. The graph indicated that by adding lignin up to 45 weight % based on binder solid does not significantly change the initial on-set cure temperature which ranged from about 200° C. to 220° C. There was also no significant change in the cure rate (slope) observed.
EXAMPLE 2
Binders with a Low MW Starch Extender
[0046] The basic binder composition of the Comparative Example was prepared as described above. Maltodextrin, a low molecular weight and readily soluble starch, specifically STAR-DRI®) 100 from A. E. Staley Mfg. Co., and water were added to the basic binder composition to obtain binder compositions comprising a 30 weight % solid aqueous solution in which the maltodextrin:polyacrylic acid ratio was set at 1%, 5%, 15%, 30% and 45%. Additional DMA was then conducted to examine the cure performance of the extended binder compositions. The DMA data for the basic binder composition and the low molecular weight starch extended binder composition are illustrated in FIG. 3.
[0047] The rheology of the starch extended binders prepared in Example 2 was further examined using 0.2 ml samples analyzed on an Advanced Rheometer 1000 from TA Instruments from 30-220° C. using a 5° C. per minute ramp rate, a 4 cm diameter sample plate, a 750 μm gap, oscillation frequency of 1 Hz and a 5% strain. The results generated for each of the samples is plotted in FIG. 4 and similar trend was observed which implied that the addition of water soluble starch will not adversely impact on the binder cure performance.
[0048] In light of the success of initial bench trials, a plant production trial examining certain embodiments of the present invention was conducted using a polyacrylic acid glycerol (PAG Plus) binder both with and without the use of a lignin extender. Specifically, sodium lignosulphonate (S-001) from Tembec, 50% solid, was used to replace 10% of the weight of PAG Plus binder in the binder composition. The PAG Plus binder was prepared by diluting a phosphite terminated polyacrylic acid glycerol resin premix (specifically Rohm and Haas' QRXP 1629S), with water, a hydrolyzed silane and a dust suppressing agent to make a 10 wt % solid binder.
[0049] The binder compositions were then applied in a conventional manner during a standard fiber glass insulation fiberizing process and cured to produce a finished R-19 fiber glass insulation batt. A standard phenolic binder was used to produce comparative examples both before and after trial examples were produced on the same manufacturing line for comparison. Each of the trial and comparative example fiberglass batts was then tested to ascertain its recovery at end of line (“EOL”), after one week under ambient conditions and in a humidity chamber (under conditions of 90° F. and 90% relative humidity and again after six weeks of being maintained under ambient conditions or in the humidity chamber. The recovery data listed below in Table 1 demonstrates that the lignin extended polyacrylic acid glycerol binder composition can produce finished products having substantially identical recovery performance when compared with a typical phenol-formaldehyde binder composition.
TABLE 1 Production Trial for PAG Plus Extender R-19 PAG PAG R-19 Recovery (inches) Phenolic plus Plus/Lignin Phenolic End of Line (EOL) 6.49 6.13 6.10 6.00 1 Week @ Ambient 5.97 5.93 5.51 6.11 1 Week @ 90° F./90% RH 5.90 5.65 5.40 5.83 6 Weeks @ Ambient 6.15 6.10 5.82 6.26 6 Weeks @ 90° F./90% RH 5.97 6.03 5.70 6.03 Average 6.10 5.97 5.71 6.05
[0050] It will be understood that the above described preferred embodiment(s) of the present invention are susceptible to various modifications, changes, and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. In particular, it is anticipated that other low molecular weight proteins and starches, as well as mixtures thereof, would be suitable for use in the present invention.
[0051] Further, although a number of equivalent components may have been mentioned herein which could be used in place of the components illustrated and described with reference to the preferred embodiment(s), this is not meant to be an exhaustive treatment of all the possible equivalents, nor to limit the invention defined by the claims to any particular equivalent or combination thereof. A person skilled in the art would realize that there may be other equivalent components presently known, or to be developed, which could be used within the spirit and scope of the invention defined by the claims. | The present invention provides a variety of extended polyacrylic acid based binder compositions comprising a low molecular weight polyacrylic acid (typically hypophosphite or sulfite terminated), a crosslinking agent (such as triethanolamine or glycerol) and one or more water soluble materials, such as lignin, low molecular weight starch and soybean protein. The extended binder composition of the present invention provides a lower cost binder composition without degrading the performance and may be selected to alter one or more characteristics of the basic binder composition such binder wetting, emulsion compatibility, dust suppression and wash water flow properties. | 3 |
BACKGROUND
1. Field
The present invention relates generally to broadcast communications systems, and more specifically, to systems and techniques for registration in a broadcast communications system.
2. Background
Radio refers to a system of communications using electromagnetic waves propagated through free space to link multiple radio devices. Radio is commonly used as a public medium to send commercial broadcasts from a radio transmitter to anyone with a radio receiver, and is often referred to as a point-to-multipoint medium. However, radio can also be used for private communications between two or more users over a point-to-point medium. Wireless telephones are common examples of radio transceivers configured to support point-to-point communications.
Various infrastructures have been developed over the years to support point-to-point communications. For example, in cellular communications, a base station controller is often used to support voice and data communications between a network and all base stations dispersed throughout a geographic area. The geographic area is typically divided into coverage regions known as cells. A base station is generally assigned to serve all subscriber stations in its cellular region. In some high traffic areas, the cellular region may be divided into sectors with one base station serving each sector. A user on a wireless subscriber station can access the network, or communicate with another wireless subscriber station, through one or more base stations.
With recent advancements in cellular technology, there has been an interest to utilize existing point-to-point cellular systems for broadcast services. The addition of commercial broadcasts into existing cellular systems requires the integration of broadcast services with those services currently provided to cellular users. The subscriber station needs to be able to function in both the broadcast mode and the point-to-point communications mode.
SUMMARY
In one aspect of the present invention, a method of communications includes selecting a broadcast channel, confirming that the broadcast channel remains selected for a period of time following the selection of the broadcast channel, and registering the broadcast channel with an access network in response to the end of the time period.
In another aspect of the present invention, a method of communications includes selecting a first broadcast channel, establishing a first time period in response to the first broadcast channel selection, preventing the first broadcast channel from being registered with an access network by deselecting the first broadcast channel before the end of the first time period, selecting a second broadcast channel, confirming that the second broadcast channel remains selected for a second period of time following the selection of the second broadcast channel, and registering the second broadcast channel with the access network at the end of the second time period.
In yet another aspect of the present invention, an apparatus includes an input device, a processor having a timer responsive to a broadcast channel selection from the input device, the processor being configured to generate a request to register the broadcast channel if the timer expires before receiving a second broadcast channel selection from the input device, and an analog front end configured to transmit the request to an access network.
In a further aspect of the present invention, computer readable media embodying a program of instructions executable by a computer program performs a method of communications, the method including receiving a broadcast channel selection, confirming that the broadcast channel remains selected for a period of time following the selection of the broadcast channel, and generating a request to register the broadcast channel with an access network in response to the end of the time period.
In yet a further aspect of the present invention, computer readable media embodying a program of instructions executable by a computer program performs a method of communications, the method including receiving a first broadcast channel selection, establishing a first time period in response to the first broadcast channel selection, preventing the generation of a request to register the first broadcast channel with an access network in response to a first broadcast channel deselection before the end of the first time period, receiving a second broadcast channel selection, confirming that the second broadcast channel remains selected for a second period of time following the selection of the second broadcast channel, and generating a request to register the second broadcast channel with the access network at the end of the second time period.
In another aspect of the present invention, an apparatus includes an input device, means for generating a time period in response to a broadcast channel selection from the input device, means for generating a request to register the broadcast channel if the time period ends before receiving a second broadcast channel selection, and means for transmitting the request to an access network.
It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only exemplary embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings wherein:
FIG. 1 is a conceptual block diagram of an exemplary communications system supporting high speed broadcast services over an existing wireless cellular infrastructure;
FIG. 2 is a functional block diagram of a subscriber station communicating with a base station in the exemplary communications system of FIG. 1 ;
FIG. 3 is a flow chart illustrating an exemplary registration algorithm implemented by a processor residing in the subscriber station of FIG. 2 ; and
FIG. 4 is a timing diagram illustrating an exemplary registration scenario between a subscriber station and an access network using the registration algorithm described in connection with FIG. 3 .
DETAILED DESCRIPTION
The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments of the present invention and is not intended to represent the only embodiments in which the present invention can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the present invention.
FIG. 1 is a conceptual block diagram of an exemplary communications system 100 capable of providing high speed broadcast services over an existing wireless cellular infrastructure. The existing wireless cellular infrastructure allows a user on a wireless subscriber station 102 to communicate with other wireless subscriber stations through an access network 104 . The access network 104 includes a collection of base stations 106 and one or more base station controllers (BSC) 108 . The access network 104 may further be connected to additional networks outside the access network, such as a broadcast network 110 , and may transport data packets between each subscriber station 102 and the broadcast network 110 . The broadcast network may include one or more content servers 112 . Alternatively, one or more content servers 112 can be located outside the broadcast network 110 . In any event, the content server 112 generates data packets containing programming from one or more broadcast channels, e.g., CBS, NBC, ABC, FOX, ESPN, etc.
The exemplary communication system 100 enables high speed broadcast services by introducing a forward broadcast shared channel (F-BSCH) 114 capable of high data rates that can be received by a large number of subscriber stations 102 . The F-BSCH 114 is a forward link “physical” channel that carries one or more broadcast channels at a fixed carrier frequency. The broadcast channels are referred to as a forward link “logical” channels because they are distinguished from on another with a broadcast channel identifier appended to each data packet. In theory, a single F-BSCH could be used to deliver all broadcast channels to the subscriber stations 102 . As a practical matter, however, the use of a single F-BSCH to handle all broadcast channels is not very feasible due mainly to bandwidth limitations. Accordingly, the broadcast channels should be allocated among multiple F-BSCHs each having a different carrier frequency.
To support point-to-point communications, a paging channel should be assigned to each F-BSCH carrier frequency. The paging channel can be used by the base station to page a subscriber station when a call arrives. By assigning a page channel to each F-BSCH carrier frequency, the user can always receive a page regardless of which broadcast channel the user has selected. A registration procedure can be used to ensure that the base station pages the subscriber station at the appropriate carrier frequency. The registration procedure can be performed in various ways depending on the particular design parameters for any given application. For example, the subscriber station can be configured to register with the access network every time the user selects a different broadcast channel. This registration procedure will provide a mechanism for the base station to know which frequency the subscriber station can be found when a call arrives.
FIG. 2 is a functional block diagram of a base station communicating with a subscriber station in the exemplary communications system of FIG. 1 . In the broadcast mode, data packets from the BSC (not shown) are received by a processor 202 through a backhaul. The processor 202 can provide various signal processing functions such as encoding and modulation of the data packets, and conversion to an analog signal. The analog signal can be provided to an analog front end (AFE) 204 where it is upconverted to the appropriate carrier frequency for transmission to the subscriber station 102 . The AFE 204 can also provide filtering and amplification before transmission over the F-BSCH via an antenna 206 .
At the subscriber station 102 , the broadcast is received by an antenna 208 and provided to an AFE 210 . The AFE 210 includes a tuner which selects one physical channel, i.e., F-BSCH. The AFE also amplifies, filters and downconverts the selected F-BSCH to a baseband signal. The baseband signal can be coupled to a processor 212 that provides the inverse processing functions performed at the base station 106 , specifically the demodulating and decoding, to recover the broadcast content. The broadcast content can then be provided to the user via a display 214 . A user input device 216 , such as a keypad or the like, can be used to select the broadcast channels. The user input device 216 can be coupled to the processor 212 where the logical broadcast channels selected by the user can be used to generate registration requests 218 for registering the broadcast channels with the access network. In a manner to be described in greater detail later, a guard timer 220 and a number of registration timers 222 can be used to control the generation of the registration requests. The logical broadcast channels selected by the user can also be mapped to their physical channels, i.e., the F-BSCH, by the processor 212 . Based on the mapping function performed by the processor 212 , the tuner can be set to the appropriate frequencies to receive the broadcast channels selected by the user.
The registration procedure can be performed in a variety of ways. In the described exemplary embodiment, the subscriber station processor maintains a registration timer for each broadcast channel subscribed to by the user of the subscriber station. When power is initially applied to the subscriber station, the subscriber station processor resets the registration timers for each broadcast channel. The subscriber station processor then sets the tuner to the designated frequency for registration with the access network using conventional hashing procedures for point-to-point communications or any other procedures known in the art. When the user selects a broadcast channel to receive broadcast services from a content server, the subscriber station processor registers the selected broadcast channel with the access network and starts the registration timer for that broadcast channel. The registration process involves transmitting a registration request from the subscriber station to the access network. The registration request is generated by the subscriber station processor and includes the broadcast channel selected by the user. If the broadcast channel remains selected when the registration timer expires, the subscriber station processor reregisters the selected broadcast channel with the access network and restarts the registration timer for the selected broadcast channel. When the user selects a different broadcast channel, the subscriber station processor registers the new broadcast channel with the access network and starts the registration timer for that broadcast channel.
The base station processor maintains a “paging set” for the subscriber station as well as a separate registration timer for each broadcast channel subscribed to by the user of the subscriber station. Upon receiving a power-up registration, the paging set for the subscriber station is initialized to include the frequency of the paging channel designated for point-to-point communications. When the base station processor receives a request to register a broadcast channel from the subscriber station, the base station processor adds the broadcast channel to the paging set and starts the registration timer for that broadcast channel. The registration timer can be retriggered by subsequent registration requests from the subscriber station. Should the registration timer expire, the base station processor removes the broadcast channel from the paging set.
When there is an incoming call for the subscriber station, the base station processor maps the contents of the paging set to the physical channels, i.e., F-BSCHs, to determine the carrier frequency for each broadcast channel in the paging set. The base station then sends a paging message to the subscriber station over each carrier frequency as well as the designated frequency for the paging channel for point-to-point communications. By sending a paging message on all frequencies carrying one or more broadcast channels with active registration timers, the chances of missing a page when the user is switching between multiple broadcast channels near or about the time an incoming call arrives is reduced.
The registration timers at the subscriber station should be synchronized with the corresponding registration timers at the base station, or the registration timers at the base station should not expire before their corresponding registration timers at the subscriber station. If the registration timer at the base station expires before the corresponding registration timer at the subscriber station, the base station may prematurely remove a broadcast channel from the paging set, while the subscriber station remains at that broadcast channel.
A guard timer can be used to avoid sending numerous registration requests to the access network when the user is browsing through the broadcast channels before deciding which broadcast channel to select. The guard timer can be triggered when the user selects a broadcast channel and the registration of that broadcast channel can be delayed until the guard timer expires. The guard timer can be implemented with a single retriggerable timer responsive to each broadcast channel selection. In this configuration, the guard timer is constantly retriggered as the user browses through the broadcast channels and does not expire until the user remains on one broadcast channel for a predetermined period of time. Alternatively, the guard timer can be implemented with a separate timer for each broadcast channel. In this configuration, a broadcast channel would be registered with the access network only if it remained selected when its respective timer expired. In any event, once a broadcast channel remains selected for a period of time set by the guard timer, a registration request can be sent to the access network and the registration timer for that broadcast channel can be started. Should the user deselect and then return to the broadcast channel while the registration timer is active, the guard timer should nonetheless be started. If the guard timer is active when the registration timer expires, the registration of the broadcast channel should be delayed until the guard timer expires. In other words, a broadcast channel should not be registered with the access network until the guard timer expires regardless of the state of its registration timer.
The time period for the guard timer and the registration timers can be fixed, or alternatively, can be configurable parameters transmitted to the subscriber station by the base station. The time period for the guard timer and registration timers may be selected based on user behavior statistics, number of broadcast channels transmitted, network loading, or any other relevant parameters known to those skilled in the art. The time period for the guard timer should be shorter than the time period for the registration timers. The time period for the guard timer should be relatively short to minimize the risk of missed pages due to delayed registration. The time period for the registration timers, on the other hand, should be relatively long to reduce bandwidth demands for registration. However, as those skilled in the art will recognize, the time period for the guard timer does not necessarily have to be shorter than the time period for the registration timers, and the actual relative time periods between the guard timer and the registration timers can be set for any values depending on the particular application and the overall design constraints.
As indicated earlier, the registration request includes the broadcast channel that is selected by the user. This information is needed by the base station to maintain the paging set. However, other related information may also be useful. For example, the particular broadcast channels that the user browses through before making a final selection may provide a content server with useful information for improving future programming. This information, however, may not be readily available if the subscriber station uses a guard timer that prevent the registration of broadcast channels that the user merely browses through. Accordingly, in at least one embodiment of the subscriber station, the processor includes memory that stores each selection made by the user regardless of the length of time the broadcast channel remains selected. Once a broadcast channel remains selected for a time period sufficient to expire the guard timer, a registration request can be transmitted to the access network with all the broadcast channels selected by the user since the last registration request. The registration request can use one or more bits appended to each broadcast channel to indicate whether the broadcast channel should be added to the paging set or whether the broadcast channel is being provided for statistical purposes only. The information from the registration request can be extracted at the base station and transported through the access network to the content server. The content server can use the information for creating a rating system, billing the user, and tracking user behavior.
Alternatively, the content server can control the content of the information provided by the subscriber station with a message sent to the subscriber station requesting that only certain broadcast channels be monitored. In communications systems where the content server is actively participating in the broadcast channel tracking function, the information can be transmitted from the subscriber station in a registration request or in a separate dedicated channel in response to inquiries from the content server.
FIG. 3 is a flow chart illustrating an exemplary registration algorithm which can be implemented by the subscriber station processor. The exemplary registration algorithm can be performed with communications software running on the subscriber station processor. The subscriber station processor can be a general purpose processor or a digital signal processor (DSP). Alternatively, the registration algorithm can be implemented with processor that is an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof.
Returning to FIG. 3 , the subscriber station processor registers with a base station for point-to-point communications in step 302 . The user then selects a broadcast channel to receive broadcast services from a content server in step 304 . In response, the subscriber station processor starts the guard timer in step 306 and monitors the user input device for other broadcast channel selections while the guard timer is active in step 308 . If the subscriber station processor detects a new broadcast channel selection before the guard timer expires, the subscriber station processor restarts the guard timer in step 312 and loops back to step 308 to monitor the user input device for further broadcast channel selections. If the broadcast channel remains selected when the guard timer expires, the subscriber station processor registers the broadcast channel with the access network in step 314 , starts the registration timer in step 316 , and monitors the user input device for new broadcast channel selections while the registration timer is active in step 318 . If a new broadcast channel is selected before the registration timer expires, the subscriber station processor loops back to step 306 to restart the guard timer. If the broadcast channel remains selected when the registration timer expires, the subscriber station processor loops back to step 314 to reregister the broadcast channel with the access network and step 316 to restart the registration timer.
The sequence of steps described above for the registration algorithm is by way of example and not by way of limitation. Those skilled in the art will appreciate that certain steps can be performed in any order, or carried out in parallel in an actual implementation. Moreover, one or more of the steps may be omitted or combined with other methods and processes known in the art.
FIG. 4 is a timing diagram illustrating an exemplary registration scenario between a subscriber station and an access network using the registration algorithm described in connection with FIG. 3 . The timing diagram includes a horizontal axis for “time” and a vertical axis showing the “carrier frequency” assignments for the physical channels below and the state of the various timers above. For the purposes of illustration, the paging channel for point-to-point communications will be represented as f 3 . Two physical channels, i.e., F-BSCH, carrying broadcast services from a content provider will have frequency assignments represented as f 1 , and f 2 . One of the physical channels carries a single logical broadcast channel CH 3 , and the other physical channel carries two logical broadcast channels CH 1 and CH 2 .
At time t 1 , power is applied to the subscriber station. The subscriber station processor sets the tuner frequency to f 3 for point-to-point communications using any procedure known in the art, resets the guard timer and registration timers, and registers with the base station. The base station initializes the subscriber station's paging set to include carrier frequency f 3 .
At time t 2 , the user selects one of the broadcast channels CH 1 on the user input device. The subscriber station processor sets the tuner frequency to f 1 , and starts the guard timer.
At time t 3 , the guard timer expires. The subscriber station processor starts the registration timer for the broadcast channel CH 1 and transmits a request to register the broadcast channel CH 1 to the access network. In response to the registration request, the base station adds the broadcast channel CH 1 to the paging set and starts its registration timer for the broadcast channel CH 1 . At this point, the paging set includes {CH 1 , f 3 }.
At time t 4 , the user selects another broadcast channel CH 2 on the user input device. The subscriber station processor starts the guard timer.
At time t 5 , prior to the expiration of the guard timer, the user selects another broadcast channel CH 3 on the user input device. The subscriber station processor sets the tuner frequency to f 2 and restarts the guard timer.
At time t 6 , the registration timer for the broadcast channel CH 1 expires. Because the user has selected a different broadcast channel, the subscriber station does not send a registration request to the access network for the broadcast channel CH 1 , and as a result, the registration timer at the base station for the broadcast channel CH 1 will expire causing the base station to remove the broadcast channel CH 1 , from the paging set. At this point, the paging set includes {f 3 }.
At t 7 , the guard timer expires. The subscriber station processor starts the registration timer for the broadcast channel CH 3 and transmits a request to register the broadcast channel CH 3 to the access network. In response to the registration request, the base station adds the broadcast channel CH 3 to the paging set and starts its registration timer for the broadcast channel CH 3 . At this point, the paging set includes {CH 3 , f 3 }.
At time t 8 , the registration timer for the broadcast channel CH 3 expires. Because the same broadcast channel CH 3 is still selected by the user, the subscriber station processor sends another request to register the broadcast channel CH 3 to the access network and restarts the registration timer for the broadcast channel CH 3 . The base station will retain the broadcast channel CH 3 in the paging set in response to the registration request.
At time t 9 , the user reselects the broadcast channel CH 2 on the user input device. The subscriber station processor sets the tuner frequency to f 1 , and restarts the guard timer.
At time t 10 , the guard timer expires. The subscriber station processor starts the registration timer for the broadcast channel CH 2 and transmits a request to register the broadcast channel CH 2 to the access network. In response to the registration request, the base station adds the broadcast channel CH 2 to the paging set and starts its registration timer for the broadcast channel CH 2 . At this point, the paging set includes {CH 2 , CH 3 , f 3 }.
At time t 11 , the registration timer for the broadcast channel CH 3 expires. Because the user has selected a different broadcast channel, the subscriber station does not send a registration request to the access network for the broadcast channel CH 3 , and as a result, the registration timer at the base station for the broadcast channel CH 3 will expire causing the base station to remove the broadcast channel CH 3 from the paging set. At this point, the paging set includes {CH 2 , f 3 }
At time t 12 , the user reselects the broadcast channel CH 3 on the user input device. The subscriber station processor starts the guard timer.
At time t 13 , prior to the expiration of the guard timer, the user reselects the broadcast channel CH 2 on the user input device. The subscriber station processor restarts the guard timer.
At time t 14 , the registration timer for the broadcast channel CH 2 expires. However, since the guard timer has not expired, the subscriber station processor does not transmit a registration request to the access network nor does the subscriber station processor restart the registration timer for the broadcast channel CH 2 . As a result, the registration timer at the base station for the broadcast channel CH 2 will expire causing the base station to remove the broadcast channel CH 2 from the paging set. At this point, the paging set includes {f 3 }.
At time t 15 , the guard timer expires. The subscriber station processor restarts the registration timer for the broadcast channel CH 2 and transmits a request to register the broadcast channel CH 2 to the access network. In response to the registration request, the base station adds the broadcast channel CH 2 back to the paging set and restarts its registration timer for the broadcast channel CH 2 . At this point, the paging set includes {CH 2 , f 3 }.
At time t 16 , a call for the subscriber station arrives at the base station. The base station maps the logical broadcast channels contained in the paging set to the physical channels supported by the communications system. The mapping function results in a carrier frequency f 1 for the broadcast channel CH 2 . As a result, the base station sends a page to the subscriber station over carrier frequencies f 1 and f 3 The subscriber station processor will receive the page over carrier frequency f 1 , and in response, set the tuner frequency to f 3 to negotiate the call parameters in the point-to-point communications mode. The registration timers in the subscriber station and base station can be reset at this time, or alternatively, allowed to expire. Either way, once the registration timers in the base station are reset (or expire), the base station will remove the broadcast channel CH 2 from the paging set in the absence of new registration request from the subscriber station.
Those of skill would appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | Systems and techniques are disclosed relating to communications. The systems and techniques include an input device, generating a time period in response to a broadcast channel selection from the input device, generating a request to register the broadcast channel if the time period ends before receiving a second broadcast channel selection, and transmitting the request to an access network. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or the meaning of the claims. | 7 |
FIELD OF INVENTION
[0001] The present invention pertains to a method to inhibit carbonyl species contamination of liquid hydrocarbon media and corrosion of metal surfaces that are in contact with such media. The method consists of a chemical treatment step with or without the use of a subsequent physical treatment step. The physical treatment step consists of contacting the chemically treated liquid hydrocarbon media with a semipermeable membrane.
BACKGROUND OF THE INVENTION
[0002] Liquid hydrocarbon media such as those present in the petrochemical industry are often subject to contamination by the presence of carbonyl compounds therein. For example, carbon dioxide in such hydrocarbon process streams forms carbonic acid. This acid and other organic acids that are present can cause acid corrosion of metallurgy in contact with the process stream. Esters present in such streams can hydrolyze to acids. Further, aldehydes and other impurities in the liquid hydrocarbon stream or product can exceed required impurity levels and, if not separated from the process stream, result in product that does not meet purity requirements or end use specifications.
[0003] These problems are encountered for example in petrochemical processes adapted to form ethylene glycols. Ethylene glycols such as monoethylene glycol, diethylene glycol, triethylene glycol, etc., are important products and intermediates that are used in a variety of applications. For example, these products are useful in the preparation of textile fibers, antifreeze agents, hydraulic fluids, heat transfer agents, humectants and adhesives. Ethers of ethylene glycol are useful as solvents and chemical intermediates, particularly in the protective coatings industry.
[0004] In the preparation of polyester textile fibers, ethylene glycol is reacted with terephthalic acid to form the desired polymer. The ethylene glycol used in this process must be of the highest purity in order to form high quality polymer. One way of measuring the purity of the ethylene glycol is to subject it to a UV light transmittance test wherein excessive impurities results in lower than desired transmittance. Carbonyl species contamination of the ethylene glycol results in lower UV transmittance and may cause problems with regard to meeting desired UV and color specifications.
[0005] Ethylene glycols (e.g., monoethylene glycol, diethylene glycol, triethylene glycol, and tetraethylene glycol) may be prepared via several well known methods. In one method reported in U.S. Pat. No. 5,034,134, a two-stage reaction system is disclosed comprising a first step in which ethylene is oxidized over a suitable catalyst to form ethylene oxide. The so produced ethylene oxide is then reacted with water in a variety of stripping and reaction steps to ultimately form the desired ethylene glycols. The glycol stream containing water and undesirable carbonyl contaminants is subjected to one or more distillation steps to separate and purify the desired product.
SUMMARY OF THE INVENTION
[0006] In accordance with the invention, carbonyl species contamination of liquid hydrocarbon process streams is decreased by addition of a high boiling amine or by using a two-step approach with amines in combination with a physical separation technique that uses membranes. The amine is chosen from high boiling primary and secondary amines and will inhibit acid based corrosion of system metallurgy and should exhibit thermal stability so that it will not volatilize during the heat processing steps that are employed so that it will therefore stay with the bottom stream in these processes.
[0007] The carbonyl based organic and inorganic contaminants, as mentioned above, react with the amine and then are removed when the hydrocarbon medium is contacted by a separatory membrane such as in one embodiment, a nanofiltration membrane. Although applicants are not to be bound to any theory of operation of the invention, it is thought that reaction of the amine with the impurities increases the size of the contaminates, thereby increasing the separation efficacy (i.e., reaction rate) of the separating membrane.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0008] Although the invention will be primarily described in connection with its use in ethylene glycol production and purification processes, it is noteworthy that the invention is also applicable to other hydrocarbonaceous media such as those encountered in a variety of petrochemical processes such as olefinic or napthenic process streams, aromatic hydrocarbons and their derivatives, ethylene dichloride, and other processes. All of these are within the ambit of the phrase hydrocarbonaceous or hydrocarbon medium as used throughout the specification and claims. As is apparent to the artisan, significant amounts of water may also be present in such media.
[0009] Primary or secondary amines are added to the desired liquid hydrocarbonaceous medium in an amount of about 0.1-100 moles per mole of carbonyl function molecules present. Preferably, the treatment range is from about 0.5-10 moles of amine per mole of carbonyl functional molecules present. The amines should be chosen to have a sufficiently high enough boiling point to remain with the desired product during heat treating and purification processes such as distillation and fractionation.
[0010] In an ethylene glycol hydrocarbon stream including aqueous components, the amine should have a boiling point of about 200° C. or greater, preferably 300° C. or greater since the ethylene glycol stream is usually subjected to such temperatures during heat processing and purification. The glycol/water streams may, for example, be present anywhere within an ethylene oxide or ethylene glycol production or purification process.
[0011] In general, the amines that can be employed in accordance with the invention are characterized by the formula described in (I) or (II) below or a combination of (I) and (II).
wherein R 1 is H, alkyl, cycloalkyl, or aryl; y is an integer from 0 to 9; x is an integer of from 1-10; and R 1 -R 6 are independently chosen from H, C 1 -C 18 alkyl or C 1 -C 18 alkyl substituted with hydroxyl, aryl, cycloalkyl, alkoxy, and amino groups.
wherein c and d are independently chosen integers of from 0 to 3; Z 1 , Z 2 , Z 3 , and Z 4 are independently chosen from H, OH, amino, C 1 -C 12 alkyl, a hydroxyalkyl or aminoalkyl moiety of C 1 -C 12 carbon atoms or aryl, preferably Z 1 , Z 2 , Z 3 , and Z 4 are all H.
[0012] Preferred for use are the polyethylene polyamines having the formula
NH 2 (CH 2 CH 2 NH) e H
wherein e is 2 or greater, preferably 3 to 10. Mixtures of these polyethylene polyamines may also be used. Present data suggests that tetraethylene pentamine is presently preferred with triethylenetetramine and pentaethylenehexamine also being exemplary.
[0013] In one embodiment of the invention, the liquid hydrocarbon medium that has been chemically treated as per above is contacted with a semipermeable membrane such as a nanofiltration membrane. Preferably, the pore size of the membranes is such that permeate molecules will have molecular weights of 300 Daltons or less, preferably 150 Daltons. The pore sizes are on the order of about 0.5-1.5 nm, preferably about 1.0 nm. The permeate, which is the material passing through the membrane, will have a lower concentration of carbonyl based impurities as compared to the impermeate or retentate stream which is the material that does not pass through the membrane. In those situations in which the combined chemical/physical separation steps of the invention are employed in an ethylene glycol process stream, the membrane separator will allow substantially all of the glycols to pass through the membrane while rejecting or inhibiting the chemically treated UV absorbers and/or other impurity components from doing so. This provides a high purity permeate with reduced UV absorbers and impurities therein. The permeate will consist primarily of water and glycols. The retentate (reject) stream will consist of the chemically treated UV absorbers and/or other impurity components, and any excess unreacted amine.
[0014] The chemical pretreatment not only reduces the amount of impurities, but also enhances the ability of the semi-permeable membrane to separate the impurities from the glycols and water at a substantially lower pressure (200-300 psig) than traditional semi-permeable membranes used to effect this separation. It should be understood that the rejection of the impurity components would be approximately 50% lower in the absence of chemical pretreatment prior to the physical separation step. Although applicants are not bound to any theory of operation of the invention, it is thought that reaction of the amine with the impurities increases the size of the contaminates, thereby decreasing the separation efficiency of the semi-permeable membrane.
[0015] One family of exemplary membrane separators that may be used in the invention is the D-Series of nanofiltration membranes available from GE. This is a spirally wound multilayer membrane in cylindrical form. Typically, these membranes operate at low feed pressures on the order of about 70-400 psig. The temperature of the feed is maintained at from about 0-100° C. Other exemplary membranes and operating conditions therefore are reported in U.S. Pat. No. 5,034,134 incorporated by reference herein.
[0016] The invention will be further described in conjunction with the following examples which should be viewed as being illustrative of exemplary embodiments and should not be construed to limit the invention.
EXAMPLES
[0017] In order to assess the efficacy of the treatment compounds in reducing carbonyl species contamination in a liquid hydrocarbon medium, glycol process aldehyde scavenging tests were conducted. A feedstock comprising ethylene glycol/H 2 O (40/10 v/v) was provided with aldehyde present in the medium in the amount indicated below. Tetraethylenepentamine/ethylene glycol candidate treatments were provided at 10% w/w.
[0018] Graduated cylinder vials were prepared with the liquid hydrocarbon medium and, where applicable, candidate treatment present. The vials were heated at 90° C. for 60 minutes. Following this reaction period, acetaldehyde concentration in the vapor phase was determined by gas chromatography. Results are as shown in Table I.
TABLE I ppm tetraethylenepentamine ppm acetaldehyde 0 249 537 120 1075 68 1612 50 2150 37
[0019] In accordance with the patent statutes, the best mode of practicing the invention has been set forth. However, it will be apparent to those skilled in the art that many other modifications can be made without departing from the invention herein disclosed and described. | Carbonyl species contamination of liquid hydrocarbon media and corrosion of metal surfaces in contact with such media are inhibited. A high boiling point primary or secondary amine is added to the desired liquid hydrocarbon medium, and in one exemplary embodiment, the medium is then brought into contact with a separatory membrane such as a nanofiltration membrane. The permeate from the membrane is a highly purified hydrocarbon stream. | 2 |
This application is related to, and claims the benefit of, Provisional U.S. patent application Ser. No. 60/415,239, filed Oct. 2, 2002, which is incorporated herein by reference in its entirety.
This application includes material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention relates to the field of power generation, and more particularly it pertains to engines of a continuous and or impulse combustion type, which utilize boundary layer effects. The present invention can also act as part of a process, rather than simply performing a function. It also has the capability to act as a power generation unit and a process at the same time, (e.g. producing hydrogen, desalinating water, or the like).
BACKGROUND OF THE INVENTION
In 1903, Nikola Tesla engineered a type of steam turbine, for which he was granted U.S. Pat. No. 1,061,142 on May 6, 1913, and U.S. Pat. No. 1,061,206 on May 6, 1913, the teachings of which are incorporated herein in their entirety. This type of turbine is commonly referred to as a continuous combustion turbine or a boundary layer turbine. FIGS. 1 a and 1 b illustrate a conventional, continuous combustion turbine. Continuous combustion turbines generally can perform two very different functions. In one arrangement, the turbine can serve as a motor, powering an external device. In another arrangement, the turbine can be used as a pump.
The principles for operation of the typical continuous combustion turbine illustrated in FIGS. 1 a and 1 b are well documented and should be known to one skilled in the art. Briefly, a continuous combustion turbine operating as a motor generally consists of a serial connection of a compressor element (not shown) and a motor element 19 . Motor element 19 includes a plurality of parallel discs 13 , which are mounted to a central drive shaft 16 through mounting brackets 15 . Motor element 19 also typically includes an inlet port 25 and an outlet port 20 .
As the compressor element compresses a gas or fluid, the compressed gas or fluid is forced into motor element 19 through inlet port 25 . The inlet port is generally configured such that the compressed gas or fluid strikes discs 13 substantially tangential to the circumference of the discs. Through adhesion, the compressed gas or fluid causes the discs to rotate as the compressed gas or fluid works its way to outlet ports 20 via holes 14 in discs 13 . As described above, drive shaft 16 is connected to discs 13 through mounting bracket 15 , and drive shaft 16 rotates with discs 13 , thereby providing motive power to a device mounted to drive shaft 16 outside of motor element 19 . Drive shaft 16 also serves to support discs 13 within motor element 19 .
In typical continuous combustion engines, the engine can be operated in reverse simply by causing the compressed gas or fluid to strike the discs 13 on the opposite side. For example, in FIG. 1 a , if the compressed gas or fluid entered motor element 19 through the left-hand inlet port 25 , discs 13 would rotate in a counter-clockwise manner. However, if the compressed gas or fluid entered chamber 19 through the right-hand inlet port 25 , discs 13 would rotate in a clockwise manner.
The continuous combustion turbine can also be used as a pump. Rotating drive shaft 16 causes discs 13 to rotate. If a fluid or gas is present in housing 19 , discs 13 can cause the fluid to be pulled from outlet 14 , and ejected at a higher pressure via inlet 28 .
Continuous combustion turbines are advantageous over other, more traditional fluid-based turbines because the motive force is supplied without the need for fans or other such devices. Fans, for example, are subject to significant stress as the fluid impacts the fan blades. This can lead to damage of the blades, and can result in the introduction of foreign matter into the fluid. In a closed-loop system, the foreign matter may be repeatedly injected into the engine compartment at high speed, and this can quickly result in catastrophic damage to both the blades and the engine itself.
Some in the prior art have adapted the basic Tesla boundary layer turbine design for specific uses. For example, U.S. Pat. No. 6,503,067, to Palumbo, the teachings of which are incorporated herein by reference in their entirety, discloses a bladeless multi-disc turbocharger for use with an internal combustion engine. Similarly, U.S. Pat. No. 6,375,412, to Dial, the teachings of which are incorporated herein by reference in their entirety, discloses a multi-disc impeller for pumps, turbines, and the like. While these references have applied and made minor modifications to the basic Tesla design, these adaptations have made only minor advancements in the art.
SUMMARY OF THE INVENTION
What is needed is a higher-level analysis of the fundamental adhesion and viscosity properties exploited by the basic boundary layer turbine to improve the overall state of the art. The present invention is directed to an improved method of and apparatus for a multi-stage boundary layer turbine and process cell that substantially obviates one or more of the problems due to limitations and disadvantages of the related art. Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention.
The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. To achieve the objectives and other advantages, and in accordance with the purpose of the present invention as embodied and broadly described herein, in one aspect of the present invention there is provided a power generation system and/or process cell which achieves high thermal efficiencies and high mechanical power output for use in power generation, geothermal, energy recovery, solar, transportation, fuel production, desalination process, hydroelectric and related fields.
The present invention also provides a power generation system comprised of a series of stages which are formed or made of disc pack configurations. The different stages provide torque to a main output shaft. The stages preferably include compressor, turbine and/or vacuum stages. According to a preferred embodiment, the compressor stage feeds external combustors which provide power to the turbine. This power is then preferably fed into the vacuum stages. A vacuum source at the exhaust end of a water turbine can increase the efficiency of the turbine 3–4% for every cubic inch of water pulled.
The present invention also provides a power generation system which preferably utilizes a technique based on the adhesion and viscosity of different mediums. The viscosity of the medium used to supply energy to the engine can be used to set the disc pack spacing. For example, the gap between the disks may be closer when air is the energy supply medium as compared to when steam is the energy supply medium because steam has a higher viscosity than air.
The present invention also provides a power generation system preferably comprised of a condenser between the disc pack turbine and disc pack vacuum stage. Another aspect of the present invention provides a power generation system energy source which can be run as a closed-loop system. In a closed-loop configuration heat exchanger can supplement or even replace the combustion cans.
The present invention also provides a power generation system which may be comprised of all ceramic discs for use in high temperature environments for increased efficiencies. Another feature or aspect of the present invention provides a power generation system which incorporates ceramic coatings, alloy coatings and nanocomposite coatings such as, but not limited to, nanocomposite mesoporous ceramics, to enhance the boundary layer effect. These coatings can also allow a turbine to operate at a higher temperature without the need for exotic materials.
The present invention may also incorporate a catalyst coating which reduces emissions. The present invention also provides a power generation system which may incorporate or use a catalyst coating which also allows the engine to act as a process for producing hydrogen, as well as desalinating water, and other such purposes.
The present invention also provides a power generation system which can employ the use of water injection in a nozzle system which will add higher efficiencies as well as reducing NO x .
Another aspect of the present invention provides a power generation system which incorporates catalytic combustors with water-cooling. The cooling water for the combustors is preferably preheated and then injected into water injection ports of the nozzles.
Another aspect of the present invention provides a power generation system which incorporates multiple catalytic combustors with water cooling. The use of multiple nozzles increases power output.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
Accordingly, it is the objective of the claimed invention to increase the efficiency, reliability and flexibility of continuous and/or impulse combustion turbine technology. The present invention may also be applied with like effect apart from present turbine processes and is intended for the broad purpose of producing power through a variety of mediums including gasoline, diesel, natural gas, biomass, methane, hydrogen, propane, liquid propane gas (LPG), steam, geothermal, solar hybrid, water, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIGS. 1 a and 1 b provide a schematic of a prior art disk turbine configuration.
FIG. 2 is an illustration of a disk pack mounted to a shaft with a locking plate using an internal dovetail configuration
FIG. 3 is an illustration of a disk pack mounted to a shaft with a locking plate using an external dovetail configuration.
FIG. 4 is an illustration of a single, one piece disk pack made of ceramics.
FIG. 5 is an illustration of a disk with a nose cone and pitch control
FIG. 6 is an illustration of a single unit disk ceramic disk pack.
FIG. 7 is an illustration of a ceramic disk with a catalyst coating.
FIG. 8 is an illustration of a single disk employing the use of MEM sensor devices.
FIG. 9 is an illustration of a Brayton type configuration which includes a built in condenser along with a vacuum stage.
FIG. 10 is an illustration of an inlet nozzle system.
FIG. 11 is an illustration of a closed loop system which has the turbine and vacuum stage on a single shaft.
FIG. 12 is a cut away side view of the vacuum, turbine, and generator segments of the closed loop system of FIG. 11 .
FIG. 13 is a cut-away front perspective view of a closed loop system similar to that illustrated in FIG. 11 .
FIG. 14 is a cut-away left-hand perspective view of a closed loop system similar to that illustrated in FIG. 11 .
FIG. 15 is a close-up view of the vacuum and generator stages illustrated in FIG. 14 .
FIG. 16 is a cut-away right-hand perspective view of a closed loop system similar to that illustrated in FIG. 11 .
FIG. 17 is an illustration of a front view of a compact, multi-stage engine which has been mounted using a preferred mounting technique.
FIG. 18 is an exploded perspective view of the multi-stage engine and mounting technique of FIG. 17 .
FIG. 19 is a front perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 .
FIG. 20 is a top perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 .
FIG. 21 is an alternative front perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 .
FIG. 22 is a cut-away view of a two-stage engine embodiment of the present invention.
FIG. 23 is a perspective view of an assembled, multi-input port, single-stage engine.
FIG. 24 is an exploded view of the engine illustrated in FIG. 23 .
FIG. 25 is a close-up of an input port and mounting means employed in the engine illustrated in FIG. 23 .
FIG. 26 is a close-up of the support disc, exhaust cone, mounting pins, and discs of the engine illustrated in FIG. 23 .
FIG. 27 is a cut-away perspective view of the engine illustrated in FIG. 23 .
FIG. 28 is a close-up view of portions of FIG. 23 .
FIG. 29 is a still closer view of portions of FIG. 23 .
FIG. 30 is a cut-away view of the engine of FIG. 23 .
FIG. 31 is a cut-away front view of the multi-port engine illustrated in FIG. 23 .
FIGS. 32 a , 32 b , and 32 c are detailed views of the front, side, and backs, respectively, of discs preferably employed in the embodiment illustrated in FIG. 23 .
FIG. 33 is a cut-away side view of a disc pack according to an embodiment of the present invention.
FIG. 34 is a cut-away side view of a disc pack according to an alternative embodiment of the present invention.
FIG. 35 is a cut-away side view of a disc pack according to another alternative embodiment of the present invention.
FIG. 36 is a side view of a disc pack according to an embodiment of the present invention.
FIG. 37 is a cut-away side view of a disc pack which better illustrates the use of supports near the outer edges of the discs as implemented in an embodiment of the present invention.
FIG. 38 is another cut-away side view of a disc pack, including the use of supports near the outer edges of the discs, according to an embodiment of the present invention.
FIG. 39 is another cut-away side view of a disc pack, including the use of supports near the outer edges of the discs, according to an embodiment of the present invention.
FIG. 40 is a perspective view of a disc pack according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Although this specification frequently makes reference to gases, liquids, and combinations thereof, it should be apparent to one skilled in the art that gases may be substituted for liquids, and liquids substituted for gases, without departing from the spirit or the scope of the present invention.
FIG. 2 is an illustration of a disk pack 1 mounted to a shaft 3 with a locking plate 2 using an internal dovetail configuration 4 . The dovetail attachment means 4 reduces stress at the spoke interfaces when disk pack 1 is operated at high RPM's or at high temperatures compared to the prior art. It also provides more stability and increases the ability to statically and dynamically balance disc pack 1 . Through this configuration, balancing can be accomplished by simply modifying locking plate 2 versus modifying disk pack 1 . Although an internal dovetail configuration is illustrated in FIG. 2 , it should be apparent to one skilled in the art that alternative configurations, including, without limitation, an external dovetail configuration such as that illustrated in FIG. 3 , can be substituted therefore without departing from the spirit or the scope of the invention.
As illustrated in FIG. 4 , an internal dovetail mounting means preferably involves cutting or otherwise causing dovetail receivers to be created in disc 400 . As FIG. 5 further illustrates, a support plate 510 , onto which a plurality of dovetail supports 500 have been preferably mounted or otherwise attached, can be used to mount individual discs or a single-piece disc pack. Referring again to FIG. 4 , a locking plate 410 can laterally secure disc 400 , a collection of discs, or a single piece disc pack, to support plate 440 .
As illustrated in FIGS. 3 through 5 , an external dovetail mounting means eliminates the need for a center shaft that passes through a disc pack, and is also advantageous because it provides a mounting configuration which can be directly attached to a main shaft. An external dovetail configuration also preferably contains an adjustable exhaust cone 520 which can be tailored to accommodate the medium being used without having to modify the disc pack. This allows the thrust performance for a desired application to be modified if needed. This is illustrated in FIGS. 13 through 15 . A pressurized fluid can be fed into the engine through a device similar to rotating union 1510 on the intake stage to the center of the shaft. Varying the pressure within rotating union 1510 can change the geometry of exhaust cone 1520 . This principle can act as a throttle for the engine. The exhaust cone geometry can be varied by expanding the tail end of the exhaust cone, by moving the exhaust cone axially to close the exhaust gap, or by other such functions.
The configuration of FIGS. 3 through 5 also lends itself towards use as a pump. As should be clear from FIGS. 3 through 5 , there are no unwanted spokes to impede the medium being pumped. The elimination of spokes and a mounting shaft strongly reduces the possibility of damage to the pump or the pumped medium, and also reduces clogging concerns.
The internal and external dovetail mounting methods illustrated in FIGS. 2 through 5 allow the turbine to operate at higher speeds by imparting less stress at the disc mounting points. The present invention also reduces stress concentrations, corrosion, and fretting in the main shaft frequently encountered in the more traditional keyway mounting technique, and also reduces backlash effects. A dovetail, shaftless mounting means also allows the exhaust to exit closer to the center of rotation and allows for internal shaft cooling, which lends itself to the possibilities of condensing fluid within the engine.
Another aspect of the present invention is the creation of disc packs as single piece parts as illustrated in FIG. 6 . By way of example, without intending to limit the present invention, a ceramic disc pack may be made through laser sculpting of a ceramic block, forming the ceramic into the desired shape through the use of a mold, creating the disc pack using a process similar to stereo lithography, or other such manufacturing techniques which are well known in the art. The use of a single piece part has several advantages, including, but not limited to, reducing the total number of parts in the engine, simplifying design and engineering concerns, reducing the likelihood of noise, reducing the points at which failure may occur. Ceramic disc packs are presently preferred as manufacturing the disc from ceramics allows the discs to run at higher temperatures, thereby increasing efficiency, reducing exhaust emissions, and allowing the engine itself to be used for a variety of purposes including power generation. Ceramic, single-piece disc packs have the added advantage of facilitating nano-scale engine fabrication. This configuration may offer substantial advantages in the small power ranges, such as those used in portable and auxiliary equipment, and in nano-scale pumps for the medical industry.
Still another aspect of the invention is the application of coatings to individual discs or disk packs. Coatings add significant improvements in the way of emission controls, boundary layer control, corrosion protection, and the like. This is discussed in more detail with respect to FIG. 32 , below.
Coatings may also allow an engine to be used as a process. FIG. 7 illustrates coating the disks with a catalyst such as Palladium, Platinum, or other catalysts, which helps reduce emissions and can provide for the “process” function described later. A similar advantage can be realized through the use of alloys or nanocomposite materials embedded with catalysts such as Palladium, Platinum, or other catalysts metals or alloys. The machine process can produce fuels such as Hydrogen by using a catalyst, such as, but not limited to, Platinum, a Nickel-tin alloy, Uranium, Zirconia, and Methanation catalysts, may strip the hydrogen from water molecules which are flowing through the turbine, while at the same time deriving power from the flowing water.
FIG. 8 is an illustration of an inlet nozzle 800 which can inject water or other fluids into the stream of medium entering the nozzle housing 830 through water exhaust ports 820 . The combustion nozzle configuration illustrated in FIG. 8 can increase the overall system efficiency, and allows the engine as a process, such as, but not limited to, one that strips hydrogen from injected water. As described above, especially where ceramic discs or disc packs are used, the present invention can be operated at very high temperatures (in excess of 2500 degrees Farenheight). At such temperatures, water injected through water exhaust ports 820 will instantly vaporize, and the water molecules will be in an extremely excited state. By causing the water vapor to interact with a catalyst, individual hydrogen atoms may be stripped from the water molecules. The hydrogen can be captured at the exhaust port, and any remaining water can be captured in a down-stream condenser and recycled to the system.
The combustion chamber nozzle configuration of FIG. 8 also allows the discs to be cleaned without disassembling the entire engine by injecting a cleaning medium through water exhaust 820 . Furthermore, the use of convergent and convergent/divergent nozzle systems provides a substantial gain in power output. The engine technology of the present invention also preferably incorporates water injection to reduce NO x , provide power, and increase power output.
FIGS. 6 and 7 also illustrate the use of torque notches on the perimeter of the discs. The torque notches can add to the overall engine power by providing a surface upon which the tangentially-entering fluid may make contact before the fluid begins its boundary layer interaction with the disc.
As illustrated in FIG. 7 , the use of microelectromechanical (MEM) sensors provides the ability to monitor engine and disk structures. MEM sensors can be used to provide on-site and remote performance data analysis, which can facilitate detection and correction of potentially catastrophic issues before they become significant.
FIG. 10 is an illustration of a Brayton type configuration which includes built-in condenser 1017 and vacuum 1013 stages. The configuration depicted in FIG. 10 is set up as a compressor 1002 , turbine 1019 , vacuum 1013 stage type embodiment. In this embodiment, external combustion chamber 1022 provides an energy source for turbine stage 1019 . Fuel is drawn into combustion chamber 1022 through fuel intake 1023 , where it is burned. The heat from the burning fuel causes the air in combustions chamber 1022 to expand, increasing the pressure in the combustion chamber. The heated, compressed air leaves combustion chamber 1022 and enters the main turbine through inlet nozzle 1021 . Air is drawn into combustion chamber 1022 through compressor ducting 1000 . The engine in the embodiment illustrated in FIG. 10 is able to extract energy from the air drawn into combustion chamber 1022 by placing a compressor chamber 1002 and associated discs 1001 between compressor ducting 1000 and air intakes 1006 .
The air passes over the main turbine discs 1020 after exiting combustion chamber 1022 , which provides the majority of the power generated by the embodiment of FIG. 10 . As described above, the air imparts momentum to turbine discs 1020 through boundary layer effects. The gas exits the main chamber through condenser 1017 , and is made available to vacuum stage 1013 . Vacuum stage 1013 acts as a pump to draw the air from condenser 1017 and expel it through exhaust duct 1018 . It should be noted that, in the embodiment of FIG. 10 , compressor 1003 , main turbine 1019 , and vacuum stage 1013 are all preferably connected to main shaft 1005 . Thus, main shaft 1005 provides power to vacuum stage 1013 . The vacuum stage illustrated in FIG. 10 can increase turbine efficiency approximately 3–4% for every cubic inch of air pulled by the vacuum stage.
With the removal of compressor stage 1002 and combustion chamber 1022 , the engine can run in a closed loop configuration. Such a configuration can be advantageous where the turbine is powered by a steam, geothermal, or other energy source.
The removal of vacuum stage 1013 can allow the engine of FIG. 10 to act as a propulsion system. In such a configuration, thrust from the gas or other medium exiting main turbine 1019 can provide forward momentum.
FIG. 11 depicts a closed loop system mounted on a single, dual-shafted generator 1155 , wherein each shaft is preferably connected to discs 1125 using the external dovetail configuration. The embodiment illustrated in FIG. 11 eliminates the need for all components to be mounted in a single case. This embodiment also lends itself to use in a geothermal fluid pressure based system. In such a system, vacuum exhaust tube 1115 may bypass condenser 1150 and may be fed back into heat exchanger inlet tube 1155 from the source.
As described above, the present invention can be used with a variety of energy sources, including, but not limited to, geothermal energy. By way of example, without intending to limit the present invention, a low boiling point medium can be used as the power transfer means within the closed-loop system. In such an embodiment, heat exchanger 1130 can be inserted into an empty oil well, abandoned mine, or the like. Generally, the earth is significantly warmer at those depths, and the geothermal heat will cause the low boiling point medium to vaporize, increasing its pressure. The pressurized gas can be returned to the surface and vented to the turbine discs 1125 . The gas can be vented through exhaust tubes 1115 and optionally run through a condenser 1150 , which further cools the medium. The cool medium is then drawn out of condenser 1150 through vacuum discs 1145 , where it is returned to heat exchanger 1130 through heat exchanger inlet tube 1135 . Rotation of the discs can thereby power generator 1155 .
Similarly, the embodiment of FIG. 11 can be used to capture thermal energy generated by automobiles and convert it to electrical power. This power can then be stored for subsequent use, and to reduce the load imposed on the engine as more and more electrical devices are introduced into the automobile.
FIG. 12 is a cut away side view of the vacuum 1210 , turbine 1220 , and generator 1200 segments of the closed loop system of FIG. 11 . In the embodiment illustrated in FIG. 12 , a pressurized gas enters inlet ports 1260 and strikes turbine discs 1220 , causing them to rotate. The gas continues on a spiral path to the center of the disc chamber, where it encounters exhaust cone 1270 . Exhaust cone 1270 gently redirects the gas to exhaust port 1240 . This is advantageous over the prior art as it provides a controlled means by which the gas exits the disc pack. In the prior art disc packs, a shaft extended through the entire disc pack, and air ventilating from the discs would encounter the shaft. This induced uneven airflow, which in turn placed unnecessary stress on different portions of the disc pack. By controlling the flow of gas from the disc pack a less stressful environment is created, thereby extending the life cycle of the disc pack, and increasing the flow rate at which material can flow through the disc pack, further increasing both power and efficiency.
In a closed loop system, such as that of FIG. 11 , the exhaust from exhaust port 1240 flows through a condenser or other cooling means, and is then fed back into inlet port 1230 . The gas is drawn into inlet port 1230 , across vacuum stage cone 1280 , which gently redirects the gas across vacuum stage discs 1210 , and into vacuum stage outlet ports 1250 . The gas is drawn into inlet port 1230 due to the rotation of discs 1210 . Discs 1210 and discs 1220 are both preferably connected to shaft 1285 , and when discs 1220 rotate, this causes shaft 1280 and discs 1210 to rotate as well. Generator 1200 preferably supports shaft 1285 using Barden bearings 1290 or other low-friction support means. FIG. 13 is a cut-away front perspective view of a closed loop system similar to that illustrated in FIG. 11 . FIG. 14 is a cut-away left-hand perspective view of a closed loop system similar to that illustrated in FIG. 11 . FIG. 15 is a close-up view of the vacuum and generator stages illustrated in FIG. 14 . FIG. 16 is a cut-away right-hand perspective view of a closed loop system similar to that illustrated in FIG. 11 .
FIG. 17 illustrates a front view of the present invention which illustrates a unique disk mounting means utilized in a preferred embodiment of the present invention. Mounting the disks using mounting stand 1703 and support pins 1702 allows the engine to be disassembled in a vertical state by allowing the turbine housing to pivot around support pins 1702 until it is in a horizontal orientation. Such disassembly eliminates split case flanges and reduces the time it takes to disassemble the engine.
In addition, FIG. 17 illustrates an external combustion chamber configuration capable of operating the turbine in either direction. The embodiment illustrated in FIG. 17 also allows thermal expansion to happen along the centerline of the engine, which eliminates the need to realign the engine with the generator as the temperature changes.
FIG. 17 also illustrates the preferred use of cooling ports 1710 in turbine housing 1711 . Cooling ports on the housing can enhance the closed loop cycle such that after being condensed in the engine, the gas or other fluids will pass through these passages to recover waste heat from the casing. This arrangement can increase engine efficiency and help cool the engine case.
FIG. 18 is an illustration of assembly/disassembly of the turbine with the turbine housing in a horizontal arrangement as described above with respect to FIG. 17 . Allowing the engine to be disassembled while horizontal reduces assembly/disassembly time and makes for easy removal/installation of critical components. FIG. 18 also illustrates a mounting technique which can allow for thermal expansion via the centerline of the engine.
The technique of rotating the main case via a set of pivot pins allows for easy removal of critical components and eliminates the need for realignment of the turbine once it is reassembled. This technique also reduces inspection and major servicing time and reduces the risk due to rotor removal, as typically experienced using a cradle removal type process. The mounting technique also allows for thermal expansion of the engine to occur along the centerline of the engine, i.e. along the rotor shaft, which in turn eliminates unwanted vibration which may be induced due to different expansion characteristics of individual components.
The power generation system also incorporates water-cooling to cool the external housing. This may be provided in a closed loop configuration such that the condensed fluids are passed to the housing to act as a pre-heater. The already pre-heated fluid makes its way to the heat exchanger where its finally heating phase takes place prior to being injected into the turbine.
FIG. 18 further illustrates a compact compressor stage 1810 /turbine stage 1840 /vacuum stage 1850 embodiment capable of driving generator 1860 . This embodiment has the advantage of placing all of the engine components in a smaller space, thereby reducing the overall physical requirements of the present invention. FIG. 19 is a front perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 . FIG. 20 is a top perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 . FIG. 21 is an alternative front perspective view of an assembled version of the multi-stage engine illustrated in FIGS. 17 and 18 .
FIG. 22 is an illustration of a closed loop system in which the turbine and vacuum stages operate on a single shaft 2290 . The configuration preferably uses an internal dovetail configuration for turbine discs 2260 and an external dove-tail configuration for vacuum discs 2220 . The turbine is fed from a heat exchanger 2240 and ultimately exhausts to a condenser 2230 through exhaust manifolds 2280 and exhaust tubes 2270 . The vacuum stage 2220 pulls gas or fluid from condenser 2230 , which is compressed and fed into heat exchanger 2240 in the closed loop configuration.
FIG. 23 is a perspective view of an assembled, multi-input port, single-stage engine. FIGS. 23 through 32 are related, and corresponding components are similarly labeled throughout the figures to facilitate understanding and identifying aspects of the invention. The embodiment illustrated in FIGS. 23 through 32 uses multiple input ports 2425 to power generator 2415 , which is preferably mounted to a sturdy stand 2400 . Gas entering input ports 2425 is preferably ventilated through exhaust port 2465 .
FIG. 24 is an exploded view of the engine illustrated in FIG. 23 . As FIG. 24 illustrates, main shaft 2420 is preferably housed within generator 2415 , and is supported by at least one high-speed, low friction bearings. Generator 2415 preferably mounts to stand 2400 through a rubber mat 2405 , to help reduce vibrations. While a rubber mat is presently preferred, it should be apparent to one skilled in the art that other vibration reduction means, including, but not limited to, attaching generator 2415 directly to stand 2400 , may be substituted therefor without departing from the spirit or the scope of the invention.
Shaft 2420 preferably attaches to the disc pack through mounting bracket 2424 . Generator 2415 is preferably otherwise isolated from the disc pack and the related heat and high-pressure gases through the use of a seal 2423 . Because mounting bracket 2424 will rotate at high speeds, mounting bracket 2424 preferably includes a plurality of vacuum notches 2426 , to help alleviate the vacuum that would otherwise build up between mounting bracket 2424 , rotor case 2430 , and support plate 2435 . Support plate 2435 preferably contains a plurality of vacuum release holes 2447 which preferably align with vacuum notches 2426 , providing a path through which the vacuum may be relieved. Exhaust cone 2475 can further assist in the relief of the vacuum pressure. As illustrated in other figures, including FIGS. 33 through 39 , exhaust cone 2475 preferably includes a ventilation tube through which air or other gases may pass from vacuum release holes 2447 to exhaust port 2465 .
Support plate 2435 also preferably includes a plurality of disc support posts 2440 , dovetail adapters, or the like. As will be described below with respect to FIG. 30 , support posts 2440 , or the corresponding dovetail or other adapters, also preferably contain ventilation tubes. Discs 2450 can be attached to support plate 2435 by sliding them onto support posts 2440 . A retaining ring 2455 is then preferably placed over discs 2450 and mated with support plate 2435 through attachment means 2480 . Attachment means 2480 is preferably open to allow support posts 2440 to properly ventilate. Support plate 2435 , discs 2450 , and retaining ring 2455 are preferably encased within rotor case 2430 , which is in turn sealed by attaching rotor case plate 2460 to the outside of the rotor case 2430 .
In the embodiment illustrated in FIG. 24 , gas enters rotor case 2430 through inlet ports 2425 , interacts with plates 2450 , and exits through 2465 . The interaction of the gas and plates 2450 causes shaft 2420 to rotate, generating power though generator 2415 .
FIG. 25 is a close-up of an input port 2425 , flow nozzle 2470 , and input port mounting means employed in the engine illustrated in FIG. 23 . FIG. 26 is a close-up of support plate 2435 , vacuum release holes 2447 , exhaust cone 2475 , mounting pins 2440 and their ventilation tubes, discs 2450 , locking ring 2455 , and mounting means 2480 of the engine illustrated in FIG. 23 . FIG. 27 is a cut-away perspective view of the engine illustrated in FIG. 23 . FIG. 28 is a close-up view of portions of FIG. 23 . FIG. 29 is a still closer view of portions of FIG. 23 , and provides a clear view of the ventilation tube preferably encased within exhaust cone 2475 .
FIG. 30 is a detailed engineering schematic of the engine of FIG. 23 . As support plate 2435 and retaining ring 2455 rotate, a vacuum, and corresponding drag, may be crated between them and rotor housing 2430 . In a preferred embodiment, the vacuum passages 2426 are sufficiently long to facilitate relieving the vacuum created between rotor housing 2430 and support plate 2435 . As described above, mounting pins 2440 preferably include ventilation tubes which allow the gap between cover 2460 and locking ring 2455 to ventilate to and through the vacuum passages 2426 , and out through vacuum passage exhaust 2978 .
FIG. 31 is a cut-away front one possible embodiment of the multi-port engine illustrated in FIG. 23 . The engine compartment illustrated in FIG. 31 is designed to operate in only a single direction, as is frequently the case in power generation systems. This embodiment utilizes multiple inlet ports 2425 to more evenly distribute the incoming gas around the circumference of the discs. The use of multiple input ports also reduces drag induced in certain regions around certain portions of the case.
The engine compartment illustrated in FIG. 31 also utilizes nozzles 2470 designed to further increase the pressure of the gas or fluid injected into the engine compartment by restricting flow to a narrow inlet. The outermost edge of nozzles 2470 , which is defined by rotor case 2430 , preferably gradually tapers down as it becomes the innermost edge of the following inlet port. This helps further reduce drag and allows the gas or fluid to first strike the discs substantially tangential to the surface of the discs.
FIGS. 32 a , 32 b , and 32 c are detailed views of the front, side, and backs, respectively, of discs preferably employed in the embodiment illustrated in FIG. 31 . Coating the disks with a ceramic, composite, or nano-composite such as, but not limited to, ceramic mesoporous nanocomposites, will also provide the capability to run the rotor at much higher temperatures. This will increase overall efficiency while at the same time reducing emissions. The use of mesoporous nanocomposite ceramics will allow the cavities to be filled with materials to facilitate finer boundary layer control and to address corrosion issues.
As described above, a preferred embodiment of the present invention includes coating the discs with one or more substances to improve adhesion, serve as a catalyst, or for other purposes. FIGS. 32 a and 32 c illustrate a preferred coating pattern. In a preferred embodiment, the entire surface of the disc is coated with the desired substance, and the substance is subsequently etched or otherwise removed from portions of the disc surface, represented by shaded regions 3200 , leaving only a bare disc surface 3201 . Etching portions of the substance from the disc surface allows fine-grained tailoring of the duration the fluid or other material stays in contact with the discs. By creating the illustrated designs, the etching can also reduce or eliminate slip and effectively eliminate any centrifugal pumping effect. Centrifugal pumping effect refers to the tendency of heavier molecules to be forced to the outside of the engine chamber, opposite the preferred direction of travel. By etching the disc surfaces and allowing the discs to touch each other, channels are effectively created through which the material supplying energy to the engine can travel, yet which traps the heavier molecules within the discs, thereby reducing the likelihood that such molecules will flow opposite the desired flow direction.
With etched discs, a disc pack can be formed by placing the discs immediately next to each other. As FIGS. 32 a and 32 c illustrate, the discs are preferably etched with complementary flow patterns, such that the etching on each disc is approximately ½ the overall width desired for the intra-disc channel. Placing individual discs in physical proximity has the added advantages of strengthening the overall disc pack, and reducing the number of parts involved in the disc pack by eliminating the need for spacers.
The size, shape, and number of swirl patterns on a disc can be varied according to a variety of factors, including, but not limited to, the viscosity of the gas or fluid providing power to the disc pack, desired flow rates, and the like. The etched design can also improve overall turbine performance while minimizing the risk of introducing large debris into closed systems.
FIGS. 33 through 40 illustrate a variety of alternative ventilation, cone attachment, disc support, and related means contemplated for use with the present invention. FIG. 33 is a cut-away side view of a disc pack according to an embodiment of the present invention. FIG. 34 is a cut-away side view of a disc pack according to an alternative embodiment of the present invention. FIG. 35 is a cut-away side view of a disc pack according to another alternative embodiment of the present invention. FIG. 36 is a side view of a disc pack according to an embodiment of the present invention. FIG. 37 is a cut-away side view of a disc pack which better illustrates the use of supports near the outer edges of the discs as implemented in an embodiment of the present invention. FIG. 38 is another cut-away side view of a disc pack, including the use of supports near the outer edges of the discs, according to an embodiment of the present invention. FIG. 39 is another cut-away side view of a disc pack, including the use of supports near the outer edges of the discs, according to an embodiment of the present invention. FIG. 40 is a perspective view of a disc pack according to an embodiment of the present invention.
As described above, one aspect of the present invention is that it takes in high-pressure gases, fluids, and the like, and expels them at a lower pressure. One anticipated embodiment of the present invention utilizes a boundary layer engine as a step-down converter for high pressure natural gas and other fluids. By way of example, without intending to limit the present invention, many homeowners utilize natural gas to heat their homes, ovens, and stove tops. When natural gas is distributed by a gas company, the natural gas is frequently distributed at very high pressures, such as 1000 pounds per square inch, which is significantly higher than can be safely used in the home. The gas companies use step-down flow regulators to reduce the pressure introduced into the home. These flow regulators waste a significant quantity of energy. An embodiment of the present invention would substitute a boundary layer engine for traditional flow regulators, thereby allowing the homeowner and/or the gas company to capture some of the energy from the natural gas line.
When used as a pump, the single-stage, multi-input port embodiment illustrated in FIGS. 23–32 can also be used to mix various compounds. In such an embodiment, as compounds are drawn into rotor case 2430 through inlet ports 2425 , the compounds are well mixed due to their adhesion to discs 2450 . Furthermore, as the compounds encounter exhaust cone 2475 , a strong vortex is created which further mixes the compounds.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A multi-staged boundary layer engine and process cell, (based on the effect known as adhesion and viscosity) which achieves high thermal efficiencies and high mechanical power output for use in the power generation, geothermal, energy recovery, solar, transportation, hydrogen production, desalinating water and hydroelectric fields. The design is novel with a dovetail attachment of the disc packs, allowing lower stress and allowing the use of next generation materials such as ceramics, composites and nanocomposites to improve the maximum temperature and the maximum RPM of the engine, thereby producing more horsepower and torque. In addition, this invention includes multi-stage vacuum, an external combustion chamber and condenser stages to improve the vortex flow through the primary disc pack cell. This engine will also encompass a closed loop cycle for ultimate efficiencies. This invention will also include the use of catalysts and/or electrical polarities applied to the disc pack and the disc pack/casing respectively to achieve low NO x and also to achieve process cell capability for applications such as desalinization and hydrogen generation. | 1 |
This is a divisional of application Ser. No. 08/676,643, filed Jul. 10, 1996, now Pat. No. 5,695,847.
FIELD OF INVENTION
This invention relates to thermally conductive materials used in heat transfer joints. More particularly it relates to a joining film composed of a thin polymeric composite sheet material containing orientated thermally conductive fibers, processes for manufacturing this film and use of this film in heat transfer joints.
BACKGROUND OF THE INVENTION
Thermal management is a major concern in the design of electronic components. All aspects of electronic system thermal management and the role of thermally conductive joining materials are discussed in ASM International's Electronic Materials Handbook, Volume 1, Packaging, 1989. Heat generated during equipment operation must be removed in order to avoid circuit damaging temperature buildups. The failure rate of semiconductor devices (chips or dies) increases exponentially with increasing temperature due to irreversible degradation of the transistor junctions. A major pathway for heat removal in electronic assemblies is by conductive diffusion of the heat through thermally conductive materials.
On-going electronic design trends dictate the need for improved thermal management materials. Improved electronic performance is accomplished by circuit miniaturization, closer component spacing, and by increasing power levels to increase circuit speed. These changes result in a higher heat flux that must be removed. The present state of the art needs materials with improved thermal transfer properties to improve removal of heat from components thereby leading to increased electronic equipment reliability and service life.
Thermally conductive joints transfer heat in electronic assemblies between physically connected parts. They are an important part of most heat removal paths. The heat transfer efficiency of these joints is defined by the concept of thermal resistance:
R=t/kA, (1)
where R is thermal resistance (° K/watt), t is the thickness of the joint (m), k is thermal conductivity (W/m·° K), and A is the area of the joint (m 2 ).
The lower a joint's thermal resistance (R) is, the greater is its heat transfer efficiency. This results in a lower temperature rise for a device at a given power level. As illustrated by equation (1), decreasing the thickness (t) of a joint decreases its thermal resistance (R). For materials that have the same thermal conductivity in all directions (thermally isotropic), this also makes thickness uniformity desirable. Otherwise, non-uniform heat flow rates will occur between the thick and thin portions. Increasing the thermal conductivity of the joint material and/or the area A decreases the thermal resistance (R). This makes it a requirement that any joint material conform to all the available surface area and not leave gaps or voids.
There are three types of thermally conductive joints important to electronic equipment:
(1) A bare contact between two rigid materials is the simplest joint. This joint cannot hold the materials together on its own and must have support provided from some other source. The thermal efficiency of this joint is related to how close the joint surfaces fit together. On a microscopic scale, the materials will only make point contacts leaving air gaps covering most of the contact area. Due to the extremely poor thermal conductivity of air (0.035 W/m·° K), the thickness of this gap must be reduced as much as possible. This thickness is determined by the smoothness and precision of the fit between the contact surfaces. Costly machining operations are typically required to allow these joints to transfer heat efficiently. Bare contact joints are also subject to corrosion and contamination problems.
(2) The bonded joint is the most common type used in electronic assemblies. A thermally conductive adhesive joining material adheres to the joint surfaces to hold the surfaces together and conducts thermal energy between the joint surfaces. Usually a thermally conductive adhesive flows over a joint surfaces when the joint is formed. The thermal efficiency of this joint is determined by how completely the adhesive covers the joint surface, the thermal conductivity of the adhesive layer and the thickness of this layer.
(3) The gasketed joint is increasingly being used in electronic assemblies. The gasket is a thermally conductive solid sheet of joining material that does not flow when the joint is formed. The gasket joint's thermal efficiency is determined by how closely the gasket joining material conforms to the joint surface, the thermal conductivity of the gasket joining material and its compressed thickness. The gasket joining material is typically a rubber (elastomeric) sheet. A joint with this material in it is typically held together with clamps or by pressure sensitive adhesive on the surface of the rubber. In some cases the rubber may have pressure sensitive adhesive properties of its own.
A desired characteristic of all thermally conductive joining materials is that they be able to intimately contact the joint surface by conforming to its shape. The joining material does this during the fabrication process by flowing as a liquid or by compressing as a solid. This allows surfaces that are not perfectly matched to be efficiently, thermally joined. This typically eliminates the surface machining required for bare contact joints and leads to lower manufacturing costs.
Another desired characteristic of thermally conductive joining materials is a low thermal joint processing temperature, which minimizes problems caused by coefficient of thermal expansion (CTE) stress. Die bonding usually entails heating the joining material for bonding with the surface to be joined. Normally the semiconductor has a CTE that is different from the substrate it is being bonded to. Therefore, the greater the temperature excursion during the processing of the die bond, the greater the CTE stress on the semiconductor chip when it cools down. This can lead to damage or lower reliability for the device. Therefore a lower processing temperature is desirable for the die bonding material.
CTE stresses can also be decreased by lowering the in-plane stiffness of the die bond itself. Therefore a die bond material with a lower in-plane rigidness (modulus) is desirable. Higher bond material thickness lowers the CTE stresses but this normally increases thermal resistance. In order to minimize CTE stress, a particularly desirable combination of attributes for a die bonding material would be a low processing temperature, a low in-plane modulus, and higher thermal conductivity to allow increased bond material thickness with the same or lower thermal resistance.
Often the electrical properties of a thermal joining material are important. The thermal joint for some electrical designs is either electrically conductive or insulating. It is desirable therefore that an improved thermal joint be capable of being either electrically conductive or non-conductive.
The most common forms of materials used for electronic joints are pastes and films. Pastes are liquid materials that are typically applied by hand application or by a machine controlled syringe. Films are thin, controlled thickness sheets of the joining material. Films can be either semi-liquid or solid materials that become liquid during processing or rubber materials that will conform under compression. Films offer advantages in uniform thickness control, reduced voids and less material waste.
The most commonly used materials for thermally conductive joints are solders, silver-glass eutectic alloys, and organic polymers. All of these materials when used in joints have serious deficiencies. For example, a major problem with thermally conducting solder joining materials is that higher thermal conductivity is attainable only by using undesirable high processing temperatures. The thermal conductivity of solders range from 35 to 73 W/m ° K. Solder thermal joints must also have a melting point that significantly exceeds subsequent processing temperatures. This limits processing temperatures with solder to a relatively high range, which leads to CTE stress problems. Solder is also subject to fatigue cracking caused by CTE stresses generated by temperature cycling during normal equipment operation.
Silver-glass bonds are normally achieved by applying a mixture of silver flake loaded glass that is dispersed in an organic matrix and firing it at 320 to 460° C. The organic matrix is burned out and an eutectic alloy bond material is formed. The high temperature firing leads to CTE stress problems, requires extra coating steps, and can have oxide formation problems. Silver-glass has a thermal conductivity of 40 to 75 W/m·° K.
Organic polymers typically have a low processing temperature, low manufacturing costs, and low in-plane modulus. Organic polymers also exhibit excellent compressibility, thus intimately contacting the joint surfaces being mated even though these surface do not exactly match in shape. However, organic polymers also have very low thermal conductivity (0.1 to 0.3 W/m·° K).
Thermally conductive fillers have been added to organic polymers to increase the thermal conductivity. While the fillers increase the thermal conductivity of organic polymers significantly, the thermal conductivity achieved is still only a tiny fraction of the conductivity of the fillers themselves. Silver has a thermal conductivity of 420 W/m·° K, but silver filled polymers achieve only 2 to 6 W/m·° K. Diamond filler has a thermal conductivity of over 1500 W/m·° K, but diamond filled polymers achieve only 8 to 11.5 W/m·° K.
Thermally conductive fibers have also been used to fill polymers to improve thermal conductivity. For example, Eddy et al., in U.S. Pat. No. 4,321,033 (1982) describes carbon or metal fibers in a brush configuration that is impregnated with an elastomer material. An improvement in thermal conductivity over silicon rubber of about 3 times is described. However, the Eddy et al composite material is not useful or adaptable as a thermally conductive joining film, because it is too thick. It is stated that the brush fabric can not be conveniently made below 30-50 mils (0.76-1.27 mm) in thickness. Yet, it is desirous that a thin film of joining material be less than 30 mils.
Lee et al., in U.S. Pat. No. 4,729,166 (1988), describe a means for fabricating an anisotropic electrical conductor having conductive fibers that run through the thickness so that they extend from surface to surface. These fibers are also oriented to extend in a direction that is substantially perpendicular to the surfaces of the conductor. The composite material in Lee et al., however, lacks the proper compressibility required to be an effective thermally conductive joining film. While polymer based matrix materials may exhibit sufficient local compressibility, the fibers extending between the matrix surfaces act as small rigid columns that resist compressive loads and therefore are incapable of compressing locally to accommodate a variable gap between substrates. Without the ability to compress, these composite materials can efficiently thermally join only two perfectly matched surfaces. Even with two matched surfaces, the fibers would have to be exactly the same length and would have to exactly match each top and bottom surface.
In order to locally compress the prior art films, the fibers therein must start to buckle under the compressive load before the elastomer around them can start to compress. A simple column buckling analysis using Euler's formula is described in Standard Handbook of Machine Design, chapter 15, 1986, McGraw-Hill, Inc. The unrestrained load (P CR ) on the ends of a fiber required to start it to buckle is given by:
P.sub.CR =π.sup.L EI/L.sup.2, (2)
For a round fiber the moment of inertia, l=0.049d 4 , therefore:
P.sub.CR =0.049π.sup.2 Ed.sup.4 /L.sup.2 (3)
In this case a conversion to the force (F cr ) applied is more useful:
F.sub.cr =P.sub.cr /A (4)
For a round fiber, the area A equals π(0.5 d) 2 , therefore:
F.sub.cr =0.1 9πEd.sup.2 /L.sup.2, (5)
where F cr is the applied critical compressive force (MPa), E is elastic modulus (MPa), d is fiber diameter (cm), and L is the length of the fiber (cm). The load required to start compressive deflection of the overall sheet is given by:
F=F.sub.cr V.sub.f, (6)
where F is the compressive force (MPa) and V f is the fiber volume fraction.
According to equation 5, a copper fiber of 0.01 cm (0.004 in) diameter (d), a length (L) of 0.1 cm (0.039 in) and an elastic modulus (E) of 131,000 MPa (19 psi) would require a force (F cr ) of over 807 MPa (116,993 psi) to start the fiber elastically buckling, thus allowing the sheet to compress. Even assuming a low fiber volume (V f ) of 0.10, a force (F) of 80.7 MPa (11,699 psi) would be required to compress this material. This is beyond anything reasonable for an elastic sheet.
For a mesophase pitch based carbon fiber with a diameter (d) of 0.001 cm (0.0004 in) and a modulus (E) of 837,000 MPa (120 psi), a force (F cr ) of 50.9 MPa (7,389 psi) would be required to start to buckle a fiber length of 0.1 cm (0.039 in). Being a very brittle fiber, it would break after a small buckling deformation, permanently disrupting the heat flow path. A fiber volume (V f ) of only 0.10 would require 5.1 MPa (739 psi) to start deforming the sheet.
An elastic material proper for thermal joining should yield easily to finger tip pressure. Therefore, it is clear that fibers extending directly between the film surfaces where they are substantially perpendicular to the film surfaces, as shown in the prior art, are not easily compressible and thus unacceptable for an effective thermal joining film. This compressibility problem is independent of the properties of the surrounding matrix and holds true even if a liquid state could somehow be embodied for the elastomer.
In summary, there is a need for a thermally conductive joining film that has the high thermal conductivity evidenced by extending thermally conductive fibers completely through its thickness, but which is capable of local compression with minimal force in order to form an effective thermally conductive joint. There is also a need for this film to have a uniform thermal conductivity even in areas that are locally compressed to a smaller film thickness. Lastly, there is a need for an efficient, low cost process to make large quantities of high quality thermally conductive thin joining films that have superior local compression characteristics. Such a process should make the film in long roll lengths with a tightly controlled thickness.
SUMMARY OF THE INVENTION
The present invention provides a novel thermally conductive joining film that exhibits high thermal conductivity as well as high local compressibility. This film also exhibits uniform conductivity even in areas that are locally compressed to a smaller film thickness. The film of the present invention is compatible with most polymeric matrix materials so that low processing temperatures can be utilized with a matrix having a low in plane modulus.
The problem of compressive conformability is solved by the invention by a novel orientation of the fibers within the film. The film properly compresses during the fabrication of a bonded joint or an elastomeric gasket resulting in efficient heat transfer through the joint while sealing out moisture or other contaminates.
The thermally conductive film of the present invention includes a film of polymeric matrix material having a thickness t defined between a top surface and a bottom surface. A plurality of fibers, having a greater thermal conductivity than the polymeric matrix material, is disposed in the film and extend between the top surface and the bottom surface. Each of the fibers are oriented in the film to form a fiber-to-film surface angle θ relative to the top and bottom surfaces that is greater than about 45° but is less than arctan t/d, where t is the thickness of the film and d is the diameter of the fibers in the direction of the angle θ.
The thermally conductive film is formed using a shear/extruder apparatus from a sheet of composite prepreg material formed of a polymeric matrix material with thermally conductive fibers disposed therein extending lengthwise in the plane of the sheet. The fibers have a greater thermal conductivity than the polymeric matrix material. The apparatus includes an upper die block and a lower die block separated by a predetermined distance to form an extrusion slot therebetween. The slot has an input opening at one end and an output opening at an opposite end. A ram blade is dimensioned to intermittently insert into the input opening. When the prepreg is positioned in front of the input opening, the prepreg is sheared to form sheared pieces that are forced into the extrusion slot and merged together to form a film when the ram blade repetitively enters the input opening. The thermally conductive film is formed by shearing pieces of the prepreg material while simultaneously pushing the sheared pieces down the extrusion slot. The sheared pieces are merged together to form a thermally conductive film with the fibers disposed in the film extending substantially between the top surface and the bottom surface of the film.
A thermal bond is formed by first forming the film of polymeric matrix material having thickness t defined between top and bottom surfaces. The film has a plurality of fibers that have a greater thermal conductivity than the polymeric matrix material and which are disposed in the film and are capable of extending between the top and bottom surfaces. Each of the fibers are oriented in the film to form a fiber-to-film surface angle θ relative to the top and bottom surfaces that is greater than about 45° but is less than arctan t/d, where t is said thickness of the film and d is the diameter of the fibers in the direction of the angle θ. The film is then inserted between first and second bonding surfaces. A bonding pressure F is applied between said first and second bonding surfaces to form the thermal joint.
Other objects and features will become apparent by a review of the specification, claims and appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of the thermally conductive film of the present invention.
FIGS. 2A and 2B are side cross-section views of the film that illustrate the formation of a thermal joint having a surface irregularity.
FIG. 3 is a perspective view of the fiber having a coating thereon.
FIG. 4A is a perspective view of the shear/extrusion apparatus of the present invention.
FIG. 4B is a side cross-sectional view of the shear/extrusion apparatus of the present invention.
FIGS. 5A to 5D are side cross-sectional views of the shear/extrusion apparatus that illustrate its operation in forming the thermally conductive film.
FIG. 6A is a perspective view of sheared piece of the prepreg.
FIG. 6B is a perspective view of the top and bottom surface shape of the sheared piece.
FIGS. 7A to 7C are side views of the film at different stages of vertical consolidation.
FIGS. 8A to 8C are cross-sectional views of the shear/extruder apparatus and mold used for vertical consolidation of the film.
FIGS. 9A to 9B are side cross-sectional views of the shear/extruder apparatus with a belt assembly for vertical consolidation.
FIGS. 10A to 10F are top views of various types of prepreg that can be used with the shear/extruder apparatus of the present invention.
FIG. 11A is a cross-sectional side view of the prepreg being fed into the shear/extruder apparatus at a predetermined angle.
FIG. 11B is a cross-sectional end view of the prepreg being fed into the shear/extruder apparatus at predetermined angles.
FIG. 12 is a side view of the nip roll assembly used to alter the fiber-to-surface angle of film.
FIGS. 13A to 13E are side views of various applications of the thermally conductive fiber of the present invention.
FIGS. 14A to 14B are side views of other applications of the thermally conductive fiber of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The thermally conductive joining film 100 of the present invention is illustrated in FIG. 1, and comprises a thin sheet of composite material composed of fibers 1 contained in a polymeric matrix material 2 that has a lower thermal conductivity than the fibers 1. The fibers 1 are capable of extending through the thickness t of the joining film 100 from the top surface 12 to the bottom surface 13. The fibers 1 are orientated with a fiber-to-film surface angle Θ that is below 90° so that a compressive force applied to the plane of the film causes the fibers to tilt over rather than act as stable columns (tilt mechanism). The fiber-to-film surface angle θ is sufficiently high enough, however, and the fibers are stiff enough, such that the fibers will spear through the matrix to surfaces 12/13 as it is compressed usually in a softened state (the spearing mechanism) so the fibers make contact with the surfaces being joined (the joint surfaces). Therefore, the joining film 100 exhibits excellent local compressibility while ensuring the fibers 1 make contact with the joint surfaces.
The fiber tilting mechanism of the present invention dictates a maximum fiber-to-film surface angle to ensure proper compressibility:
θ.sub.f =arctan t/d, (7)
where θ f is the maximum angle between fiber and film surface plane, t is the fully compacted film thickness, and d is the fiber diameter in the same plane as θ f .
The maximum angle θ f is the point at which all of the top of the fiber tilts past all of the bottom of the fiber. If the fiber were standing on end by itself, θ f is the angle at which gravity would tip it over. Determining the fiber diameter in the same plane as the fiber angle (θ f ) accounts for non-round fibers. In practice this is nearly always the minimum diameter of the fiber. As an example of this minimum fiber angle requirement, a film with a thickness (t) of 0.25 mm (0.01 in) and a
fiber diameter (d) of 0.025 mm (0.001 in), would require the maximum fiber angle (θ f ) to be 84°.
The fiber spearing mechanism of the present invention requires that the fibers 1 be stiff enough (rod-like) to push their way through the (softened) matrix 2 without buckling under the load of the matrix pushing on their ends to make contact with the joint surfaces. This load is given by:
P=sinθ.sub.f F.sub.j A.sub.f, (8)
where P is the effective load on the fiber end along the fiber axis, F j is the joint fabrication pressure (MPa), sin θ f is the load vectoring factor, and A f is the fiber area. Equation (8) can be substituted back into the Euler equation described earlier and rearranged to give a required minimum fiber column stiffness (E f ):
E.sub.f =EI/L.sup.2 A.sub.f =sinθ.sub.f F.sub.j /π.sup.2,(9)
where E f is the minimum fiber column stiffness, E is the elastic modulus (MPa), I is the moment of inertia (cm 4 ), and L is the fiber length (cm).
For a circular fiber cross section l=0.049d 4 and A f =(0.5d) 2 , therefore:
E.sub.f =0.196Ed.sup.2 /L.sup.2 =sinθ.sub.f F.sub.j /π.sup.2(10)
Moments of inertia for other cross section shapes are obtainable from Machinery's Handbook 24th edition, page 189 to 198. The minimum fiber column stiffness (E f ) can be used to judge the suitability of a fiber for use in the joining film of the present invention. An example of this procedure is provided below for a joint being made with a required 0.69 MPa (100 psi) bonding pressure (F j ) with a joining film of 0.1 cm (0.039 in) thickness and a fiber angle of 84°. In this case the minimum column stiffness (E f ) required is: ##EQU1##
Two fibers can be compared against this value:
______________________________________nylon copper______________________________________E = 3,300 MPa E = 131,000 MPad = 0.001 cm d = 0.001 cmL = 0.1 cm L = 0.1 cmE.sub.f = 0.065 MPa E.sub.f = 2.57 MPa______________________________________
Comparing these values with the calculated minimum column stiffness, the nylon fiber is not suitable for the invention, but the copper fiber is.
The fiber spearing mechanism also dictates that the fiber-to-film surface angle θ be no less than about 45°. Below this minimum angle value, the fiber ends will drop below the surfaces 12/13 due to fiber tilting more than it will spear toward the surface due to compression of the matrix around it. Further, the thermally conductive fibers must also be in long enough lengths that nearly all the fibers will be able to span the final joint thickness given their fiber angle θ.
FIGS. 2A and 2B illustrate the film's fiber tilt mechanism and how the film can compressively contour to an irregular joint surface. In FIG. 2A, two joint surfaces 47 are shown ready to be joined by the thermally conductive film 100. A surface irregularity 48 is shown on the upper joint surface 47. In FIG. 2B the completed joint is shown. Fibers 49 in the area of the surface irregularity have tilted and slid slightly along the surface in order to make room for the thinner area of the joint. Because the length of the fiber determines the thermal resistance across the joint, the heat flux in the thinner area is the same as the thicker portions. Therefore, thin and thick areas of the joint have a uniform thermal resistance. Further, as the fiber tilt increases, the force required for further compression decreases. This makes the material particularly adept at yielding to high points on a joint surface.
Most fibers made from ceramics, glasses or metals are suitable for use in the present invention. Fibers can also be made by cutting strips from materials available in foil or deposited film form by laser machining or other methods. The fibers must have a thermal conductivity that is higher than the matrix they will be combined with. Low thermal conductivity fibers can be coated with higher thermal conductivity materials such as diamond, graphite, nickel, copper or aluminum. The fibers must also be capable of being precisely sheared in combination with the matrix (as described below). The thinnest available diameter fibers are preferred so long as they are stiff enough to allow the spearing mechanism to work.
The electrical conductivity properties of the film 100 can be determined by proper selection of the fiber. For example, copper or copper/metal plated fibers can be chosen for high electrical conductivity through the film 100. Alternately, diamond or silicon carbon can be selected for low electrical conductivity through the film 100.
While most ceramic or glass fibers are suitable, the higher thermal conductive ceramic or glass fibers are preferred in forming thermally conductive film 100. Examples of possible fiber materials include:
(e=electrically conductive, n=non-electrically conductive)
aluminum coated glass: TRACOR chaff fiber (e)
aluminum nitride coated fibers (e or n)
aluminum nitride coated films, laser cut strips (e or n)
aluminum nitride fibers (n)
alumina fibers: 3M's NEXTEL™ 610 (n)
boron nitride coated ceramic fibers: Advanced Ceramic Corp.'s BORALLOY® PBN (n)
carbon fibers: Mitsubishi Rayon's GRAFIL® HM (e)
diamond film, laser cut strips (n)
diamond fibers (n)
diamond coated fibers (e or n)
diamond coated films, laser cut strips (e or n)
mesophase pitch based carbon fiber (e):
Amoco's P120, P100, EWC-300x and K1100
Mitsubishi Chemical's DIALEAD® K13C2U
Nippon Graphite Corp.'s GRANOC
pyrolytic graphite coated fibers (e)
metal plated carbon fibers (e)
metal coated ceramic or glass fibers (e)
silicon carbide fibers: Dow Corning's SYLRAMIC™ (n)
Examples of metal fibers include:
aluminum wire, (e)
beryllium wire, (e)
bronze wire, (e)
copper wire, (e)
copper foil, layer cut strips (e)
silver foil, layer cut strips (e)
copper/silver wire, (e)
silver wire, (e)
tungsten wire, (e)
zirconium copper wire, (e)
FIG. 3 illustrates a coating 59 formed on the fiber 1 using standard techniques to give the fibers desirable properties. For example, coating 59 can be added to produce the desired thermal and electrical conductivity or magnetic properties. Coating 59 could also be added to aid curing of the matrix material 2. The orientation of the fiber in the matrix allows light to go all the way through the film's thickness provided the matrix is sufficiently transparent. In most conventional composites the fibers are plane orientated and the first layer of fibers absorbs the light. A reflective coating on the fiber will make them act as parallel mirrors and will enhance the transmission of light down into the film. Preferred examples would be aluminum, silver or gold coatings. Light transmission can also be enhanced by the addition of transparent fibers parallel to the thermally conductive fibers. A preferred example would be quartz fibers. Fiber coatings could aid other electromagnetic energy assisted cures. An absorptive coating would absorb the curing energy, converting it into heat, and the thermal conductivity of the fibers would efficiently transmit it throughout the entire film layer. A carbon and/or metal coating would be a preferred example for microwave, induction, or electron beam curing techniques.
It is well known in the art how to impregnate relatively long fibers with a lower thermal conductivity matrix to form parallel fibers within a sheet of matrix material (commonly called "prepreg"). Prepreg can be made in very thin sheets with the fibers running through the length of the sheets. Therefore, it is preferable that the joining film of the present invention be formed by cutting or shearing prepreg to form a thin film with fibers extending through the film's thickness at the predetermined fiber-to-film surface angle θ.
Most of the polymeric materials used as composite material matrixes or as joining materials are suitable for this invention. The matrix should have a brittleness sufficient to allow a clean shear fracture of the composite prepreg. The matrix should also be capable of allowing merging of sheared pieces into a film and the subsequent processing of the film that results in a completed joint material having the desired thickness.
Many suitable matrix materials are brittle enough at room temperature to be properly sheared. If not, the matrix can achieve its brittleness by cooling, if necessary. This may involve simple refrigeration for modest reductions in temperature. Liquid nitrogen can be sprayed on the prepreg to achieve temperatures down to -195° C. In extreme cases liquid helium could be used to lower the temperature to -268° C. It is preferred that the matrix not require cooling below liquid nitrogen temperatures. Brittleness can be also be increased by increasing the shearing rate due to visco-elasticity properties of the prepreg.
The finished film should also be capable of consolidation, where the film is permanently compressed in its thickness direction to form a finished film product with properly aligned fibers extending through the film's thickness. Matrix materials are suitable for consolidation if they can be permanently deformed under pressure. In addition, matrix materials used to form a joining film from prepreg need to exhibit the ability to merge or weld pieces of sheared prepreg together either by temperature and/or applied pressure processing. It is preferred that the pieces of prepreg be capable of being welding together at between 6.9 to 345 MPa (1000 to 50,000 psi). The temperature required for consolidation varies greatly depending on the matrix polymer. Some, such as many thermoset polymers, exhibit the ability for the sheared pieces to be compressively welded together at the same temperature required for shearing. Others may require only a slight warming to temperatures still well below room temperature. Other matrix materials, such as high temperature thermoplastics, may require warming to high temperatures to start to achieve softening.
It is preferred that the matrix material exhibit a broad temperature range of softening rather than a narrow temperature range melting point. This makes the material more controllable during processing. Polymeric materials that exhibit a sharp melting point can be typically compounded or alloyed with other materials to give them a much broader melting temperature range and therefore exhibit softening at the bottom end of this range. The matrix material must typically turn to a full liquid state to be processed into a bonded joint or a gasket material. Depending on the material type, the matrix may turn liquid and reactivity convert into a solid or it may melt and turn back into a solid after cooling.
Using the same techniques used for polymeric composite matrixes or joining materials, the matrix materials suitable for the invention can be modified to desirably change their properties. Low or negative thermal expansion materials, such as carbon fibrils or zirconium tungstate particles, can be added to lower the thermal expansion coefficient. Microspheres can be added to lower the density and lower the modulus. Thermally conductive fillers can be added to improve thermal transfer from the fibers to the joint surfaces. Reaction initiators can be added to aid polymer cure by light or other initiated means.
Processing during the joint fabrication process can change the matrix into a non-polymeric material. A polymeric matrix could be converted to carbon. A polymer matrix loaded with silver filled glass particles could be converted into a silver-glass joint. A polymer matrix loaded with the starting ingredients for ceramic materials could be converted into a ceramic joint.
The preferred matrixes are those polymeric materials commonly used for composites or joints. Examples include:
acrylates
bismaleimides
bismaleimide triazines
cyanate esters
cyanate resins
cycloaliphatics
epoxies
fluoropolymers
polyacrylonitriles
polyamides
polycarbonate
polyetheretherketone
polyesters
polyether-imides
polyether sulfone
polyethylenes
polyimides
polystyrenes
urethanes
silicones
siloxane-polyimide copolymers
A method and shear/extruder apparatus 101 for making the above described thermally conductive joining film 100 from a sheet of prepreg composite material is described below and illustrated in FIGS. 4A and 4B. The shear/extruder apparatus includes a ram assembly 29, and an extrusion slot 66. The extrusion slot is formed by a top die block 5, a bottom die block 4 and walls 65. The top die block 5 has a sharpened shearing edge 6 on it to aid the shearing operation. The top and bottom die blocks are clamped or bolted together with walls 65 therebetween. The ram assembly 29 has a ram blade 28 that provides the shearing action and rams the cut material into the slot 66. The ram blade has a face 8 with a sharpened shearing edge 7. The face 8 is oriented at an angle φ relative to the extrusion slot opening that allows the ram blade 28 to optimally shear the prepreg 3. A clamp bar 9 holds the prepreg 3 in place with a defined force determined by a spring 10 or other controlled compression force device. Anti-friction surfaces 11 allow the ram blade 28 to freely move and to be held in place by the clamp bar 9. Alignment rails 61 guide the ram assembly 29 during operation. Side guides 60 keep the width of the prepreg 3 aligned with the slot 66.
The composite prepreg 3 used to form film 100 is made from fibers impregnated with a matrix material using any of the well known methods in the art. The preferred range of fiber volume percentages is from 0.5 to 75%, depending upon the desired thermal resistance for the joint to be formed. The fibers should be well dispersed in the matrix. The thickness range of the prepreg is preferred to be between the thickness of the fiber and 1 mm (0.039 in). The prepreg must be capable of being precisely sheared by the shear/extrusion apparatus 101. This means that sheared pieces of prepreg have a separation between the fracture planes with a preferred standard deviation of no more than 0.025 mm (0.001 in), which is dictated by the matrix's brittleness range, the fiber's strength range, the ram blade angle and the cutting temperature. It is important to keep the prepreg free from condensed moisture contamination if it is cooled. This can be accomplished by the use of a dry air enclosure around where the prepreg is cooled and fed into the shear/extruder 101.
FIGS. 5A to 5D illustrate the process of making the thermally conductive joining film 100 of the present invention using the shear/extruder apparatus 101. After the prepreg 3 is formed, the prepreg material is cooled (if necessary) and fed in the direction of arrow A into the shear/extrusion apparatus 101 as shown in FIG. 5A. The ram assembly 29 is then moved forward in the direction of arrow B toward the prepreg 3 by a cam, crankshaft or other controlled motion mechanism, as illustrated in FIG. 5B. The clamp bar 9 makes initial contact with the prepreg 3 and holds it in place with a clamping force from the compressing spring 10. The ram assembly 29 continues to move forward until the ram blade 28 contacts the prepreg 3 and causes a shearing action between the ram blade shearing edge 7 and the top die block shearing edge 6. A clean shear fracture 14 forms in a characteristic shear fracture "V" shape, which is described in further detail below.
As illustrated in FIG. 5C, a sheared piece 16 shears off the end of the prepreg 3 and is pushed into the slot 66 by face 8 of the ram blade 28. The remaining prepreg 3 is simultaneously pushed up in the direction of arrow C by the shearing forces and by the forward motion of sheared piece 16, which raises the end of the prepreg 3 out of the way and avoids fiber damage as the ram blade 28 passes underneath it. The "V" shaped bottom edge of the sheared separated piece 16 caused piece 16 to tilt slightly as it is pushed into the extrusion slot 66. This avoids wedging the sheared piece 16 in the slot 66 and fracturing the ends of the fibers. To complete the process cycle, the ram assembly 28 moves back in the direction of arrow D (FIG. 5D), thus returning the shear/extruder apparatus to the cycle starting point illustrated in FIG. 5A.
FIG. 5D illustrates the shear/extruder apparatus 101 after several cycles. The separate sheared pieces 16 are pushed up against each other with a high compressive force supplied by the ram blade 28. For many matrix materials, this compressive force is enough to weld the sheared pieces 16 into a continuous extruded film 17. Other matrix materials may require heating while in the extrusion slot to merge the sheared pieces 16 into a continuous film.
FIGS. 6A and 6B illustrate the attributes of a correctly sheared piece 16. The shearing operation is controlled such that the same shape of sheared piece 16 is consistently produced. The shear fractures on the top surface 71 and bottom surface 72 have the same shape 73. This results in the fiber length 20 being consistent across the piece 16 and between the different pieces. The shape 73 is typically a blunted, slightly lopsided "V" shape. The shorter side of the "V" tends to be on the leading side 74 of the sheared piece 16.
The top trailing edge 67 of the piece has a ramp shape that aids in pushing the prepreg 3 above it out of the way after the fracture line 14 is formed. The bottom leading edge 68 has a shape that allows the slight tilting of the piece 16 as it is pushed into the extrusion slot 66. Piece 16 will rock onto the sloping trailing edge 68 as it is pushed by angled face 8 of the ram blade 28.
The shape and location of the "V" shaped shear fracture 14 is dictated by the prepreg composite material and by the angle φ of the ram blade 28. If the ram blade angle φ is too large, the "V" shaped shear fracture 14 will be too deep and will cause compressive compaction problems. If the ram blade angle φ is too small, then the shear fracture line 14 will be too high above the shearing edge 6 so that the sheared pieces 16 will not fit into the extrusion slot 66.
FIGS. 7A to 7C illustrate vertical consolidation of the film 100, which is the squeezing of the film that occurs either during processing after the film has left the extrusion slot or during fabrication of a joint. FIG. 7A illustrates the film 17 is as it typically leaves the extrusion slot 66. This film is not ideal as a bonding film at this point because it's top and bottom surfaces 21/22 are ridged resulting from the original "V" shaped shear fracture 14. Vertical consolidation is accomplished by compressing top and bottom surfaces 21/22 together to form smooth surfaces. FIG. 7B illustrates the state of the softened film 100 after the film compression process has started where the first contacts have been made by fiber ends to the surfaces 21/22. The surface ridges are starting to disappear. The stiffness of the fibers is enough that they will spear through the matrix when pushed by a surface contact on one end. If enough compressive compaction is applied, nearly all of the fibers will make contact with both surfaces 21/22. FIG. 7C shows the completely compressed film 100. The film surfaces 21/22 are smooth and the fibers are in contact with the film surfaces on both ends.
FIGS. 8A to 8C illustrate an apparatus for consolidating the film 100. The film leaving the extrusion slot 66 is fed directly into the slot 33 of a consolidation mold 32 consisting of a top plate 34, a bottom plate 35, and compressible slot spacers 40 that act as side walls. A spacer ram 36 provides back pressure on the film material as it is fed into the mold slot 33. As shown in FIG. 8C, after enough film is placed in the mold 32, it is removed from the end of the extrusion slot 66. The spacer ram 36 is removed and a pair of mold dams 39 are inserted into the ends of the compressible mold slot 33. The mold is then put in a press where the film is compressed. Shims may be inserted into the slot 33 to control the final thickness of the film. For gaskets that require pressure sensitive adhesive (PSA) properties, a PSA adhesive can be coated on the surfaces of the mold before the film is fed in, or the PSA adhesive can be coated on the gasket after the film is cured, or a matrix material can be chosen that has PSA properties on its own.
FIG. 9A and 9B show another apparatus for consolidating a long length sheet coming out of the extrusion slot 66. Belts 42 driven by rollers 43 form movable top and bottom walls to slot 37 formed therebetween. The sides of the slot 37 are formed by compressible belt spacers 41 that are on the outside edges of one of the belts 42. Pressure, and heat if necessary, are applied to the belts by heat/pressure blocks 44. The pair of opposing back rollers 43 (furthest from the ram assembly 29) are closer together than the front rollers 43 thereby applying a compressive squeezing action to the film as it travels down slot 37. If necessary, a release film 45, common to the production of composite films, can be introduced as the film exits the extruder slot 66. This release film 45 can be removed after the film exits slot 37 or before the film is fabricated into a thermal joint. The elastomeric gasket version of the invention is cured either in the belted area or after it exits this compaction process.
The desired fiber-to-film surface angle θ can be achieved in several ways. For example, the fiber angle can be altered in the prepreg before manufacture into the joining film 100. FIGS. 10A to 10F show various angled fiber forms that can be made into prepreg 3. In FIG. 10A, unidirectional fibers 1 run the length of the prepreg sheet 3 held in place only by the matrix 2. In FIG. 10B the fibers 1 form two separate, cross directional, layers running across the prepreg 3, which is held together by the matrix 2. In FIG. 10C a bi-angular woven fabric is shown, where the weave pattern of the fibers holds them together. In FIG. 10D a triaxial woven fabric is shown with the fill direction made with a low modulus weaving filament 27 to hold the conductive fibers 1 together. In FIG. 10E a leno weave is shown with the warp direction comprised of low modulus weaving filaments 27. In FIG. 10F a triaxial fabric is shown with the warp direction comprised of a low modulus weaving thread 27. The possibilities for orientated fiber forms are not limited to these examples.
The fiber-to-film surface angle θ can also (or further) be affected by introducing the prepreg 3 into the shear/extruder apparatus at an angle, either in the forward direction as illustrated in FIG. 11A, or in a sideways direction (from either side) as illustrated in FIG. 11B. The die blocks 4/5 and/or the side guides 60 can be specially formed to aid feeding the prepreg 3 into the shear/extruder apparatus 101 at the desired angle to produce the desired fiber-to-film surface angle θ for the film exiting the extruder slot 66.
The fiber angle θ can also (or further) be altered by processing film 100 after it leaves the extrusion slot 66. FIG. 12 shows a nip roll squeezing process that is used to alter the fiber angle θ. The film 100 is fed into two nip rolls 30 while in a softened state with a gap 26 between the rolls 30 that is less than the starting thickness of the film. The top roller runs at a slightly faster speed than the bottom roller's speed which results in a shearing action that realigns the fibers 1 to a greater angle θ within the film having a smaller thickness.
The minimum thickness of the joining film 100 is limited by how thin the ram blade 28 can be made before it starts to buckle under the pressure required to make the film. Under the right conditions, this thickness could be as low as 0.025 mm (0.001 in). The maximum thickness is limited by the fiber column stiffness needed for the spearing mechanism. The preferred thickness range for the film 100 is 0.025 mm (0.001 in) to 1 mm (0.039 in), which is ideal for joining films used in bonded and gasketed thermal joints.
The film 100 of the present invention provides superior local compression for making intimate contact with the entire joint surfaces while providing superior thermal conductivity. The film 100 also has the advantage that it can be made from a matrix materials that are processed at a low temperature but still achieve high thermal conductivity. The low processing temperature reduces CTE stress in bonded thermally conductive joints. The film can also be made from a low modulus material, with the fibers 1 configured to minimize in-plane stiffness, thereby giving the film a low in-plane modulus. The film offers an increase in thermal conductivity great enough that in many cases it is possible to allow an increase in joint thickness while still achieving the same or lower thermal resistance. These properties can be used in combination to optimally minimize CTE stress. Lastly, the film can be made of materials requiring a low joining pressure, thus reducing mechanical stress applied to the joint surfaces during joint fabrication.
FIGS. 13A to 13E illustrate several applications of the joining film 100 of the present invention. FIG. 13A shows a semiconductor device 50 die bonded by the film 100 to a heat sink 51. FIG. 13B shows a semiconductor device 50 directly attached to a printed circuit board 53 by a ball grid array (BGA) of solder balls 52. A heat flow path is provided out of the device by the film 100, that directly thermally connects the device 50 with a heat fin 54. An underfill 55, common to BGA packaging, seals off the device. FIG. 13C shows the film 100 being used as a self-bond heat sink 56 on top of device 50, where the film 100 takes the place of a heat sink, typically a copper slug, to provide a heat path to the outside of an electronic package. The device 50 is also bonded underneath by film 100 to its lead frame 57. A typical plastic package 58 is molded in place to complete encapsulation of the device. For bonding a thermally conductive film to a single surface for use as a heat sink, as illustrated in FIG. 13C, a release film or agent can be used on a plate that presses the film 100 onto the semiconductor device. Alternately, a cooled plate can be used. FIG. 13D shows the film 100 on the opposite side of the lead frame 57 from where the device 50 is bonded by the film 100. FIG. 13E shows the film being used between two copper foils 80. The device 50 is bonded by the film 100 onto the inner copper foil 80.
FIGS. 14A and 14B show the film 100 applied to PWB thermal vias. In FIG. 14A the film 100 is used to establish a top to bottom thermal pathway. It is cured at the same time as the PWB fiberglass laminate 78. The copper cladding 77 is bonded in the same laminate process or plated on later. In FIG. 14B the film 100 thermally connects the PWB surface with a thermally conductive plane 79 of film 100 in the center of the PWB, where the orthogonally oriented films 100 mesh together where they meet.
The preferred embodiment of the shear/extruder apparatus 101 of the present invention is discussed below. Before shearing, the prepreg 3 can be clamped with any material and force that will properly hold it in place for shearing, but will allow it to be pushed up as the sheared piece is pushed into the slot. Smooth steel faced clamp bars are preferred. A prepreg clamping force of between 0.069 and 3.45 MPa (10 and 500 psi) is preferred, which adequately allows the prepreg 3 to move up during the shearing process.
The ram blade 28 can be of any material that will shear the prepreg 3 and push the sheared pieces 16 down the slot 66. Hardened steel is preferred. The unsupported length of the ram blade must be short enough that it will not buckle under the shearing and pushing loads. The ram blade angle φ is preferred to be greater than 0° but not great enough to cause too deep a shear fracture line. The ram blade thickness must be no greater than the thickness of the slot and is preferred to be thinner by no more than 0.013 mm (0.0005 in).
The anti-friction surfaces 11 that guide and support the ram blade 28 can be any surface that prevents gauling and does not cause adverse contamination of the film being made. Coating with a dry lubricant such as graphite powder or a dry lubricant film is preferred. The anti-friction surfaces 11 must be close enough together and correctly aligned so that the ram blade 28 can not hit the top of the slot 66.
The materials of the extrusion slot 66 can be any that will stand-up to the forces and wear of the shear/extrusion process. The top and bottom die blocks 4/5 are preferred to be steel harder than the ram blade 28. The inner surfaces can be chrome plated. It is preferred that the inner surfaces be flat within ±0.005 mm (0.0002 in). The walls 65 of the slot 66 can be separate sheets of material or machined into one of the slot die blocks. They are preferred to have a thickness that causes the slot thickness to vary no more than ±0.013 mm (0.0005). They must allow the ram blade 28 and the film material to fit into the slot 66 and are preferred to leave an edge gap of no more than 0.5 mm (0.02 in).
The mold plates 34/35 for film consolidation can be made from any material that will stand-up to the vertical consolidation process. Steel or aluminum are acceptable. The surface accuracy requirements are preferred to be the same as the extrusion slot die blocks 4/5. The slot spacers 40 and mold dams 39 can be made out of any material that can compress adequately during the consolidation process, yet be rigid enough to contain the film. TEFLON is an acceptable material.
The consolidation belts 42 can be commonly available metal belts. The belts 42 preferably have a thickness tolerance of ±0.005 mm (0.0002 in). The belt spacers 41 have the same requirements as the slot spacers 40 and mold dams 39 above. TEFLON is again an acceptable material. It is preferred that the belt spacers 41 be bonded to one of the plates or fit with enough tension that they will stay in place. The belt rollers 43 should maintain the belts 42 under a preload tension of 14 to 70 MPa (1,000 to 10,000 psi), and be accurate enough to maintain a gap between the belts 42 of ±0.025 mm (0.001 in). The gap should also be adjustable on the rollers. The rpm speed ratio between the rollers and the ram blade cycle is preferred to be controllable within 1%. The heater/pressure blocks 44 should deliver enough heat and pressure to the belts 42 to allow consolidation and cure of the film into a gasket, if necessary. Steel or aluminum heated with hot oil channels or electric heaters is acceptable. Pressure can be supplied by numerous clamping arrangements such as springs or hydraulic equipment. Lubricant or an anti-friction surface is preferred between the blocks 44 and the belts 42. If release film 45 is required, it can be any of the films used for making composite prepregs, adhesive films or elastomeric sheets, such as silicone polymer coated papers, polyethylene films and polyimide films.
It is preferred that all of the metal surfaces the film materials come in contact with during the production of the film 100 be coated with a mold release agent, such as Chem-Trend Inc.'s MONO-COAT® E91 N-ODS.
A thermally conductive film 100 of the present invention has been produced using the extruder apparatus 101, as described below.
A shear/extruder apparatus as illustrated in FIG. 4A was prepared, where the extrusion die blocks 4/5 were made from D2 tooling steel with heating/cooling channels drilled through them. They were then hardened to 53-58 RC (Rockwell C). The interior surfaces were surface ground to a flatness with a variation of less than ±0.005 mm (0.0002 in). These surfaces were polished with 600 grit polishing compound. Side walls 65, a spacer ram 36, and a ram blade 28 were cut from the same sheet of spring steel that had a specified hardness of 48-51 RC. The side walls 65 were shims that were surface ground to a thickness of 0.530 ±0.005 mm (0.0210 ±0.0002 in). The ram blade 28 and a spacer ram 36 were ground to a thickness of 0.523 ±0.005 mm (0.0206 ±0.0002 in). The ram blade 28 was prepared with a ram blade angle φ of 2.1°. The clamp bar was made from unhardened O1 steel and surface ground. Springs 10 were provided to give a clamping pressure of 0.77 to 0.94 MPa (112 to 137 psi) as the ram blade 28 contacted the prepreg 3. Graphite powder lubricant was placed between the bottom of the ram blade and the top of the bottom die block 4. Graphite powder was also placed between the top of the ram blade and the bottom of the clamp bar 9. All of the metal surfaces that would be in contact with the film material were coated with MONO-COAT® E91-N-ODS and heated to at least 100° C. for 5 minutes. The ram blade 28 was set to cycle back and forth 1.45 mm (0.057 in) with a travel into the extrusion slot of 1.27 mm (0.050 in). The spacer ram 36 was put in the extrusion slot to allow short experimental runs.
The following epoxy resin combination was selected for the prepreg matrix material, which would provide for a processing temperature for the finished film of 177° C.:
48.0 parts cresol novolac epoxy (Ciba Geigy: ECN 1873)
17.0 parts bis F novolac epoxy (Dainippon Ink and Chemicals: EPICLON 830)
17.0 parts phenoxy resin thermoplastic (Phenoxy Associates: PAPHEN™ PKHP)
18.8 parts 4,4'diaminodiphenylsulphone (Ciba Geigy micronized HT9664)
The matrix material was formed using the following steps:
1) The epoxies were melted together at 163° C.
2) The phenoxy was melted into this mixture at 171° to 179° C.
3) This mixture was cooled to 163° C. and the DDS was mixed in until the mixture turned a cloudy amber in appearance.
4) This mixture was spread on a release paper to cool.
5) This resin mixture was remelted at 94° C. and drawn into a film.
The film was flexible at room temperature if bent slowly. It fractured easily if bent with a sharp motion. Examination at various temperatures revealed that it started to soften at 40° C. and did not completely melt until 92° C. was reached.
The following thermally conductive fiber was selected:
coal tar pitch-based carbon fiber
Mitsubishi Chemical: K13C2U, Grade: 01101P2001
thermal conductivity: 610 W/m·° K
tensile modulus: 923,7545 MPa (134 psi)
fiber diameter: 0.001 cm (0.0004 in)
fiber form: 2,000 fiber count, long length yarns
Parallel strands of this fiber were attached to a frame and impregnated with the epoxy resin film at 155° C. Three pieces of prepreg were produced with fiber volumes of 18, 26, and 35%.
The front end of the shear/extruder 101 was enclosed in a plastic film enclosure with desiccant bags inside to keep it dry. The ram assembly end of the shear/extruder was cooled to 2° C. The ram assembly was set to a cycle rate of 100 cycles per minute. In three separate runs, the pieces of prepreg were fed in to the machine until each produced sufficient film for a test sample. The machine was stopped and the extrusion die blocks 4/5 were raised to a temperature of 65° C. The die blocks were cooled and the film removed.
In all three runs a film was removed that looked like the material in FIG. 7B with a slight off axis fiber angle. Light could be shined through the films allowing a microscopic examination that showed very few broken or out of place fibers. The fibers had a fiber-to-film surface angle θ of 88° as determined by microscopically examining their broken edges, which corresponds to the 2.1° angle φ of the ram blade face 8. The thickness between the fracture surfaces was determined by measuring the broken edges under a microscope. This measurement was confirmed by dissolving the resin in solvent and measuring the washed out fiber lengths under a microscope. The measurement results were:
______________________________________fibervol- averageume thickness thickness range standard deviation% mm (in) mm (in) mm______________________________________ (in)18 0.507 (0.0200) 0.503-0.516 (0.0198-0.0203) <0.007 (0.0003)26 0.507 (0.0200) 0.488-0.526 (0.0192-0.0207) <0.019 (0.0008)35 0.495 (0.0195) 0.483-0.507 (0.0190-0.0200) <0.012 (0.0005)______________________________________
The films were placed between two sheets of 0.018 mm (0.0007 in ) thick Reynolds 8111 aluminum foil. Shims of 0.462 mm (0.0182 in) were placed on both sides of the specimens, between the foils. This assembly was spring clamped between two steel plates and put in an oven for curing. The specimens were raised to a temperature of 171° C. and cured for 90 minutes. Microscopic examination of broken edges and peeling off the foil of portions of these specimens indicated that the film had completely conformed to the foils on both sides and both ends of the fibers were in contact with foil. The fiber-to-film surface angle θ was reduced further below 88° during this operation.
Disks with a diameter of 12.7 mm (0.5 in) were prepared from the specimens and tested for thermal conductivity using a laser flash test. The specimens were exposed to a pulse of laser light on one side and the temperature rise was recorded as a function of time. Using this data, coupled with the heat capacity for the fiber and the resin, a thermal conductivity for the test film was calculated while taking into account the effects of the aluminum foil. The results were:
______________________________________fiber volume thermal conductivity(%) (W/m·° K.)______________________________________18 79.926 10135 154______________________________________
It is to be understood that the present invention is not limited to the embodiments described above and illustrated herein, but encompasses any and all variations falling within the scope of the appended claims. | A thermally conductive film that includes a film of polymeric matrix material having a thickness t defined between a top surface and a bottom surface. A plurality of fibers, having a greater thermal conductivity than the polymeric matrix material, is disposed in the film and extends between the top surface and the bottom surface. Each of the fibers are oriented in the film to form a fiber-to-film surface angle θ relative to the top and bottom surfaces that is greater than about 45° but is less than arctan t/d, where t is the thickness of the film and d is the diameter of the fibers in the direction of the angle θ. A shear/extruder apparatus is used to form the thermally conductive film from a sheet of composite prepreg material. An upper die block and a lower die block separated by a predetermined distance form an extrusion slot therebetween. A ram blade is dimensioned to intermittently insert into the input opening of the extrusion slot so that when the prepreg is positioned in front of the input opening, the prepreg is repetitively sheared by the ram blade to form sheared pieces that are forced into the extrusion slot and merged together to form the thermally conductive film with the fibers disposed therein extending substantially between the top surface and the bottom surface of the film and oriented to have the fiber-to-film surface angle θ. | 8 |
BACKGROUND
a. Field of the Invention
The present invention relates to an optical element for use in a camera system for the inspection of passageways, a camera system for the inspection of passageways and a method of illuminating a passageway during inspection with a camera. In particular the invention relates to an optical element for protecting the video camera and the light source of a wellbore inspection system while permitting good illumination of the field of view of the camera.
b. Related Art
In oil and gas wells, the wellbore may be open or may be clad with a well casing. Visual inspection of the wellbore is important to check the integrity of the wellbore, and to investigate any downhole problems that may delay or prevent use of the well. For example, it is important to regularly inspect the casings for corrosion and wear.
Although visual inspection of the wellbore is important, the conditions typically found in a wellbore tend to hinder the ability to use many camera systems. Wellbores can have diameters in the range 10 centimeters to 1 meter and can reach depths of hundreds or thousands of meters. In order to inspect these bores, therefore, it is not only necessary to provide a camera system that can operate at these depths, but also to provide the lighting required to be able to capture still images or video in this confined environment.
Furthermore, any camera system must be able to withstand the pressures and temperatures encountered at depth in a borehole. Pressures at these depths can be very large and can reach around 150 MPa, and in addition, temperatures may exceed 100° C.
Typically, downhole camera systems comprise a camera and light source contained in a protective steel sheath. These camera systems are lowered into the wellbore on an electrical cable or a shaft, with the images from the camera being relayed back to the surface where they are displayed and recorded.
The confined environment of the wellbore causes problems in designing a camera and lighting arrangement that is small enough while still delivering high enough light levels to capture the required images.
Several camera systems use a backlight system in which the light source is mounted at a distance behind the camera. The light is then directed into the field of view of the camera by means of a reflector mounted adjacent to the camera. However, this approach is less successful in narrower passageways as the size of the camera becomes too large compared to the diameter of the bore to allow sufficient light to be reflected.
It is also known to provide an array of light emitting diodes (LEDs) as the light source due to their relatively low power consumption and small size. These LEDs are typically mounted around the outside of the camera approximately level with the camera lens. The LEDs therefore directly illuminate the field of view of the camera.
In order to protect the camera and the light source from the harsh environment of the wellbore, a cover or window is typically placed over the distal end of the camera system. Any light emitted from the light source, therefore, must pass through this window before it illuminates the wellbore.
This has a disadvantage, however, because some of the light that travels through the window is internally reflected and does not pass through the window. Furthermore, some of the internally reflected light is directed back towards the lens of the camera, leading to poor images.
It is an object of the present invention to provide an improved window for a subsea camera system that overcomes these problems.
SUMMARY OF THE INVENTION
According to the invention, there is provided an optical element for use in a camera system for the inspection of passageways, the element comprising:
a first optical portion arranged to transmit light into a camera; a second optical portion arranged to transmit light emitted from a light source, the second optical portion located adjacent the first optical portion; and barrier means arranged to prevent light being transmitted from the second optical portion into the first optical portion.
Also according to the invention, there is provided a camera system for use in the inspection of passageways, the system comprising:
a housing having opposing first and second ends; a camera mounted in the housing, the camera positioned proximate the first end of the housing; a light source arranged to direct emitted light out of the first end of the housing; and an optical element mounted at the first end of the housing, the element comprising: a first optical portion arranged to transmit light into the camera; a second optical portion arranged to transmit light emitted from the light source, the second optical portion located adjacent the first optical portion; and barrier means arranged to prevent light being transmitted from the second optical portion into the first optical portion.
Also according to the invention, there is provided a method of illuminating a passageway during inspection with a camera system, the camera system being according to the invention, and the method comprising the steps of:
illuminating the light source to provide emitted light; transmitting the emitted light through the second optical portion in a first direction to illuminate an object; and transmitting light through the first optical portion in a second direction, substantially opposite to the first direction, into the camera so that the camera captures the image of the object; wherein, in use, the emitted light is prevented from being transmitted directly into the first optical portion from the second optical portion by said barrier means.
Preferably, the barrier means comprises reflecting means to reflect light in the second optical portion and to prevent light from the second optical portion being transmitted into the first optical portion. The reflecting means may comprise a reflecting surface, which may comprise a peripheral surface of the first optical portion and/or the second optical portion.
In a preferred embodiment the barrier means comprises an interface between the first optical portion and the second optical portion. The interface may be formed by an unpolished surface of at least one of the first and second optical portions.
In other embodiments, the barrier means comprises a gap between the first optical portion and the second optical portion. Preferably the gap is filled with silicone.
Preferably, the second optical portion surrounds the first optical portion. The first and second optical portions may be concentric. Preferably, the first optical portion is cylindrical and the second optical portion is annular and surrounds the first optical portion.
Preferably, the first and second optical portions are made of sapphire. However, the first and second optical portions may be made of any other suitable materials.
Preferably the optical portions are made of a ceramic material. More preferably the optical portions are made of quartz, diamond or crystal.
The optical element may be disc-shaped having parallel opposing first and second end faces and the barrier means may be substantially perpendicular to the first and second end faces.
In preferred embodiments, the optical element further comprises a base plate attached to the second end face. Preferably, the base plate is made of titanium and the first and second optical portions are bonded to the base plate by diffusion bonding.
When the optical element is mounted in a camera system, preferably the first end face of the optical element is closer to the first end of the housing than the second end face, and the camera and the light source are located adjacent to the second end face.
Preferably the light source is arranged, in use, to illuminate an object, the image of which is being captured by the camera.
Preferably, the camera system comprises a plurality of light sources. The plurality of light sources may comprise light emitting diodes.
Preferably, the plurality of light sources are arranged in a circle around the camera.
In embodiments in which the optical element comprises a base plate in contact with the second end face, preferably the base plate includes at least two apertures, and the camera and the light source are arranged so that at least a part of each of the camera and the light source are located within an aperture.
Preferably the second optical portion is arranged to transmit light from the light source in a first direction through the optical element. Preferably the first optical portion is arranged to transmit light into the camera in a second direction through the optical element. Preferably the first direction is the opposite direction to the second direction.
The barrier means may prevent light from the second optical portion travelling in the second direction being transmitted into the first optical portion.
Preferably the reflection means substantially maintains the light from the light source within the second optical portion as the light is transmitted from a second end of the second optical portion to a first end of the second optical portion.
Preferably the second optical portion extends from a first end face of the optical element to a second end face of the optical element and transmits light from the second end to the first end. Preferably the first optical portion extends from a first end face of the optical element to a second end face of the optical element and the camera receives light entering from the first end and which is transmitted to the second end of the optical element.
Preferably, the barrier means reflects light in the second optical portion and prevent light from the second optical portion being transmitted into the first optical portion. The barrier means may comprise a shroud. The shroud may locate around an outer peripheral surface of the first optical portion and/or an inner peripheral surface of the second optical portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described, by way of example only, and with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of an optical element for use in a camera system according to a first embodiment of the invention;
FIG. 2 a is a schematic diagram illustrating light reflection by an interface present in the optical element of FIG. 1 ;
FIG. 2 b is a schematic diagram illustrating internal light reflection by a front surface of an optical element when an interface is not present;
FIG. 3 is a perspective view of an optical element for use in a camera system according to a second preferred embodiment of the invention;
FIG. 4 is a sectional view of the optical element of FIG. 3 ;
FIG. 5 is a rear view of the optical element of FIG. 3 showing the arrangement of apertures in the base plate;
FIG. 6 is a cross-sectional view of the optical element of FIG. 3 with the gap between the first and second optical portions exaggerated;
FIG. 7 is a cross-sectional view of a camera system including the optical element of FIG. 3 ; and
FIG. 8 is an enlarged view of the front end of the camera system of FIG. 7 , showing the arrangement of the camera lens, light sources and optical element.
DETAILED DESCRIPTION
FIG. 1 shows a window or optical element 1 for use in a camera system that may be used to inspect wellbores or other passageways. These camera systems typically include a camera and one or more light sources arranged to light the field of view of the camera. Typically these are housed in a front, distal end region of an elongate cylindrical housing which is lowered down the wellbore by cables or a shaft attached at a second end. In most cases, the camera systems will also include a viewport or optical element at the front end of the camera housing that serves to protect the camera, in the harsh environmental of a wellbore for example.
In this embodiment the optical element 1 of the present invention comprises an optical layer 2 which includes an interface 4 which prevents light emitted from a light source being internally reflected within the optical element 1 back towards the camera.
The optical element 1 comprises a disc-shaped optical layer 2 , which has a first, inner optical portion 6 and a second, outer optical portion 8 . The inner portion 6 is cylindrical, and the ring-shaped outer portion 8 surrounds it so that an inner surface 10 of the outer portion 8 is substantially in contact with the outer surface 12 of the inner portion 6 thereby forming a cylindrical interface 4 between the inner and outer portions 6 , 8 .
The thickness of the inner and outer portions 6 , 8 is the same so that the front and rear faces 14 , 16 of the inner portion 6 are co-planar with the respective front and rear faces 14 ′, 16 ′ of the outer portion 8 .
Preferably, both the inner and outer portions 6 , 8 of the optical layer 2 are made of sapphire, however, the optical layer 2 may be made of quartz, diamond, crystal or any other suitable material. The material of the optical layer 2 must be optically clear, for example transparent or translucent, and must also be able to withstand the harsh conditions within a wellbore. For example, the optical layer must be able to withstand high pressures of over 100 MPa as well as high temperatures of up to around 200° C. The material should also be able to withstand any corrosive chemicals that are encountered in the wellbore.
In a simplest embodiment the cylindrical interface 4 extends for the full thickness of the optical layer 2 and the plane of the interface 4 is substantially perpendicular to the front and rear faces 14 , 16 of the layer 2 . The inner and outer surfaces 10 , 12 are unpolished so as to create a more optically reflective interface. When the optical element 1 is installed within a camera system as described above, light entering a camera 20 is transmitted predominantly through the inner optical portion 6 , and the light emitted by light sources 22 is transmitted substantially through the outer optical portion 8 . Due to the nature of the interface 4 , emitted light travelling in a range of angles towards the central axis 18 of the apparatus is reflected by the interface 4 and is directed outwards, away from the central axis 18 . This is shown most clearly in FIG. 2 a . If the interface 4 was not present, then emitted light travelling in the same direction, as shown in FIG. 2 b , would be reflected from the front surface 14 of the optical element 1 back towards the camera.
The presence of the interface 4 , therefore, has two important advantages. Emitted light that would otherwise be internally reflected towards the camera is now reflected outwards through the front face 14 of outer portion 8 of the optical element 1 . This means that, firstly, more light is available to illuminate the field of view of the camera, and in particular the walls of the wellbore passageway, and secondly emitted light is prevented from being internally reflected into the camera which would otherwise adversely affect picture quality.
FIG. 3 shows a second preferred embodiment of an optical element 100 . In this example, the optical layer 102 is mounted on a base layer or base plate 30 . The base plate 30 is disc-shaped and has an outer diameter equal to the outer diameter of the optical layer 102 . The thickness of the base plate 30 is significantly less than the thickness of the optical layer 102 , and in this embodiment the base plate 30 is about one quarter of the thickness of the optical layer 102 .
The base plate 30 supports the optical layer 102 and includes a plurality of apertures 32 , 34 for receiving other parts of the camera system, as will be described in more detail below. In this example, the base plate 30 is made of titanium, however, the base plate may be made of any other suitable metallic material. Of importance in the selection of material for the base plate 30 is the matching of the coefficients of thermal expansion of the materials of the base plate 30 and the optical layer 102 . This is important as the optical element will be subjected to a large range of temperatures in use, for example −40° C. to 200° C., and a mismatch of coefficients of thermal expansion may lead to cracking or at least de-bonding of the optical layer 102 .
The base plate 30 and the optical layer 102 are bonded together so that the rear face 116 of the optical layer 102 is in intimate contact with a front face 36 of the base plate 30 . In particular, in a preferred embodiment, a sapphire optical layer 102 is bonded to a titanium base plate 30 by a process known as diffusion bonding. This process uses high compressive forces and heat to bond the two materials at an atomic level. Preferably, a layer of aluminium 38 is introduced between the optical layer 102 and the base plate 30 to act as a ‘glue’ and aid in the diffusion bonding process. Other soft metals may be used to form the bond layer, however, the bond layer must be compliant.
The base plate 30 includes a larger central aperture 32 and several smaller apertures 34 arranged in a circle around the central aperture 32 , as shown most clearly in FIG. 5 . The smaller apertures 34 are spaced equidistantly around the circle and in this example there are ten apertures 34 . The central aperture 32 is sized to receive a lens of a camera that is mounted behind the base plate 30 when the optical element is installed in a camera system, and the smaller apertures 34 are designed to each house a single one of a number of light sources that are arranged to emit light to illuminate the field of view of the camera.
The dimensions of the inner and outer portions 106 , 108 of the optical layer 102 are such that the central aperture 32 is aligned with the inner portion 106 and the outer apertures 34 are aligned with the outer portion 108 so that the interface 104 between the portions lies between the central aperture 32 and the outer circle of apertures 34 , as shown most clearly in FIG. 4 .
As shown in FIG. 6 , in another preferred embodiment, the interface 204 is in the form of a tapered annular gap 204 between the inner and outer optical portions 206 , 208 . This tapered gap 204 is such that the outer surface 212 of the inner portion 206 and the inner surface 210 of the outer portion 208 are in contact at the rear face 216 of the optical layer 202 , but are spaced apart at the front face 214 . The size of the gap 204 shown in FIG. 6 is exaggerated and typically the gap is minimal and primarily due to manufacturing tolerances between the inner and outer portions 206 , 208 of the optical layer 202 .
The gap 204 is filled with silicone which is preferably aerospace grade. In other embodiments other fillers may be used such as other grades of silicone, epoxies, rubbers or adhesives. Typically the choice of filler will be dependent on the environment in which the optical element will be used. The gap 204 must be filled to prevent contamination reaching the bond between the optical layer 202 and the base plate 230 . This is particularly important when aluminium is used to aid the bonding process due to the relatively reactive nature of aluminium with many different chemicals.
Further, in a preferred embodiment, the inner and outer surfaces 210 , 212 forming the interface 204 include a vapour deposition surface coating. This roughens the surfaces, further increasing the reflective nature of the interface 204 .
In other embodiments, the inner and outer surfaces 210 , 212 forming the interface 204 may be processed or treated in some other way to increase the reflective nature of the interface 204 . For example, one or both of the surfaces 210 , 212 may be painted, or the surfaces may be textured by a process other than vapour deposition.
FIGS. 7 and 8 show the optical element 100 in place in the distal end 42 of a camera system 40 . The camera system 40 comprises a cylindrical housing 44 which is typically made of stainless steel to withstand the operating environment at depth in a wellbore. In addition to the camera 120 and light sources 122 , the camera system 40 may also include a power supply, data transmitters and receivers, and controllers for controlling the camera 120 and light sources 122 .
Connectors 46 are located at one end of the cylindrical camera system 40 for connecting to cables or a shaft used to lower the camera 40 down a wellbore and also for permitting electrical connections to be made to transmit data back up to the surface.
The optical element 100 is located in a recess 48 in the distal end 42 of the housing 44 at the opposite end to the connectors 46 .
The camera is mounted directly behind the base plate 30 of the optical element 100 such that the lens of the camera 120 is aligned with the central aperture 32 in the base plate 30 . The light sources 122 , which in this embodiment are light emitting diodes (LEDs) 122 , protrude through the smaller apertures 34 such that at least a front portion of the LEDs 122 are within the base plate 30 , as shown most clearly in FIG. 8 .
An O-ring 50 is used to form a seal between the optical layer 102 of the optical element 100 and the internal surface of the housing 44 . The use of a single optical element 100 having distinct inner and outer portions within an optical layer bonded to a unitary base plate means that only a single high pressure seal is required to seal the entire optical element 100 in the end of the camera system 40 . If the two optical portions were provided by two separate optical elements, or if the optical layer was not securely bonded to the base plate, then a number of high pressure seals would be required within the camera system to provide effective seals around each of the components. This would take up valuable space within the camera system and would decrease the available field of view of the camera.
Although in the above-described embodiments the optical layer is disc-shaped and comprises concentric inner and outer optical portions the optical layer may be of any suitable shape for use within a camera system. Furthermore, the second optical portion may not surround the first optical portion but, instead, the first and second optical portions may be located side by side or in any other relative positions depending on the corresponding relative positions of the camera and light sources in the camera system.
The optical element of the present invention, therefore, provides an improvement over existing camera system viewports by preventing unwanted internal reflections while maximising the illumination provided by the light sources and maximising the available field of view of the camera. | The present invention relates to an optical element for use in a camera system for the inspection of passageways, a camera system for the inspection of passageways and a method of illuminating a passageway during inspection with a camera. An optical element for use in a camera system for the inspection of passageways comprises a first optical portion arranged to transmit light into a camera, a second optical portion arranged to transmit light emitted from a light source, the second optical portion located adjacent the first optical portion, and barrier means arranged to prevent light being transmitted from the second optical portion into the first optical portion. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to thermoplastic molding composition and particularly to compositions containing a compatibilized blend of an aromatic polycarbonate resin and a graft copolymer. The composition is useful in making molded articles having improved energy absorption at low temperatures.
Thermoplastic molding compositions containing polycarbonates (PC) and ABS polymers have been known for some time. Such compositions which find use in a variety of applications are available commercially, for instance, from Bayer Corporation under the Bayblend trademark. Also, the art is noted to include a large number of relevant patents, including U.S. Pat. No. 5,420,181 which disclosed stabilized PC/ABS system, and U.S. Pat. Nos. 5,672,645 and 5,674,924 which disclosed flame resistant PC/ABS molding compositions. However, the energy absorption at low temperatures characterizing these compositions is recognized to be inadequate for some applications. While it is possible to increase the energy absorbing characteristics of the composition by adding rubber, this often results in decreased modulus. It has now been found that the incorporation of a particular compatibilizer in the polycarbonate/ABS blend improves its energy absorption characteristics without the addition of more rubber. U.S. Pat. No. 4,713,415 which disclosed a compatibilizing agent for a polymeric system containing nylon and ABS is relevant in the present context.
The present invention concerns a thermoplastic molding composition comprising:
A) 20 to 90 parts by weight (pbw) of an aromatic polycarbonate resin,
B) 4.5 to 70 pbw of a vinyl copolymer,
C) 5 to 70 pbw of a graft polymer, and
D) 0.5 to 5 pbw of a compatibilizer.
Articles molded from the inventive composition are characterized in their improved capacity to absorb energy at low temperature.
DETAILED DESCRIPTION OF THE INVENTION
The thermoplastic molding composition of the present invention comprises:
A) 20 to 90 pbw, preferably 30 to 80 pbw and, more preferably, 40 to 70 pbw of an aromatic polycarbonate,
B) 4.5 to 70 pbw, preferably 5 to 60 pbw and, more preferably, 10 to 50 pbw of a vinyl copolymer of
B.1) 50 to 99 percent relative to the weight of the copolymer of at least one member selected from the group consisting of styrene, alpha-methyl styrene, nucleus-substituted styrene, C 1-8 -alkyl methacrylate and C 1-8 -alkyl acrylate and
B.2) 1 to 50 percent relative to the weight of the copolymer of at least one member selected from the group consisting of acrylonitrile, methacylonitrile, C 1-8 -alkyl methacrylate, C 1-8 -alkyl acrylate, maleic anhydride, C 1-4 -alkyl-N-substituted maleic imide and C 1-4 -phenyl-N-substituted maleic imide,
C) 5 to 70 pbw, preferably 10 to 60 pbw and, more preferably, 20 to 50 pbw of a graft polymer containing
C.1) 5 to 95 percent, preferably 30 to 80 percent, relative to the weight of the graft polymer of a grafted phase, and
C.2) 5 to 95 percent, preferably 30 to 80 percent, relative to the weight of the graft polymer of a graft base,
wherein said grafted phase contains a polymerized mixture of
C.1.1) 50 to 99 percent, relative to the weight of said mixture, of at least one member selected from the group consisting of styrene, alpha-methyl styrene, nucleus-substituted styrene, C 1-8 -alkyl methacrylate and C 1-8 -alkyl acrylate and
C.1.2) 1 to 50 percent, relative to the weight of said mixture, of at least one polar monomer selected from the group consisting of acrylonitrile, methacrylonitrile, C- 1-8 -alkyl methacrylate, C 1-4 -alkyl acrylate, maleic anhydride, C 1-4 -alkyl-N-substituted maleic imide and C 1-4 -phenyl-N-substituted maleic imide, and
wherein said graft base includes
C.2) a crosslinked elastomer in particulate form having an average particle diameter (d 50 value) of 0.05 to 5, preferably 0.1 to 0.6, micron and a glass transition temperature lower than 10° C., preferably lower than -10° C., the sum of the pbw of A, B and C being 100 pbw, and
D) 0.5 to 5 parts by weight per one hundred parts of the total A, B and C, herein phr, of a compatibilizing agent which contains 0.05 to 4 mole percent, relative to the moles of monomers making up the compatibilizer, of secondary amine functional groups.
Aromatic polycarbonates within the scope of the present invention are homopolycarbonates and copolycarbonates and mixtures thereof.
The polycarbonates generally have a weight average molecular weight of 10,000 to 200,000, preferably 20,000 to 80,000 and their melt flow rate, per ASTM D-1238 at 300° C., is about 1 to about 65 g/10 min., preferably about 2 to 15 g/10 min. They may be prepared, for example, by the known diphasic interface process from a carbonic acid derivative such as phosgene and dihydroxy compounds by polycondensation (see German Offenlegungsschriften 2,063,050; 2,063,052; 1,570,703; 2,211,956; 2,211,957 and 2,248,817; French Patent 1,561,518; and the monograph H. Schnell, "Chemistry and Physics of Polycarbonates", lnterscience Publishers, New York, N.Y., 1964, all incorporated herein by reference).
In the present context, dihydroxy compounds suitable for the preparation of the polycarbonates of the invention conform to the structural formulae (1) or (2). ##STR1## wherein
A denotes an alkylene group with 1 to 8 carbon atoms, an alkylidene group with 2 to 8 carbon atoms, a cycloalkylene group with 5 to 15 carbon atoms, a cycloalkylidene group with 5 to 15 carbon atoms, a carbonyl group, an oxygen atom, a sulfur atom, --SO-- or --SO 2 -- or a radical conforming to ##STR2## e and g both denote the number 0 to 1; Z denotes F, Cl, Br or C 1 -C 4 -alkyl and if several Z radicals are substituents in one aryl radical, they may be identical or different from one another; d denotes an integer of from 0 to 4; and f denotes an integer of from 0 to 3.
Among the dihydroxy compounds useful in the practice of the invention are hydroquinone, resorcinol, bis-(hydroxyphienyl)-alkanes, bis-(hydroxyphenyl)-ethers, bis-(hydroxyphenyl)-ketones, bis-(hydroxyphenyl)-sulfoxides, bis-(hydroxyphenyl)-sulfides, bis-(hydroxyphenyl)-sulfones, and α,α-bis-(hydroxyphenyl)-diisopropylbenzenes, as well as their nuclear-alkylated compounds. These and further suitable aromatic dihydroxy compounds are described, for example, in U.S. Pat. Nos. 3,028,356; 2,999,835; 3,148,172; 2,991,273; 3,271,367; and 2,999,846, all incorporated herein by reference.
Further examples of suitable bisphenols are 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A), 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, α,α'-bis-(4-hydroxyphenyl)-p-diisopropylbenzene, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfide, bis-(3,5-dimethyl-4-hydroxy-phenyl)-sulfoxide, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfone, dihydroxybenzophenone, 2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-cyclohexane, α,α'-bis-(3,5-dimethyl-4-hydroxyphenyl)-p-diisopropylbenzene and 4,4'-sulfonyl diphenol.
Examples of particularly preferred aromatic bisphenols are 2,2,-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-cyclohexane.
The most preferred bisphenol is 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A).
The polycarbonates of the invention may entail in their structure units derived from one or more of the suitable bisphenols.
Among the resins suitable in the practice of the invention are included phenolphthalein-based polycarbonates, copolycarbonates and terpolycarbonates such as are described in U.S. Pat. Nos. 3,036,036 and 4,210,741, both incorporated by reference herein.
The polycarbonates of the invention may also be branched by condensing therein small quantities, e.g., 0.05 to 2.0 mol % (relative to the bisphenols) of polyhydroxyl compounds.
Polycarbonates of this type have been described, for example, in German Offenlegungsschriften 1,570,533; 2,116,974 and 2,113,374; British Patents 885,442 and 1,079,821 and U.S. Pat. No. 3,544,514. The following are some examples of polyhydroxyl compounds which may be used for this purpose: phloroglucinol; 4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane; 1,3,5-tri-(4-hydroxyphenyl)-benzene; 1,1,1-tri-(4-hydroxyphenyl)-ethane; tri-(4-hydroxyphenyl)-phenylmethane; 2,2-bis- 4,4-(4,4'-dihydroxydiphenyl)!-cyclohexyl-propane; 2,4-bis-(4-hydroxy-1-isopropylidine)-phenol; 2,6-bis-(2'-dihydroxy-5'-methylbenzyl)4-methylphenol; 2,4-dihydroxybenzoic acid; 2-(4-hydroxylphenyl)-2-(2,4-dihydroxyphenyl)-propane and 1,4-bis-(4,4'-dihydroxy-triphenylmethyl)-benzene. Some of the other polyfunctional compounds are 2,4-dihydroxybenzoic acid, trimesic acid, cyanuric chloride and 3,3-bis-(4-hydroxyphenyl)-2-oxo-2,3-dihydroindole.
In addition to the polycondensation process mentioned above, other processes for the preparation of the polycarbonates of the invention are polycondensation in a homogeneous phase and transesterification. The suitable processes are disclosed in the incorporated herein by reference, U.S. Pat. Nos. 3,028,365; 2,999,846; 3,153,008; and 2,991,273.
The preferred process for the preparation of polycarbonates is the interfacial polycondensation process.
Other methods of synthesis in forming the polycarbonates of the invention such as are disclosed in U.S. Pat. No. 3,912,688, incorporated herein by reference, may be used.
Suitable polycarbonate resins are available in commerce, for instance, Makrolon FCR, Makrolon 2600, Makrolon 2800 and Makrolon 3100, all of which are bisphenol based homopolycarbonate resins differing in terms of their respective molecular weights and characterized in that their melt flow indices (MFR) per ASTM D-1238 are about 16.5 to 24, 13 to 16, 7.5 to 13.0 and 3.5 to 6.5 g/10 min., respectively. These are products of Bayer Corporation of Pittsburgh, Pa.
A polycarbonate resin suitable in the practice of the invention is known and its structure and methods of preparation have been disclosed, for example in U.S. Pat. Nos. 3,030,331; 3,169,121; 3,395,1119; 3,729,447; 4,255,556; 4,260,731; 4,369,303 and 4,714,746, all of which are incorporated by reference herein.
The rubber-free, thermoplastic vinyl copolymer, Component B, of the present invention, contains
B.1) 50 to 99 percent relative to the weight of the copolymer of at least one member selected from the group consisting of styrene, alpha-methyl styrene, nucleus-substituted styrene, C 1-8 -alkyl methacrylate and C 1-8 -alkyl acrylate and
B.2) 1 to 50 percent relative to the weight of the copolymer of at least one member selected from the group consisting of acrylonitrile, methacrylonitrile, C 1-8 -alkyl methacrylate, C 1-8 -alkyl acrylate, maleic anhydride, C 1-4 -alkyl-N-substituted maleic imide and C 1-4 -phenyl-N-substituted maleic imide.
The molecular weight (weight average, as determined by gel permeation chromatography) of the copolymer of Component B is in the range of 15,000 to 200,000.
Particularly preferred ratios by weight of the components making up the copolymer B are 60 to 95 percent of B.1 and 40 to 5 percent of B.2. Particularly preferred copolymers B include those of styrene with acrylonitrile, optionally with methyl methacrylate; copolymers of alpha-methyl styrene with acrylonitrile, optionally with methyl methacrylate and copolymers of styrene and alpha-methyl styrene with acrylonitrile, optionally with methyl methacrylate.
The styrene/acrylonitrile copolymers of Component B are known and the methods for their preparation by radical polymerization, more particularly by emulsion, suspension, solution and bulk polymerization, are also well documented in the literature.
Component C according to the invention, a graft polymer having rubber-elastic properties, is well known in the art and is commercially available. A general description of such graft polymers is included in "Methoden der Organischen Chemie" (Houben Weyl), Vol. 14/1, Georg Thieme Verlag, Stuttgart 1961, pages 393-406 and in C. B. Bucknall, "Toughened Plastics", Appl. Science Publishers, London 1977, incorporated herein by reference. The graft polymer, incorporated as 5 to 70 pbw, preferably 10 to 60 pbw and, more preferably, 20 to 50 pbw relative to the total A, B and C, contains
C.1) 5 to 95 percent, preferably 30 to 80 percent, relative to the weight of the graft polymer of a grafted phase, and
C.2) 5 to 95 percent, preferably 30 to 80 percent, relative to the weight of the graft polymer of a graft base,
wherein said grafted phase contains a polymerized mixture of
C.1.1) 50 to 99 percent, relative to the weight of said mixture, of at least one member selected from the group consisting of styrene, alpha-methyl styrene, nucleus-substituted styrene, C 1-8 -alkyl methacrylate and C 1-8 -alkyl acrylate and
C.1.2) 1 to 50 percent, relative to the weight of said mixture, of at least one member selected from the group consisting of acrylonitrile, methacrylonitrile, C 1-8 -alkyl methacrylate, C 1-8 -alkyl acrylate, maleic anhydride, C 1-4 -alkyl-N-substituted maleic imide and C 1-4 -phenyl-N-substituted maleic imide, and
wherein said graft base includes
C.2) at least one crosslinked elastomer selected from the group consisting of diene and alkylacrylate in particulate form having an average particle diameter (d 50 value) of 0.05 to 5, preferably 0.1 to 0.6, micron and a glass transition temperature lower than 10° C., preferably lower than -10° C.
Suitable graft polymers have been disclosed in U.S. Pat. Nos. 3,564,077; 3,644,574 and 3,919,353 which are incorporated herein by reference.
Particularly preferred graft polymers C are obtainable by grafting of at least one (meth) acrylate and/or acrylonitrile and/or styrene as the grafted phase onto a graft base containing butadiene polymer having a gel content of at least 70% by weight (as measured in toluene), the degree of grafting (that is, the ratio between the weight of graft monomers grafted on to the graft base and the weight of the graft base) being between 0.15 and 0.75. In addition to butadiene units, the graft base may contain up to 50% by weight, based on the weight of the butadiene units, of other ethylenically unsaturated monomers, such as styrene, acrylonitrile, esters of acrylic or methacrylic acid containing 1 to 4 carbon atoms in the alcohol component (such as methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate), vinyl esters and/or vinyl ethers. The preferred graft base contains polybutadiene or is a copolymer of polybutadiene/acrylonitrile or a copolymer of polybutadiene/styrene.
Since the graft monomers do not have to be completely grafted onto the graft base in the grafting reaction, graft polymers C in the context of the invention are also understood to include products which are obtained by polymerization of the graft monomers in the presence of the graft base.
The average particle size (d 50 ) is the diameter above which 50% by weight of the particles and below which 50% by weight of the particles lie. It may be determined by ultracentrifuge measurement (W. Scholtan, H. Lange, Kolloid Z. und Z. Polymere 250 (1972), 782-796).
Other particularly preferred polymers useful as the graft base include acrylate rubber having a glass transition temperature below -20° C., as the graft base. These include alkyl acrylates, optionally with up to 40% by weight of other polymerizable, ethylenically unsaturated monomers. Most preferred polymerizable acrylic acid esters include C 1-8 -alkyl esters, for example methyl, ethyl, butyl, n-octyl and 2-ethylhexyl ester and haloalkyl esters, and mixtures of these monomers. Preferred "other" polymerizable, ethylenically unsaturated monomers which may optionally be used in addition to the acrylates for the production of the graft base include, for example, acrylonitrile, styrene, alpha-methyl styrene, acrylamides, vinyl C 1-6 -alkyl ethers, methyl methacrylate and butadiene.
Other suitable graft bases are silicone rubbers containing graft-active sites of the type described in DE-OS 3 704 657, DE-OS 3 704 655, DE-OS 3 631 540 and DE-OS 3 631 539.
For attaining crosslinking, monomers containing more than one polymerizable double bond are copolymerized according to known procedures. Examples of crosslinking monomers are esters of unsaturated monocarboxylic acids containing 3 to 8 carbon atoms and unsaturated monohydric alcohols containing 3 to 12 carbon atoms or saturated polyols containing 2 to 4 OH groups and 2 to 20 carbon atoms, for example ethylene glycol dimethylacrylate, allyl methacrylate; polyunsaturated heterocyclic compounds, such as for example trivinyl and triallyl cyanurate; polyfunctional vinyl compounds, such as di- and trivinyl benzenes; and also triallyl phosphate and diallyl phthalate. Preferred crosslinking monomers are allyl methacrylate, ethylene glycol dimethacrylate, diallyl phthalate and heterocyclic compounds containing at least three ethylenically unsaturated groups. Particularly preferred crosslinking monomers are the cyclic monomers triallyl cyanurate, triallyl isocyanurate, trivinyl cyanurate, triacryloyl hexahydro-s-triazine, triallyl benzenes.
The crosslinking monomers are incorporated preferably at a level of 0.02 to 5 percent, preferably 0.05 to 2 percent, based on the weight of the graft base. In the case of cyclic crosslinking monomers containing at least three ethylenically unsaturated groups, it is of advantage to limit the quantity to below 1% by weight of the graft base.
The gel content of the graft base may be determined in dimethyl formamide at 25° C. (M. Hoffmann, H. Kromer, R. Kuhn, Polymeranalytik I und II, Georg Thieme-Verlag, Stuttgart 1977).
The graft polymers may be produced by known methods, such as bulk, suspension, emulsion or bulk suspension polymerization.
Preferred polymers are crosslinked and have gel contents of more than 20% by weight, preferably more than 40% by weight and, more preferably, more than 60% by weight.
The compatibilizing agent, Component D, is a polymeric resin having a number average molecular weight (measured by gel permeation chromatography) of at least about 21,000 and preferably at least about 30,000 and a weight average molecular weight of at least about 40,000 and preferably at least about 60,000, miscible with the grafted phase of the grafted rubber (Component C) and containing about 0.05 to 4.0 mole percent of secondary amine reactive groups. The secondary amine reactive groups of the compatibilizing agent react under the time and temperature conditions prevailing in the course of its melt blending with the Components A, B, and C, with the carbonate groups of Component A. Determining the miscibility of component D in the grafted phase is preferably carried out by measurements of the relevant glass transition temperatures.
An example of the compatibilizer, Component D, is an amine-functional copolymer of (a) and (b) where (a) is a vinylaromatic monomer selected from the group consisting of styrene, alpha-methyl styrene, nucleus-substituted styrene, C 1-8 -alkyl methacrylate and C 1-8 -alkyl acrylate and where (b) at least one member selected from the group consisting of acrylonitrile, methacrylonitrile, C 1-4 -alkyl methacrylate, C 1-4 -alkyl acrylate in a weight ratio of (a) to (b) in the range of 85:15 to 15:85.
The vinylaromatic polymer may be functionalized by polymerizing the vinylaromatic monomer with monomers (a) and/or (b) with minor amount of monomer containing a carboxylic acid such as acrylic or methacrylic acid or C 1-2 -monoalkyl esters of diacids such as monomethyl maleate and mono-dodecyl fumarate, a dicarboxylic acid such as fumaric acid, maleic acid, itaconic acid, aconitic acid or citraconic acid, an anhydride, such as maleic, itaconic, aconitic or citraconic anhydride, or other monomers containing similar functional groups. Critically, the functional group is then converted to a secondary amine. The preparation of a compound suitable as a compatibilizer has been disclosed in co-pending U.S. patent application Ser. No. 08/992,729 filed Dec. 17, 1997. The preparation of a suitable compatibilizer is disclosed in the experimental section below.
The preferred Component D is a terpolymer containing styrene, alpha-methylstyrene or p-methylstyrene, acrylonitrile and from about 0.05 to about 4.0 mole percent amine functionality. A more preferred Component D is a styrene-acrylonitrile-maleic anhydride terpolymer containing from about 0.3 to about 9.5 mole percent maleic anhydride and the most preferred contains about I mole percent maleic anhydride. The styrene monomer:acrylonitrile weight ratio in Component D is in the range of 85:15 to 15:85 and is preferably in the range of 80:20 to 50:50. Preferably, the same styrene monomer is selected for the graft of component C and the compatibilizer, Component D. With such a terpolymer, miscibility with the grafted phase of the graft polymer, Component C, is obtained when the graft polymer and the compatibilizer both contain styrene and acrylonitrile and the weight percentage of the styrene monomer in the graft copolymer differs from the weight percentage of styrene monomer in Component D by no more than +/-5 percent.
The preferred amount of Component D in the polyblend is in the range of 0.5 to 5 percent relative to the total weight of A, B and C. A more preferred amount of Component D in the polyblend is 2 to 3 weight percent.
In addition to the above components, the composition of the invention may advantageously contain conventional additives such as plasticizers, antioxidants, stabilizers, flame-retardants, fibers, mineral fibers, mineral fillers, dyes, pigments and the like in conventional, functional amounts.
The inventive composition was found useful for the preparation of thermoplastically molded articles, including injection molded and extruded articles.
The components of the polyblend can be melt blended by any of the known customary and convenient processes. Usually, however, the components are blended in a high intensity blender such as a Banbury Mixer or twin-screw extruder.
The invention is described below with reference to the specific examples which are for the purposes of illustration only and are not intended to imply any limitation on the scope of the invention.
COMPONENTS USED
The polycarbonate used was a linear aromatic polycarbonate resin based on Bisphenol A having a melt index of 4.5 grams per 10 minutes at 300° C. with 1.2 kg load.
ABS refers to an emulsion graft containing polymerized styrene and acrylonitrile in a weight ratio of 70:30 in the presence of polybutadiene/acrylonitrile (93/7 by weight) rubber. It contained 40 percent by weight rubber. The weight average molecular weight of the un-grafted SAN copolymer fraction (determined by gel permeation chromatography--GPC) is about 150,000. ASTM Method D-3536-76 is used in GPC, modified in that four columns in series using micro Styragel.™. (A trademark of Waters Assoc.) packing are used with a nominal exclusion limit of 5,000 nm, 10,000 nm, 100,000 nm and 1,000,000 nm. The detector is an ultraviolet light detector set at wavelength 254 nm. The test samples are prepared at a concentration of 0.25 weight percent of polymer in tetrahydrofuran. The sample injection size is 0.2 ml and a flow rate of 2 ml/min. at ambient temperature is used. The grafted rubber has a weight average particle size (d 50 ) of about 0.2 micron, measured by Photon Correlation Spectroscopy using a Brookhaven Instrument Company BI-90 Particle Sizer.
The ABS polymer is recovered from the emulsion by conventional coagulation, filtration and washing.
SAN refers to a copolymer of styrene and acrylonitrile made by continuous bulk polymerization. The copolymer contains 67.2 weight % styrene and 32.5 weight % acrylonitrile. The number and weight average molecular weights, as measured by GPC, are 51,000 and 107,000, respectively.
Compatibilizer refers to a terpolymer and is prepared as follows:
A mixture of 49.8 parts styrene, 29.1 parts acrylonitrile, 0.8 parts maleic anhydride, 20 parts methylethyl ketone, 0.105 parts t-butyl-2-ethyl-hexyl peroxycarbonate (peroxide initiator) and 0.25 parts isooctyl thioglycolate (chain transfer agent) were fed to a continuously stirring reactor operating at 145° C. at a rate necessary to give a 45 minute residence time. The level of solids in the reactor of about 45% is achieved at steady state and the polymer solution is continuously devolatilized to yield a precursor polymer having styrene:acrylonitrile:maleic anhydride in a weight ratio of 66.5:32.5:1.0. The weight average molecular weight is about 119,000, measured by GPC and intrinsic viscosity (MEK, 25° C.) of 0.45 dl/g. The precursor polymer was then fed to a 34 mm Leistritz co-rotating twin screw extruder fitted with an injection port, a vacuum vent devolatilization zone, and a die face peiletizer. The extruder was operated at 150 RPM and 260° C. with a vacuum of 5 to 50 mm Hg. The precursor was fed at a rate of 9.1 kg/hr. The difunctional amine, 1-(2-aminoethyl)-piperazine, was pumped to the injection port at rates from about 1.25 to 2.0 moles per mole of anhydride or 2.5 to 4.0 ml/min.
In each of the examples and the control example, 1.0% of a lubricant, 0.2% of an antioxidant and 0.2% of citric acid (the percents based on the total weight of the composition) were addled. None of these are believed to have criticality in the present context.
The components were physically blended by an extrusion process. This involves a pre-blending step of physically mixing the ABS, SAN, polycarbonate, terpolymer and antioxidant and feeding the mixture into a 34 mm Leistritz twin-screw extruder (L:D=24:1 screw) at about 250 revolutions per minute at 260°C. The extruder is connected to a die also maintained at 260° C. The extruded material is passed through a water bath and pelletized. The rate of extrusion is 20 kgs per hour.
The pelletized blended material is then injection molded into specimens for testing according to the procedures as set forth above with the testing results concurrently listed for each example in Table 1. The injection molding is conducted using an Engel 225 molding machine, possessing a general purpose screw with a check ring and a straight through nozzle. The minimum injection pressure required to fill the mold is measured as a means of assessing the melt viscosity of the composition.
Multi-axial impact strength was measured on a Fractovis manufactured by CEAST according to ASTM 3763. The energy to maximum (E(max)) is the energy needed to achieve the yielding of the sample. The energy to failure (E(fail)) represents the energy necessary to cause a failure of a sample. The samples are conditioned at room temperature and at -30° C. to determine the effect of temperature on the performance of the polymer.
Examples 1 to 6 and Control 1, shown in Table 1, illustrate the effect of varying the amount of compatibilizer in the polymer blend. At room temperature, no effect of the compatibilizer on energy absorption is noted. However, at -30° C., improved energy absorption is observed, with the maximum improvement noted at about 3% of compatibilizer.
TABLE 1______________________________________ Control 1 2 3 4 5 6______________________________________ABS 25 25 25 25 25 25 25SAN 25 24.5 24 23 22 21 20Polycarbonate 50 50 50 50 50 50 50Compatibilizer 0 0.5 1 2 3 4 5Stock Temp, ° C. 265 265 265 265 265 265 265Mold Temp, ° C. 77 77 77 77 77 77 77Molding pressure, 624 600 609 624 638 653 667PSIEmax, 23° C. 38.5 39.3 37.8 38.8 37.6 35.8 34.1Efail, 23° C. 43.9 44.4 43.3 43.5 43.9 43.1 41.2Emax, -30° C. 36.7 41.8 40.7 41.9 43.9 39.5 40.1Efail, -30° C. 41.6 43.8 43.8 43.6 46.1 42.2 42.7______________________________________
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | A thermoplastic molding composition containing a blend of polycarbonate, vinyl copolymer, such as SAN, and a graft polymer, such as ABS is disclosed. The invention resides in the finding that the incorporation of a compatibilizing agent which comprises a polymeric resin having a number average molecular weight of at least about 21,000 and which is miscible with the grafted phase of the graft polymer and which contains secondary amine reactive groups in its structure yields stable compositions having improved mechanical properties especially at low temperatures. | 2 |
This application is a continuation of Ser. No. 08/722,026 filed Jan. 3, 1997, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the removal of impurities from a titaniferous material.
The term “titaniferous material” is understood herein to mean a material which contains at least 2 wt % titanium.
In a particular embodiment the present invention provides a process whereby silica and alumina are removed from a titaniferous material using an aqueous leach in the presence of acid, with the effectiveness of the leach in removing these impurities enhanced by the combination of pretreatments and the conditions of the leach.
In industrial chlorination processes titanium dioxide bearing feedstocks are fed with coke to chlorinators of various designs (fluidised bed, shaft, molten salt), operated to a maximum temperature in the range 700-1200° C. The most common type of industrial chlorinator is of the fluidised bed design. Gaseous chlorine is passed through the titania and carbon bearing charge, converting titanium dioxide to titanium tetrachloride gas, which is then removed in the exit gas stream and condensed to liquid titanium tetrachloride for further purification and processing.
The chlorination process as conducted in industrial chlorinators is well suited to the conversion of pure titanium dioxide feedstocks to titanium tetrachloride. However, most other inputs (i.e. impurities in feedstocks) cause difficulties which greatly complicate either the chlorination process itself or the subsequent stages of condensation and purification. The attached table provides an indication of the types of problems encountered. In addition, each unit of inputs which does not enter products contributes substantially to the generation of wastes for treatment and disposal. Some inputs (e.g. heavy metals, radioactives) result in waste classifications which may require specialist disposal in monitored repositories.
Preferred inputs to chlorination are therefore high grade materials, with the mineral rutile (at 95-96% TiO 2 ) the most suitable of present feeds. Shortages of rutile have led to the development of other feedstocks formed by upgrading naturally occurring ilmenite (at 40-60° TiO 2 ), such as titaniferous slag (approximately 86% TiO 2 ) and synthetic rutile (variously 92-95% TiO 2 ). These upgrading processes have had iron removal as a primary focus, but have extended to removal of manganese and alkali earth impurities, as well as some aluminium.
Elemental
Input
Chlorination
Condensation
Purification
Fe, Mn
Consumes
Solid/liquid
chlorine,
chlorides
coke,
foul
increases
ductwork,
gas volumes
make sludges
Alkali &
Defluidise
alkali earth
fluid beds due
metals
to liquid
chlorides,
consume
chlorine, coke
Al
Consumes
Causes
Causes
chlorine,
corrosion
corrosion,
coke
makes
sludges
Si
Accumulates
Can encourage
May require
in
duct
distillation
chlorinator,
blockage.
from product
reducing
Condenses in
campaign
part with
life.
titanium
Consumes
tetrachloride
coke,
chlorine
V
Must be
removed by
chemical
treatment and
distillation
Th, Ra
Accumulates
in
chlorinator
brickwork,
radioactive;
causes
disposal
difficulties
In the prior art synthetic rutile has been formed from titaniferous minerals, e.g. ilmenite, via various techniques. According to the most commonly applied technique, as variously operated in Western Australia, the titaniferous mineral is reduced with coal or char in a rotary kiln, at temperatures in excess of 1100° C. In this process the iron content of the mineral is substantially metallised. Sulphur additions are also made to convert manganese impurities partially to sulphides. Following reduction the metallised product is cooled, separated from associated char, and then subjected to aqueous aeration for removal of virtually all contained metallic iron as a separable fine iron oxide. The titaniferous product of separation is treated with 2-5% aqueous sulphuric acid for dissolution of manganese and some residual iron. There is no substantial chemical removal of alkali or alkaline earths, aluminium, silicon, vanadium or radionuclides in this process as disclosed or operated. Further, iron and manganese removal is incomplete.
Recent disclosures have provided a process which operates reduction at lower temperatures and provides for hydrochloric acid leaching after the aqueous aeration and iron oxide separation steps. According to disclosures the process is effective in removing iron, manganese, alkali and alkaline earth impurities, a substantial proportion of aluminium inputs and some vanadium as well as thorium. The process may be operated as a retrofit on existing kiln based installations. However, the process is ineffective in full vanadium removal and has little chemical impact on silicon.
In another prior art invention relatively high degrees of removal of magnesium, manganese, iron and aluminium have been achieved. In one such process ilmenite is first thermally reduced to substantially complete reduction of its ferric oxide content (i.e. without substantial metallisation), normally in a rotary kiln. The cooled, reduced product is then leached under 35 psi pressure at 140-150° C. with excess 20% hydrochloric acid for removal of iron, magnesium, aluminium and manganese. The leach liquors are spray roasted for regeneration of hydrogen chloride, which is recirculated to the leaching step.
In other processes the ilmenite undergoes grain refinement by thermal oxidation followed by thermal reduction (either in a fluidised bed or a rotary kiln). The cooled, reduced product is then subjected to atmospheric leaching with excess 20% hydrochloric acid, for removal of the deleterious impurities. Acid regeneration is also performed by spray roasting in this process.
In all of the above mentioned hydrochloric acid leaching based processes impurity removal is similar. Vanadium, aluminium and silicon removal is not fully effective.
In yet another process ilmenite is thermally reduced (without metallisation) with carbon in a rotary kiln, followed by cooling in a nonoxidising atmosphere. The cooled, reduced product is leached under 20-30 psi gauge pressure at 130° C. with 10-60% (typically 18-25%) sulphuric acid, in the presence of a seed material which assists hydrolysis of dissolved titania, and consequently assists leaching of impurities. Hydrochloric acid usage in place of sulphuric acid has been claimed for this process. Under such circumstances similar impurity removal to that achieved with other hydrochloric acid based systems is to be expected. Where sulphuric acid is used radioactivity removal will not be complete.
A commonly adopted method for upgrading of ilmenite to higher grade products is to smelt ilmenite with coke addition in an electric furnace, producing a molten titaniferous slag (for casting and crushing) and a pig iron product. Of the problem impurities only iron is removed in this manner, and then only incompletely as a result of compositional limitations of the process.
A wide range of potential feedstocks is available for upgrading to high titania content materials suited to chlorination. Examples of primary titania sources which cannot be satisfactorily upgraded by prior art processes for the purposes of production of a material suited to chlorination include hard rock (non detrital) ilmenites, siliceous leucoxenes, many primary (unweathered) ilmenites and large anatase resources. Many such secondary sources (e.g. titania bearing slags) also exist.
Clearly there is a considerable incentive to discover methods for upgrading of titaniferous materials which can economically produce high grade products almost irrespectively of the nature of the impurities in the feed.
At present producers of titania pigment by the choride process require feedstocks to have silica levels as low as possible. In general most feedstocks are less than 2% SiO 2 . Where, for various reasons, feedstocks with high levels of silica may be taken in, they are blended against other low silica feedstocks, often with significant cost and productivity penalties. Therefore suppliers of titaniferous feedstocks for chlorination traditionally select ores and concentrates which will result in beneficiated products with low levels of silica. This is generally achieved by mineral dressing techniques based on physical separations. In these processes it is only possible to reject essentially the majority of free quartz particles without sacrificing recovery of the valuable titania minerals. A level of mineralogically entrained silica will normally remain in titaniferous concentrates. In the upgrading processes for ilmenite to synthetic rutile which are presently operated, the removal of iron and other major impurities result in a concentration effect for the silica which exacerbates the requirements for ilmenite concentrates as feedstocks to upgrading plants. Silica is not removed by any commercial upgrading process.
Chemical removal of silica from titaniferous concentrates and upgraded materials can be achieved theoretically by aqueous leaching under alkaline conditions. However, when such leaching is attempted under practical conditions it has been found that the effectiveness of the leach is reduced by forms of silica in the material which are not amenable to alteration, i.e. are inert to leaching, or by reactions between silica which has entered solution and other components of the titaniferous material which result in the precipitation of solid siliceous material. This precipitation thus limits the effectiveness of the leach in removing silica.
Thus, in the prior art, silica and other impurities have been removed from titaniferous materials by aqueous leaching with very high excesses of simple caustic solutions. An excess is necessary to prevent impurities present within the titaniferous materials (e.g. alumina) from interfering with the effectiveness of the leach. In some cases, the spent leachants, containing excesses of unused reagent are directly discarded. Recycle of leachant simply has the effect of concentrating deleterious impurities in the leachant and reducing the effectiveness of the leach. The cost of the caustic leachant in such cases is prohibitive, especially when neutralisation costs incurred for the purpose of liquor discard into the environment are considered.
There is no prior art in existence or contemplated in which removal of silica in a leach conducted in the presence of acid is indicated to be effective for the treatment of titaniferous materials. In summary there is presently no industrially realistic process for the effective removal of silica from titaniferous materials.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides an industrially realistic process for upgrading of titaniferous materials, which process comprises the following steps:
(i) a pretreatment which has the effect of rendering silica amenable to leaching under the particular conditions of a subsequent leach, and
(ii) an aqueous leach in the presence of an acid, the conditions of which are chosen such that silica which enters solution is not hydrolysed or precipitated as a silicate.
It is preferred that pretreatment step (i) includes an aqueous caustic treatment.
DETAILED DESCRIPTION OF THE INVENTION
It has been surprisingly discovered that the process of the invention can remove silica, alumina and other impurities.
The treatment in step (i) may include any treatment which has the effect of ensuring that the form of the silica in the titaniferous material entering step (ii) is amenable to alteration under the conditions of step (ii). For example, the treatment may include smelting of the titaniferous material to make a titaniferous slag. It may include roasting of the titaniferous material with additives which have the effect in roasting of converting contained silica to silicates or transferring Silica into a glassy phase. The treatment may also be an alkaline leach treatment, with or without other additives, which has the effect of converting silica to amorphous or crystalline silicates. The treatment may be a combination of these treatments or of these treatments and other treatments which in combination have the desired effect.
Step (i) may be conducted in any suitable equipment, which equipment will depend in part on the method chosen to perform this step.
Step (ii) is a leach conducted in the presence of acid. Any suitable acid may be used, including hydrochloric and sulphuric acids, but also including weak acids such as organic acids and sulphurous acid. However, the leach step must be conducted in such a manner that precipitation of silica to a solid precipitate or gel is avoided. The most effective means of ensuring that hydrolysis is avoided is by conducting the leach at low solids densities, thereby limiting the level of silica in the solution.
The leach may be conducted in any suitable arrangement. Typically it will be conducted in stirred tank reactors. Leaching may be conducted in multiple stages or in a single stage, continuously or in batches. Solids and liquids flows through leaching may be cocurrent or countercurrent. Reagents may be added stagewise to maintain reagent strength through the leach or may be added in a single stage.
Solid/liquid separation may be conducted after leaching in any suitable manner, including cycloning, thickening, filtration, pressure filtration and centrifugation. The spent leachant may be cycled through leachant treatment for the removal of impurities and back into the leach. Alternatively, spent leachant may be discarded or proceed to be used in other process stages.
Additional steps may be incorporated into the process as desired. For example:
(i) The leach residue may pass to further processing, e.g. hot acid leaching for the removal of impurities such as iron, magnesium and manganese.
(ii) The leach residue may be washed.
(iii) The leach residue may be dried and/or calcined and/or agglomerated.
(iv) Where leachant is recycled a bleed stream may be removed in order to limit the concentration of particular impurities.
(v) A proportion of the wash liquors may be, recycled as water make up.
(vi) The process may be preceded by upgrading of the titaniferous material for the removal of impurities such as iron, magnesium and manganese, and partial removal of silica and alumina.
(vii) Spent leachant and wash streams, whether or not treated for silica removal, may report to leach/acid regeneration circuits wherein any radioactive elements removed in leaching are deported to a suitable solid residue.
Clearly there is great flexibility within the process as disclosed to accommodate a wide range of feed materials, as well as pretreatment, leach and solution treatment conditions and arrangements. The process steps disclosed herein may be incorporated in any Suitable manner into any other process operated for the purpose of the upgrading of titaniferous materials.
EXAMPLES
Example 1
This example illustrates a multi stage pretreatment followed by a leach in the presence of acid which has the effect of silica removal.
A titaniferous concentrate was ground, mixed and agglomerated with the addition of 0.65% anydrous borax and 0.65% soda, added as sodium carbonate, and roasted with char at 1000° C. The composition of the roasted product after char separation is given in Table 1. The roasting was conducted to enhance the amenability of silica in the fees to subsequent leaching by formation of a glassy phase.
The roasted material was subjected to leaching with boiling 45 gpL NaOH in the presence of 45 gpL Na2B4O7, 1.8 gpL SiO 2 and 0.66 gpL Al 2 O 3 under reflux at 5% solids density for 4 hours. The leach residue (after solid/liquid separation and washing) contained 2.53% SiO 2 and 1.04% Al 2 O 3 . That is, silica and alumina removal was ineffective. However, with the exception of inert silica and alumina the form of alumina and silica in the residue had been converted to aluminosilicates of the feldspathoid type.
The leach residue was then subjected to room temperature (25° C.) leaching with 100 gpL sulphurous acid at 10% solids density for 30 minutes. After solid/liquid separation and washing the residue of this leach contained 1.2% SiO 2 and 0.3% Al 2 O 3 . The precipitated aluminosilicate was completely removed.
Example 2
A sample of a quartz bearing titania concentrate was fully oxidised with air at 900° C. and then reduced in a fluidised bed using a hydrogen/CO 2 mixture such that the final state of virtually all contained iron was the 2+oxidation state. A 700 g sample of this concentrate (whose composition is recorded in Table 2) was then leached at 40 wt % solids density for 4 hours at 175° C. in a solution made up by adding 242 g/L of 40% sodium silicate solution (3.2:1 SiO 2 :Na 2 O weight basis) and 150 g/L of NaOH.
A washed and dried sample of the leach residue had the composition which is also recorded in Table 2. The majority of the residual silica in this material was as a sodium aluminosilicate which has formed during the leach.
A 300 g sample of the leach residue was leached at 10% solids density for 1 hour at 25° C. in a solution of 5% HCL. After this cold acid leach a washed and dried sample of residue had the composition which is also recorded in Table 2.
Clearly the acid leach had been effective for the removal of silica deposited as aluminosilicate in the initial leach.
Example 3
Pellets of a ground titania slag (a product of ilmenite smelting) having a composition recorded in Table 3 were made up with addition of 1% Na 2 B 4 O 7 and roasted at 1000° C. for two hours in a flow of 1:19 H 2 O/CO 2 gas mixture, to oxidise trivalent titania.
A sample of the pellets was then subjected to leaching at 25 wt % solids density with 20% H 2 SO 4 at 135° C. for 6 hours. The analysis of the leach residue recorded in Table 3 shows that there was negligible removal of silica in the acid leach.
A further sample of the pellets were subjected to leaching with boiling 100 gpL NaOH for 6 hours at 10 wt % solids density at 165° C. The composition of the caustic leach residue is recorded in Table 4. Even at low slurry densities silica is retained as aluminosilicate due to saturation of the leachant with alumina.
The caustic leached residue was subjected to an acid leach with 20% HCL at 30% solids density for 6 hours at reflux. The composition of the residue of acid leaching is recorded in Table 4. The combination of the caustic leach treatment with the acid leach treatment had been highly effective in the removal of silica in the acid leach.
TABLE 1
Composition of Thermally Processed Feed in Example 1.
wt. %
TiO 2
63.4
FeO
25.7
SiO 2
3.81
Al 2 O 3
0.83
Na 2 O
0.88
MgO
0.88
MnO
1.10
Other
2.0
TABLE 2
Compositions of Feed and Leach Residues in Example 2.
Alkaline
Leach
Acid Leach
Feed
Residue
Residue
TiO 2
65.7
66.4
67.7
FeO
26.5
26.9
26.4
SiO 2
3.1
0.94
0.37
Al 2 O 3
0.8
0.67
0.49
Na 2 O
n.d.
0.2
n.d.
MgO
1.1
0.88
0.88
MnO
1.1
1.2
1.2
CaO
n.d.
0.03
0.01
Other*
1.4
2.8
2.9
*N.B. includes water of hydration.
TABLE 3
Compositions of Slag Feed and Acid Leach Residue
in Example 3.
Feed Slag
Acid Leached Slag
TiO 2
77.9
88
FeO
9.1
4.0
SiO 2
2.8
3.1
Al 2 O 3
3.1
0.95
Na 2 O
0.08
0.05
MgO
4.8
2.15
MnO
0.24
0.11
CaO
0.47
0.17
Other
0.5
1.5
TABLE 4
Compositions of Caustic Leach and Subsequent Acid
Leach Residues in Example 3.
Caustic Leach
Acid Leach
Residue
Residue
TiO 2
78.4
82.7
FeO
9.1
7.7
SiO 2
3.1
0.96
Al 2 O 3
3.1
2.7
Na 2 O
n.d.
n.d.
MgO
4.8
4.8
MnO
0.25
0.23
CaO
0.38
0.13
Other
0.9
0.8 | A process for upgrading of titaniferous material containing silica, including pretreating the titaniferous material by alkaline leaching to precipitate the silica as an aluminosilicate which is amenable to further leaching. Subsequently, the pretreated titaniferous material is leached under acid conditions, causing the silica to enter solution under conditions such that the silica is not hydrolysed or precipitated as a silicate. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application of International Application No. PCT/FR2008/050814, filed on May 7, 2008, which claims the benefit of French Patent Application No. 07 03394 filed on May 11, 2007, the entire contents of both applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a package for a food product taken out from the package using a predetermined utensil serving as a measuring device. More particularly, the invention relates to a package comprising:
a container having a wide upper opening extending in a substantially horizontal plane and delimited by a perimeter; a closure system comprising a lid able to be moved between an open position and a closed position, wherein latter it covers the opening of the container; and a first leveling element having an upper face and a free edge located in the space of said opening.
A package of this type is known for example from document EP-A-1 157 936. The presence of a leveling element proves useful in practice for leveling the contents of a spoon or any other more complex measuring device by sliding the open side of the cup of this spoon past the free edge of this leveling element. Such a free edge may also be used to scrape the blade of a knife.
Nevertheless, when a granular or powdery product needs to be measured precisely, it is preferable for the user to use for each use the same utensil or measuring device the volume of which is precisely defined. Moreover, if variable volumes of product need to be measured, as is the case in particular for baby milk powder, where the volume to be taken out depends on the quantity of milk to be prepared, the measuring device may prove to be rather more complex than a simple spoon. It is therefore highly useful for the user to be able to retrieve the measuring device immediately for each use. However, for this purpose, the user should not have to carry out an unnatural or relatively tiresome operation at the end of the preceding use.
By contrast, a relatively widespread practice consists in simply replacing the measuring device on the top of the food product. However, simply taking hold of the measuring device may contaminate its handle with contaminants which may then come into contact with the food product if the measuring device is simply laid in the container.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide the user with a system enabling the particularly easy returning of a specific or nonspecific measuring device to the package, such that the user may retrieve this device during a subsequent use while limiting the risks of product contamination.
To this end, the subject of the present invention is a package of the abovementioned type which is characterized in that it comprises a second leveling element spaced apart from the first and also having an upper face and a free edge located in the space of said opening, the upper faces of the first and second leveling elements each having a configuration and being arranged with respect to one another such that they form two spaced-apart bearing zones extending substantially parallel to the plane of the opening of the container and on which a measuring device is able to rest.
Thus, by providing a second leveling element and arranging it in an opportune manner with respect to the first, bearing zones are provided which enable a measuring device to be returned to the package by using a very natural and simple movement to position it while preventing it from making any contact with the food product. The first and second leveling elements thus fulfill, according to the invention, a supporting function in addition to their leveling function. Even though the presence of two elements demands a little more material to produce the package, this is fully compensated for by the double role fulfilled by the first and second leveling elements. In addition, the leveling elements are clearly visible and used as soon as product is taken out from the box. As a result, their additional function as supports is easily understood by users, especially if their upper face bears an indication, such as a pictogram, for example.
In addition, the presence of two leveling elements is found to make it easier for left-handers to use the measuring system. This is because the leveling elements are quite often placed on the left of the package when it is facing the user in order to make leveling easier with the right hand, but this is disadvantageous for left-handers.
In preferred embodiments of the invention, use is furthermore made of one or other of the following arrangements:
the opening of the container has a basically rectangular shape defining first and second opposing long sides and first and second opposing short sides of the perimeter, the first and second leveling elements being arranged at an angle in corners respectively adjacent to the first and second short sides of the perimeter; the lid is mounted such that it pivots about an axis along the first long side of the perimeter and the leveling elements are arranged in corners which are both adjacent to the second long side of the perimeter; the predetermined measuring device provided extends between a first end and a second end, said ends being spaced apart at a predetermined distance such that they rest on the first and second leveling elements and preferably at a predetermined distance which is slightly shorter than a long side of the opening; the predetermined measuring device provided extends between a first end having a cup and a second end defined by the free end of a handle and at least one of the upper faces of the first and second leveling elements has at least one positioning relief designed to engage with an end region of the predetermined measuring device; the lid has an inner face having at least one protruding immobilizing member arranged so as to be close to the measuring device positioned on the bearing zones of the first and second leveling elements and shaped so as at least to limit the possibility of said measuring device lifting with respect to said bearing zones when the lid is in the closed position, and preferably also so as to limit the possibilities of said measuring device moving in the plane of the opening; the first and second leveling elements constitute part of the perimeter of the opening and are formed in one piece with the container, and a peel-off membrane seal is sealed onto an annular strip of the perimeter of the opening; said at least one positioning relief on the first and second leveling elements is arranged in a region of the upper face of the leveling element located outside the outline defined by the annular sealing strip, said at least one relief preferably protruding from said upper face; the annular sealing strip of the membrane seal is located as close as possible to the opening, and the membrane seal extends beyond the annular sealing strip at least partially above each of the upper faces of the first and second leveling elements so as to form first and second peeling-off tongues over said leveling elements; said at least one positioning relief on the first and second leveling elements is formed by a hole designed to engage with a protruding part of the predetermined measuring device, said relief being arranged in a region of the upper face of the leveling element located inside the outline defined by the annular sealing strip; the annular sealing strip of the membrane seal is formed by an annular relief protruding from the perimeter of the opening of the container; the closure system also comprises a frame mounted on a neck of the container located close to the perimeter of the opening, on which neck the lid is hinged, and the first and second leveling elements are formed in one piece with said frame and arranged so as to be above the plane of the opening of the container; the frame is made of injection-molded plastic and said at least one relief is an elastically deformable member protruding from the upper face of the first or second leveling element and designed to come into engagement with the predetermined measuring device; the lid has an inner face having a coupling member designed to hold a predetermined measuring device against said inner face of the lid; the lid has an inner face from which an annular belt extends which is arranged so as to have a free edge close to the perimeter of the opening when the lid is in the closed position; and the lid has a domed inner face having a profile designed to loosely clasp part of the predetermined measuring device with at least one of the first and second leveling elements.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will become apparent from the following description given by way of nonlimiting example with reference to the figures, in which:
FIG. 1 is a schematic view of a first preferred embodiment of the package according to the invention, comprising a container closed by a peel-off membrane seal and a lid in the open position, in which lid a measuring device is placed;
FIG. 2 is a top view of the container from FIG. 1 from which the membrane seal has been peeled off and on which the measuring device is resting;
FIG. 3 is a bottom view of the lid from FIG. 1 without the measuring device;
FIG. 4 is a partial cross-sectional view on the line IV-IV in FIG. 2 with the lid in the closed position; and
FIG. 5 is a view similar to FIG. 2 of a second embodiment of the package.
DETAILED DESCRIPTION
In the various figures, identical reference numerals designate identical or similar elements.
FIG. 1 shows a package 1 comprising a container 2 , a closure system 3 and a measuring device 5 .
The container 2 has a base 21 from which an annular side wall 22 extends along a central vertical axis Z as far as an upper face 23 . The upper face has a wide opening 24 surrounded by a perimeter 25 . The perimeter 25 extends essentially in a horizontal plane coincident with the plane of the opening 24 and is formed by a collar extending radially toward the central axis Z. However, it is perfectly conceivable for this perimeter to be formed simply by the thickness of the material forming the side wall 22 .
Perpendicular to the central axis Z, the container 2 has a basically rectangular cross section with rounded corners. This cross section varies somewhat along the central axis Z in order to form a waist for gripping, but these variations remain limited in order to ensure the vertical strength of the packages when they are stacked. Also for gripping purposes, the cross section preferably lies within a rectangle measuring 150 to 130 mm by 105 to 125 mm. The height from the base 21 to the upper face 23 is preferably between 130 and 170 mm in order to provide the customary volume for boxes intended to contain powdered baby milk. It is thus a relatively deep container, the opening 24 of which needs to be made as wide as possible in order to make it easier to extract powder from close to the base 21 of the container 2 .
Due to this basically rectangular cross section, the perimeter 25 of the opening of the container 2 may be considered to have a first long side 25 a , a second opposing long side 25 b and first and second short sides 25 c , 25 d connecting the long sides.
The container 2 is produced in one piece from blow-molded plastic. This plastic is preferably a multilayer compound forming a very effective oxygen barrier when the product is milk powder, for example. However, it may, of course, be a container produced from another material, in particular metal or multilayer board.
The wide opening 24 of the container 2 is closed by a membrane seal 26 , shown in FIG. 1 , which is sealed onto an annular sealing strip 27 indicated by dashed lines. This sealing strip 27 is in the form of a slightly protruding bead, but it could be perfectly flat. Thus, the milk powder is perfectly preserved in the container 2 until used for the first time when the membrane seal 26 is peeled off with the aid of one of the portions 26 a or 26 b of the membrane seal which constitute peeling-off tongues.
As can be seen more clearly in FIG. 4 , the container 2 has a stepped neck 28 between the top of its annular wall 22 and its upper face 23 . As will be explained below, the presence of this neck 28 enables the mounting of a frame for the closure system 3 .
The closure system 3 first of all comprises a lid 31 having a relatively domed shape such that it may be considered to have a substantially flat upper portion 31 a and an annular peripheral portion 31 b substantially coaxial with the central axis.
The lid 31 also has an inner face 31 c oriented toward the opening 24 in the closed position, this inner face being basically dish-shaped due to the domed shape of the lid 31 .
The closure system 3 further comprises a frame 32 mounted with a tight fit on the neck 28 of the container 2 . The frame 32 is fastened nondetachably to this part of the container, in particular by snap fastening, but could also be fastened by adhesive bonding or welding.
The frame 32 has an external periphery 32 a continuing the side wall 22 of the container 2 , followed by an inward recess 32 b , then an annular portion 32 c extending as far as an upper face 32 d of the frame. The upper face 32 d of the frame extends horizontally in a plane parallel to the plane of the opening 24 comprising the perimeter 25 , and slightly below this plane in the embodiments shown. This prevents the frame from interfering with the membrane seal 26 sealed onto the perimeter 25 . The radially inner end of the upper face 32 d constitutes here the inner periphery of the frame 32 which is adjacent to the neck 28 of the container. The upper face 32 d of the frame forms with the perimeter 25 of the opening 24 the upper face 23 of the container part.
However, it is perfectly conceivable for the membrane seal 26 to be sealed onto the frame 32 , depending on the nature of the food product contained and depending on the degree of sealing obtained between the neck 28 of the container 2 and this frame 32 . In such a case, it is then preferable for the upper face 32 d of the frame to be located above the plane of the perimeter 25 of the opening 24 and possibly for it to extend toward the central axis Z in order to cover the perimeter 25 .
The lid 31 and the frame 32 are hinged together by a connection 34 enabling the lid 31 to move with respect to the frame 32 and to the container 2 between an open position, shown in FIG. 1 , in which the opening 24 is easily accessible, and a closed position, shown in FIG. 4 , in which the lid 31 covers this opening. It is thus a reclosable package of which the lid is handled each time it is used, for example for preparing babies' bottles.
In this case the connection 34 is a hinge connection, the pivot axis P of which is perpendicular to the central axis Z. More precisely, the pivot axis P is parallel and located close to the first long side 25 a of the perimeter 25 .
In the embodiment shown, it is a plastic hinge formed by a fold line enabling the lid 31 and the frame 32 to be produced as a single part. Said part is obtained by injection-molding a plastic, for example polypropylene. However, the hinge connection 34 could of course also be produced as two separate parts joined together and it is likewise possible to provide some other type of connection between the frame and the lid, or even to do without a frame by employing a lid mounted removably on the neck 28 of the container 2 .
The locking device comprises a lug 35 integral with the lid 31 and engaging with a nose 29 protruding from the neck 28 of the container. The locking device produced in this form, or in any other form, is intended to prevent any accidental escape of product once the package has been opened for the first time when the membrane seal 26 has been peeled off, but is not intended to provided a sealed closure such as was obtained previously with the membrane seal.
As can be seen in FIGS. 1 and 4 , the inner face 31 c of the lid has an annular belt 37 extending downward in the direction of the axis Z as far as a free edge 37 a arranged so as to be close to the perimeter 25 of the opening of the container 2 such that it increases the degree of closure of the container without, however, producing an airtight closure.
As can be seen clearly in FIG. 1 , the inner face 31 c of the lid 31 also has a coupling member 38 , formed here by two elastic lugs having inclined noses and facing one another, in order to hold the measuring device 5 against the inner face of the lid. The coupling member 38 produced in this manner holds the measuring device 5 by snap fastening such that the latter can be repositioned against the lid after being used for the first time. However, for reasons that will become apparent below, it is perfectly possible to produce the coupling member 38 from breakable elements which are only able to hold the measuring device 5 until it is used for the first time.
With regard to the measuring device 5 , this is similar to a spoon in the embodiment shown, that is to say it has a cup 51 which defines a fixed measuring volume and is substantially cylindrical up to the open side of this cup. A handle 53 extends from the cup 51 as far as a free end 53 a . The measuring device 5 thus has an elongate form having a first end region 51 a defined by the part of the cup opposite the handle 53 and a second end region encompassing the free end 53 a of the handle.
The device 5 shown in the figures is a measuring device of predetermined form designed to be sold with the package and the fixed measuring volume of which is specific to the food product in question. Using a predetermined measuring device 5 enables the package elements, such as the coupling member 38 , to be configured such that they engage tightly with a portion of the measuring device that has a known and precise geometry. However, the package could also be used with a standard teaspoon or tablespoon, with some of its advantages still being obtained.
As can be seen more clearly in FIG. 2 , the package 1 comprises a first leveling element 41 and a second leveling element 42 , each having a free edge ( 41 a ; 42 a ) located in the space of the opening 24 of the container. It should be understood from the expression “space of the opening” that the free edges ( 41 a ; 42 a ) can be located precisely in the plane of the opening 24 defined by the perimeter 25 , but also a little above or below this plane as long as they fulfill their primary function, namely to level off the product contained in the measuring device 5 .
Leveling is performed by sliding the open side of the cup 51 of the measuring device 5 against the free leveling edge ( 41 a ; 42 a ), thereby obtaining a volume of product in the measuring device which corresponds very precisely to the volume of the cup 51 . For this purpose, each of the free edges ( 41 a , 42 a ) must have a rectilinear portion having a length at least equal to the open side of the cup 51 . This is because, if there were no rectilinear portion, for example if there were a concave free edge, the powder would not be leveled off correctly at the top of the open side, and what is worse, in the case of a convex free edge, the protruding part thereof could catch on the cup and cause powder to tip out. On the other hand, it is necessary for each of the leveling edges 41 a , 42 a to protrude sufficiently into the interior from the side wall 22 of the container so that the user is not obliged to incline the measuring device 5 almost vertically which could cause some of the product to fall out and thereby lead to a mismeasurement.
Moreover, each of the first and second leveling elements ( 41 ; 42 ) has an upper face ( 41 b ; 42 b ) having a certain size and basically located in a horizontal plane coincident with the plane of the opening 24 . Nevertheless, it is possible for the upper faces ( 41 b , 42 b ) to be inclined so as, for example, to slope toward the central axis and thus make it easier to return powder spillages into the container 2 .
The upper faces ( 41 b , 42 b ) each have a configuration and are arranged with respect to one another so as to form two spaced-apart bearing zones onto which it is easily possible to put the measuring device 5 . The measuring device 5 rests on these bearing zones ( 41 b , 42 b ) away from the food product contained, in the container whether it is a measuring device of predetermined form or a simple spoon.
The bearing zones of the upper faces ( 41 b , 42 b ) extend in a horizontal plane in order that the measuring device 5 rests simply by virtue of gravity and parallel to the plane of the opening 24 in order to minimize the space necessarily taken up in the package 1 . However, it is possible for the measuring device 5 stored in this way to have a certain inclination or else to engage with nonflat bearing zones creating a certain amount of friction.
It should be noted that the measuring device 5 has a predetermined distance between its first and second ends ( 51 a , 53 a ), in order that the latter rest on the first and second leveling elements ( 41 , 42 ). Preferably, this predetermined distance is slightly shorter than a long side of the opening 24 . It is clear that such a length offers a good compromise between the capacity to extract powder from the bottom of the container 2 and the ease of storing the measuring device on the leveling elements. As can be seen more clearly in FIG. 2 , the leveling elements are formed by basically triangular wings arranged in the corners of the perimeter 25 of the opening in order that their respective free edges ( 41 a , 42 a ) are oriented at approximately 45 degrees to the short sides ( 25 c , 25 d ) of the perimeter which are adjacent to these corners.
In addition, these first and second leveling elements are both adjacent to the second long side 25 b of the perimeter, that is to say the side opposite the hinge 34 of the lid 31 . This configuration proves to be particularly practical not only for right-handed users but also for left-handers when carrying out leveling. In addition, such an arrangement does not impose an excessive length on the measuring device 5 for certain configurations of the container, given that the opening 24 thereof must be relatively wide. This advantageous arrangement of the first and second leveling elements ( 41 , 42 ) could also be obtained with a nonrectangular, for example circular, opening 24 .
It should also be noted in this embodiment that the leveling elements are formed in one piece with the container 2 and thus constitute part of the perimeter 25 of the opening. This arrangement has, in addition to an economic advantage, an advantage with respect to the membrane sealing of the container.
Specifically, it is thus advantageous for the annular sealing strip 27 to be arranged as close as possible to the opening 24 and thus adjacent to the leveling edges ( 41 a , 42 a ). Thus, firstly the surface closed by the membrane seal 26 is minimized and secondly the peeling-off tongues ( 26 a , 26 b ) can be arranged above the leveling elements ( 41 , 42 ). They are thus easier to take hold of than smaller peeling-off tongues folded down at the periphery of the upper face of the box. Similarly, the advantageous arrangement for left-handers and right-handers is also apparent for the peeling-off tongues ( 26 a , 26 b ) by virtue of this arrangement.
It should also be noted that by placing positioning reliefs ( 43 , 44 ) which protrude with a suitable height into this outer region, the peeling-off tongues ( 26 a , 26 b ) can be lifted easily which makes them easier to grasp.
The role of the bearing zones on the upper faces ( 41 b , 42 b ) of the leveling elements can be easily understood by the user if pictograms are etched or printed on them. It appears advantageous, however, to provide one or more positioning reliefs ( 43 , 44 ) on at least one of the upper faces ( 41 b , 42 b ) of the leveling elements ( 41 , 42 ), said positioning reliefs being designed and arranged to engage more or less tightly with the measuring device 5 , particularly if the latter is a standard utensil or a measuring device of predetermined form.
More particularly, in the embodiment shown, the first leveling element 41 has on its upper face 41 b two circularly arcuate guards 43 arranged around the outer outline of the first end region 51 a of the measuring device 5 . The second leveling element 42 also has two circularly arcuate guards 44 which are arranged around the outline of the second end region formed by the end 53 a of the handle. Thus, besides a visual indication of the possibility of positioning the measuring device 5 , it is possible to immobilize this measuring device in the plane of the perimeter 25 , particularly in order to prevent it from falling into the container 2 as a result of the package 1 being handled more or less roughly.
In this first embodiment, the reliefs ( 43 , 44 ) of the leveling elements ( 41 , 42 ) thus protrude, but they could also be recesses or even through-holes as will become apparent from the description of the second embodiment.
In order further to immobilize the measuring device 5 when it rests on the bearing zones of the leveling elements ( 41 , 42 ) and more particularly in order to prevent the measuring device 5 from lifting off these zones and falling into the container if the package is handled severely, at least one immobilizing member 46 is arranged on the inner face 31 c of the lid 31 . This member 46 can be seen in FIGS. 1 , 3 and 4 and is in the form of a panel extending vertically downward as far as a free edge having an indentation 46 a . The indentation 46 a is positioned and located at a distance from the inner face 31 c of the lid so as to be just above a mid-portion of the handle 53 of the measuring device 5 , and preferably at a distance less than the depth of engagement of the measuring device with the reliefs ( 43 , 44 ) of the leveling elements. Thus, when the lid 31 is in the closed position shown in FIG. 4 , the measuring device cannot leave its storage position on the bearing zones of the leveling elements ( 41 , 42 ). The immobilizing member 46 also has on both sides of the indentation 46 a extended portions 46 b limiting, just like the reliefs 43 , 44 , any possibility of the measuring device moving in a direction parallel to the plane of the opening 24 . This immobilization is all the more effective if a measuring device 5 of predetermined form is provided.
The immobilizing member 46 could also form an integral part of the annular belt 37 in a variant which is not shown. Specifically, this belt 37 could be vertically beneath the annular sealing strip 27 shown in FIG. 2 and have indentations of a suitable height for the cup and the handle 53 in the regions of the annular sealing strip 27 shown by the dotted lines in this figure.
With the same aim, and as can be seen in FIG. 4 , the profile of the inner face 31 c of the domed lid 31 is determined such that this inner face clasps the measuring device 5 and more precisely its cup 51 when it rests on the leveling elements ( 41 , 42 ) and the lid 31 is in the closed position.
A second embodiment of the package is shown in FIG. 5 in a view analogous to that of the first embodiment in FIG. 2 . In this second embodiment, the first and second leveling elements ( 41 , 42 ) are still formed by triangular wings formed in one piece with the perimeter 25 of the container 2 , but are arranged diagonally, that is to say with a first leveling element 41 located in the corner adjacent to the first short side 25 c and to the second long side 25 b of the perimeter while the second leveling element 42 is located in the corner adjacent to the second short side 25 d and to the first long side 25 a . The measuring device 5 can then have a longer form which may prove useful in the case of a taller, narrower container.
It should be noted that in this embodiment the upper face 41 b of the first leveling element has no relief except the bead of the annular sealing strip 27 which in this case is adjacent to the free edges 41 a . The upper face 42 b of the second leveling element 42 has in this case a relief 45 formed by a through-hole, through it could be a well. The measuring device 5 then has a projection 55 having a complementary form on the end region 53 a bearing against the bearing zone of the second leveling element 42 in order to engage with the recess 45 . The hole 45 and the projection 55 have concentric ovoid cross sections, or any other noncircular form. Thus the positioning relief formed by the hole 45 not only limits the translational movement of the second end 53 a of the measuring device 5 but also fixes the longitudinal orientation of the latter such that the first end 52 a is above the first leveling element 41 .
It should be noted that at the second leveling element 42 the annular sealing strip 26 follows the outer periphery of the perimeter 25 . Subsequently, the relief formed by the hole 45 may pass through the leveling element 42 which is in the form of a wing of the same thickness as the side wall 22 of the container without affecting the sealing when the container is closed by the membrane seal 26 before being used for the first time. Of course, the measuring device 5 may be held against the inner face 31 c of the lid before the first use, for example by means of a coupling member similar to the first embodiment but arranged diagonally with respect to the lid 31 .
The method of manufacturing and using the package 1 may proceed, inter alia, in the following manner. Containers 2 having as yet no closure system 3 are conveyed on a line where they are filled with baby milk powder and after filling are immediately sealed hermetically by the membrane seal 26 . Any protruding reliefs ( 43 , 44 ) located outside the annular sealing strip 27 do not hamper this membrane sealing operation and this also applies in the case of any recesses 45 .
Next, the closure system 3 comprising the lid 31 and the frame 32 and also the predetermined measuring device 5 coupled to the lid to prevent handling is mounted on the neck 28 of the container 2 , preferably by snap fastening. It should be noted that the peeling-off tongues ( 26 a , 26 b ) do not interfere with this mounting operation given that they do not extend beyond the upper faces ( 41 b , 42 b ) of the leveling elements ( 41 , 42 ).
When the package is used for the first time, the user peels off the membrane seal 26 and uncouples the measuring device 5 from the inner face of the lid 31 . Any pictograms or reliefs ( 43 , 44 ) on the leveling elements ( 41 , 42 ) are then perfectly visible. The user takes the required amount of product by digging into the powder in the container 2 using the measuring device 5 . The volume of powder is leveled off by sliding the open side of the cup 51 along the free edge 41 a of the first leveling element, or along the free edge 42 a of the second leveling element if he is a left-hander.
After taking the required quantity, the user rests the measuring device in a natural manner on the first and second leveling elements ( 41 , 42 ) which then form supports, the open side of the cup 52 either being oriented toward the upper face 41 a of the first leveling element or toward that of either of the first and second leveling elements ( 41 , 42 ) if the latter have identically configured positioning reliefs ( 43 , 44 ; 45 ). The measuring device is then held in position and immobilized in this position after the lid has been closed by virtue of the immobilization member 46 and/or by virtue of the configuration of the inner face 31 c of the domed lid. This immobilization has a certain amount of play in order that the plastic parts do not have to be given a very precise form, the aim being simply to prevent the measuring device 5 from falling into the container 2 if the package is handled energetically.
When the package is used the next time, the measuring device 5 is immediately visible and can be withdrawn very easily if it is only resting lightly on the corresponding zones of the first and second leveling elements ( 41 , 42 ).
Of course, the embodiments described above are in no way limiting, their features can be combined and other variants are conceivable. It is in particular possible to produce leveling elements formed in one piece with the frame 32 of the closure system 3 . In that case, it is preferable for the upper face 32 d of the frame 32 to be located above the perimeter 25 of the opening of the container 2 and for the leveling elements 41 , 42 to be in the form of wings covering this frame and part of the opening 24 . If this opening 24 is closed by a membrane seal, attention must be paid to the ease of peeling the latter off. It should be noted that in that case the leveling elements are produced, in the same way as the frame, from injection-molded plastic. This enables geometric forms which are rather more precise and more complex than in the case of a thermoformed or blow-molded container 2 . It is then possible to provide for at least one of the reliefs on the upper face of a leveling element to be an elastically deformable member protruding from this face. This makes it possible to hold the measuring device 5 against the first and second leveling elements by snap fastening and without an immobilizing member, or else to provide greater adaptability to the geometry of the measuring member, especially if the latter does not have a well-known predetermined form. | A package for a food product sampled using a metering device, including a receptacle ( 2 ) having a wide top opening ( 24 ) and defined by a rim ( 25 ), a closure system ( 3 ) including a cover ( 31 ) that can be moved between an open position and a closed position, and a first levelling element ( 41 ) having a top face ( 41 b ) and a free edge ( 41 a ) situated in the space of the opening. The package also includes a second levelling element ( 42 ) spaced apart from the first and also having a top face ( 42 b ) and a free edge ( 42 a ), wherein the top faces ( 41 b, 42 b ) of the first and second levelling elements ( 41, 42 ) each have a configuration and are mutually arranged in order to form two spaced-apart bearing zones substantially parallel to the plane of the opening for supporting the metering device. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/877,251, filed Dec. 27, 2006.
BACKGROUND
[0002] This invention relates to a catalytic electrode, particularly an electrode with a nano-catalytic material, an electrochemical cell containing the catalytic electrode, and processes for making the catalytic electrode and the electrochemical cell.
[0003] There is a wide variety of electrochemical cells that have catalytic electrodes. Examples include, but are not limited to, fuel cells, metal-air battery cells, gas (e.g., hydrogen) generating cells, and electrochemical sensor cells. Examples of such cells are found in U.S. Pat. Nos. 5,242,565; 5,308,711; 5,378,562; 5,567,538; 5,707,499; 6,060,196; 6,461,761; 6,602,629; 6,911,278; 7,001,689 and 7,001,865; and in International Patent Publication No. WO 00/36677.
[0004] An advantage of cells with catalytic electrodes is that they can use one or more active materials that are not contained within cell or battery housings, thereby providing long use time (e.g., discharge capacity) with a cell having a minimum volume. There is an ongoing desire to improve the performance of such electrochemical cells, such as by improving electrical characteristics (e.g., operating voltage, power output, energy density, discharge capacity, charging efficiency, cycle life and fade), storage characteristics, leakage resistance, cost, environmental impact of waste disposal, and safety in manufacturing.
[0005] One way to improve the electrical characteristics is through the use of a catalytic material having greater catalytic activity. One approach to doing so has been to use nano-catalysts (catalyst materials with particles smaller than one micrometer (μm) because their large surface area provides more reactive sites. To provide good electrical conductivity and low internal resistance within the catalytic electrode and to provide a large reactive surface area with the electrode, the catalytic material is often combined with a porous material with excellent electrical conductivity. Examples of such efforts can be found in U.S. Pat. No. 7,087,341; U.S. Patent Publication No. 2006/0226564; U.S. Patent Publication No. 2006/0269823; U.S. Patent Publication No. 2007/0092784; U.S. patent application Ser. No. 11/482,290, filed Jul. 7, 2006; and Unexamined Japanese Patent Publication No. 2006-252,797.
[0006] Because of the high reactivity of nano-catalyst materials, it may be necessary to process the nano-catalyst material in an inert environment, such as an Argon atmosphere. This places restrictions on and adds cost to the manufacturing process that can be undesirable, especially for large scale, high speed manufacturing. Previous efforts to control the reactivity of nano-particulate catalyst compositions include processes in which the substrate particles (e.g., an activated carbon) and nano-catalyst particles (e.g., a nano-metal) are treated in a liquid medium (e.g., a lower alcohol such as methanol), and the nano-particles are oxidized by removing the liquid medium and contacting the nano-particles with an oxidant.
[0007] Previous efforts have not been completely successful in producing catalytic electrodes and electrochemical cells using catalytic electrodes that have improved performance characteristics and are easy, economical and safe to manufacture.
SUMMARY
[0008] Some disclosed embodiments provide a process for manufacturing a catalytic electrode and/or an electrochemical cell using the catalytic electrode in an easy, economical and safe manner. Some embodiments eliminate the need for mixing in an inert atmosphere the components of the catalytic material or the resultant catalytic composition used to make the active layer of the electrode. Some embodiments eliminate the use of liquids that are highly volatile, flammable and/or explosive, that may pose potential health risks to workers, or that may pose a risk to the environment.
[0009] Some embodiments provide a catalytic electrode with a nano-catalyst material that has improved electrical properties and that will work well in an electrochemical cell when operated at high power.
[0010] Some embodiments provide an electrochemical cell that has good leakage resistance and improved performance (e.g., greater energy density, improved discharge capacity, and higher power on discharge) than cells made according to the prior art and is also stable during periods of storage and non-use.
[0011] Disadvantages of the prior art are overcome through the use of the materials and processes described below for mixing components of a catalytic material including nano-catalyst particles, forming a catalytic electrode from the catalytic material, and assembling the electrode into an electrochemical cell.
[0012] Accordingly, one aspect of the invention is an electrochemical cell comprising a catalytic electrode, a counter electrode, a separator between the catalytic and counter electrodes, and an electrolyte, all disposed within a housing having at least one opening for allowing a gas to enter into or escape from the housing; wherein: (a) the catalytic electrode has a multilayer structure comprising an active layer and a gas diffusion layer; (b) the active layer comprises a catalytic material for oxidizing or reducing an active material, an electrically conductive material, and a binder; (c) the gas diffusion layer comprises a material that is permeable to the gas entering or escaping the housing and is essentially impermeable to the electrolyte to seal the electrolyte within the housing; and (d) the gas diffusion layer has a surface with a gas diffusion area for diffusion of the gas therethrough, the entire gas diffusion area is adhered to the active layer, and adhesion of the gas diffusion area to the active layer has areas of relatively high adhesion and areas of relatively low adhesion.
[0013] Another aspect of the invention is an electrochemical cell comprising a catalytic electrode, a counter electrode, a separator between the catalytic and counter electrodes, and an aqueous alkaline electrolyte, all disposed within a housing having at least one opening for allowing oxygen to enter the housing; wherein: (a) the catalytic electrode has a multilayer structure comprising an active layer, a gas diffusion layer and a current collector; (b) the active layer comprises a catalytic material, an electrically conductive carbon and a binder; (c) the gas diffusion layer comprises a polytetrafluoroethylene material that is permeable to the oxygen entering the housing and is essentially impermeable to the electrolyte to seal the electrolyte within the housing; (d) the gas diffusion layer has a surface with a gas diffusion area for diffusion of the oxygen therethrough to the active layer, the entire gas diffusion area is adhered to the active layer, and adhesion of the gas diffusion area to the active layer has areas of relatively high adhesion and areas of relatively low adhesion; (e) the catalytic electrode has sufficient permeability to be capable of providing 220 mW/cm 2 to 700 mW/cm 2 maximum power on a Half Cell AC Impedance/Potential Dynamic Scan test; (f) the current collector comprises an expanded metal comprising nickel, coated with graphite; and (g) the cell contains no added mercury.
[0014] Yet another aspect of the invention is a process for making a catalytic electrode for an electrochemical cell, comprising the steps: (a) mixing a catalytic material for oxidizing or reducing an active material with an electrically conductive material and a binder; (b) forming the mixture from step (a) into an active layer sheet; (c) disposing a first surface of a gas diffusion layer sheet against a first surface of the active layer sheet; (d) applying pressure to a second surface of the active layer sheet and a second surface of the gas diffusion layer sheet to bond the gas diffusion layer sheet to the active layer sheet to produce a gas diffusion area is bonded to the active layer with areas of relatively high adhesion and relatively low adhesion between the gas diffusion layer and active layer; and (e) forming the bonded layers into an electrode having adhesion between essentially the entire adjacent second surfaces of the bonded layers.
[0015] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
[0016] Unless otherwise specified, the following definitions and methods are used herein:
1. Anode means the negative electrode of an electrochemical cell. 2. Cathode means the positive electrode of an electrochemical cell.
[0019] Unless otherwise specified herein, all disclosed characteristics and ranges are as determined at room temperature (20-25° C.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the drawings:
[0021] FIG. 1 is an elevational view, in cross-section, of a prismatic shaped metal-air cell with a catalytic electrode;
[0022] FIG. 2 is an enlarged cross-sectional view through the material construction of the anode casing at line 2 - 2 of FIG. 1 , illustrating one embodiment of the anode casing material;
[0023] FIG. 3 is an elevational view, in cross-section, of a button shaped metal-air cell with a catalytic electrode;
[0024] FIG. 4 is a graph showing Tafel curves, with observed current on the x-axis and applied potential on the y-axis, for a zinc-air cell with an electrode containing a conventional manganese oxide catalyst compared to a cell with an electrode containing a nano-manganese catalyst;
[0025] FIG. 5 is a graph showing power curves, with current density on the x-axis and voltage vs. zinc on the y-axis, for half cells with catalytic electrodes containing activated carbon, one with and one without a nano-manganese catalyst; and
[0026] FIG. 6 is a graph showing polarization curves, with current on the x-axis and voltage on the y-axis, for a zinc-air cell with an air electrode containing a conventional manganese oxide catalyst compared to a cell with an electrode containing a nano-manganese catalyst.
DESCRIPTION
[0027] Electrochemical cells according to the invention can be metal-air, hydrogen generating or oxygen generating cells, for example. The invention is exemplified by metal-air battery cells as described below. Metal-air battery cells can be made in a variety of shapes and sizes, including button cells, cylindrical cells and prismatic cells.
[0028] Examples of prismatic and button metal-air cells are shown in FIGS. 1 and 3 , respectively. An embodiment of a button cell 10 including an anode casing 26 that is generally a cup-shaped metal component is illustrated in FIG. 3 . Cell 10 is an air cell that includes a cathode casing 12 that is cup-shaped, and is preferably formed of nickel-plated steel such that it has a relatively flat central region 14 which is continuous with and surrounded by an upstanding wall 16 of uniform height. Alternatively, in one embodiment the central region 14 of the can bottom may protrude outward from the peripheral part of the can bottom. At least one hole 18 is present in the bottom of cathode can 12 to act as an air entry port. The casings 12 , 26 can include single or multiple steps if desired.
[0029] An embodiment of a prismatic cell 110 including an anode casing 126 of the present invention is shown in FIG. 1 . The cell 110 illustrated is an air cell that includes cathode casing 112 , preferably formed of nickel-plated steel. Anode casing 126 and cathode casing 112 are generally prismatic-shaped, and preferably rectangular, with each casing 126 , 112 defining four linear or nonlinear sidewalls connected to a base or central region, preferably planar. Alternatively, cathode casing 112 can have a base with an area that protrudes outward from the peripheral part of the casing base. At least one hole 118 is present in the bottom of cathode can 112 to act as an air entry port. The casings 112 , 126 , can include single or multiple steps if desired.
[0030] Referring to FIGS. 1 and 3 , a catalytic positive electrode, such as air electrode 20 , 120 is disposed near the bottom of the cathode casing 12 , 112 . As shown in greater detail in FIG. 1 , the air electrode 120 can include a catalytic layer containing a mixture of carbon, a nano-catalyst, and a binder. Air electrode 20 , 120 also preferably has a hydrophobic layer 22 , 122 , such as a hydrophobic membrane or film, laminated thereon. The hydrophobic layer 22 , 122 is laminated on the side of the air electrode closest to the bottom of the cell when oriented as shown in FIGS. 1 and 2 . Air electrode 20 , 120 also preferably contains an electrically conductive current collector 123 ( FIG. 1 ), typically a metal screen or expanded metal, such as nickel or a nickel plated or clad iron or steel, embedded therein, preferably on the side of the electrode opposite the hydrophobic layer 22 , 122 . The air electrode may also optionally contain a barrier membrane 137 , such as a PTFE film, between the laminated hydrophobic layer 22 , 122 and flat central region 14 , 114 of the bottom of the casing 12 , 112 .
[0031] In a preferred embodiment, the catalytic layer 121 contains a catalytic composition that includes composite particles comprising nano-catalyst particles adhered to (e.g., adsorbed onto) the external and internal surfaces (including surfaces of open pores) of highly porous carbon substrate particles.
[0032] The carbon material can be an activated carbon, preferably steam activated carbon, and more preferably steam activated carbon derived from coal. An activated carbon is a carbon with a specific surface area (BET method) of at least about 500 m 2 /g, with 1500 m 2 being achievable. Examples of steam activated carbons are Type PWA carbon (Calgon Carbon Corp., Pittsburgh, Pa., USA) and NORIT® Supra carbon, NORIT® Super carbon and DARCO® G-60 carbon (all from American Norit Co., Inc., Marshall, Tex., USA), with DARCO® G-60 carbon being a preferred steam activated carbon. Typical properties of DARCO(® G-60 carbon include: carbon particles pass through a No. 100 sieve but do not pass through a No. 325 sieve (US Standard Series sieves per ASTM E-11); a particle size distribution with a d 50 of about 34 μm, a d 5 of about 5.5 μm and a d 95 of about 125 μm; a specific surface area (BET method) from about 600 to about 1000 m 2 /g; a pore volume of about 0.95 ml/g, dry basis; a bulk density (tamped) of about 0.40 g/ml; and an iron content of the carbon no greater than 200 parts per million (ppm).
[0033] The nano-catalyst can be a metal, metal alloy or metal oxide with particles of sub-micron size, at least one and preferably all of the metals of which can be selected from the transition metals (metals having incomplete d subshells) of groups 3-12, the metals of groups 13-16, the lanthanides, mixtures, combinations and/or alloys thereof. Preferred metals include manganese, nickel, cobalt and silver, with manganese being especially preferred. The nano-catalysts have primary particles with a maximum dimension of from about 1 nm to about 999 nm (0.999 em), referred to herein as nano-particles. As used herein, primary particles are particles that are bound together chemically rather than physically (e.g., by electrostatic charge, van der Waals forces or moisture). Primary particles can form agglomerates of primary particles that are held together physically. Preferably the majority of the nano-catalyst particles are generally spherical with maximum dimensions of less than 50 nm, more preferably less than 20 nm, and most preferably less than 10 nm. The nano-catalyst can include oxidized nano-particles. The oxidized nano-particles can be fully or partially oxidized metal. A partially oxidized nano-particle can have a metal core with an oxide shell. The oxide shell is preferably an essentially complete shell, covering essentially the entire external surface of the particle. Preferably at least the majority of the primary nano-particles have at least an oxide shell (i.e., they are oxidized on at least their exterior surfaces) to minimize agglomeration of the primary particles and facilitate uniform mixing. More preferably at least 80 percent, and even more preferably at least 90 percent, of the primary nano-particles have at least an oxide shell. Most preferably no more than 5 percent of the nano-particles do not have at least an oxide shell. Nano-catalysts including oxidized nano-particles are available from QuantumSphere, Inc. (QSI), Santa Ana, Calif., USA.
[0034] A preferred nano-catalyst is a nano-manganese such as QSI-NANO® Manganese/Manganese Dioxide Powder, as disclosed in U.S. patent application Ser. No. 11/482,290, filed Jul. 6, 2006. In one embodiment, the nano-manganese can include a mixture of phases, such as metallic manganese and one or more oxides of manganese, such as MnO, Mn 2 O 3 , and Mn 3 O 4 . The overall composition of the nano-manganese can be MnO x , where x is from about 0.5 to about 2.0, preferably from about 0.7 to about 1.3, and more preferably from about 0.9 to about 1.1. The primary oxidized particles are generally sphere-like in shape, typically with a maximum dimension of about 20-30 nm in size, with some smaller particles, down to 10 nm or less. The primary metallic manganese particles are generally rod-like in shape and typically about 20 nm in width and about 100 to 200 nm long. Primary particles can agglomerate to form larger clusters. It is generally desirable to minimize agglomeration or break up agglomerates to achieve the most uniform distribution of the nano-catalyst in the catalytic composition.
[0035] The catalytic composition can include a binder for binding the particles of carbon together. The binder can be a fluorocarbon material, such as polytetrafluoroethylene (PTFE). Suitable PTFE materials that can be used to make the catalytic layer composition include TEFLON® materials (available from E.I. duPont de Nemours & Co., Polymer Products Div., Wilmington, Del., USA), including powders such as TEFLON® 7C and, preferably, dispersions such as TEFLON® T30B, T30N, TE3857, TE3859 and modifications thereof. More preferably the PTFE material is T30B or a modification of TE3859 (e.g., TE3859 fluorocarbon resin plus 2 percent TRITON™ X-100 octylphenol ethoxylate nonionic surfactant (Dow Chemical Company, Midland, Mich., USA) based on the weight of the TE3859). The fluorocarbon binder can be fibrillated in the catalytic material mixing process.
[0036] In a preferred embodiment, the catalytic layer 121 of the electrode 120 contains oxidized nano-manganese and activated carbon in a ratio of from about 0.01/1 to about 0.10/1 by weight and from 1-25 weight percent PTFE binder (the minimum amount is more preferably at least 2, even more preferably at least 5 and most preferably at least 7 weight percent; the maximum amount is more preferably no greater than 15 and most preferably no greater than 12 weight percent).
[0037] The hydrophobic layer 22 , 122 is hydrophobic material that has a low enough surface tension to be resistant to wetting by the electrolyte, yet porous enough to allow the required gas (e.g., oxygen in the air for a metal-air cell) to enter the electrode at a rate sufficient to support the desired cell reaction rate. Fluorocarbon membranes such as polytetrafluoroethylene (PTFE) can be used for the hydrophobic layer. A preferred PTFE material is a high permeability material with an air permeability value of from 1 to 300 seconds. A preferred PTFE material has an apparent density from about 1.5 to 1.7 g/cm 2 . Examples of preferred materials are unsintered natural PTFE film, such as 0.10 mm (0.004 inch) thick PTFE membrane, product number N6389A (from Performance Plastics Product (3P), Houston, Tex., USA) with an air permeability value of about 100-200 seconds and an apparent density of about 1.60±0.5 g/cm 2 ; and expanded TEFLON® film, such as 0.076 mm (0.003 inch) thick expanded film sample number 12850830.1 (from W.L. Gore & Associates, Inc., Elkton, Md., USA). The air permeability value is the time required for 2.5 cm 3 of air under a constant pressure of 30.94 g/cm 3 (12.2 inches of water, or 0.44 pounds/in 2 ) to pass through an area of 0.645 cm 2 (0.1 in 2 ) and can be measured with a Gurley Densometer, Model 4150, for example.
[0038] At least one layer of separator 24 , 124 is positioned on the side of the air electrode 20 , 120 facing the anode 28 , 128 . The separator 24 , 124 is ionically conductive and electrically nonconductive. The total thickness of the separator 24 , 124 is preferably thin to minimize its volume, but must be thick enough to prevent short circuits between the anode 28 , 128 and air electrode 20 , 120 . While there are advantages to a single layer, two (or more) layers may be needed to prevent short circuits through a single pore, hole or tear in the material. For aqueous alkaline metal-air cells, cellulosic materials such as rayon, cotton and wood fiber (e.g., paper) and combinations thereof are preferred. An example of a preferred separator is a combination of a layer of water-wettable nonwoven polypropylene membrane treated with surfactant (adjacent to the anode 28 , 128 ) and a layer of hydrophobic polypropylene membrane (adjacent to the air electrode 20 , 120 ), such as CELGARD® 5550 and CELGARD® 3501 separators, respectively, both from Celgard, Inc., Charlotte, N.C., USA. Another example of a preferred separator material is rayon bound with polyacrylic acid (e.g., FS22824AB grade separator from Carl Freudenberg KG, Weinheim, Germany, and BVA 02530 grade separator from Hollingsworth & Vose, East Walpole, Mass., USA). The separator 24 , 124 is preferably adhered to the entire surface of the air electrode 20 , 120 to provide the best ion transport between the electrodes and to prevent the formation of air pockets between the air electrode 20 , 120 and the separator 24 , 124 . Similarly, adjacent layers of the separator 24 , 124 are adhered to each other.
[0039] A layer of porous material 138 can be positioned between air electrode 20 , 120 and the bottom of casing 12 , 112 to evenly distribute air to electrode 20 , 120 . A sealant 129 such as a thermoplastic hot melt adhesive, for example SWIFT® 82996 (from Forbo Adhesives, LLC of Research Triangle Park, N.C., USA) can be used to bond portions of the cathode to cathode casing 112 .
[0040] Cell 10 , 110 also includes anode casing 26 , 126 which forms the top of the cell. The anode casing 126 in FIG. 1 has a rim 135 is flared outward at its open end. The anode casing 26 in FIG. 3 has essentially straight side walls and that has a rim 35 with little or no outward flare. Alternatively, a cell can have a refold anode casing in which the rim is folded outward and back along the side wall to form a substantially U-shaped side wall with a rounded edge at the open end of the casing.
[0041] The anode casing 26 , 126 can be formed from a substrate including a material having a sufficient mechanical strength for the intended use. The anode casing 26 , 126 can be a single layer of material such as stainless steel, mild steel, cold rolled steel, aluminum, titanium or copper. Preferably the anode casing includes one or more additional layers of material to provide good electrical contact to the exterior surface of the anode casing 26 , 126 , resistance of the external surface to corrosion, and resistance to internal cell gassing where the internal surface of the anode casing 26 , 126 comes in contact with the anode 28 , 128 or electrolyte. Each additional layer can be a metal such as nickel, tin, copper, or indium, or a combination or alloy thereof, and layers can be of the same or different metals or alloys. Examples of plated substrates include nickel plated steel, nickel plated mild steel and nickel plated stainless steel. Examples of clad materials (i.e., laminar materials with at least one layer of metal bonded to another layer of metal) include, as listed in order from an outer layer to an inner layer, two-layered (biclad) materials such as stainless steel/copper, three-layered (triclad) materials such as nickel/stainless steel/copper and nickel/mild steel/nickel, and materials with more than three clad layers.
[0042] The anode casing 26 , 126 can include a layer that is post-plated (i.e., plated after forming the anode casing into its desired shape). The post-plated layer is preferably a layer of metal with a high hydrogen overvoltage to minimize hydrogen gassing within the cell 10 , 110 . Examples of such metals are copper, tin, zinc, indium and alloys thereof. A preferred metal is tin, and a preferred alloy is one comprising copper, tin and zinc.
[0043] In one embodiment, illustrated in FIG. 2 , the material of the anode casing 126 in FIG. 1 has a substrate having a steel layer 144 pre-plated with a layer of nickel 142 on each side, as well as a post-plated layer 140 of tin or a copper-tin-zinc alloy for example. The anode casing 126 in this embodiment can also be provided with a strike layer 146 between the substrate and the post-plated layer 140 . A preferred strike layer 146 is a post-plated layer of copper which promotes adhesion between the substrate and the final post-plated layer 140 .
[0044] In the embodiment shown in FIG. 3 , anode casing 26 is made from a nickel-stainless steel-copper triclad material, with the copper layer on the inside, post-plated with tin or an alloy of copper, tin and zinc. The preferred composition of a layer of an alloy of copper, tin and zinc includes 50 to 70 weight percent copper, 26 to 42 weight percent tin, and 3 to 9 weight percent zinc. A strike layer of copper can be post-plated onto the anode casing 26 prior to the final post-plated layer to improve its adhesion to the triclad substrate material. The copper-tin-zinc alloy can be applied in multiple layers with the under layer(s) having a higher copper content than the surface layer, as described in detail in U.S. patent application Ser. No. 11/933,552, filed Nov. 1, 2007, which is hereby incorporated by reference.
[0045] The anode casing 26 , 126 can be formed using any suitable process. An example is a stamping process. A button cell anode casing 26 is preferably formed using three or more progressively sized stamping dies, after which the casing 26 is punched out of the coil of triclad strip.
[0046] During manufacture of the cell, anode casing 26 , 126 can be inverted, and then a negative electrode composition or anode mixture 28 , 128 and electrolyte put into anode casing 26 , 126 . The anode mixture insertion can be a two step process wherein dry anode mixture materials are dispensed first into the anode casing 26 followed by KOH solution dispensing. In a prismatic cell, the wet and dry components of the anode mixture are preferably blended beforehand and then dispensed in one step into the anode casing 126 . Electrolyte can creep or wick along the inner surface 36 , 136 of the anode casing 26 , 126 , carrying with it materials contained in anode mixture 28 , 128 and/or the electrolyte.
[0047] An example of an anode mixture 28 , for a button cell comprises a mixture of zinc, electrolyte, and organic compounds. The anode mixture 28 preferably includes zinc powder, a binder such as SANFRESH™ DK-500 MPS, CARBOPOL® 940 or CARBOPOL® 934, and a gassing inhibitor such as indium hydroxide (In(OH) 3 ) in amounts of about 99.7 weight percent zinc, about 0.25 weight percent binder, and about 0.045 weight percent indium hydroxide. SANFRESH™ DK-500 MPS is a crosslinked sodium polyacrylate from Tomen America Inc. of New York, N.Y., and CARBOPOL® 934 and CARBOPOL® 940 are acrylic acid polymers in the 100% acid form and are available from Noveon Inc. of Cleveland, Ohio.
[0048] The electrolyte composition for a button cell can be a mixture of about 97 weight percent potassium hydroxide (KOH) solution where the potassium hydroxide solution is 28-40 weight percent, preferably 30-35 weight percent, and more preferably about 33 weight percent aqueous KOH solution, about 3.00 weight percent zinc oxide (ZnO), and a very small amount of CARBOWAX® 550, which is a polyethylene glycol based compound available from Union Carbide Corp., preferably in an amount of about 10 to 500 ppm, more preferably about 30 to 100 ppm, based on the weight of zinc composition in the anode.
[0049] An anode mixture 128 , for a prismatic cell can include a mixture of zinc, electrolyte, and organic compounds. The anode mixture 128 preferably includes zinc powder, electrolyte solution, a binder such as CARBOPOL® 940, and gassing inhibitor(s) such as indium hydroxide (In(OH) 3 ) and DISPERBYK® D190 in amounts of about 60 to about 80 weight percent zinc, about 20 to about 40 weight percent electrolyte solution, about 0.25 to about 0.50 weight percent binder, about 0.045 weight percent indium hydroxide and a small amount of DISPERBYK® D190, preferably in an amount of about 10 to 500 ppm, more preferably about 100 ppm, based on the weight of zinc. DISPERBYK® D190 is an anionic polymer and is available from Byk Chemie of Wallingford, Conn.
[0050] The electrolyte composition for a prismatic cell can be a mixture of about 97 weight percent potassium hydroxide (KOH) solution where the potassium hydroxide solution is about 28 to about 40 weight percent, preferably about 30 to about 35 weight percent, and more preferably about 33 weight percent aqueous KOH solution, and about 1.00 weight percent zinc oxide (ZnO).
[0051] Preferred zinc powders are low-gassing zinc compositions suitable for use in alkaline cells with no added mercury. Examples are disclosed in U.S. Pat. No. 6,602,629 (Guo et al.), U.S. Pat. No. 5,464,709 (Getz et al.) and U.S. Pat. No. 5,312,476 (Uemura et al.), which are hereby incorporated by reference.
[0052] One example of a low-gassing zinc is ZCA grade 1230 zinc powder from Zinc Corporation of America, Monaca, Pa., USA, which is a zinc alloy containing about 400 to about 550 parts per million (ppm) of lead. The zinc powder preferably contains a maximum of 1.5 (more preferably a maximum of 0.5) weight percent zinc oxide (ZnO). Furthermore, the zinc powder may have certain impurities. The impurities of chromium, iron, molybdenum, arsenic, antimony, and vanadium preferably total 25 ppm maximum based on the weight of zinc. Also, the impurities of chromium, iron, molybdenum, arsenic, antimony, vanadium, cadmium, copper, nickel, tin, and aluminum preferably total no more than 68 ppm of the zinc powder composition by weight. More preferably, the zinc powder contains no more than the following amounts of iron, cadmium, copper, tin, chromium, nickel, molybdenum, arsenic, vanadium, aluminum, and germanium, based on/the weight of zinc: Fe-3.5 ppm, Cd-8 ppm, Cu-8 ppm, Sn-5 ppm, Cr-3 ppm, Ni-6 ppm, Mo-0.25 ppm, As-0.1 ppm, Sb-0.25 ppm, V-2 ppm, Al-3 ppm, and Ge-0.06 ppm.
[0053] In another embodiment, the zinc powder preferably is a zinc alloy composition containing bismuth, indium and aluminum. The zinc alloy preferably contains about 100 ppm of bismuth, 200 ppm of indium, and 100 ppm of aluminum. The zinc alloy preferably contains a low level of lead, such as about 35 ppm or less. In a preferred embodiment, the average particle size (D 50 ) is about 90 to about 120 microns. Examples of suitable zinc alloys include product grades NGBIA 100, NGBIA 115, and BIA available from N.V. Umicore, S.A., Brussels, Belgium.
[0054] Cell 10 , 110 also includes a gasket 30 , 130 made from an elastomeric material which serves as the seal. The bottom edge of the gasket 30 , 130 has been formed to create an inwardly facing lip 32 , 132 , which abuts the rim of anode casing 26 , 126 . Optionally, a sealant may be applied to the sealing surface of the gasket, cathode casing and/or anode casing. Suitable sealant materials will be recognized by one skilled in the art. Examples include asphalt, either alone or with elastomeric materials or ethylene vinyl acetate, aliphatic or fatty polyamides, and thermoplastic elastomers such as polyolefins, polyamine, polyethylene, polypropylene and polyisobutene. A preferred sealant is SWIFT® 82996, described hereinabove.
[0055] The cathode casing 12 , 112 , including the inserted air electrode 20 , 120 and associated membranes can be inverted and pressed against the anode cup/gasket assembly, which can be preassembled with the casing inverted so the rim of the casing faces upward. While inverted, the edge of the cathode casing 12 , 112 can be deformed inwardly, so the rim 34 , 134 of the cathode casing 12 , 112 is compressed against the elastomeric gasket 30 , 130 , which is between the cathode casing 12 , 112 and the anode casing 26 , 126 , thereby forming a seal and an electrical barrier between the anode casing 26 , 126 and the cathode casing 12 , 112 .
[0056] Any suitable method may be used to deform the edge of the casing inward to seal the cell, including crimping, colleting, swaging, redrawing, and combinations thereof as appropriate. Preferably the button cell is sealed by crimping or colleting with a segmented die so that the cell can be easily removed from the die while a better seal is produced. As used herein, a segmented die is a die whose forming surfaces comprise segments that may be spread apart to enlarge the opening into/from which the cell being closed is inserted and removed. Preferably portions of the segments are joined or held together so they are not free floating, in order to prevent individual segments from moving independently and either damaging the cell or interfering with its insertion or removal. Preferred crimping mechanisms and processes are disclosed in commonly owned U.S. Pat. No. 6,256,853, which is hereby incorporated by reference. Preferably a prismatic cell is sealed by crimping.
[0057] A suitable tab (not shown) can be placed over the opening 18 , 118 until the cell 10 , 110 is ready for use to keep air from entering the cell 10 , 110 before use.
[0058] A catalytic composition for the active layer of a catalytic electrode can be made from a catalytic mix using a nano-catalyst or precursor to provide a composite catalytic material containing at least partially oxidized nano-catalyst particles adhered to the external surfaces and the internal surfaces (the surfaces of the pores) of the carbon particles. Oxidation of the nano-catalyst particles or formation of oxidized nano-catalyst particles from a precursor can take place before or during the mixing process. The degree of oxidation can be controlled. The oxide can provide one or more functions, such as aiding the catalytic reaction, imparting stability, and/or reducing agglomeration of the nano-particles.
[0059] In a process in which the nano-catalyst is oxidized during mixing of the catalytic mix ingredients, nano-metal particles are at least partially oxidized after being adhered to carbon particles by separately mixing both the nano-metal particles with a liquid medium, preferably a deoxygenated liquid medium such as a deoxygenated lower alcohol, mixing together the nano-metal and carbon mixtures, and then partially oxidizing the nano-metal particles by bringing the nano-particles into contact with an oxidant after the nano-metal particles are adhered to the carbon particle surfaces. A binder, such as a fluorocarbon material, can be used to adhere the nano-metal particles to the carbon. The deoxygenated liquid medium can be removed prior to adding the oxidant, or an oxidant can be added before removing the liquid medium. To prevent non-controlled oxidation of the nano-metal before adding the oxidant, the mixing steps prior to addition of the oxidant can be carried out in an environment in which oxidation of the nano-metal is substantially prevented, such as in an inert gas (e.g., argon) atmosphere. Any suitable oxidant can be used, such as O 2 , O 3 , nitrogen oxides (e.g., N x O y , where x=1−2 and y−1−5), and halogen oxides. In some embodiments water can be used as an oxidant. Mixtures of oxidants can also be used.
[0060] The nano-catalyst can be formed from a precursor, such as by the reduction of potassium permanganate dissolved in a liquid medium, to form particles of the insoluble nano-catalyst (manganese oxide) on the internal and external surfaces of the carbon particles. In one embodiment, a catalytic composition for an active layer of an electrode can be made as follows; the quantities are representative and quantities and proportions can be varied. About 400 g to 1500 g distilled water is placed into a large beaker with a volume of about 3 times the water volume. About ⅓ the water weight of activated carbon (e.g., DARCO® G-60 from American Norit Corp. or equivalent) is added to the water. Potassium permanganate (KMnO 4 ) in an amount up to about the weight of the carbon (e.g., about ⅓ the weight of the carbon) is added to the mixture slowly while stirring, resulting in up to about 15% by weight as manganese (Mn) in the final dry catalytic composition. The KMnO 4 can be added as dry crystals or as a prepared solution of about 20% KMnO 4 in water. The above components are mixed for sufficient time (e.g., at least 20 minutes) for the activated carbon to reduce the KMnO 4 in situ to Mn(+2); water can be added if the mixture is too viscous to be easily stirred. From about 0.07 g to about 0.44 g of PTFE dispersion (TEFLON® 30b from E.I. DuPont de Nemours & Co., Polymer Products Division) per gram of carbon can be added while stirring the mixture to provide a dry PTFE content of from about 3 weight percent to about 25 weight percent of the total mixture; electrodes comprising up to about 50 weight percent PTFE are useful in some applications. The mixture is further mixed, e.g., for at least about 30 minutes, to insure that all of the PTFE particles to attach themselves to the carbon particles. The mixture is then filtered to remove a substantial portion of the liquid and transferred to a non-corrosive pan, preferably with a thickness of the damp mix of not more than about 5.1 cm (2 inches), dried in a preheated ventilation oven at 75° C. for at least 24 hours, then further dried in a preheated oven at 120° C. for 12 hours in an open container to produce dried Teflonated carbon. The Teflonated carbon is covered, cooled to below 100° C. and then sealed in a plastic bag. Nano-catalyst material is added to the Teflonated carbon (from about 0.01 to about 20 weight percent nano-catalyst in the resultant catalytic composition). The catalytic composition can be blended in a very high sheer blender for from about 30 seconds to about 5 minutes.
[0061] In another embodiment, a catalytic composition can be made as follows; the quantities are representative and quantities and proportions can be varied. Distilled water (500 g) is placed into a large beaker, to which activated carbon powder (e.g., 15 g of DARCO® G-60 or equivalent) is slowly added, mixing slowly to dampen the carbon. Using a mixer such as a propeller type mixer, the water and carbon are stirred sufficiently to create a stable vortex while mixing for about 20 minutes, without drawing air into the mixture (i.e., without the vortex touching the blade). Slowly (over about 30 seconds) about 250 g of 20% KMnO 4 solution is added to the stirring mixture, and then mixing is continued for about 30 minutes more. Very slowly (over about 1 minute), 25 cc of PTFE dispersion (TEFLON® 30b) is added while stirring, and stirring is continued for 30 minutes more, while maintaining the stable vortex and not drawing air into the mixture. When the PTFE dispersion is added, the mixture initially becomes very viscous, then less so as the PTFE particles become adhered to the carbon particles. The mixture is then filtered to remove a substantial portion of the liquid and transferred to a non-corrosive pan, dried in a preheated ventilation oven at 75° C. for 24 hours, then further dried in a preheated oven at 120° C. for 12 hours to produce dried Teflonated carbon. The Teflonated carbon is covered, cooled to below 100° C. and then sealed in a plastic bag. Nano-catalyst material is added to the Teflonated carbon (e.g., about 10 weight percent nano-catalyst in the resultant catalytic composition). The catalytic composition can be blended in a very high sheer blender for from about 30 seconds to about 5 minutes.
[0062] In yet another embodiment, a catalytic composition can be made as follows; the quantities are representative and quantities and proportions can be varied. Distilled water (about 500 g) is placed into a large beaker, and activated carbon powder (150 grams of DARCO® G-60 or equivalent) is added, mixing slowly to dampen the carbon. Using a mixer such as a propeller type mixer, the water and carbon are stirred sufficiently to create a stable vortex while mixing for about 20 minutes, without drawing air into the mixture (i.e., without the vortex touching the blade). Very slowly (over about 1 minute), 25 cc of PTFE dispersion (TEFLON® 30b) is added while stirring, and stirring is continued for 30 minutes more, while maintaining the stable vortex and not drawing air into the mixture. When the PTFE dispersion is added, the mixture initially becomes very viscous, then less so as the PTFE particles become adhered to the carbon particles. The mixture is then filtered and transferred to a non-corrosive pan, dried in a preheated ventilation oven at 110° C. for 24 hours to produce dried Teflonated carbon. The Teflonated carbon is covered, cooled to below 100° C. and sealed in a plastic bag that is stored in an inert atmosphere (e.g., in a chamber filled with nitrogen and/or argon gas). In an inert atmosphere, a nano-catalyst (preferably nano-manganese or nano-manganese alloy particles that are at least partially oxidized) are mixed with about 3 times their weight of deoxygenated methanol (MeOH) to form an ink (e.g., a black, substantially opaque liquid), the ink is optionally mixed ultrasonically, and the ink is then sealed in a vial. A mixture of 1 part of the dried Teflonated carbon and 4 parts MeOH was prepared under an inert atmosphere. Under an inert atmosphere, nano-catalyst ink is mixed with Teflonated carbon for at least 2 minutes; the quantities of ink and carbon are typically selected to provide from about 5 weight percent to about 15 weight percent nano-catalyst on a dry basis. The ink and carbon mixture is removed from the inert atmosphere after standing for about 15 minutes to allow the nano-catalyst to adsorb into the carbon particles to coat the pores (i.e., the internal surfaces of the carbon). The ink and carbon mixture is dried by placing it in a ventilated oven pre-heated to 105° C. until the mixture reaches 105° C. (e.g., for about 100 minutes for 5 g of the mixture); the nano-catalyst can be oxidized in situ (e.g., nano-manganese is oxidized to catalytically active MnO x in this drying step. The dried catalytic composition can be covered and cooled to room temperature.
[0063] A catalytic composition for the active layer of a catalytic electrode can be made, at least partially oxidizing the nano-catalyst metal in situ, according to the following steps:
1. Add distilled water to activated carbon, cover and allow the carbon to wet up. 2. Thoroughly mix the carbon and water with a high intensity, variable speed mixer, adjusting the mixer speed to produce a vortex that extends about half way to but does not reach the bottom of the container. 3. While continuing the mixing, add PTFE dispersion dropwise to the vortex, adjusting the mixer speed to maintain the desired vortex, and continue mixing until the mixer reaches about the same speed as prior to adding the PTFE dispersion. 4. Filter the water from the mixture, rinsing with distilled water. 5. Dry the remaining carbon mix at 90° C. until the mix reaches 90° C., increase the drying temperature to 105° C. and continue drying until the mix reaches 105° C., continue drying at 105° C. for several more hours, and reduce the temperature to 50° C. and continue drying until the mix reaches 50° C.; place the dry carbon mix in a sealed container while hot and allow to cool to room temperature. 6. In an argon atmosphere, mix each of the carbon mix and nano-catalyst (with or without at least partially oxidized particles) with deoxygenated methanol separately, mix the two together, add a small amount of distilled water, and mix well; cover and remove from the argon atmosphere. 7. Dry the carbon-catalyst mixture at 90° C. until the mix reaches 90° C., increase the drying temperature to 105° C. and continue drying until the mix reaches 105° C., continue drying at 105° C. for several hours more, reduce the temperature to 50° C. and continue drying until the mix reaches 50° C.; place the mix in a sealed container and allow to cool to room temperature.
[0071] The catalytic composition can also be prepared using nano-catalyst particles that have been partially oxidized before mixing with other ingredients of the catalytic composition. In some embodiments this can eliminate the need to perform mixing operations in an inert environment as well as the need to use a liquid such as deoxygenated alcohol. Accordingly, in one embodiment the liquid medium contains no more than 20 weight percent alcohol, preferably no more than 10 weight percent alcohol and more preferably no more than 5 weight percent alcohol; most preferably the liquid medium is essentially alcohol-free.
[0072] In an embodiment of the invention, the catalytic composition for the active layer of the catalytic electrode is made according to the following steps:
1. Add distilled water to activated carbon, cover and allow the carbon to wet up. 2. Thoroughly mix the carbon and water with a high intensity, variable speed mixer, adjusting the mixer speed to produce a vortex that extends about half way to but does not reach the bottom of the container. 3. While continuing the mixing, slowly add nano-catalyst (with at least partially oxidized particles); continue to mix thoroughly, adjusting the mixer speed as necessary to maintain the desired vortex. 4. Add PTFE dispersion dropwise to the vortex; continue to mix, adjusting the mixer speed as necessary to maintain the desired vortex, until the mixer reaches about the same speed as prior to adding the PTFE dispersion. 5. Filter the water from the catalytic mix, rinsing with distilled water and filter again. 6. Dry at 90° C. until the mix reaches 90° C.; increase the drying temperature to 105° C. and continue drying until the mix reaches 105° C.; continue drying at 105° C. for several more hours; reduce the temperature to 50° C. and continue drying until the mix temperature reaches 50° C.; place the mix in a sealed container and allow to cool to room temperature.
[0079] In another embodiment, larger batches of catalytic composition can be made in an air environment without dangerous solvents using commercially available mixers. Examples of mixers that can be used include an IKA® Universulmühle M20 Mix Mill (IKA North America, Wilmington, N.C., USA), and a PK® blender (Patterson-Kelly, Stroudsburg, Pa., USA). The catalytic mix can be made according to the following steps:
1. Weigh the desired quantities of nano-catalyst (with at least partially oxidized particles), activated carbon, PTFE dispersion (mix the PTFE dispersion well before weighing), and water (optional). 2. Load the activated carbon and nano-catalyst into the mixer and blend thoroughly. 3. Add the PTFE dispersion and mix thoroughly. 4. Dry the catalytic mix. This can be done in a drying mixer, such as an FM50 PLOUGHSHARE® horizontal mixer from Littleford Day, Inc. (Forence, Ky., USA) set at 381 mm (15 inches) vacuum, a plow blade speed of 180 revolutions per minute (RPM), a chopper blade speed of 3000 (RPM) cycling 20 seconds per minute and a temperature of about 74 to 85° C. (165 to 185° F.), for a total of about 94 minutes. Drying the mix in a mixer can advantageously keep the mix in constant motion and fibrillate the PTFE during drying.
[0084] In an embodiment of the invention, the catalytic mix is milled to form a sheet of catalytic material that is used as the catalytic layer of the catalytic electrode according to the following steps:
1. Mix the dried catalytic mix in a high sheer blender to fluff the mix. 2. Feed the fluffed mix between the rollers of a roller mill (preferably from the top) operating at a speed that will produce about 1.5 meters (5 feet) per minute of catalytic sheet at the desired thickness.
[0087] In an embodiment of the invention, a catalytic electrode is made according to the following steps:
1. Embed a piece of current collector into a surface of the catalytic sheet. This can be done, for example, by pressing between two flat plates or, preferably between the rollers of a roller mill. When using a roller mill, feed the current collector and catalytic sheet between the rollers (preferably horizontally, with the current collector on the bottom, to facilitate feeding), preferably with the roller mill operating at a speed of about 1.5 meters (5 feet) per minute to embed the current collector into the catalytic sheet. It is desirable to embed the current collector to a sufficient depth to provide a relatively smooth surface on the electrode in order to get the desired adhesion of the separator layer to the electrode. 2. Trim the catalytic sheet and/or current collector as desired. 3. Pressure laminate a corresponding sheet of hydrophobic film to the catalytic sheet using a roller mill, preferably on the side opposite that of the current collector. Preferably the hydrophobic film and catalytic sheet are feed into the roller mill horizontally, with the hydrophobic film on top. Optionally, the bond strength between the hydrophobic layer and the catalytic layer can be increased, such as by one or both of the following:
a. Spray one surface of the hydrophobic film with a dilute fluorocarbon resin emulsion, such as 10 weight percent T30 PTFE dispersion in water, allow to dry, and then pressure laminate the hydrophobic film to the catalytic layer; and b. Pattern laminate the hydrophobic film to the catalytic layer to create areas of increased bond strength while leaving areas therebetween in which any reductions in air permeability of the hydrophobic film and the catalytic layer are minimized. Preferred methods of pattern-laminating the hydrophobic film to the catalytic layer include using a textured roller against the hydrophobic film and using a removable textured interleaf material (e.g., a woven material with high strength threads, such as silk) between the hydrophobic film and the adjacent roller. When using a textured roller, a fine pattern with very thin (e.g., 0.03 to 0.1 mm) raised portions with small areas (e.g., 0.15 to 0.25 mm across) located therebetween. An example of a suitable silk material is one having a thickness of about 0.16 mm (0.006 inch) and a thread count of about 100 per 2.54 cm (1.0 inch) in each direction, with each thread containing about 50 strands of silk.
[0093] In an embodiment of the invention, the surface of the current collector is treated to minimize the internal resistance of the electrode. A preferred current collector material, particularly for small cells such as button cells, is an expanded nickel (e.g., nickel EXMET™ from Dexmet Corp., Naugatuck, Conn., USA), preferably one with a base metal thickness from 0.05 to 0.127 and more preferably from 0.06 to 0.08 mm. The expanded nickel material is preferably equivalent to a 40 mesh (40 openings per inch) screen. Another preferred current collector material, particularly for cells larger than button cells, is a woven wire cloth with cross-bonded wires (wires welded where they cross), preferably 40 to 50 mesh (40 to 50 openings per inch) with a wire diameter of 0.10 to 0.15 mm (available from Gerard Daniel Worldwide, Fontana, Calif., USA). The surface of the current collector can be treated by acid etching, such as with nitric acid, to roughen the metal surfaces. Alternatively, the current collector can be coated with a carbon containing material, such as a graphite coating. Examples of suitable graphite coating materials include: TIMREX® LB1000, LB1016 and LB1090 aqueous graphite dispersions (TIMCAL America, Westlake, Ohio, USA), ECCOCOAT® 257 (W. R. Grace & Co.), and ELECTRODAG® 109 and 112 and EB0005 (Acheson Industries, Port Huron, Mich., USA).
[0094] In an embodiment of the invention, the density of the catalytic sheet prior to lamination of the hydrophobic sheet is about 8 to 20 mg/cm 2 , preferably 9 to 13 mg/cm 2 . If the density is too high, the thickness of the final electrode can be too great, and if the density is too low, the electrode may have insufficient strength.
[0095] In an embodiment of the invention, the bond strength between the hydrophobic layer and the catalytic layer of the electrode is preferably at least 65, more preferably at least 75 and most preferably at least 85 g per 25.4 mm (1 inch), as determined by a peel strength test. To maintain sufficient permeability and prevent damage to the air electrode, the bond strength is preferably no greater than 250, and more preferably no greater than 200 g per 25.4 mm (1 inch). The peel strength test measures the force required to peel the hydrophobic layer away from the air electrode and is done using a Chatillon Model TCD200 tester, fitted with 25.4 mm (1 inch) wide serrated jaw clamps. The tester is programmed with a bottom stop, at which the clamps are about 8.5 mm (⅓ inch) apart, and a top stop that allows the clamps to separate to about 50.8 mm (2 inches). The top clamp is brought to the bottom stop position and the force gauge is zeroed. A sample piece of electrode about 38.1 mm (1.5 inches) long is cut, and the hydrophobic membrane is peeled back evenly by a small amount (no more than 12.7 mm (½ inch)) from a cut edge. The exposed catalytic layer is clamped to the bottom clamp and the loose end of the hydrophobic membrane is clamped to the top clamp, with the sample centered and square. The top clamp is raised, recording the initial high gauge reading. The peel strength is calculated as the initial high gauge reading per unit width of the sample.
[0096] In an embodiment of the invention, the catalytic electrode, including the catalytic layer, current collector and hydrophobic layer, has a thickness from about 0.15 to 0.35 mm, preferably from 0.19 to 0.25 mm, and more preferably from 0.19 to 0.21 mm. If the electrode is too thick, it will occupy excessive volume within the cell. If it is too thin, it may be weak, leading to distortion or damage. Preferably the variation in thickness will be no greater than 0.03 mm and more preferably no greater than 0.015 mm. If the variation is too great, manufacturing problems such as cell assembly problems, damage, camber and scrap can result due to dimensional variation of the sheet. For cell designs such as those shown in FIGS. 1 and 3 , excessive thickness variation can also contribute to increased electrolyte leakage. Areas of high and low pressure can be also be created during electrode manufacturing, leading to areas of high and low permeability of the laminated electrode and areas of high and low bond strength of the hydrophobic layer to the catalytic layer, thereby adversely affecting cell performance and resistance to leakage.
[0097] In an embodiment of the invention, one or more layers of separator are adhered to the surface of the catalytic electrode opposite the hydrophobic layer. This can be done using an adhesive applied to one or both of the adjacent surfaces of the electrode and the separator and adjacent surfaces of layers of separator. A preferred adhesive contains a polyvinyl alcohol (PVA), more preferably PVA thickened with carboxymethylcellulose (CMC) or polyacrylic acetate (PAA). Preferably the PVA adhesive contains as little PVA as possible. An example of a preferred PVA adhesive is one prepared by slowly adding about 7 weight percent PVA (e.g., PVA 52-22) to cold water while mixing with a high sheer mixer, slowly heating to 95° C. while continuing to mix, slowly adding about 1.4 weight percent CMC while continuing to mix, mixing until the solution is dissolved to clarity, sealing the solution in a sterile glass container, and allowing to cool to room temperature.
[0098] In an embodiment of the invention, a sheet of separator is adhered to the electrode and, when there is a second separator layer, a second sheet of separator is adhered to the first by painting a thin layer of adhesive on the electrode or layer of separator on the electrode and drying at 80° C., painting a thin layer of adhesive onto the sheet of separator to be adhered, applying the adhesive-painted separator sheet to the electrode or separator-laminated electrode, and drying.
[0099] In an embodiment of the invention, a sheet of separator is pressure laminated to the catalytic electrode, using, for example, a roller mill. Preferably the separator is laminated to the catalytic layer with embedded current collector before laminating the hydrophobic layer to avoid damage to the hydrophobic layer, since higher pressure may be required for separator lamination. For a 2-layer separator, the second layer is adhered to the layer adjacent the catalytic layer of the electrode using an adhesive. This can be done after pressure laminating the first separator layer to the electrode, or, preferably, the two separator layers can be laminated together with an adhesive, followed by pressure lamination of the two-layer separator to the electrode.
[0100] In an embodiment of the invention, the catalytic electrode is capable of providing a maximum power from 220 mW/cm 2 to 700 mW/cm 2 on a Half-Cell Potential Dynamic Scan test as described below. Preferably the maximum power is at least 250 mW/cm 2 , more preferably at least 275 mW/cm 2 .
EXAMPLE 1
[0101] A conventional air electrode for an alkaline zinc-air cell was made. The electrode had a catalytic layer containing 70 weight percent carbon (Calgon PWA), 25 weight percent PTFE with surfactant (from TE30B), and 5 weight percent MnO x . The catalytic layer was formed with a thickness of about 0.203 mm (0.008 inch) and a packing of about 38 percent (percentage of maximum theoretical density based on the theoretical densities of the component materials). An expanded nickel current collector (4Ni5-060 P&L 0.127 mm (0.005 inch) thick nickel EXMET™ from Dexmet), painted with an aqueous graphite dispersion (50 weight percent TIMREX® LB1016 in water)) was embedded under 684 kg (1508 pounds) force into the catalytic layer, with a final thickness of about 0.279 mm (0.011 inch). A sheet of 0.076 mm (0.003 inch) thick expanded PTFE membrane (Sample No. 12850830.1 from W.L. Gore) was pressure laminated to the surface of the catalytic layer opposite the surface into which the current collector was embedded to produce a laminated air electrode sheet.
EXAMPLE 2
[0102] A nano-catalyst air electrode was made with nano-MnO x according to the following steps:
1. 300 g DARCO® G-60 carbon was placed in a 2000 ml glass container, 1000 g distilled water was added, and the container was covered and allowed to sit for one hour. 2. The mixture was mixed for about 30 minutes with an adjustable speed mixer, adjusting the speed to maintain a vortex extending about half way to the bottom of the container. 3. 55 g T30B PTFE was added dropwise while mixing, and mixing was continued for about 20 minutes, adjusting the speed to maintain the desired vortex. 4. The mixture was filtered, while rinsing with about 200 ml distilled water. 5. The remaining solids (the mix) were dried at about 85-90° C. for about 16 hours, then the temperature was increased to 105° C. and drying continued until the temperature of the mix reached 105° C.; then the mix was covered and allowed to cool to room temperature. 6. In an argon gas atmosphere, 10 grams of the mix was put into a porcelain bowl and mixed with 50 grams deoxygenated methanol. 7. In argon, 0.256 g nano-MnO x (QSI-NANO® Manganese) was mixed with 3 grams deoxygenated methanol. 8. In argon, the carbon/methanol and nano-MnO x /methanol mixtures were mixed together for about 30 seconds, about 10 ml distilled water was mixed in, and the mixture covered and removed from the argon atmosphere. 9. The mix from step 8 was put at 105° C. until the mix temperature reached 105° C., then covered and allowed to cool to room temperature. 10. The mix was blended in a high sheer blender for 30 seconds and then fed between the rollers of a roller mill, set to 0 clearance and operating at a rate of 1.37 m (4.5 feet) per minute, to form a sheet of catalytic material 0.18 mm thick, with a density of 0.213 mg/cm 3 and containing 2.50 weight percent nano-manganese. 11. The catalytic sheet was placed on top of a strip of current collector (3Ni3.3-05P nickel EXMET™, painted with an aqueous graphite dispersion (50 weight percent TIMREX® LB1016 in water)), and both were fed horizontally between the rolls of a roller mill, operating at a rate of 1.37 m (4.5 feet) per minute and applying 684 kg (1508 pounds) force, to embed the current collector into the catalytic sheet and form a sheet with a thickness of 0.248 mm (0.00975 inch). 12. A sheet of 0.076 mm (0.003 inch) thick expanded PTFE membrane (Sample No. 12850830.1 from W.L. Gore) was placed on top of the catalytic sheet with embedded current collector, and a sheet of 100 mesh (100 threads per inch) silk cloth was placed over the PTFE membrane. All three were fed horizontally between the rolls of a roller mill operating at a rate of 1.37 m (4.5 feet) per minute and applying 684 kg (1508 pounds) force to pressure laminate the PTFE membrane to the catalytic layer, thereby forming an air electrode stock.
EXAMPLE 3
[0115] A sheet of BVA 02530 separator (Hollingsworth & Vose) was glued to the electrode sheets from each of Examples 1 and 2, on the surfaces of the air electrodes opposite the PTFE membranes, using pressure and a PVA/CMC adhesive. Sample electrodes were cut from each of the sheets and assembled into PR44 size alkaline zinc-air button cells.
[0116] Cells with electrodes from each of Examples 1 and 2 were tested for open circuit voltage, followed by AC impedance, with a peak to peak potential amplitude of 10 mV, over a frequency range from 65 KHz to 0.1 Hz. This was followed by a potential dynamic scan in the cathodic direction, beginning at 0.025 V above the open circuit voltage and scanning at 1 mV/sec. to 0.7 V. This initial AC impedance and potential dynamic scan testing served to condition the catalytic electrodes. After 30 minutes open circuit, the AC impedance and potential dynamic scan tests were repeated, and these results were used. From the potential dynamic voltage scan, a voltammogram (Tafel curve) and a polarization curve were plotted. The Tafel curve is shown in FIG. 4 , where the observed current (amps/cell) is on the x-axis using a log scale, and applied potential (volts) is on the y-axis. The results of the AC impedance and potential dynamic voltage scan testing are summarized in Table 1.
[0000]
TABLE 1
Parameter
Units
Example 1
Example 2
CCV at 4 mA
volts
1.294
1.298
CCV at 10 mA
volts
1.221
1.255
Power at 1.0 V
mW
27.2
72.8
Steady State R of iR
ohms
9.52
5.27
10 KHz Capacitance
μF
39.5
125
1 KHz Capacitance
μF
491
1527
65 KHz Impedance
ohms
0.554
0.510
10 KHz Impedance
ohms
0.731
0.489
1 KHz Impedance
ohms
1.310
0.612
[0117] Cells were also discharged at 100 ohms continuous. The closed circuit voltage of cells with electrodes from Example 2 was about 40 mV higher than that of cells with electrodes from Example 1.
EXAMPLE 4
[0118] A nano-catalyst air electrode was made with nano-MnO x according to the following steps:
1. 200 g DARCO® G-60 carbon was placed in a 1500 ml glass container, 900 g distilled water was added, and the container was covered and allowed to sit for about 15 minutes. 2. The mixture was mixed for about 15 minutes with an adjustable speed mixer, adjusting the speed to maintain a vortex extending about half way to the bottom of the container. 3. Mixing was continued while 5.6 g nano-MnO x (QSI-NANO® Manganese) was slowly (over about 30 seconds) added to the vortex and the sides of the container were rinsed with deionized water, followed by about 15 minutes of additional mixing, adjusting the mixer speed to maintain the desired vortex. 4. Mixing was continued while 26 g of T30B PTFE was added dropwise to the vortex, followed by about 20 minutes of additional mixing, adjusting the mixer speed to maintain the desired vortex. 5. The mixture was filtered, while rinsing with about 500 ml distilled water. 6. The remaining solids (the mix) were dried at 90° C. until the mix temperature reached 90° C., the temperature was increased to 105° C. and drying continued until the temperature of the mix reached 105° C., drying at 105° C. was continued for about another 4-6 hours, and the drying temperature was reduced to 50° C.; then the mix was sealed in a container and allowed to cool to room temperature. 7. The dried mix was fluidized by blending in a high speed mixer (5 g for 30 seconds or 50 g for 5 minutes), and then fed between the rollers of a roller mill, set to 0 clearance and operating at a rate of 1.52 m (5 feet) per minute, to form a sheet of catalytic material 0.19 mm thick, with a density of 0.212 mg/cm 3 and containing 2.50 weight percent nano-manganese. 8. The catalytic sheet was placed on top of a strip of current collector (3Ni3.3-05P nickel EXMET™, and both were fed horizontally between the rolls of a roller mill, operating at a rate of 1.52 m (5 feet) per minute, to embed the current collector into the catalytic sheet and form a sheet with a thickness of 0.19 mm (0.0075 inch). 9. A sheet of 0.076 mm (0.003 inch) thick expanded PTFE membrane (Sample No. 12850830.1 from W.L. Gore) was placed on top of the catalytic sheet with embedded current collector, a sheet of 100 mesh silk cloth was placed over the PTFE membrane, and all three were fed horizontally between the rolls of a roller mill operating at a rate of 1.52 m (5 feet) per minute to pressure laminate the PTFE membrane to the catalytic layer, thereby forming an air electrode stock.
EXAMPLE 5
[0128] An air electrode was made following the same steps in Example 4, except that step 3 was skipped, so no catalyst was added to the carbon mixture and only the activated carbon was present as a catalytic material.
EXAMPLE 6
[0129] Electrodes from each of Examples 4 and 5 were tested in half cell fixture with a platinum counter electrode and a zinc reference electrode and flooded with 33 weight percent KOH. For each electrode the open circuit voltage was tested, followed by AC impedance, with a peak to peak potential amplitude of 10 mV, over a frequency range in the cathodic direction, beginning at 0.025 V above the open circuit voltage and scanning at 1 mV/sec. to 0.7 V vs. the reference electrode. This initial AC impedance and potential dynamic scan testing served to condition the catalytic electrodes. After 30 minutes open circuit, the AC impedance and potential dynamic scan tests were repeated, and these results were used. This test is referred to herein as the Half Cell AC Impedance/Dynamic Potential Scan Test. From the dynamic potential scan data, a polarization curve (similar to a Tafel curve, but with a linear rather than log scale for current density) was plotted. The results of the AC impedance and potential dynamic scan tests are summarized in Table 2.
[0000]
TABLE 2
Parameter
Units
Example 4
Example 5
CCV at 10 mA
volts
1.363
1.311
CCV at 100 mA
volts
1.342
1.225
Maximum Power
mW/cm 2
527
327
Power at 1.0 V
mW
400
273
Current Density @ 1.1 V
mA/cm 2
268
188
Current Density @ 1.0 V
mA/cm 2
400
273
Limiting Current
mA/cm 2
652
523
Steady State R of iR
ohms
1.52
1.06
65 KHz Impedance
ohms
0.66
0.60
65 KHz Capacitance
μF
5.87
7.12
10 KHz Capacitance
μF
190
216
1 KHz Capacitance
μF
8393
8842
EXAMPLE 7
[0130] An air electrode sheet was made with conventional MnO x catalyst as described in Example 1, except that the hydrophobic membrane was a 0.10 mm (0.004 inch) thick CD123 PTFE film from 3P, and the current collector was made from 3Ni3.3-05P nickel EXMET™. Two layers of separator (CELGARD® 3501 adjacent to the electrode sheet and CELGARD® 5550) were laminated to the surface of the electrode sheet opposite the hydrophobic layer using a PVA adhesive. Individual electrodes were cut from the sheet and assembled into PR44 size alkaline zinc-air button cells.
EXAMPLE 8
[0131] An air electrode sheet was made with nano-MnO x as described in Example 2, but with a 3Ni3.3-05P nickel EXMET™ current collector. Two layers of separator were laminated to the surface of the electrode sheet as in Example 7. Individual electrodes were cut from the sheet and assembled into PR44 size alkaline zinc-air button cells.
EXAMPLE 9
[0132] Cells from each of Examples 7 and 8 were tested as described in Example 3. The polarization curve is shown in FIG. 6 .
EXAMPLE 10
[0133] Sheets of air electrodes made as described in Example 4 using two types of current collector materials (4Ni5-060 P&L nickel EXMET™ from Dexmet and cross-bonded 40 mesh (40 openings per inch) nickel screen with 0.15 mm (0.006 inch) diameter wires from Gerard Daniel Worldwide, Fontana, Calif., USA). Some were painted with an aqueous graphite dispersion (50 weight percent TIMREX® LB1016 in water) as shown in Table 3. Electrodes were cut from each sheet and tested on an AC impedance test, at open circuit potential, with a peak to peak potential amplitude of 10 mV, over a frequency range from 100 KHz to 0.1 Hz. The average ohmic resistance (Re), charge transfer (Rct) and double layer capacitance (Cdl) for each are shown in Table 3.
[0000]
TABLE 3
Current Collector
Re (ohms)
Rct (ohms)
Cdl (μF)
EXMET ™ uncoated
1.06
0.03
2568
EXMET ™ coated
0.64
0.07
2660
Screen coated
0.71
0.07
1337
EXAMPLE 11
[0134] Two nano-catalyst mixes were made with nano-MnO x as described in Example 4 except for the amounts of activated carbon, nano-catalyst and binder used. The quantities used and the compositions of the catalytic layers of the resultant dried electrodes are summarized in Table 4. Two catalytic electrodes were made with each of the mixes as described in Example 4 except the material used for the current collectors was 4Ni5-060 EXMET™, the current collectors were coated with TIMREX® LB1016 graphite dispersion as described in Example 10, and a silk cloth interleaf material was not used in laminating the PTFE membrane to the catalytic sheet for one of the electrodes made with each mix.
[0000]
TABLE 4
Mix A
Mix B
Mix Ingredients (grams)
Activated Carbon
205.8
205.9
Nano-Manganese
5.3
7.1
PTFE Dispersion
26.5
118.4
Dry Composition (wt %)
Activated Carbon
90.5
72.5
Nano-Manganese
2.5
2.5
PTFE
7.0
25.0
[0135] Each of the four lots of electrodes made was tested on the Half Cell AC Impedance/Potential Scan Test described in Example 6. Results of the potential dynamic scan portion of the test are summarized in Table 5.
[0000]
TABLE 5
Mix A
Mix B
No
Silk
No
Silk
Parameter
Units
Interleaf
Interleaf
Interleaf
Interleaf
CCV at 10 mA
volts
1.380
1.380
1.359
1.377
CCV at 100 mA
volts
1.202
1.265
1.178
1.258
Maximum Power
mW/cm 2
202
318
134
288
[0136] All references cited herein are expressly incorporated herein by reference in their entireties. To the extent publications and patents or patent applications incorporated by reference contradict the disclosure contained in the present specification, the present specification is intended to supersede and/or take precedence over any such contradictory material.
[0137] It will be understood by those who practice the invention and those skilled in the art that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law. | A process for making a catalytic electrode, a process for making an electrochemical cell with a catalytic electrode, and an electrochemical cell made according to the process. The catalytic electrode has an active layer comprising a catalytic material, an electrically conductive material and a binder, and a gas diffusion layer including a material that is permeable to gas entering or escaping from the cell but essentially impermeable to electrolyte. The gas diffusion layer is adhered to the active layer by a patterned pressure bonding process to provide the catalytic electrode in which the entire gas diffusion area is adhered to the active layer, with areas of relatively high and relatively low adhesion. The electrode has a high overall bond strength, and the permeability of the gas diffusion layer remains high it has been adhered to the active layer to provide excellent high power capability. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a dust separator for use with dust-generating machines and/or plant for use in underground mining and tunnel construction, comprising a drive acting upon a fan impeller and disposed at the inlet side of the washer housing, inlet-side water nozzles and the separating elements for the dust-containing water, which are disposed at the outlet side, as well as a water tank with a valve-controlled water inlet and water outlet as well as a drain valve for the sludge.
In underground mining as well as in other branches of industry, dust separators are used to separate, in particular, respirable dust from the ambient air and deposit it in a safe place. So-called dry dust separators are known, in which the dust is conveyed through filter elements and so the dust is removed, wherein the filters equipped with a suitable filter cloth are dedusted at regular intervals in order to ensure a long service life of such filters. Apart from the fact that such dust separators are relatively large, it is a disadvantage that they have to be cleaned at specific intervals. For said purpose so-called rotary or wet washers are used, whereby the air containing dust is sucked, by means of a fan impeller operating in the air stream, into the washer housing before being loaded with finely distributed water and separated from said dust-containing water in downstream separating elements. The problem here is keeping the discharging clean air dry because, particularly in underground mining, moist air in turn poses additional problems.
SUMMARY OF THE INVENTION
The object of the invention is therefore to provide a powerful wet dust separator having a stable characteristic as well as a high dust separation and moisture separation efficiency.
The object is achieved according to the invention in that a gear unit is associated with the drive of the fan impeller acted upon by the mixture of air, dust and water, and that the separating elements comprise a demister, which is positioned so as to be inclined until approximately horizontal in the air stream.
Given a dust separator constructed in said manner, wet dust separation is advantageously effected without operation being hindered by the problems arising with previous wet dust separators. In particular, the gear unit ensures that the dust separator operates virtually independently of the dust and water content and/or independently of the quantity. The gear unit ensures uniform operation and hence a stable characteristic, which in turn also contributes towards uniformly clean air being discharged from the dust separator independently of the dust and water content and/or independently of the quantity. By virtue of the fact that the separating elements, i.e. here, in particular, the demister, are disposed so as to be inclined until approximately horizontal in the air stream, optimum dewatering of the air stream is ensured, wherein further units disposed downstream may additionally contribute towards an approximately dry air stream leaving the dust separator. It is moreover advantageous that, by virtue of the special arrangement of the demister, clogging of said unit may be avoided because the sludge-containing water continuously drips downwards and may be removed.
According to an advantageous embodiment of the invention, it is provided that a jetwashing device is disposed upstream of the demister. By means of said jetwashing device the demister may be cleaned at regular intervals to ensure that its separation efficiency is also in an optimum range in each case. There is moreover also the possibility of using the jetwashing device to bond yet more dust particles or the residual dust particles with the water shortly before entry into the demister in order also to ensure that all dust particles are actually consolidated and may drain into the water tank.
According to the present invention, the demister is to be disposed as horizontally as possible in the air stream. Depending on the dust content and/or the nature of the dust, it may be advantageous to vary the inclination of the demister. It is therefore particularly advantageous when, according to the present invention, the inclination of the demister is adjustable. To said end, the invention provides that in the inlet region of the washer housing suitable probes check the dust content and the nature of the dust before varying the inclination of the demister either during operation or during breaks in operation. It goes without saying that variation of the inclination may also be advantageous when the dust quantity varies and varies noticeably over extended periods of time.
It was earlier pointed out that it is advantageous to dispose a jetwashing device upstream of the demister, wherein a precise influencing of the air stream is ensured by designing demister and jetwashing device so as to be jointly pivotal by means of a positioning motor. The jetwashing with water or alternatively with other liquids may therefore be effected always from the same angle, with the result that the cleaning effect in particular may be kept within the optimum range.
In order also to ensure a slewing or adjustment of the jetwashing device together with the demister without entailing problems with the water supply, the invention provides that the jetwashing device has a flexible water connection. Here, a piece of hose may be interposed or alternatively turning knuckles, which allow the jetwashing device to move back and forth relative to the corresponding connection pipe.
In the demister, dust-containing sludge water is extensively removed from the air stream. For said purpose, the demister has a suitable filling, wherein according to the invention it is provided that the demister is equipped with a sponge-like woven or braided steel filling. The air stream is repeatedly deflected by said woven steel material so that the sludge particles are acted upon accordingly and separated from the air by the impact energy. They are then carried along by the water and drain into the tank where the sludge separates from the water, thereby allowing the water to be recycled. As tests have demonstrated, said woven or braided steel material is eminently suitable for reliable collection of water drops carrying even superfine dust particles and their separation from the air stream.
Depending on the nature or condition of the dust, it is advantageous to add e.g. tension-relieving agents to the water. For said purpose, the invention provides that the water nozzles are disposed so as to project counter to the inflow direction of the dust-containing air and are connected to a supply pump, which is disposed between water nozzles and water tank and at the same time has an intake connection to an additional tank for water additives. First of all, the water nozzles by virtue of their clever arrangement ensure that the water droplets may bond very easily and reliably with the dust particles, wherein said bonding is improved by the water additives, i.e. for example, tension-relieving agents. The supply pump in said case removes the required quantity of water additives from the additional tank, mixes it simultaneously with the water and sprays said mixture counter to the air stream. An intimate bonding of the dust particles with the water is ensured and, with it, also a collection in the demister and a discharge from the air.
In the case of particularly tenacious dust which because of its origin or other influences is difficult to wet, it may be advantageous when, in addition to the water nozzles, further spray nozzles are arranged distributed over the flow path in the washer housing. In particular, said spray nozzles are connected in such a way that they simultaneously operate only when needed and otherwise remain inoperative.
The water removed from the air stream by the demister and the downstream units passes into the water tank and from there back into circulation. Naturally, a certain water loss is bound to occur and has to be replaced in the circuit. According to the invention, this is achieved in that the water tank comprises a float, which is designed so as to control the supply pump pipe and a valve disposed in the fresh water inlet. Said float may be used first of all e.g. to vary the inclination of the supply pump pipe so that further water may be removed from the water tank even when the water level drops. However, given a specific value, the float is used to activate the valve disposed in the fresh water inlet, which valve then ensures an intake of fresh water. Said design enables economic operation because fresh water is actually supplied only when further trouble-free operation would otherwise be no longer guaranteed.
It was already pointed out earlier that the water tank is designed in such a way that the separation of dust and water may be effected therein. In said case, however, it is ensured that only clean water is actually removed by the supply pump pipe by associating the float and pivotally arranged supply pump pipe with a chamber, which is separated from the rest of the water tank by a partition wall. This then offers precisely the possibility mentioned earlier, namely of swivelling the supply pump pipe in such a way that water may be removed over an extended period of time without fresh water having to be supplied. There is always clean water available in the chamber suitably separated off by the partition wall, even when at the other side of the partition wall there is still sludge-containing water or even a greater or smaller quantity of sludge.
Given a chamber separated in said manner, it is advantageous when the partition wall is connected to the tank base by a joint because there is then the possibility of swivelling the partition wall and hence allowing more or less water to flow into the separate chamber. The inclination of the partition wall may be swivelled e.g. in combination or in a corresponding manner with the supply pump pipe in order in said manner, as already mentioned, to enable the removal of clean water from the chamber.
Further units are disposed downstream of the demister in order to obtain air which is as dry as possible. In said case, the invention provides that a mist collector is disposed downstream of the demister and equipped with traps, which are disposed in the air stream in order to separate residual dust and above all water drops. The number of traps is high enough for the residual drops also to be always effectively caught and separated as the air stream winds accordingly around the traps, releases the drops but itself passes in a “dried” state out of the demister or out of the mist collector. Wear of said traps is prevented in that the traps in the form of baffle plates are coated with TEFLON, polytetrafluoroethylene. Thus, even given a continuous presence of residual moisture in the mist collector, it is ensured that long service lives are achievable. The Teflon even ultimately has the added advantage of promoting the precipitation of water or water drops. By Teflon is meant polytetrafluoroethylene.
The blades of the fan impeller rotate in the air stream, which carries along not only dust but also water or a mixture of both. To avoid overstressing of the blades, the invention provides that the blades of the fan impeller are made of highly wear-resistant steel and/or have a corresponding surface and/or coating. In said case, the surface should at the same time also be smooth enough to prevent sludge from collecting thereon. Because of the jetwashing of the air stream and hence ultimately also of the fan impellers, however, there is as a rule no baking-on of sludge.
Especially in underground mining, because of the deepness of the pits, the atmosphere, i.e. the air, has to be cooled. Operation of the mine air coolers is in said case adversely affected by the fact that air streams carrying a greater or lesser amount of dust flow into the mine air cooler, collect on the cooling pipes and hence impair the cooling effect. The mine air coolers therefore have to be cleaned at regular intervals, which is time-consuming and possible virtually only when the mine air coolers are stopped. Since the dust particles frequently bake hard on the cooling pipes, the effort required to detach them is occasionally quite considerable. According to the invention, it is now possible to equip the washer housing at the outlet side with a multi-purpose connection for a mine air cooler so that such a mine air cooler is connected directly to the dust separator. The mine air cooler therefore cools clean air, is virtually no longer subject to fouling and has a uniformly high cooling capacity and cooling effect because dust cannot settle on the cooling pipes. Thus, by virtue of such a combination of dust separator and mine air cooler, the occasionally considerable problems associated with the underground operation of mine air coolers are advantageously avoided.
A method of operating extracting plant at high temperatures, which is advantageously usable particularly in underground mining, provides that entrained dust is removed from the air immediately prior to cooling. Said preliminary cleaning of the air ensures a cooling operation of uniform quality because fouling of the used cooling pipes is ruled out. Furthermore, the air at the same time is also dried to such an extent that the formation of condensation water is reduced sufficiently for cooling of the air to be effected reliably and quickly.
The invention is notable for the fact that a dust separator in the form of a rotary washer is provided which, by virtue of its special construction and the units associated with it, enables operation with a stable characteristic and at the same time works with a high dust separation efficiency and relatively dry air. The air containing dust is taken in via a fan impeller disposed in the air stream, is already sprayed with water at the inlet of the washer housing and then freed of the sludge-containing water so that pure, clean air leaves the washer housing. The demister which separates the sludge-containing water is in said case so cleverly arranged and designed that it optimally performs its allocated task without the collected sludge leading to clogging of said unit. The sludge-containing water is fed to a water tank, wherein sludge and water are separated from one another and the clean water is then recycled. Recycling of the clean water is effected in such an automated manner that always only as much clean water or fresh water as is absolutely necessary need be supplied.
Where necessary, tension-relieving liquid or some other water additive is also added to the water by the supply pump in order to facilitate, speed up but at any rate ensure consolidation of the dust particles in the spray water.
Further details and advantages of the subject matter of the invention are evident from the following description of the accompanying drawings, in which a preferred embodiment with the requisite details and individual parts is illustrated. The drawings show:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a dust separator in side view, partially in section,
FIG. 2 a plan view of the outlet end of the dust separator and
FIG. 3 a side view of the outlet end with the water tank.
DETAILED DESCRIPTION
The dust separator 1 illustrated in side view in FIG. 1 is a so-called rotary washer. The dust-containing air is sucked by means of a fan impeller 6 into the washer housing 2 , namely from the inlet side 3 . The dust-containing air then passes through the washer housing from the inlet side 3 to the outlet side 4 , wherein the fan impeller 6 with the blades 7 unlike the actual drive 5 lies in the air stream 21 .
Disposed at the inlet side 3 is firstly a plurality of water nozzles 8 , which spray water into the air counter to the inflow direction of said air in order to set the entrained dust. Here, in order to be able to operate with a uniform characteristic independently of the air quantity, the dust quantity and the remaining load, a gear unit 10 is associated with the drive 5 . Said gear unit is shown by dashes in FIG. 1 . It lies inside the washer housing 2 but at least in such a way as to be not visible.
Disposed downstream of the fan impeller 6 and the drive 5 in the washer housing 2 is one or more separating elements 11 , by means of which the sludge-containing water is separated from the air and directed into the water tank 12 .
FIG. 1 reveals that the demister 20 serving as a first separating element is positioned obliquely in the air stream 21 in order to facilitate outward passage of the sludge-containing water. What is not shown is that said demister 20 is pivotal about an axis (not shown) in such a way that it lies approximately horizontally in the air stream so that the collected sludge-containing water may easily and reliably drip downwards and be directed into the water tank 12 .
The water tank 12 is provided with a water inlet or fresh water inlet 13 and a water outlet 14 . Both or only the fresh water inlet 13 are controlled by means of the float 15 , which moves up and down with the water level and in so doing, for example, opens or blocks fresh water inlet 13 . The water outlet 14 or the supply pump pipe 33 is disposed in a pivotal manner to allow it to adapt to the rising or falling water level 18 .
The sludge-containing water however passes first into the region disposed directly below the demister 20 , wherein the sludge 17 may be removed via the drain valve 16 when sufficient sludge 17 has settled on the tank base 37 . The tank base 37 is therefore disposed obliquely to allow the sludge 17 to slide automatically in the direction of the drain valve 16 .
Disposed upstream of the demister 20 in the air stream 21 is a jetwashing device 22 , by means of which the demister 20 may when necessary be charged with water in order to remove accumulated dirt. Although such an operation is as a rule required only at very long intervals because the oblique position or approximately horizontal arrangement of the demister 20 allows the sludge-containing water or the sludge to trickle downwards, the operating device 22 is necessary as a precaution. In said case, the inclination of the demister 20 and also of the jetwashing device 22 may be varied in each case by means of a positioning motor 23 , i.e. in dependence upon the composition of the air and also upon moisture. Said swivelling of, in particular, also the jetwashing device 22 is easily possible because the jetwashing device 22 has a flexible or even pivotal water connection 24 .
The demister 20 has a woven steel filling 25 , which is merely indicated in FIG. 1 . As a result of repeated deflection of the air stream, the dust-containing water is retained and may trickle down along the appropriate steel parts in order to be conveyed out of the washer housing 2 . When the demister 20 is to be swivelled by means of the positioning motor 23 , it is advantageous to dispense with the supporting feet 26 , as shown in FIG. 1 . The jetwashing device 22 and the demister 20 may then be swivelled about an axis, which is not visible here, into the horizontal or approximately into the horizontal.
Both the water nozzles 8 and the jetwashing device 22 are supplied by a supply pump 28 with jetwashing water from the water tank 12 . In addition, the supply pump 28 is connected by a supply line 27 to an additional tank 29 in order where necessary to take in water additives from the latter and add them to the circuit to facilitate consolidation of the dust in the spray water. In the case of particularly tenacious dust, it may be necessary also to switch on the additional spray nozzles 31 , 32 which are arranged distributed over the flow path 30 . Said spray nozzles likewise spray counter to the air stream 21 and additionally ensure that a consolidation of the dust in the water drops is possible.
The flow path of the air stream enriched with sludge-containing water is denoted by 30 . It is evident here that the flow path 30 passes around the drive 5 so that said component need not be disposed inside the washer housing 2 but may instead be disposed in a suitable recess or a suitable cavity so that the heat may be removed directly outwards.
It was already pointed out earlier that the water is conveyed as far as possible in the circuit and that only the naturally occurring loss is replaced with fresh water. In said case, the water is removed from the chamber 36 via the supply pump 28 and the supply pump pipe 33 and added to the circuit. The chamber 36 is separated from the rest of the water tank 12 by a partition wall 35 in order to ensure that said region does not silt up and also that the float 15 always retains its function. In said case, the partition wall 35 is pivotal by means of a joint 38 so that, where necessary, removal of water is still possible even with a dropping water level 18 . The valve 34 in the fresh water supply line 13 ′ is controlled by the float 15 and ensures that in each case only as much fresh water as is absolutely necessary flows into the water tank 12 .
Downstream of the demister 20 , which is illustrated also with regard to its insides in FIG. 1, a mist collector 40 is provided. Said mist collector 40 comprises a plurality of traps 41 , 42 , in which any water still carried along by the air is caught before then draining into the water tank 12 .
FIG. 2 shows a plan view of the outlet side 4 of the washer housing 2 , wherein it is clear from the traps 41 , 42 that said purely mechanically operating unit ensures with the necessary certainty that the very last drops of water are extracted from the air stream 21 .
Finally, FIG. 3 again shows the region of the outlet side 4 of the washer housing 2 , namely in side view, wherein it is once more clear that the demister 20 is disposed so as to be steeply inclined until horizontal in the washer housing 2 , while the mist collector 40 is positioned vertically therein. The sludge-containing water, which has drained into the water tank 12 , arrives in a relatively large settling zone so that water and sludge may separate from one another. The water intended for further jetwashing passes over the partition wall 35 and into the region of the chamber 36 , from which it may be removed by the supply pump 28 with the aid of the control system regulated by float 15 .
The water connection 24 is to be flexible enough to participate in the motion of the jetwashing device 22 and the demister 20 . Here, said water connection may comprise e.g. a piece of hose, which should additionally be telescopic in order not to impede the swivelling of demister 20 and jetwashing device 22 .
The outlet side 4 of the washer housing 2 has a multi-purpose connection 45 . Said multi-purpose connection 45 allows the connection of downstream cooling units, in particular of so-called mine air coolers used in underground mining. This has the enormous advantage that the mine air cooler only has to cool purified air or purified mine air, whereas in prior art the mine air always contains dust, which leads to clogging or at least however to a function-impairing coating on the cooling pipes.
Should it prove absolutely necessary for some reason, there is moreover the possibility of disposing both a second demister and a second mist collector in the housing, or in a downstream housing which may be connected thereto by the multi-purpose connection. This also increases the flexibility of such a device without entailing an excessively high capital expenditure.
All the described features, including the features inferrable from the drawings alone, are—on their own or in combination regarded as central to the invention. | For purifying dust-containing air, particularly in underground mining and tunnel construction, a dust separator 1 in the form of a rotary washer 1 is proposed. The drive 5 of said rotary washer 1 is equipped with a gear unit 10 in order to enable long-term operation with a straight characteristic. Furthermore, disposed downstream of the fan impeller 6 is a special separating element 11 in the form of a demister 20, which is disposed so as to be suspended approximately horizontally in the air stream. Clogging of the demister 20 is therefore effectively prevented and so uniform and reliable operation is guaranteed. The demister 20 together with its associated jetwashing device 22 may be swivelled by a positioning motor 23 into an, in each case, optimum position. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional application 60/622,848 filed Oct. 29, 2004.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The inventive subject matter relates to an apparatus and method for the collection of dental wastewater during dental procedures without interrupting the dental vacuum system.
[0004] 2. Description of Related Art
[0005] Hg is generally found in three forms: elemental, inorganic and organic. Each form possesses its own characteristic toxicokinetics and human health effects. Elemental Hg volatilizes at room temperature and human exposure is primarily through inhalation of the vapor. Hg vapor is lipid soluble and easily crosses alveolar membranes of the lungs. Consequently, the Hg is taken up by red blood cells and transported to the central nervous system (Stone, et al, 2003).
[0006] Inorganic Hg (also known as ionic Hg) is absorbed by the gastrointestinal tract in humans in only limited amounts. Only approximately 7% of ingested inorganic Hg is absorbed (Stone, et al, 2003) with kidney tissue accumulating the highest concentration. However, elemental Hg in human saliva can be oxidized to ionic Hg, which may be protective since ionic Hg is less toxic (Liang and Brooks, 1995 ).
[0007] Organic Hg is the most environmentally important form of Hg. Organic Hg produces neurotoxic effects in adults. Additionally, the toxic effects on fetuses and young children is particularly acute due to the toxic effects on the developing nervous systems (Stone et al, 2003; Vogel, et al, 1985). Absorption of organic Hg can be as high as 95% with a marked affinity for the central nervous system (Vogel, et al, 1985; Steuerwal, et al, 2000).
[0008] The environmental impact of mercury (Hg) release from dental operations is frequently dismissed due to the assumption that Hg in dental amalgam is unavailable for uptake by biologic organisms. The environmental significance of dental Hg was predicated on the assumption that dental Hg in dental amalgam is unavailable for uptake by biological organisms (Berthold, 2001). Recently, however, this notion has been dispelled (Arenholt-Bindslev, 1992; Stone, et al, 1999; Fan, et al, 1997).
[0009] Previous dental collection systems are designed to remove particulate waste (amalgam separators), or both particulate and dissolved waste, from the dental wastewater slurry using a combination of gravity sedimentation, filtration, chemical oxidation, and ion-exchange materials (U.S. Pat. No. 3,138,873 to Bishop; U.S. Pat. No. 3,777,403 to Ritchie; U.S. Pat. No. 5,885,076 to Ralls, et al; U.S. Pat. No. 4,385,891 to Ligotti; U.S. Pat. No. 5,205,743 to Ludvigsson, et al; and U.S. Pat. No. 5,795,159 to Ralls, et al).
[0010] The apparatus disclosed by U.S. patents to Ludvigsson, et al (U.S. Patent No. 5,205,743) and to Ralls, et al (U.S. Pat. No. 5,885,076) are relatively complex systems where waste material is passed through a series of filters. The apparatus disclosed by the U.S. patent to Bishop (U.S. Pat. No. 3,138,873) describes a system wherein slurry is passed through a porous bag that traps and collects particulate matter. The apparatus disclosed in U.S. Pat. No. 3,777,403 (to Richie) utilizes a system wherein liquid slurry is drawn by vacuum through a collection container and out the vacuum riser and into the drainage system. In U.S. Pat. No. 4,385,891 (to Ligotti), particulate matter settling to the bottom of a canister is enhanced by multiple aperatures in a baffle, separating the canister into two sections. Liquid is drawn out of the canister but particulate matter is allowed to settle and which is ultimately collected. The latter (i.e. U.S. Pat. No. 5,795,159 to Ralls, et al) is also designed to provide remove particulate matter and trapped in a seal-able container while liquid is passed through the system.
[0011] The systems previously disclosed either require filtering or pass liquid slurry through the apparatus for disposal via the normal drainage system or other collection methods. Furthermore, the more complex systems operate with various efficiencies and complexity depending on particulate size distribution and flow rate. The most effective mercury removal systems are typically centrally located collection systems such as found in U.S. Pat. No. 5,885,076 to Ralls, et al and U.S. Pat. No. 6,521,131 to Hamilton, et al.
[0012] Centrally located systems, while often effective at removing total mercury from dental wastewater suffer a number of disadvantages, even under optimum conditions. These include:
1) location of the apparatus at a distance from the source (i.e. the dental chair),which allows amalgam and mercury to settle and accumulate in dental office plumbing lines, eventually rendering these lines a hazardous waste material in themselves; 2) requirement to accurately size the system relative to the number of dental chairs serviced, total wastewater accumulation and amount of amalgam waste produced per unit of time; 3) complexity of installation; 4) accumulation over time of amalgam waste sludge in settling tanks in addition to the collection within the filters; 5) and complexity of chemical interactions that can occur over time, especially within holding tanks, between various materials, disinfectants, and chemicals used in the practice of dentistry (and contained within the wastewater slurry), and bacteria and waste materials that accumulate in settling tanks in constant contact with the wastewater slurry containing same (these interactions can produce compounds resistant to removal by the apparatus or even serve as an environment that fosters bacterial conversion of inorganic elemental mercury to organic methyl mercury).
[0018] Therefore, large centrally located systems necessitate dental clinics from discharging hazardous waste into sewer systems or require the dental office to install expensive dental amalgam separators. A need, therefore, exists for collection systems that generate small volumes of wastewater for easier and less expensive waste management and sample collection. This can be achieved via a chairside collection system that is capable of separating of dental amalgam as particulate matter for easy transport to an off-site facility for storage or to remove harmful pollutants. Additionally, such a system can be utilized for collection of dental wastewater for clinical or laboratory sample analysis.
SUMMARY OF THE INVENTION
[0019] The inventive subject matter relates to a self-contained mercury filtration system that can effectively remove mercury particulate and finely dispersed particles from dental wastewater suction lines and permit collection of the wastewater and particulate matter.
[0020] The inventive subject matter also relates to a self-contained waste collection system for chairside use that is contained within or attached to a dental chair or dental unit in line with the existing high vacuum evacuation (HVE) suction line.
[0021] The inventive subject matter further relates to a self-contained a dental chair wastewater collection system that generates low volumes of dental wastewater.
[0022] The inventive subject matter additionally relates to a self-contained mercury filtration container that can be safely removed and replaced at regular intervals for transport to off-site treatment and management of hazardous materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a drawing of the collection container showing the operational relationship to patient, inlet line and vaccum.
[0024] FIG. 2 is a cross-sectional view of the inlet apparatus connected to the collection container.
[0025] FIG. 3 is a cross-sectional view of the inlet apparatus.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] The invention contemplates a simple dental wastewater collection system intended for placement in-line with an existing High Vacuum Evacuation (HVE) suction line in dental units that is capable of collecting wastewater and dental waste particulate matter. The inventive apparatus is capable of collecting dental waste, chair side, without waste flowing from the apparatus into the vacuum line and drainage system.
[0027] An example of the inventive apparatus is illustrated in FIGS. 1, 2 and 3 . The apparatus contains a container ( 1 ) capable of holding dental evacuation wastewater and dental-waste particulate matter. The container is of suitable size for holding an adequate volume of waste from a dental patient or multiple dental patients. A preferred size is 1-2 liters in size. However, any size container be used. The container is constructed of any number of materials, including metal, glass or plastic. The container, containing an inside portion, and outside portion and an upper and bottom portion and lid ( 3 ) connected to upper portion. The container ( 1 ) contains a gasket ( 21 ) around the inside of the lid in order to permit a tight seal and maintenance of pressure until released. The container also contains a pressure release value ( 23 ) to permit easy disconnect from the vacuum tube ( 19 ) to permit transport and emptying of contents or the re-attachment of a replacement container.
[0028] Connected and protruding through the lid ( 3 ) and into the container ( 1 ) is an inlet apparatus ( 5 ). The inlet apparatus contains an inside ( 7 ) and outside portion ( 9 ). The inside portion ( 7 ) of the inlet apparatus ( 5 ) is disposed lengthwise through the inlet apparatus and is operationally connected to an inlet line ( 11 ) from the patient. The outside portion ( 9 ) of the inlet apparatus forms a space ( 13 ) between the inside portion ( 7 ) and the outside portion ( 9 ). The space ( 13 ) protrudes into the container ( 1 ) such that the inlet apparatus space ( 13 ) contains an opening ( 15 ) exposed to the inside of the container ( 1 ). The space ( 13 ) is also operationally connected to a vacuum line operationally connected to a vacuum source ( 17 ) via a vacuum tube ( 19 ). The inside portion ( 7 ) also protrudes into the container ( 1 ) such that wastewater and dental-waste particulate matter is permitted to pass from the patient and into the container ( 1 ). The distance of said protrusion of the inside portion ( 7 ) of the inlet apparatus ( 5 ) into the container must be sufficiently far such that matter flowing out of the inlet portion ( 7 ) is not sucked into the opening ( 15 ) of said inlet apparatus space ( 13 ) and ultimately into the vacuum tube ( 19 ). The distance of the protrusion of the inlet portion ( 7 ) into the container is dependent on the distance that the inlet apparatus space ( 13 ) protrudes into the container ( 1 ) and the strength of the vacuum supplied to the container ( 1 ) via the vacuum tube ( 19 ). The inlet apparatus can be made of any material including glass, metal or plastic.
[0029] The representation of each element is diagrammatic. The figures illustrate relative relationships of each of the elements to one another and are general rather than actual. The figures are not representative of precise ratios of dimensions. However, while size (height and circumference) is to some extent variable with respect to desired volume, placement on or next to the dental chair or even dental unit, the total volume of air capacity within the invention must be sufficient suction and flow rate to permit movement of material through the tubes. Placement of the device is primarily intended to be next to the dental chair. However, the device can be placed anywhere as long as sufficient suction is provided by the HVE.
[0030] Removal and collection of dental wastewater and particulate matter can be achieved by drawing dental waste, as a liquid slurry, from the patient into the above described apparatus. Particulate matter and liquid is deposited, by gravity, into the container ( 1 ) of FIG. 1 and 2 . Vacuum to the container is maintained by a vacuum line supplied to the opening to the container in the inlet apparatus ( 15 ) by the vacuum pump ( 17 ) via the vacuum tube ( 19 ). The contents of a nearly full container ( 1 ) is either emptied into another container for storage or transport to a treatment facility or the container ( 1 ) replaced with a new container. Detachment of the full container is accomplished by first releasing the vacuum via the pressure release value ( 23 ) and removing the lid ( 3 ).
[0031] Liquid and/or particulate matter samples, such as dental amalgam or mercury, can be collected from the container following dental procedures. Samples, containing both particulate matter and liquid can be collected directly as described above. However, samples containing only particulate matter or liquid without large particulate matter can also be collected by first allowing the particulate matter, such as dental amalgam, to settle to the bottom of the container ( 1 ). After the particulate matter has settled to the bottom, the liquid wastewater is either poured or aspirated off the underlying particulate matter. The liquid can then be collected and stored for clinical use or, alternatively, deposited in another container for disposal as dental-waste. Similarly, the particulate matter can be collected, free of liquid wastewater for further use or disposed of as necessary.
[0032] The above example is given to illustrate specific applications of the invention including the best mode now known to perform the invention. The example is not intended to limit the scope of the invention described in this application.
REFERENCES
[0033] 1. Arenholt-Bindslev, D., (1992) Dental amalgam-environmental aspects. Adv. Dent Res. 6: 125-30.
[0034] 2. Berthold M., (2001) Proven track record: Science shows dental amalgam is safe, effective. ADA News 32 (13):13. Comment by Rodway J. Mackert, Jr. DMD, Ph.D.
[0035] 3. Bishop, Harold P. 1964. Vacuum attachment for dental aspirator unit. U.S. Pat. No. 3,138,873 issued Jun. 30, 1964.
[0036] 4. Fan, P. L., D. Arenbolt-Bindslev, G. Schmalz, S. Halback, H. Berendsen, (1997) Environmental issues in dentistry-mercury. Int. Dent. J. 47: 105-9.
[0037] 5. Hamilton, Richard A., Scott P. Fulton, Ted M. Shields. 2003. Combined oxidation and chelating adsorption system for removal of mercury from water. U.S. Pat. No. 6,521,131 Feb. 18, 2003.
[0038] 6. Liang, L., R. J. Brooks, (1995) Mercury reactions in the human mounth with dental amalgams. Water Air and Soil Pollut, 80: 103-7.
[0039] 7. Ligotti, Eugene, F. 1983. Dental apparatus for preventing loss of precious metal particles. U.S. Pat. No. 4,385,891 issued May 31, 1983.
[0040] 8. Ludvigsson, Bjorn M., D. L. Stromberg. 1993. Dental treatment method. U.S. Pat. No. 5,205,743 issued Apr. 27, 1993.
[0041] 9. Ralls, Stephen Alden, William Corry Roddy. 1998. Mercury removal method and apparatus. U.S. Pat. No. 5,795,159 issued Aug. 18, 1998.
[0042] 10. Ralls, Stephen Alden, William Corry Roddy, Ernest David Pederson. 1999. Method and system for removing mercury from dental waste water. U.S. Pat. No. 5,885,076 issued Mar. 23, 1999.
[0043] 11. Ritchie, John, K. 1973. Dental silver retrieval apparatus. U.S. Pat. No. 3,777,403 issued Dec. 11, 1973.
[0044] 12. Steuerwal, U., P. Weihe, P. J. Jorgensen, K. Bjerve, J. Brock, B. Heinzow, E. Budtz-Jorgensen, P. Grandjean, (2000) Maternal seafood diet, methyl mercury exposure, and neonatal neurologic function. J. Pediatr. 136(5): 599-605.
[0045] 13. Stone, M. E., M. E. Cohen, L. Liang, P. Pang, (2003) Determination of methyl mercury in dental-unit wastewater. Dental Materials 19: 675-679.
[0046] 14. Stone, M. E., E. D. Pederson, G. K. Jones, J. C. Ragain, R. S. Karaway, R. A. Auxer, S. L. Davis, (1999) Mercury removal from the dental-unit wastewater stream. Proceedings of specialty conference: mercury in the environment. Air and waste management association in conjunction with the EPA, Sep. 15-17, Minn. Minnesota, VIP-91: 413-24.
[0047] 15. Vogel, D. G., R. L. Margolis, N. K. Mottet, (1985) The effects of methyl mercury binding to microtubules. Toxicol Appl Pharmacol., 80: 473-86. | The invention relates to a dental chair side wastewater collection system for dental-unit wastewater for sample analysis or collection and management of dental-unit wastewater hazardous materials. The system is small enough to be installed chair side to permit collection of an entire days wastewater or wastewater from a single patient for immediate disposal or for sample collection. Collected wastewater can then be easily emptied and stored elsewhere until disposed. | 0 |
FIELD OF THE INVENTION
This invention relates to the field of pharmaceutically active or otherwise beneficial compounds obtained from natural sources. In particular, the invention provides a seed preparation enriched in phenethyl isothiocyanate, a naturally-occurring anticancer and cancer preventative substance.
BACKGROUND OF THE INVENTION
Various scientific articles are referred to in parentheses throughout the specification, and complete citations are listed at the end of the specification. These articles are incorporated by reference herein to describe the state of the art to which this invention pertains.
Most people are familiar with the biting taste of horseradish and mustard, the pungent flavors of cabbage and Brussels sprouts and the peppery sensation of watercress. These plants belong to a broad group of species consisting of the Cruciferae and fourteen other families, which contain over 100 related natural chemical compounds, called glucosinolates, which are responsible for the familiar flavors and aromas of these plants. Plants that contain glucosinolates are widely consumed by people and livestock. The occurrence and biochemistry of glucosinolates has been well-documented. The variation in glucosinolate content among these plants is tremendous. Some plants can contain predominantly one form of glucosinolate while others are characterized by as many as fifteen different forms.
Glucosinolates are nitrogenous natural products that are derived from one of several different amino acids. Glucosinolates also contain sulfur from cysteine as well as a molecule of glucose, which is attached by a thioglucosidic bond. Many plants contain very high concentrations of glucosinolates, which presumably serve a protective function (Mithen, 1992). When plant tissues are disrupted, the glucosinolates rapidly break down into one of several forms. The first step of this breakdown is catalyzed by a class of enzymes generally referred to as myrosinases. The unstable aglycone which results from the removal of the glucose moiety by the myrosinase then rearranges into one of three basic forms by a process which is generally spontaneous. The basic forms that result from this rearrangement are either isothiocyanates, nitrites or thiocyanates. The wide variety of forms of glucosinolates and their breakdown products results from a biosynthetic pathway that originates from different amino acids, followed by subsequent modifications, all of which seem to be species specific. Although glucosinolates have been the focus of intensive research, many aspects of this diverse biochemical system have yet to be resolved.
Vegetables that contain glucosinolates have long been known to be a healthy part of the daily diet. For instance, the isothiocyante, sulforaphane, has been shown to be a powerful cancer preventive compound that specifically induces phase II detoxification enzymes (Zhang et al., 1992). Sulphoraphane is one example of several isothiocyanates that are characterized by similar kinds of health benefits. PEITC (phenethyl iosthiocyanate) is a glucosinolate breakdown product which is similar to sulforaphane and has also been a focus of intensive cancer preventive research. In addition to the extensive research done with animal systems, PEITC from fresh watercress has been shown to specifically inhibit the oxidation of nitrosamines from tobacco in human smokers as measured by urinary excretion of metabolites (Hecht et al., 1995). PEITC has been repeatedly shown to be both an effective and stable cancer preventive and anticancer compound. Not only does it inhibit the carcinogenic activation of many of the components of tobacco products, but prevents similar effects of many other toxins as well as even promote the death of cancerous cells.
The health promoting and anticancer benefits of PEITC may be obtained by consuming large amounts of the vegetables that are rich in this substance. However, such consumption may not be practical or desirable. It would be preferable if PEITC could be obtained in a more concentrated form such that its benefits could be enjoyed, for instance, through daily consumption of a small capsule, rather than large amounts of PEITC-containing vegetables.
SUMMARY OF THE INVENTION
In accordance with the present invention, plant varieties and specific tissues have been identified that are rich natural sources of PEITC, and methods have been devised to increase the production of PEITC in these tissues and to obtain preparations of certain plant tissues that are highly enriched in PEITC.
According to one aspect of the present invention, a preparation of disrupted plant tissue, comprising at least 1 mg PEITC per gram fresh weight of the plant tissue, is provided. Preferably, the preparation comprises at least 5 mg PEITC per gram fresh weight plant tissue, and most preferably at least 10 mg PEITC per gram fresh weight plant tissue. In a preferred embodiment, the preparation is made from seeds of upland cress, and may be provided as a dried product.
According to another aspect of the invention, a nutraceutical formulation is provided, which comprises the plant tissue preparation described above.
A preferred embodiment of the present invention provides a crushed, dried preparation of upland cress seed, comprising at least 5 mg PEITC per gram dry weight. A nutraceutical formulation also provided, comprising this preparation.
According to another aspect of the present invention, a method is provided for obtaining a plant tissue preparation that contains at least 1 mg PEITC per gram fresh weight of the tissue. The method comprises: (a) providing fresh or fresh-frozen plant tissue; (b) disrupting the tissue; and (c) incubating the disrupted tissue in an aqueous solution for a time and at a temperature effective to produce the preparation that contains at least 1 mg PEITC per gram fresh weight of the tissue. In one embodiment, the disrupted tissue is incubated in water, a method preferred when the tissue is incubated at slightly elevated temperature, e.g., 30° C. In another embodiment, the disrupted tissue is incubated in a biologically compatible buffer. Preferably, the pH of the disrupted tissue in the aqueous solution is between 4.0 and 8.0, more preferably between 4.5 and 7.2.
In the aforementioned method, the incubation is performed at a temperature between 20° C. and 37° C., more preferably between 27° C. and 32° C., and most preferably at 30° C. The incubation is performed for at least 2 minutes and preferably between 10 and 40 minutes, most preferably for 20 minutes.
It is preferred that the aforementioned method be practiced on upland cress seeds. It is also preferred that the seeds are frozen in liquid nitrogen before disruption. After disruption, the plant material may be subjected to freeze-drying, preferably to a final temperature of less than 10° C., more preferably to 0° C.
According to another aspect of the invention, a plant tissue preparation comprising at least 1 mg PEITC per gram fresh weight plant tissue, prepared by the aforementioned method, is provided.
According to a specific aspect of the present invention, a method of obtaining a preparation of upland cress seed containing PEITC is provided. The method comprises: (a) providing fresh or fresh-frozen upland cress seed; (b) crushing the seeds; and (c) incubating the seeds in an aqueous solution at 30° C. for 20 minutes. The method may further comprise freeze-drying the preparation to a final temperature of 0° C. A PEITC-containing upland cress seed preparation, prepared by the aforementioned method, is also provided, as is a nutraceutical formulation for prevention or treatment of cancer, which comprises the upland cress seed preparation.
Other features and advantages of the present invention will be better understood by reference to the drawings, detailed description and examples that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . Gas chromatograph and mass spectrum (shown as inset figure) of PEITC from upland cress seed after standard treatment as described in Example 1.
FIG. 2 . The effect of incubation time on the release of PEITC from water-treated seed meal maintained at 22° C. All values are given ± standard error.
FIG. 3 . The effect of temperature on the release of PEITC from water-treated seed meal during a 20 min incubation period. All values are given ± standard error.
FIG. 4 . The effect of pH on the release of PEITC from treated seed meal incubated for 20 min at 22° C. All values are given ± standard error.
FIG. 5 . The effect of pH on the release of PEITC incubated for 20 min at 30° C. All values are given ± standard error.
DETAILED DESCRIPTION OF THE INVENTION
The release of isothiocyanates from glucosinolates has been commonly observed in cruciferous vegetables, which are known to offer substantial health benefits. PEITC has been shown specifically to be an important anticancer and cancer preventive agent in various experimental systems. Time, temperature and pH are factors known to influence glucosinolate degradation, but a pragmatic investigation of the production of PEITC from various plant species and the conditions influencing PEITC production heretofore had not been performed. The present inventors have systematically investigated (1) the occurrence and amounts of PEITC in several plant species and in specific tissues, and (2) factors influencing the release, accumulation and recovery of PEITC from selected plant material.
In accordance with the present invention, it has been found that the seed of upland cress provides the greatest potential source of PEITC, and methods have been devised to ensure maximal release of PEITC from upland cress ( Barbarea verma ) seeds, yielding processed seed meal containing as much as 2% (on a dry weight basis) of the desired product. Freeze-drying of the wetted seed meal yields a dried form appropriate for commercial processing with a high recovery of product which is stable over time.
The description below exemplifies upland cress (also referred to as winter cress), particularly the seeds, as the plant and tissue of choice for obtaining significant quantities of PEITC. However, it will be appreciated by persons skilled in the art that the same methods could be applied to any PEITC-containing plant species, with an expectation of obtaining PEITC in high proportion to whatever amount is contained within that species.
Thus, the inventors have developed a method for obtaining high yields of PEITC from plant sources, particularly upland cress seeds. In its most basic form, the method comprises the following steps: (1) provide fresh or fresh-frozen plant material; (2) optionally, freeze the tissue in liquid nitrogen; (3) grind or otherwise macerate the tissue in an aqueous solution; and (4) incubate the wetted tissue at a slightly elevated temperature (e.g., 30° C.) for several minutes, which promotes optimum release of PEITC. Water may be removed from the tissue by freeze drying. Details of the protocol are set forth below.
Using the aforementioned procedure on upland cress seeds, a dried seed preparation is obtained which contains between about 1 and 20 mg PEITC per gram fresh weight starting material. The determination of the amount of PEITC in a plant tissue preparation is made as set forth in Example 2: the crushed plant material (subjected to the treatment set forth above or to some comparative treatment) is extracted with a suitable solvent, e.g., ethyl acetate, then subjected to chromatographic or mass spectral analysis. By way of comparison, upland cress seeds which are directly extracted with solvent release very little PEITC (about 12 μg/gfw tissue), whereas upland cress seeds subjected to the methods of the present invention yield in the range of 1,000 fold more PEITC (1-20 mg or more per gfw) due to the optimization of conditions that favor release of the PEITC from the tissue.
As mentioned, the plant species chosen for obtaining PEITC plays a very important role in how much PEITC can be obtained from the plant source. Upland cress contains a high concentration of PEITC. However, other plant species also contain significant amounts of these compounds, and could be used instead of upland cress as a plant source of PEITC. These include various members of the cruciferae, and related genera, particularly watercress. However, upland cress exceeds any of these plant species in PEITC content.
As mentioned, the PEITC content in upland cress also varies with the tissue type. Seeds contain the highest concentration of PEITC. Leaves have been reported to produce as much as 6.7 mg PEITC per gram dry weight tissue (Palaniswamy et al., 1997); however, since leaf tissue has about a ten-fold more higher water content than does seed tissue, this number extrapolates to about 0.67 mg PEITC per gram fresh weight of tissue. Accordingly, seeds are preferred for use in the present invention, but leaves or other plant parts may be used. For instance, an alternative embodiment utilizes the entire plant as a convenient source of PEITC.
Plant tissue, preferably seed, is ground or otherwise macerated, preferably after freezing with liquid nitrogen. The macerated tissue is then wetted with a small volume of aqueous solution, preferably at a ratio of at least 1:1 (w:w) liquid to plant material, more preferably 1:2 (larger volumes of liquid may be used, but results in increased drying time in embodiments where the preparation is dried). In a preferred embodiment, the aqueous solution is water. In alternative embodiments, the aqueous solution may be a buffer, such that the pH of the wetted plant material may be adjusted. The pH of wetted upland cress seed in water is about 4.5. Optimum release of PEITC was found to occur at pH 7.2 at 22° C., therefore a preferred embodiment of the invention comprises use of a buffer for wetting the plant material, to achieve the higher pH in embodiments using the lower temperature.
The wetted plant material is then incubated for an appropriate time and at an appropriate temperature to effect maximum release of PEITC. Preferably, the wetted plant material is incubated for at least two minutes, more preferably 10 to 40 minutes, and most preferably about 20 minutes, at a temperature between about 20° C. and 37° C., more preferably between 27° C. and 32° C. and most preferably about 30° C. Temperature is an especially significant factor affecting release of PEITC from plant tissue. As can be seen by referring to FIGS. 3, 4 and 5 , release of PEITC from upland cress seeds was greatest after incubation at 30° C., at pH ranges from 4.5 (the pH of the mixture when incubated with water) to 7.2. By comparison, at an incubation temperature of 22° C., the release of PEITC from upland cress seeds was less, but a pH effect was observed.
Following the incubation, the macerated tissue is reduced to dryness to produce a residue highly enriched in PEITC. The inventors have found that lyophilization to a final temperature of 0° C. to, e.g., 10° C., results in recovery of a residue containing significant amounts of intact PEITC, e.g. up to 2% based on the dry weight of the residue.
Following the specific steps recited above, a particularly preferred embodiment of the invention utilizes the following steps, which are described in detail in Example 2: (1) grind upland cress seeds in liquid nitrogen; (2) wet the seeds in an aqueous solution, preferably water; (3) incubate the wetted seed mixture at 30° C. for 20 minutes; and (4) lyophilize the seed preparation to a final temperature of 0° C.
The dried PEITC-containing plant preparations can be tabletted or encapsulated or otherwise formulated for oral administration. The formulations preferably are administered as a dosage unit of PEITC. The term “dosage unit” refers to a physically discrete unit of the preparation appropriate for a patient undergoing treatment or using the compound for prophylactic purposes. Each dosage unit contains a quantity of active ingredient, in this case PEITC, calculated to produce the desired effect in association with the selected formulation. Preferred dosages of PEITC range from 10-50 mg as a daily dose for an average adult human.
Nutraceutical formulations of PEITC prepared as described above are useful for general health benefits and for prevention or treatment of a variety of diseases or other detrimental conditions. For instance, as mentioned earlier, PEITC may be administered for treatment or prevention of cancer. PEITC also may be administered to prevent deleterious effects of environmental toxins or pollutants, or their formation in the body, inasmuch as it has been shown to prevent oxidation of certain toxins into more toxic forms.
The following examples are provided to describe the invention in greater detail. They are intended to illustrate, not to limit, the invention.
EXAMPLE 1
Analysis of Watercress and Upland Cress for Phenethyl Isothiocyanate Content
Methods
Two grams of fresh leaf material was ground in liquid nitrogen and extracted in 20 mL of water. One mL was removed, cleared of particulates by centrifugation at 10,000 g for 10 min in a 13×100 mm test tube and partitioned 2 times with 2 mL ethyl acetate:cyclopentane:2-propanol (100:99:1). The organic mixture was then reduced to 1 mL in vacuo and analyzed by GC-MS. The samples were manually injected in the splitless mode into a gas chromatograph (model 5890, Hewlett-Packard) /mass spectrometer (model 5971, Hewlett-Packard) equipped with a 30-m×0.25 mm DB-5MS fused silica capillary column (J&W Scientific, Folsom Calif.). Chromatographic parameters were as follows: injection temperature at 150° C., initial oven temperature at 50° C. for 5 min followed by a ramp at 30° C. min to 280° C. for 3 min. The MS was operated by scanning from 50 to 650 (m/z). The retention time of PEITC was 11.3 min which appeared as the primary metabolite using this technique (see FIG. 1 ). The major ion of PEITC has a mass of 91 (m/z) (FIG. 1) which was used as the basis for the calculation of the concentration of PEITC within the sample by comparison with corresponding standards of known concentration. Standard curves were constructed across a broad range of PEITC concentrations. These concentrations were also verified using the molecular ion of mass 163 (m/z) of the sample and standard. These conditions were used for all subsequent analyses and standards were used to verify instrument linearity on a daily basis. All measurements consisted of the average of at least 3 replicate samples injected with the same sample volume.
Results Several glucosinolates have been measured in various species and within specific plant structures such as leaves, seeds, flowers, pods and roots. Watercress ( Nasturtium officinale ) and upland cress ( Barbarea verma ) are know for the presence of gluconasturtiin, a common glucosinolate which releases PEITC. Concentrations of PEITC in watercress leaf tissue were shown to increase from 3.0 to 6.7 mg/g DW with the modification of temperature and photoperiod (Palaniswamy et al., 1997). Seeds of upland cress were shown to contain high concentrations of gluconasturtiin (Zrybko et al., 1997) reaching several percent. Our initial investigations of watercress and upland cress showed that upland cress contained about 200 μg/g FW of PEITC, which was at least 20% more PEITC than found in watercress. It was not determined, however, if this PEITC was present as a free form or released from gluconasturtiin during sample preparation.
Broccoli seedlings have been well-documented as a rich source of sulforaphane, the isothiocyanate of that crucifer (Fahey et al., 1997). Our initial investigations of seed showed that watercress seed contained about 7 fold lower concentrations of PEITC than did upland cress seed while the seedlings from each appeared to contain dilutions thereof.
EXAMPLE 2
Standard Processing of Seed to Obtain a Preparation Enriched in PEITC
Initial protocols for obtaining PEITC from seed comprised grinding the seed in liquid nitrogen, followed by solvent extraction. These conditions may not have precluded the release of PEITC from the cold seed meal which may have condensed moisture from the air. Results of preliminary experiments indicated that the release of PEITC from upland cress tissue after tissue disruption began within minutes. It has been previously shown that the release of PEITC can occur at low temperatures (Gil and MacLeod, 1980a,b,c). Direct grinding and extraction of upland cress seed into ethyl acetate showed that the concentration of free PEITC was only about 12 μg/g FW. The protocol described below resulted in an increase of about 1000-fold in PEITC content in upland cress seed.
Methods
One gram of seed was ground in liquid nitrogen with a mortar and pestle and transferred to a 50 mL plastic conical centrifuge tube. The seed material was then wetted with 2 mL of pure water, capped and incubated at 30° C. for 20 min. The treated seed meal was then partitioned into 5 mL of ethyl acetate, transferred to a 13×100 mm test tube and centrifuged at 10,000 g for 10 min at 4° C. A portion of the ethyl acetate fraction was then either directly injected or diluted 50 times followed by GC-MS analysis as described above. Such modifications of the analytical techniques were necessarily made in response to the higher concentrations of PEITC achieved within the samples. For time course experiments, the incubation time was extended to both 40 and 60 min while the incubation temperature was maintained at room temperature (22° C.). For experiments investigating the effects of pH on the release of PEITC, pure water was replaced with 2 mL of 200 mM phosphate buffer, pH 7 or 200 mM phosphate buffer pH 8 which produced a pH of treated seed mixtures of 6.8 and 7.2 respectively. The pH of the seed mixture in pure water was 4.5. A solution of 200 mM sodium bicarbonate solution was also used for the treatment of the seed meal and yielded a final pH of 7. The release of PEITC after the 20 min incubation was also measured at 22° C. and 37° C. In addition, experiments with the combinations of the variables which influence the release of PEITC were performed in order to determine which conditions were optimal for the release of PEITC from the wetted seed. Similar experiments were performed with leaf tissue as well as 3-day-old seedlings grown in the dark for 3 days at 22° C. Most experiments were performed with upland cress, which was determined to be the richest source of PEITC release. Some experiments were performed with watercress plants, seed and seedlings for comparative purposes.
The process of lyophilization (freeze-drying) was used to remove the water from the treated seed meal in some of the experiments. Lyophilization was performed in a Vitris Genesis 12ES freeze dryer which removed the water from the processed samples with vacuum starting at a temperature of −50° C. followed by slow warming to a final temperature of either 26° C. or 0° C. Lyophilization to a final temperature of 26° C. or 0° C. took approximately 2 or 3 days respectively. Samples to be analyzed after lyophilization were then rewetted with 2 mL of water and processed using the standard method described above.
The stability of PEITC was investigated in seed meal kept in the dark at 22° C. Five grams of seed for each treatment were processed as described above, lyophilized to 0° C. and placed into either a capped or open 50 mL centrifuge tube. The samples were reground with a mortar and pestle after lyophilization to ensure homogeneity. On days 4, 7, 10 17 and 25, 100 mg from each treatment was processed as described above, with the omission of the final dilution of ethyl acetate. On day 68, the measurement of PEITC was performed using 1 gram from each treatment and processed as described above for the 1 gram samples.
Results
The effect of incubation time on the release of PEITC from water-treated seed meal maintained at 22° C. is shown in FIG. 2 . Since the release of PEITC was determined to occur rapidly, the release of PEITC from seed meal was measured at 20, 40 and 60 minutes prior to solvent extraction. The optimal time for the release of PEITC in pure water at room temperature (22° C.) was about 40 min. PEITC degradation may begin to occur after extended incubation times.
FIG. 3 shows the effect of temperature on the release of PEITC from water-treated seed meal during a 20 minute incubation period. Temperature has been a well-documented factor which can influence the accumulation of glucosinolate breakdown products (Virtanen, 1964). The breakdown of glucosinlolates occurs as a two step process, both steps of which could be differentially influenced by temperature. FIG. 3 shows that at 37° C., more PEITC was released than at 22° C. while the maximum amount of PEITC was released at an incubation temperature of 30° C. Temperatures higher than 30° C. may not only have a negative influence on the release of PEITC but may also promote further degradation and loss of PEITC. PEITC has been shown, however, to be stable under conditions analogous to the cooking of cruciferous vegetables (Chen et al., 1998)
The effect of pH on the release of PEITC from treated seed meal incubated for 20 min at 22° C. is shown in FIG. 4 . As with temperature, the pH of damaged or macerated tissues can have a profound effect on the release and accumulation of glucosinolate breakdown products. Considerable variation in the effects of pH have been reported in the literature, but this variation appears to correlate with species and glucosinolate diversity. FIG. 4 shows that the final pH of the seed mixture did influence the release of PEITC from ground seed meal after 20 min of exposure at 22° C. Similar amounts of PEITC were released at pH 4.5 which resulted from the addition of pure water and at pH 6.8 after the addition of phosphate buffer with a pH of 7. At pH 7.2, however, which resulted from the addition of phosphate buffer pH 8, the release of PEITC was significantly elevated. Somewhat improved results were obtained using a sodium bicarbonate solution which yielded a final pH of 7. This buffer was investigated for practical reasons of eventual mass production as an herbal supplement to be consumed. These results contradict some of the earlier literature which describes the formation of the isothiocyanates to be promoted at a pH of less than 5 (Virtanen, 1964) but is supported by more current literature which agrees with the data presented above (Gil and MacLeod, 1980b). In studies with Lepedium sativum, the pH range of 6.69-7.42 was observed to have a negligible effect on the products released during autolysis (Gil and MacLeod, 1980c).
FIG. 5 shows the effect of pH on the release of PEITC incubated for 20 min at 30° C. Since the most dramatic increases in the release of PEITC were observed after 20 min at a pH of 7.2 or at a temperature of 30° C., these conditions were combined in order to determine whether pH or temperature was the more dominant factor influencing the release of PEITC or if there was a synergistic effect of both factors. These results clearly demonstrated that the temperature of the incubation medium was the most important factor and that the elevated temperature promoted even greater release of PEITC at the pH which was not optimal at 22° C. Other experiments were also performed showing that at 30° C., longer incubation times or the use of sodium bicarbonate as a buffer, lead to lower amounts of PEITC release (52% and 72% respectively).
Once the proper conditions were determined for the optimized release of PEITC from the treated seed, it was necessary to define those processing methods which would permit the greatest recovery of PEITC in a form suitable for industrial packaging. In order to have a dried plant product for encapsulation, the water from the treatment procedure had to be removed in such a way as to minimize the breakdown or loss of PEITC. Lyophilization to a final temperature of 26° C. led to non-detectable recoveries of PEITC within treated leaf tissues and only 31% recovery from treated seed meal as compared to similar samples which were not lyophilized. This recovery was increased to greater than 84% in treated seed meal, however, when the final temperature of lyophilization was decreased to 0° C., producing concentrations as high as 20 mg/g DW. The increase in the total PEITC content of these samples as compared to those reported in FIGS. 2-5 was due to the increase in the accuracy of the analytical methods which occurred during these studies. Leaf tissues lyophilized to 0° C. contained concentrations of nearly 195 μg/g DW of PEITC, but this concentration is nearly 100 times lower than found in the processed seed meal.
Lyophilized seed meal after treatment was kept at 22° C. in both open and closed containers in order to determine the stability of the PEITC within it. These experiments showed that both the open and closed treatments were very similar and contained an average concentration of 16.7 mg/g DW after 25 days which did not decrease significantly during that period. This concentration did decrease by an average of 18% after 68 days, but both of these samples were not protected from potential atmospheric hydration or oxidation. In general, the PEITC content of the treated seed meal appeared to be stable over extended periods of time.
References
Chen C-W, Rosen RT, Ho C-T (1998) Analysis and thermal degradation products of allyl isothiocyanate and phenethyl isothiocyanate. Pp 152-163 in: Challenges in the Isolation and Characterization of Flavor Compounds (Eds. C J Mussinan, M J Morello, ACS Symposium Series 705, American Chemical Society, Washington D.C.
Fahey J W, Zhang Y, Talalay P (1997) Broccoli sprouts: an exceptionally rich source of inducers of enzymes that protect against chemical carcinogens. Proc Natl Acad Sci 94:10367-10372
Gil V, Macleod A J (1980a) Degradation of glucosinolates of Nasturium offininale seeds. Phytochemistry 19:1657-1660
Gil V, MacLeod A J (1980b) Some glucosinolates of Farsetia aegyptia and Farsetia ramosissima. Phytochemistry 19:227-231
Gil V, Macleod A J (1980c) Studies on glucosinolate degradation in Lepidium sativum seed extracts. Phytochemistry 19:1369-1374
Hecht S S, Chung F-L, Richie J P, Akerkar S A, Borukhova A, Skowronski L Carmella SG (1995) Effects of watercress consumption on metabolism of a tobacco-specific lung carcinogen in smokers. Cancer Epidemology, Biomarkers, and Prevention. 4:877-884
Mithen R (1992) Leaf glucosinolate profiles and their relationship to pest and disease resistance in oilseed rape. Euphytica 63:71-83
Palaniswamy U, McAvoy R, Bible B (1997) Supplemental light before harvest increases phenethy isothiocyanate in watercress under 8-hour photoperiod. HortScience 32: 222-223
Virtanen AI (1964) Studies on organic sulfur compounds and other labile substances in plants. Phytochemistry 4:207-228
Wiley Registry of Mass Spectral Data. 6th edition with structures, Copyright 1994 by John Wiley and Sons, Inc.
Zhang Y, Talalay P, Cho C-G, Posner G H (1992) A major inducer of anticarcinogenic protective enzymes from broccoli: isolation and elucidation of structure. Proc Natl Acad Sci 89:2399-2403.
Zrybko C L, Fukuda E K, Rosen R T (1997) Determination of glucosinolates in domestic and wild mustard by high-performance liquid chromatography with confirmation by electrospray mass spectrometry and photodiode-array detection. Journal of Chromatography 767:43-52
The present invention is not limited to the embodiments described and exemplified above, but is capable of variation and modification without departure from the scope of the appended claims. | The present invention provides methods for obtaining phenethyl isothiocyanate (PEITC), a natural glucosinylate derivative, from plant tissue. The methods involve selection of plant tissue naturally rich in PEITC, followed by aqueous extraction under conditions that promote optimal release of PEITC from the tissue. The invention further provides plant preparations containing significant quantities of PEITC and nutraceutical formulations comprising these preparations. | 0 |
This application is a continuation-in-part of U.S. patent application Ser. No. 09/413,698 filed Oct. 6, 1999 now U.S. Pat. No. 6,254,349 and claims the benefit of provisional application No. 60/142,256 filed Jul. 2, 1999.
BACKGROUND OF THE INVENTION
The present invention relates to a device and method for detachably connecting an impeller member to a pinion shaft member in a high speed fluid compressor, and more particularly the invention relates to a connection device and method where one of the members includes at least one tab that is inserted into a corresponding at least one slot provided on the other member.
A high speed fluid compressor such as a centrifugal compressor includes a rotor assembly that is comprised of an impeller that is coupled to a pinion shaft which includes a pinion gear that meshes with a drive gear to drive the impeller at high rotational velocities of up to 76,000 rpm, for example. The suitable attachment between the impeller and pinion must be able transmit torque from the pinion gear to the impeller, maintain zero relative motion of the impeller relative to the pinion, permit easy assembly and disassembly of the rotor assembly, and consistently relocate the pinion and impeller at their original relative positions when the components are reassembled. Accurate maintenance of the relative positions of the impeller and rotor is critical to ensure that the rotor assembly retains its dynamic balance.
The impeller and pinion shaft are conventionally coupled by a polygon attachment method. The principal advantages of the polygon attachment method are its ease of assembly/disassembly and self centering characteristic. The polygon must consistently lock up the impeller and pinion shaft at the same position to maintain the needed level of rotor balance. Any relative movement between the pinion shaft and impeller leads to unacceptable levels of vibration during compressor operation. To ensure the requisite consistency is obtained, the mating parts must be machined to very exacting tolerances.
FIG. 1 illustrates a prior art rotor assembly generally comprised of pinion shaft 12 coupled to an impeller 14 by a polygon attachment method. The pinion shaft 12 includes pinion gear 16 which is engageable with a power transmission assembly (not shown) which drives the pinion about a pinion axis 18 at a predetermined rotational velocity during operation of the centrifugal compressor. The pinion shaft 12 includes a drive end 20 which has formed therein a polygonally dimensioned bore 22 . The polygonally dimensioned bore 22 has an interior bore surface which defines a generally triangular cross section composed of circular arcs.
The impeller 14 incorporates a backward-leaning type blade geometry 24 , and the impeller includes a polygonally dimensioned stem portion 26 which is defined by an exterior stem surface 28 . The stem portion 26 includes a first end 26 a and a second end 26 b . The polygonally dimensioned stem portion 26 is suitably matingly dimensioned to be received by the polygonally dimensioned bore 22 . The stem portion 26 is typically dimensioned to have a cross section which deviates from a circular pattern and which has a shape that is convex on all sides and essentially elliptical, triangular or quadratic as illustrated in FIG. 2 . After coupling the pinion shaft and impeller, the pinion shaft is rotated and the lobes along the stem 26 are locked against adjacent portions of bore 22 .
The polygon attachment method has a number of shortcomings. The polygon attachment method is useful because it is repeatable and maintains permanent location by its shape. However, if the mating parts are not parallel and the shapes of the lobes are not accurately calculated and precisely machined, as the rotor assembly comes up to speed stresses in the components may alter the shapes of the lobes and as a result loosen the connection between the pinion shaft and impeller. Also, the compressor could experience surge or vibration that occurs during operation and as a result the surge or vibration could displace the impeller to a new location and out of balance. The polygon is expensive and difficult to manufacture. The mating polygon surfaces are difficult to measure for quality and precision. The continuous rubbing and surface contact on highly stressed polygonally shaped parts causes galling and fretting of the parts and the galling and fretting could cause the impeller and pinion shaft to be fused together.
The foregoing illustrates limitations known to exist in present devices and methods for assembling impellers and pinion shafts. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing a rotor assembly that includes an impeller including an impeller stem, the stem including a first coupling end having a first face and first coupling means along the first face; and a pinion shaft having a second coupling end with a second face and second coupling means along the second face, the first and second coupling means adapted to be mated when the impeller and pinion shaft are assembled to prevent relative displacement of the impeller and pinion shaft.
The first coupling means is comprised of at least one arcuate tab, and the second coupling means is comprised of at least one arcuate slot adapted to receive the at least one arcuate tab when the impeller stem and pinion shaft are mated. Each tab includes an inner arcuate surface, and substantially planar terminating surfaces joining the inner and outer arcuate surfaces; the arcuate tabs having different arclengths and widths. If one tab is included, the tab is simply inserted into the mating slot, and if more than one tab is provided, the tabs are different with different arclengths so that they can only be inserted into their mating slot and in this way the required relative orientation between the stem and pinion shaft is maintained.
In addition to the tab/slot coupling structure the pinion shaft includes a hub that extends outwardly from the second face and is adapted to be mated with a bore formed in the impeller stem. The wall of the bore and hub are tapered so that an interference fit is created when the hub is inserted in the bore.
In summary, the present invention is comprised of an attachment device and method comprised of a set of tabs/slots and tapered cylindrical hub. The tab/slot feature is used to transmit power between the mated parts and the tab/slot feature limits assembly of the component parts to a single orientation ensuring that the pinion shaft and impeller will be assembled at the same relative position when the parts are disconnected and then reassembled. The tapered cylindrical hub achieves an interference fit between the mating parts, and thus ensures that the two mating parts do not move relatively in the radial dimension. This ensures retention of dynamic balance of the assembly. Also, the interference fit that is achieved, provides additional power transmission capability. This design provides means to achieve the needed joint stiffness, balance retention, and power transmission capabilities while it can more easily be manufactured than the conventional polygon and other attachment methods.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an exploded, side elevational view of an impeller and a pinion shaft of a prior art rotor assembly for a centrifugal compressor.
FIG. 2 is an end view of a polygonally dimensioned stem portion of the prior art impeller illustrated in FIG. 1 .
FIG. 3 is a longitudinal sectional view of the impeller and pinion shaft of the rotor assembly of our present invention.
FIG. 4 is a lateral sectional view taken along line 4 — 4 of FIG. 3 .
FIG. 5 is a perspective view of the coupling end of the impeller shaft of FIG. 3 .
FIG. 6 is a perspective view of the coupling end of the pinion shaft of FIG. 3 .
FIG. 7 is a longitudinal sectional view of the impeller and pinion shaft of the rotor assembly of an alternate embodiment.
FIG. 8 is a lateral sectional view taken along line 8 — 8 of FIG. 7 .
FIG. 9 is a perspective view of the coupling end of the impeller shaft of FIG. 7 .
FIG. 10 is a perspective view of the coupling end of the pinion shaft of FIG. 7 .
FIG. 11 is a longitudinal sectional view of the impeller and pinion shaft of the rotor assembly of another alternate embodiment.
FIG. 12 is a lateral sectional view taken along line 11 — 11 of FIG. 11 .
FIG. 13 is a perspective view of the coupling end of the impeller shaft of FIG. 11 .
FIG. 14 is a perspective view of the coupling end of the pinion shaft of FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings wherein like parts are referred to by the same number throughout the several views, FIGS. 3-6 illustrate the rotor assembly coupling of the present invention.
Specifically, FIG. 3 shows the rotor assembly 40 that includes impeller 14 that is made integral with impeller stem 42 , and pinion shaft 44 that includes pinion (not shown) like pinion 16 . The pinion shaft and impeller shaft are detachably joined by assembly coupling 46 .
As will be described hereinbelow, the assembly coupling of the present invention ensures that the mating impeller stem and pinion shaft do not move relatively in the radial dimension during compressor operation. The assembly coupling 46 provides means to achieve the needed joint stiffness, balance retention, and power transmission capabilities and it can more easily be manufactured than the conventional polygon and other attachment methods.
Turning to FIGS. 4 and 6, the unitary pinion shaft 44 includes a coupling end 61 , a free end 63 , and axis 62 . The coupling end includes a lateral face 64 . A coupling hub 66 extends axially away from face 64 and has a tapered exterior surface that tapers inwardly as the hub extends away from the pinion shaft lateral face 64 . A threaded bore 67 adapted to receive a bolt or another conventional fastener extends along axis 62 through the hub 66 and a portion of the pinion shaft 44 . Opposed arcuate slots 68 and 70 are provided in lateral face 64 . Each slot includes inner and outer arcuate surfaces that are joined by substantially planar terminating surfaces. However, the arcuate slots are not the same and slot 70 has a greater arclength and width than slot 68 . As shown in FIGS. 4 and 6, the slots are separated by approximately 180 degrees.
Turning now to FIGS. 4 and 5, the unitary impeller stem portion 42 includes a coupling end 48 , free end 50 , and longitudinal axis 45 . The coupling end 48 terminates in lateral face 49 and free end 50 terminates in lateral face 51 . A substantially cylindrical bore 52 extends inwardly from coupling end face 49 to position within the stem, and the bore 52 includes a wall that is tapered inwardly as it extends inwardly away from the lateral face 49 . See FIG. 4 . The bore terminates at lateral end face 53 , and the end face and inwardly tapered side wall define a cavity 55 . A countersunk bore 54 extends between bore 52 and lateral face 51 .
First and second tabs 56 and 58 are provided along lateral face 51 . The tabs are used to accurately and consistently relatively orient and locate the coupled impeller stem and pinion shaft. The tabs extend outwardly from lateral face 49 and are substantially perpendicular to the face and are offset by about 180 degrees. Each tab is substantially arcuate with inner and outer arcuate surfaces joined by substantially planar terminating surfaces. As shown in FIG. 4, first tab 56 includes inner and outer arcuate surfaces 56 a and 56 b respectively which are joined by terminating surfaces 56 c and 56 d , and second tab 58 includes inner and outer arcuate surfaces 58 a and 58 b respectively which are joined by terminating end surfaces 58 c and 58 d . As shown in FIG. 4, the tabs are not the same and have different arc lengths and widths. Tab 58 is adapted to be fitted into slot 70 and tab 56 is adapted to be fitted into slot 68 . In this way, when the rotor assembly is disassembled, it can be assembled so that the impeller and pinion shaft are coupled in the same relative position before they were disassembled.
Although two slots and tabs are illustrated and described, it should be understood that any suitable number of mating slots and tabs may be used to obtain and maintain the desired relative positioning and orientation between the pinion shaft and impeller stem. Although in the description the tabs are provided on the stem lateral face 49 , and the slots are provided on the pinion shaft lateral face 64 , it should also be understood that the tabs could be provided on the pinion shaft face 64 and the slots could be provided on lateral coupling face 49 .
Assembly and disassembly of the rotor assembly 40 will now be described. When it is necessary to assemble rotor assembly 40 , axes 45 and 62 are aligned and hub 66 is slid into bore 52 . The hub and bore are dimensioned so that as the hub is inserted into the bore an clamping load is produced as a result of the interference fit between the tapered bore and hub surfaces. It has been determined by the coinventors that the resultant clamping load is sufficient to prevent relative movement of the impeller and pinion shaft.
As the hub is slid into the bore, tabs 70 and 68 are aligned with their respective slots 58 and 56 , so that the tabs are located in the respective slots when the hub is located in the bore 52 . The tabs ensure the desired relative location of the stem and pinion shaft after the completion of maintenance. After seating an o-ring seal 90 in the large diameter portion of countersunk bore 54 , bolt 92 is passed through bore 54 and bore 67 and is tightened until the ends of the tabs are in contact with the back of the slots. See FIG. 3 .
When it is necessary to service the rotor assembly, the bolt 92 is removed and the impeller is displaced axially from its location along the pinion shaft.
An alternate embodiment of an assembly coupling 146 is illustrated in FIGS. 7-10. FIG. 7 shows the assembly coupling 146 that detachably joins an impeller stem 142 with a pinion shaft 144 . Similar to the previously described embodiment, the assembly coupling 146 of this alternate embodiment transmits torque and prevents the mating impeller stem 142 and pinion shaft 144 from moving relative to one another in the radial dimension during operation.
As shown in FIG. 9, the impeller stem 142 has an outer stem surface 143 around the exterior of the impeller stem 142 , and a first coupling end 148 having a first coupling face 149 . The first coupling face 149 is illustrated as a lateral face at the first coupling end 148 and may be transverse to an impeller axis 145 . A tab 156 projects axially outward from the first coupling face 149 , and terminates at a tab surface 158 . The tab 156 extends across the first coupling face 149 intersecting with the outer stem surface 143 . Two driving surfaces 159 extend along the sides of the tab 156 between the first coupling face 149 and the tab surface 158 . A hub 166 extends axially away from the first coupling face 149 , and has a tapered exterior surface that tapers radially inward as the hub 166 extends away from the first coupling face 149 .
FIG. 10 illustrates the pinion shaft 144 having an outer shaft surface 147 around the exterior of the pinion shaft 144 , and a second coupling end 161 having a second coupling face 164 . The second coupling face 164 is illustrated as a lateral face at the second coupling end 161 , and may be transverse to a pinion axis 162 . A slot 168 is formed in the second coupling face 164 , and extends axially inward from the second coupling face 164 terminating at a slot surface 171 . The slot 168 extends across the second coupling face 164 intersecting with the outer shaft surface 147 . Two side walls 170 extend between the second coupling face 164 and the slot surface 171 . A cylindrical bore 152 extends axially inward from the second coupling face 164 to a position within the pinion shaft 144 , and the bore 152 includes a wall that is tapered radially inward as it extends away from the second coupling face 164 .
As shown in FIGS. 7-10, the hub 166 is sized to mate with the bore 152 when the impeller stem 142 and pinion shaft 144 are assembled. The mating hub 166 and bore 152 align the impeller stem 142 and pinion shaft 144 , and prevent the impeller stem 142 and pinion shaft 144 from moving relative to one another in the radial direction. The hub 166 and bore 152 arrangement of this embodiment is similar to the previously described embodiment, but in this alternate embodiment the hub 166 extends from the first coupling face 149 on the impeller stem 142 , and the bore 152 extends into the second coupling face 164 on the pinion shaft 144 . This arrangement is reversed from the previous embodiment, shown in FIGS. 5 and 6, which illustrate the hub 66 on the pinion shaft 44 and the bore 52 in the impeller stem 42 . Either arrangement is possible, and the hub 166 and the bore 152 may be disposed at either the first coupling face 149 or the second coupling face 164 as long as both the hub 166 and the bore 152 are present.
As illustrated in FIGS. 8-10, the tab 156 has a tab width dimension 180 , and the slot 168 has a slot width dimension 184 . The tab width dimension 180 is the distance between the driving surfaces 159 , and the slot width dimension 184 is the distance between the side walls 170 . In the illustrated arrangement, the tab width dimension 180 is greater than the diameter of the hub 166 at the intersection of the hub 166 and the tab surface 158 . The slot width dimension 184 is greater than the diameter of the bore 152 at the intersection of the bore 152 and the slot surface 171 .
As shown in FIGS. 7 and 8, when the impeller stem 142 and pinion shaft 144 are assembled together, the tab 156 and the slot 168 mate with one another to transmit torque between the pinion shaft 144 and impeller stem 142 . The tab 156 fits within the slot 168 , and the side walls 170 are aligned with the driving surfaces 159 . As the pinion shaft 144 rotates about the pinion axis 162 , the side walls 170 contact the driving surfaces 159 and rotate the impeller stem 142 about the impeller axis 145 .
As explained above, the tab 156 and slot 168 are arranged to properly align when the impeller stem 142 and pinion shaft 144 are assembled. In FIGS. 9 and 10, the tab 156 and slot 168 may be centered about the impeller axis 145 and pinion axis 162 respectively, or the tab 156 and slot 168 may be offset from each respective axis. When the tab 156 and slot 168 are centered, the driving surfaces 159 are both substantially equidistant from the impeller axis 145 , and the side walls 170 are both substantially equidistant from the pinion axis 162 . With the centered arrangement, the impeller stem 142 and pinion shaft 144 may have two possible mating positions, with each mating position being a 180 degree rotation from the other mating position.
When the tab 156 and slot 168 are offset, the distance from the impeller axis 145 to each individual driving surface 159 is different, and the distance from the pinion axis 162 to each side wall 170 is different. Even though the tab 156 and slot 168 are offset, they are equally offset so that the tab 156 and slot 168 still align with one another. With the offset arrangement, the impeller stem 142 and pinion shaft 144 only have one mating position, and will always align at substantially the same orientation to one another when being reassembled.
In the illustrated arrangement, the driving surfaces 159 are substantially planar, and are substantially parallel to each other. Also, the side walls 170 are illustrated as substantially planar, and are substantially parallel to each other. Alternatively, the shape of the tab 156 and slot 168 could be altered as long as the corresponding shapes are similar and the tab 156 and slot 168 still mate with one another. For example, the tab 156 could be tapered across the first coupling face 149 , and the slot 168 could be similarly tapered across the second coupling face 164 . The tapered arrangement provides another arrangement in which the impeller stem 142 and pinion shaft 144 would only have one mating position, and would always align at the same orientation to one another when being reassembled.
In the previously described embodiment, the tab 156 is disposed on the first coupling face 149 , and the slot 168 is disposed on the second coupling face 164 . Alternatively, the slot 168 could be formed in the first coupling face 149 , and the tab 156 could project outward from the second coupling face 164 . The tab 156 and slot 168 design could be reversed and the assembly coupling 146 would still transmit torque between the pinion shaft 144 and impeller stem 142 .
Another alternate embodiment of an assembly coupling 246 is illustrated in FIGS. 11-14. This alternate embodiment uses a hub 266 and a bore 252 arrangement similar to the previous embodiments to align an impeller stem 242 and a pinion shaft 244 radially, but a different interface is used to transmit torque between the impeller stem 242 and pinion shaft 244 . As shown in FIG. 13, a raised elliptical surface 256 projects axially outward from a first coupling face 249 . A driving surface 259 extends along the side of the elliptical surface 256 between the elliptical surface 256 and the first coupling surface 249 . The elliptical surface 256 is substantially parallel to the first coupling face 249 , and is disposed near the intersection of the first coupling face 249 and the hub 266 .
As shown in FIGS. 12 and 13, the elliptical surface 256 has a maximum surface dimension 280 and a minimum surface dimension 282 . The maximum surface dimension 280 represents the distance across the elliptical surface 256 at its widest point, and the minimum surface dimension 282 represents the distance across the elliptical surface 256 at its narrowest point. The maximum surface dimension 280 is shown as smaller than the diameter of the first coupling surface 249 . The minimum surface dimension 282 is shown as larger than the diameter of the hub 266 at the intersection of the hub 266 and the elliptical surface 256 .
As shown in FIG. 14, an elliptical bore 268 is formed in a second coupling face 264 , and extends axially inward from the second coupling face 164 terminating at a shoulder 271 . A side wall 270 runs around the perimeter of the elliptical bore 268 , and extends from the second coupling face 264 to the shoulder 271 . The shoulder 271 intersects with the tapered wall of the cylindrical bore 252 .
As shown in FIGS. 12 and 14, the elliptical bore 268 has a maximum bore dimension 284 and a minimum bore dimension 286 . The maximum bore dimension 284 represents the distance across the elliptical bore 268 at its longest point, and the minimum bore dimension 286 represents the distance across the elliptical bore 268 at its shortest point. The maximum bore dimension 284 is smaller than the diameter of the second coupling surface 264 . The minimum bore dimension 286 is larger than the diameter of the tapered cylindrical bore 252 at the intersection of the bore 252 and the shoulder 271 .
As shown in FIGS. 11 and 12, when the impeller stem 242 and pinion shaft 244 are assembled together, the elliptical surface 256 and the elliptical bore 268 mate with one another to transmit torque between the pinion shaft 244 and impeller stem 242 . The elliptical surface 256 fits within the elliptical bore 268 , and the side wall 270 is aligned with the driving surface 259 . As the pinion shaft 244 rotates about a pinion axis 262 , the side wall 270 contacts the driving surface 259 and rotates the impeller stem 242 about a impeller axis 245 .
The elliptical surface 256 , as illustrated in FIGS. 12-14, is shown as symmetrical about both the maximum surface dimension 280 and the minimum surface dimension 282 , and centered on the impeller axis 245 . Similarly, the elliptical bore 268 is shown as symmetrical about the maximum bore dimension 284 and the minimum bore dimension 286 , and centered about the pinion axis 262 . With this symmetrical arrangement of the mating elliptical surface 256 and elliptical bore 268 , the impeller stem 242 and pinion shaft 244 may have two possible mating positions, and each mating position being a 180 degree rotation from the other mating position.
Alternatively, the elliptical surface 256 and elliptical bore 268 may be non-symmetrical as long as they are still mating. With the non-symmetrical arrangement, the impeller stem 242 and pinion shaft 244 only have one mating position, and will always align at the substantially same orientation to one another.
The elements of this alternate embodiment could also be reversed similar to the alternative arrangements of the previously described embodiments. The elliptical surface 256 or the hub 266 could project outward from the second coupling face 264 , and the elliptical bore or the cylindrical bore 252 could extend inward from the first coupling face 249 . The elliptical surface 256 and elliptical bore 252 design could be reversed and the assembly coupling 246 would still transmit torque between the pinion shaft 244 and impeller stem 242 .
While we have illustrated and described preferred embodiments of the invention, it is understood that this is capable of modification, and we therefore do not wish to be limited to the precise details set forth, but desire to avail ourselves of such changes and alterations as fall within the purview of the following claims. | A compressor rotor assembly including an impeller including an impeller stem, the stem including a first coupling end having a first face and at least one arcuate coupling tab along the first face; the impeller stem further comprising a bore that extends inwardly from the first face, the bore having an interior wall that is tapered. The rotor assembly further comprising a pinion shaft having a second coupling end with a second face and at least one arcuate coupling slot along the second face; and a hub extending outwardly from the second face, the hub including a tapered outer wall; the first and second coupling means and the hub and bore are adapted to be mated when the impeller and pinion shaft are assembled to prevent relative displacement of the stem and shaft. | 5 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a process for producing a ceramic layer containing Bi as a component, from at least two precursors, on a substrate, in particular a ceramic layer having ferroelectric, paraelectric or superconducting properties.
In semiconductor technology, increasing interest is being shown in the use of ceramic thin films. That group of substances includes compounds having superconducting, ferroelectric or dielectric properties with a high dielectric constant. The latter two groups of compounds are, in particular, advantageous for use as a storage dielectric in capacitors of an integrated circuit. The ceramic substances are oxides which have at least two components, besides oxygen. Examples of the components include Ba, Sr, Bi, Pb, Zr, La, Ti and Ta.
One example of a semiconductor circuit having a capacitor is a DRAM storage cell. In order to increase the integration density, the cell may be produced in the form of a so-called stacked capacitor cell, in which the storage capacitor is disposed above the associated selection transistor. Among other things, the choice of the capacitor dielectric has an essential effect on the space required for a capacitor of that type.
Conventional capacitors mostly use layers of silicon oxide or nitride, which have a dielectric constant of at most 8, as the storage dielectric. The paraelectric materials in that group of substances, for example BST (barium strontium titanate, (BaSr)TiO 3 ) and the like have a dielectric constant ε>150 and therefore allow a smaller capacitor to be used for an equal capacitance.
Storage elements of that type, having a paraelectric material as the capacitor dielectric (DRAMs) lose their charge, and therefore their stored information, when the supply voltage is interrupted. Furthermore, because of the residual leakage current, conventional storage elements need to be continually refreshed (refresh time). Due to the different polarization directions, the use of a ferroelectric material as a storage dielectric permits the construction of a non-volatile memory, which does not lose its information when the supply voltage is interrupted and does not need to be refreshed constantly. The residual leakage current of the cell does not affect the stored signal. Examples of a ferroelectric material of that type from that group of substances include PZT (lead zirconium titanate, Pb(Zr,Ti)O 3 ) and SBT (strontium bismuth tantalate, SrBi 2 Ta 2 O 9 ).
Since the production of those new ferroelectrics and paraelectrics generally takes place at high temperatures in an oxidizing atmosphere, a material compatible with those conditions is needed, in particular, for the first capacitor electrode. Pt, Ru, RuO 2 or a similar material is conventionally used.
There are three essential methods known for the production of ceramic thin films: a sputtering process, a CVD process and a so-called sol-gel process. In the sol-gel process, metallorganic starting chemicals are generally dissolved in a nonpolar aromatic solvent (for example in xylene), then the solution is applied to the wafer and spun (spin-on process). The thin film of metallorganic molecules which is obtained in that way is subsequently converted into an oxide film in the presence of oxygen. That oxide film is transformed into the phase with the desired electrical properties during a subsequent heat treatment, which in the case of SBT is typically carried out in a temperature range of from 700 to 800° C. In the case of an SBT layer, a lamellar perovskite phase with ferroelectric properties is formed, while BST or PZT involve a simple perovskite (heat treatment at 450-650° C.).
An example of a sol-gel process of that type is described in International Publication No. WO 93/12538. In that production process, the use of the usual solvents, in particular the nonpolar aromatic solvents, causes problems because of the toxicity and potential carcinogenic nature of the vapors.
A production process for SBT is also described in an article entitled "Formation of SrBi 2 Ta 2 O 9 : Part I. Synthesis and Characterization of a Novel "Sol-Gel" Solution for Production of Ferroelectric SrBi 2 Ta 2 O 9 Thin Films", by T. Boyle et al., in Journal of Material Research, Vol. 11, No. 9, September 1996, pages 2274 to 2281. In that case, the precursor containing Ta and the precursor containing Sr are dissolved in acetic acid. The article states that the precursor containing Bi is insoluble in acetic acid, and must therefore be dissolved in pyridine. A disadvantage with that process is the outlay due to the unavoidable use of two different starting solutions, which are mixed immediately before the wafer is coated. There is also the problem of aging of the starting solution containing the acetic acid. In that solution, the precursor containing Ta (tantalum ethoxide) reacts with the acetic acid to form ethyl acetate and water. The water hydrolyzes the precursor containing Ta, with the result that tantalum oxide clusters with high molecular weight are formed. Over the course of time, a colloidal and later suspended Ta 2 O 5 is produced, which can be detected by a change in viscosity after about 1 week and turbidity after about 2 weeks. It is consequently not possible to store the precursor containing Ta in acetic acid for long periods of time.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a simple process for producing a ceramic layer that contains Bi as a component, on a substrate, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known methods of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, a process for producing a ceramic layer containing Bi as a component, from at least two precursors on a substrate, which comprises using only an organic acid C n H 2n+1 COOH, where n=0, 1 or 2 and, where appropriate, water, as a solvent for the precursor containing Bi; dissolving a further precursor in a further solvent and/or providing a further precursor in a liquid state; then applying the dissolved and, where appropriate, liquid precursor to the substrate; and then producing the layer by heating.
According to the invention, an organic acid C n H 2n+1 COOH, wherein n=0, 1 or 2, that is to say methanoic acid, acetic acid or propionic acid, is used as a solvent for the precursor containing Bi. It has surprisingly been found that, in contradiction to the article by Boyle et al., the customary precursors, in particular including precursors containing Bi, are soluble in these acids. When the precursors were combined and, for example, added to acetic acid, good solubility was observed. This may be attributed to cooperative effects of the individual precursors, for example through altering the polarity of the acetic acid by one precursor or by interactions of the precursors with one another. The solubility can be improved further by the addition of water. The dissolved precursors are then applied to the substrate in a spin-on process, the film is dried and annealed at high temperatures, typically >250° C.
According to a further refinement of the invention, the problem of the lack of long-term stability can also be solved. In the aforementioned example of SBT, the precursor containing Bi and the precursor containing Sr are dissolved in acetic acid, for example. This solution L1 is stable, and none of the precursors react chemically with the acetic acid. Further increased long-term stability can be achieved by the addition of water (L2). The precursor containing Ta can then be added to it in two different ways:
(a) The existing solution L1 or L2 is heated to a temperature which lies above the melting point of the precursor containing Ta. Immediately before the coating, the described solution and the liquid precursor containing Ta are mixed. It is necessary to heat the whole system to a temperature above the melting temperature described. The solution and the liquid precursor containing Ta are intimately mixed directly, with it being necessary in the case of a solution containing water (L2) for the mixing to be carried out quickly in order to reduce the concentration of the precursor containing Ta quickly and thus prevent rapid coagulation of the hydrolysis product. The mixture obtained is applied to the substrate using the spin-on process.
(b) It is also possible to dissolve the precursor containing Ta in a different solvent, and then to mix this mixture with L1 or L2 in the mixer. When L2 is used, the mixing should be carried out quickly, as described under (a). The advantage of this variant is that local excess concentrations of the precursor containing Ta during the mixing are avoided, and the risk of hydrolysis is thus reduced. Furthermore, heating is not necessary. Suitable solvents are substances which do not react with the precursor to form water. One example is tetrahydrofuran (THF), which only has a small potential health risk.
A fundamental advantage of the present invention is the use of the non-toxic acid as a solvent for the precursor containing Bi and, where appropriate, other precursors. This entails fewer protective measures and makes waste disposal more straightforward. A further advantage of the acids is that, because of their polarity, not only are they capable of dissolving the heretofore used metallorganic chemicals, but they are also capable of dissolving other compounds of less complex structure. A broad spectrum of starting chemicals is therefore available. The heretofore used metallorganic chemicals also have the disadvantages that, on one hand, they are not always readily available on the market and, on the other hand, they can often only be obtained with a low degree of purity. Those advantages also lead to a reduction in cost.
Suitable precursors in many cases are the acetates or oxides of the metals, but it is also possible for the metals, in particular Sr, to be dissolved directly in the acid. The compounds Ta(OEt) 4 (acac), Ta(OEt) 5 or Ta(OMe) 5 may be used as the precursor containing Ta.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a process for producing a ceramic layer containing Bi, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are flow charts for a process according to the invention; and
FIG. 3 is a cross-sectional view of a FRAM storage cell, as an example of an integrated semiconductor structure having a layer produced according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a first illustrative embodiment, in which the following precursors are used for the production of SBT:
Ta(OEt) 4 (acac) as Ta precursor, Bi(OAc) 3 as Bi precursor and Sr(cybu) 2 (H 2 O) 2 as Sr precursor (where OEt=ethoxide, acac=acetyl acetonate, OAc=acetate, cybu=cyclohexyl butyrate).
3.012 g of the Ta precursor, 2.552 g of the Bi precursor and 1.451 g of the Sr precursor are dissolved in 13.880 g of acetic acid while heating. After cooling, the solution is filtered through a 0.2 μm filter and further solutions can be obtained from the stock solution obtained in this way by diluting with acetic acid. The solution is applied to the substrate and spun at about 2500 rpm for 1 min. The layer is then dried by heating it to 100° C. within 30 min. The pyrolysis is carried out at about 460° C. in air, for example in a blast furnace, and typically lasts 8 hours. The temperature is preferably stepped up at 60° C./h in order to avoid evaporation of the Bi precursor. A variety of SBT layer thicknesses are obtained depending on the degree to which the stock solution is diluted. The undiluted stock solution gives a layer thickness of about 200 nm, on a substrate formed of platinum. The reduction in the achieved layer thickness due to dilution of the stock solution with acetic acid is represented in the following table (substrate=Pt).
______________________________________ Amount of Amount of Layer stock acetic acid thickness Solution solution [g] added [g] [nm, ±5 nm]______________________________________1 Stock -- 200 solution 2 0.582 0.014 195 3 0.587 0.027 190 4 0.578 0.040 185 5 0.582 0.050 180 6 0.584 0.056 175 7 0.577 0.070 170 8 0.583 0.082 160 9 0.579 0.106 155 10 0.582 0.122 150 11 0.575 0.132 145 12 0.581 0.155 140 13 0.581 0.164 135 14 0.587 0.184 130 15 0.582 0.203 125 16 0.586 0.221 120 17 0.578 0.245 115 18 0.575 0.282 110 19 0.581 0.294 105 20 0.580 0.333 100 21 0.578 0.359 100 22 0.583 0.378 95 23 0.585 0.416 90 24 0.577 0.449 90 25 0.577 0.491 85 26 0.582 0.536 85______________________________________
If SiO 2 is used as the substrate, then thick solutions give rise to greater layer thicknesses, for example a thickness of 220 nm in the case of the stock solution. No increase in the layer thickness is observed with thin solutions.
A greater layer thickness can be achieved with the following stock solution: 2.768 g of the Ta precursor, 2.345 g of the Bi precursor, 1.334 g of the Sr precursor and 10.629 g of acetic acid. A layer thickness of 280 nm is achieved on a Pt substrate with this stock solution. In this case as well, the layer thickness can be reduced by diluting the stock solution with acetic acid. For example, a layer thickness of 245 nm is achieved with a mixture made up of 0.7 g of stock solution and 0.038 g of acetic acid.
Larger layer thicknesses may also be achieved by repeated spin application and drying.
The process described above can be used to produce an SBT layer having ferroelectric properties. A problem arises, however, with regard to aging of the solution, to be precise a change in the viscosity after about 1 week and turbidity after about 2 weeks, which may be attributed to hydrolysis of the precursor containing Ta, as described above. The problem of aging can be avoided without the need to use hazardous solvents or precursors with a complex structure, with the second embodiment of the invention described below. The second embodiment is likewise explained with reference to the example of producing an SBT film.
FIG. 2 shows a process flow chart of the second illustrative embodiment:
2.552 g of Bi(OAc) 3 and 1.451 g of Sr(OAc) 2 are dissolved in 13.880 g of acetic acid, preferably while heating. After the precursors have been dissolved, the solution may be diluted with further acetic acid. For example, 41.64 g of acetic acid may be added. A solution L1 which is obtained in this way is stable. In order to increase the long-term stability further, water may also be added to this solution, for example a 2 g quantity of water may be added to obtain a solution L2. The precursor containing Ta may be added to it either in the liquid state in a variant (a) or in the dissolved state in a variant (b), as follows:
(a) Ta(OEt) 5 is preferably used as the precursor containing Ta, since this is a simple compound having a relatively low melting point (about 30° C.). The solution and the Ta precursor are stored separately. They are mixed together immediately before the coating, with the precursor containing Ta being used in the liquid state. During the mixing process, the Ta precursor is intimately mixed, directly as a liquid, together with the solution L1 or L2, for example in a nozzle of a mixer. If necessary, the mixer should be heated so that the Ta precursor is kept liquid. The mixture is produced from the aforementioned amounts of the solution L1 or L2 and 2.66 g of precursor containing Ta. The mixture is then applied to the substrate in a spin-on process.
(b) Ta(OEt) 5 is again used as the precursor containing Ta, and is dissolved in a solvent, for example in tetrahydrofuran (THF). 2.66 g of Ta(OEt) 5 are dissolved in 5 g (about 6 ml) of THF.
If the mixture is produced from the solution L2 containing water and the Ta precursor according to variant (a) or the Ta precursor solution according to variant (b), it is important that the mixing take place quickly, in order to reduce the concentration of the precursor containing Ta rapidly, and thus to prevent coagulation of the hydrolysis product. This is especially true of variant (a), since in the case of variant (b) the precursor is already diluted. The time which elapses before the components have been intimately mixed together, especially in the case of variant (a), is preferably less than one second.
After application to the substrate and spinning, the layer is firstly dried, for example for 5 min at 150° in air. It is then heated for about 10 min to 290° in a normal atmosphere (prebake) and then annealed for 10 min at about 750° in air. It is, however, also possible for a one-stage annealing step to be used. In this way, an about 40 nm thick SBT layer is obtained. In order to produce larger layer thicknesses, the described procedure may be repeated. Once the desired layer thickness has been obtained, a final heat treatment step may then be carried out (for example 800° C./1 h/O 2 ).
The process according to the invention may also be carried out with propionic acid and propionates instead of acetic acid and acetates. In order to produce an SBT layer, Bi propionate and Sr propionate are used, and propionic acid (C 2 H 5 COOH) is used as the solvent. Methanoic acid and its salts may further be used.
It is further possible to produce other ceramic layers by using the process according to the invention. Acetic acid is preferably used as the solvent for the precursor containing Bi and, where appropriate, further precursors, but methanoic acid or propionic acid, respectively diluted with water if appropriate, may also be used. The suitable precursors can be determined by simple experiments, and in particular the group of substances including acetates or propionates, ethoxides, acetyl acetonates, simple organic salts of the required metals, their oxides or the metals themselves (for example the dilution of Sr metal in acetic acid) may be considered. The essential criteria for the selection are the properties of the respective compound which are known to the person skilled in the art, the availability on the market, the obtainable purity and safety. The quantity ratios between the precursors and the solvents can likewise be determined by simple experiments according to the thickness achieved and the structure of the layer.
The process can, in particular, be used during the production of a capacitor in an integrated circuit, for example in a DRAM or FRAM memory. An example of a memory of this type is represented in FIG. 3. An MOS transistor having doped regions 2, 4 and a gate 3 is produced in an Si semiconductor substrate 1 and is separated by an insulation region 5 from a transistor of a neighboring storage cell. The configuration is covered with an insulation layer 6. The doped region 2 is connected through a connection structure 7, for example made of W or polySi, and through the insulation layer 6, to a first electrode 8 of a storage capacitor. A barrier layer 9 for preventing O 2 diffusion (for example TiN) may be disposed below or on the first electrode. The structure which is produced so far then forms the substrate to which a ceramic layer 10 containing Bi, in particular a ferroelectric SBT layer, is applied as a storage dielectric using the process according to the invention. The storage cell is completed by a second electrode 11. | A process for producing a ceramic layer containing Bi, in particular having ferroelectric, dielectric or superconducting properties, includes using only an organic acid C n H 2n+1 COOH wherein n=0, 1 or 2 and, where appropriate, water, as a solvent for the precursor containing Bi. | 2 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an elevator consisting of an elevator cage movable in an elevator shaft, and a counterweight. The elevator cage and the counterweight are connected by means of a support and drive means guided over deflecting rollers. A drive drives the elevator cage and the counterweight.
[0002] An elevator installation is known from European reference EP 01811132.8, in which an elevator cage and a counterweight are movable in an elevator shaft along guide rails. The elevator cage and the counterweight are connected by means of a belt, wherein a 2:1 belt guide with underlooping of the elevator cage is provided. The belt ends are each arranged at an upper end of a guide rail. The belt is guided by way of two deflecting rollers arranged underneath the elevator cage and supports the elevator cage, by way of a drive roller of a drive arranged at the upper end of a guide rail and by way of a deflecting roller supports the counterweight. The guide rails supporting the elevator cage, the counterweight and the drive introduce the vertical forces into the shaft pit.
[0003] A disadvantage of the known equipment resides in the fact that the deflecting rollers arranged outside the elevator cage or the counterweight oblige a larger shaft height, a larger shaft width and a deeper shaft pit.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an object of the present invention to provide an elevator installation that avoids the disadvantages of the known equipment and is constructed to be smaller.
[0005] Pursuant to this object, and others which will become apparent hereafter, one aspect of the present invention resides in an elevator having an elevator shaft, an elevator cage movable in the elevator shaft, and having a floor and a roof, and a counterweight. A support and drive means is arranged to connect the elevator cage with the counterweight. Deflecting rollers are integrated in either the floor or the roof of the elevator cage between two plates. A support and drive means is guided over the deflecting rollers and is driven by a drive so as to drive the cage and the counterweight.
[0006] In another embodiment of the invention, the deflecting rollers are integrated in the floor and the support and drive means is guided in a channel in the floor.
[0007] In still another embodiment of the invention, the deflecting rollers are integrated in the roof and the support and drive means is guided in a channel in the roof.
[0008] In still a further embodiment of the invention, elements are provided for supporting the deflecting rollers. The support elements are connected with either the cage floor or the cage roof. The floor or roof to which the elements are connected is of a sandwich construction.
[0009] In another embodiment of the invention, additional deflecting rollers are integrated into the counterweight. The counterweight has a cut out for receiving the additional deflecting rollers.
[0010] The counterweight is provided with an offset in a further embodiment of the invention, which off set is configured so that the counterweight can move past the drive.
[0011] The advantages achieved by the invention are essentially to be seen in that the elevator cage as well as the counterweight can be constructed to be more compact. By integration of the deflecting rollers in the elevator cage or in the counterweight, the shaft height, shaft width and pit depth can be dimensioned to be smaller. The cogged belt employed as support and drive means allows small bending radii and thus small diameters for the deflecting rollers and the drive wheels. Moreover, the cogged belt is disposed in mechanically positive connection with the drive wheels of the mechanical linear drive and with the deflecting rollers provided with a brake. A mechanically positive connection of the drive and support means with the drive wheels or with the brake rollers enables a lightweight mode of construction of the elevator cage. In particular, the cage floor or the cage roof with the integrated deflecting rollers can be realized by a stiff sandwich mode of construction capable of bearing loads. By comparison with a conventional cage floor with deflecting rollers (bottom blocks) arranged underneath, the cage floor of the present invention is constructed to be very small in height, which has a direct effect on the shaft pit depth. The height gained by the cage floor can be saved in the shaft pit depth. Moreover, the belt can be guided near the cage wall, which in turn has a favorable effect on shaft width. By comparison with a conventional cage roof with deflecting rollers (top blocks) arranged at the top the cage roof of the present invention can be constructed to be very small in height, which has a direct effect on the shaft head height. The height gained by the cage roof can be saved in the shaft head height.
[0012] For a more complete understanding of the elevator of the present invention, reference is made to the following detailed description and accompanying drawings in which the presently preferred embodiments of the invention are illustrated by way of example. That the invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention. Throughout the following description and drawings, identical reference numbers refer to the same component throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 shows an elevator with deflecting rollers integrated in the floor of the elevator cage;
[0014] [0014]FIG. 1 a shows a cage floor without a centrally arranged profile roller;
[0015] [0015]FIGS. 2, 3 and 4 show different arrangements of the deflecting rollers in the cage floor;
[0016] [0016]FIGS. 5 and 6 show a deflecting roller arranged at the guide center of the elevator cage;
[0017] [0017]FIGS. 7 and 8 show a deflecting roller arranged outside the guide center of the elevator cage;
[0018] [0018]FIGS. 9 and 10 show a counterweight with integrated deflecting rollers; and
[0019] [0019]FIG. 11 shows an elevator with deflecting rollers integrated in the roof of the elevator cage.
DETAILED DESCRIPTION OF THE INVENTION
[0020] An elevator, which consists of an elevator cage 3 movable in an elevator shaft 2 and a counterweight 4 and which is denoted by 1 , is illustrated in FIG. 1. The elevator cage 3 is guided by means of a first guide rail 5 and by means of a second guide rail 6 . The counterweight 4 is guided by means of a third guide rail 7 and by means of a fourth guide rail, which is not illustrated. The guide rails are supported in a shaft pit 8 , wherein the vertical forces are conducted into the shaft pit 8 . The guide rails 5 , 6 and 7 are connected with the shaft wall by brackets, which are not illustrated. Buffers 9 , on which buffer plates 10 of the elevator cage 3 or the counterweight 4 can be placed, are arranged in the shaft pit 8 .
[0021] A belt 11 , for example a cogged belt, with a 2:1 belt guidance is provided as support and drive means. When a mechanical linear drive 12 , which is arranged at the second guide rail 6 , for example in the shaft head 2 . 1 , advances the belt 11 by means of a drive wheel 13 through one unit, the elevator cage 3 or the counterweight 4 moves through a half unit. One end of the belt 11 is arranged at a first cable fixing point 14 and the second end of the belt 11 is arranged at a second cable fixing point 15 . The belt 11 is guided over a first deflecting roller 16 , over a profiled roller 17 , over a second deflecting roller 18 , over a third deflecting roller 19 , over the drive wheel 13 and over a fourth deflecting roller 20 . The first deflecting roller 16 , the second deflecting roller 18 and the profiled roller 17 are integrated in the floor 21 of the elevator cage 3 , wherein the belt runs in a floor channel 21 . 1 . As in the embodiment of FIG. 1 a , the profiled roller 17 can be omitted. The profiled roller 17 has a toothing corresponding with the toothing of the belt 11 . The first deflecting roller 16 and the second deflecting roller 18 guide the belt 11 on the untoothed side by means of flanges arranged at the end faces of the rollers. The third deflecting roller 19 arranged at the second guide rail 6 is disposed by its toothing in engagement with the toothed side of the belt 11 and comprises a brake for normal operation. The drive wheel 13 is disposed by its toothing in engagement with the toothed side of the belt 11 . Diverting rollers 22 of the linear drive 12 increase the angle of looping of the belt 11 at the drive wheel 13 . The motor or motors for the drive wheel 13 is or are not illustrated. The fourth deflecting roller 20 is arranged in the counterweight and is comparable in construction with the first deflecting roller 16 or with the second deflecting roller 18 .
[0022] [0022]FIG. 2, FIG. 3 and FIG. 4 show different arrangements of the deflecting rollers 16 , 18 in the cage floor 21 in the region of the guide center 23 of the elevator cage 3 . FIG. 2 shows the deflecting rollers 16 , 18 , which are arranged behind the guide rails 5 , 6 , with a first roller R 1 and a second roller R 2 , wherein each roller is provided with a belt 11 . The rollers R 1 , R 2 are independent of one another and are free-running. The belts 11 run behind the guide shoe. Details with respect to these variants are illustrated in FIG. 5 and FIG. 6.
[0023] [0023]FIG. 3 shows rollers R 1 , R 2 disposed outside the guide rails 5 , 6 . The belts 11 run behind the guide shoe. The roller spacing determines the belt spacing and thus the spacing of the drive wheels 13 and the length of the mechanical linear drive 12 .
[0024] [0024]FIG. 4 shows doubly executed deflecting rollers 16 , 18 , which are comparable in construction with FIG. 2, with rollers R 1 , R 2 disposed outside the guide rails 5 , 6 . This arrangement for four belts 11 is provided for larger support forces.
[0025] [0025]FIG. 5 and FIG. 6 show the detail A of FIG. 1 a with a first deflecting roller 16 arranged at the guide center 23 of the elevator cage 3 . FIGS. 5 and 6 are also applicable in the same sense for the second deflecting roller 18 . The section of the cage floor 21 is taken through the guide center 23 . The cage floor 21 constructed in sandwich mode of construction consists of a roof plate 24 and of a floor plate 25 , between which a foam filling 26 is arranged, wherein the floor channel 21 . 1 for the belt 11 is cut out. The roof plate 24 supports a floor covering 27 and, in the edge regions, a base profile member 28 on which wall elements 29 can be placed. In the corners of the cage floor 21 the base profile 28 is connected by means of rods, which are not illustrated, with the cage roof, which is not illustrated. The rollers R 1 , R 2 are arranged to be free running on an axle 30 , wherein the axle 30 is mounted in a base 31 . The base 31 is connected with the floor plate 25 and the roof plate 24 , and consists of a support element 31 . 1 , an insulating element 31 . 2 and a top element 31 . 3 . A safety brake device 3 . 1 , which stops the elevator cage 3 in the case of emergency, is arranged underneath the deflecting roller 16 . As shown in FIG. 6, the deflecting roller 16 is arranged below a bracket supporting a guide shoe 32 , wherein there is still place for the belts 11 between the bracket 33 and the rollers R 1 , R 2 .
[0026] [0026]FIG. 7 and FIG. 8 show the detail A of FIG. 1 a with first deflecting rollers 16 , which are arranged outside the guide center 23 of the elevator cage 3 , according to FIG. 4. FIGS. 7 and 8 are applicable in the same sense for the second deflecting rollers 18 . The construction and arrangement in the cage floor 21 of the deflecting roller 16 is comparable with the embodiments according to FIGS. 5 and 6.
[0027] [0027]FIG. 9 and FIG. 10 show a counterweight 4 with integrated deflecting rollers 20 . In the upper region the counterweight 4 has an offset 4 . 1 , wherein the offset 4 . 1 is so dimensioned that the counterweight 4 can move past the mechanical linear drive 12 . Moreover, a cut-out 4 . 2 , in which the deflecting rollers 20 are integrated, is arranged at the counterweight 4 . With the offset 4 . 1 in the counterweight 4 and the deflecting rollers 20 integrated in the cut-out 4 . 2 the shaft height or the shaft head height can be fully utilized.
[0028] [0028]FIG. 11 shows an elevator with deflecting rollers 16 , 18 integrated in the roof 40 of the elevator cage 3 . The mechanical linear drive 12 and the counterweight 4 are constructed according to FIGS. 9 and 10. The roof 40 of the elevator cage 3 has a roof channel 40 . 1 in which the belt 11 , which serves as support and drive means, is guided. The arrangement of the deflecting rollers 16 , 18 is in the same sense as FIGS. 1 a to 8 .
[0029] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | An elevator having deflecting rollers integrated in the cage floor or in the counterweight. The support and drive element is guided in the cage floor through a floor channel. By comparison with a conventional cage floor with deflecting rollers (bottom blocks) arranged underneath the cage floor, the cage floor is constructed to be very small in height overall, which has a direct effect on the shaft pit depth. The height gained by the cage floor can be saved in the shaft pit depth. | 1 |
SUMMARY OF THE INVENTION
The invention relates to a friction element for a false twisting apparatus for the texturizing of yarns, whereby bushings, rings, disks, rods, belts and the like are provided for providing the twist, as friction elements.
False twisting devices are known where yarns of top quality are produced according to the false twisting method by means of slowly moving spindles and hooks and, further, with the aid of high speed spindles and thread guides, for example in the form of diabolos. Bushings, rings, disks, bars, belts and the like are used as friction elements, for example, which are driven with the aid of spindles, whereby in order to be twisted, the yarn adheres at the appropriate surfaces of the friction elements. The important disadvantage of these friction members according to prior art consists in providing an insufficient twist, so that turned spots occur due to slippage, the removal speeds and the number of twists per meter of the turns are limited and irregular.
An increase of the friction by rougher surfaces has failed in the elastic vulcollane and plastic materials used until now due to the high rate of wear of the material, producing yarns whose properties change during the lifetime of the friction members and thus cannot be mixed with each other during the processing. This, among other reasons, because the dye affinity of fabrics woven from such yarns varies. Experiments with such friction members, whereby they were replaced by hard materials, showed that here a technical limit is set when the friction between yarn and friction member is maintained so low, sufficient twisting is no longer imparted. If these materials were to be replaced by a rougher surface, broken filaments very easily are caused thereby leading to slubby yarn.
The invention is based on the problem of so designing such friction elements that the advantage of harder materials and thus a high service life can be used without having to accept the disadvantage of less friction or increased slub formation.
According to the invention this problem is solved in that in an element or member consisting of a hard material, for example oxide ceramic, saphire, glass, agate, spinell, carbides or the like, the surface in contact with the yarn has longitudinal grooves of high smoothness which extend parallel with the axis of rotation.
The longitudinal grooves advantageously have a cross section approximately semicircular in shape.
Another advantageous embodiment is characterized by the fact that in a member consisting of elastic rubber or synthetic masses or polyurethane formed bodies or small spherelets with a smooth surface of hard materials with high resistance to abrasion are embedded into the surface in contact with the yarn.
It is further advantageous for the formed bodies to be arranged in tiers parallel to the axis of rotation and/or radially.
The advantages reside particularly in the fact that the friction elements produced according to the invention have a long life and that the design and arrangement of the longitudinal grooves and/or of the molded bodies may be such that in function of the type of yarn and the properties of the yarn, the entrainment coefficient is adjustable in axial and tangential direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained more in detail in the following description by means of embodiments represented in the drawings.
FIG. 1 is a longitudinal section through a bushinglike friction element;
FIG. 2 is a cross section along line A--A of FIG. 1;
FIG. 3 is a friction element of disklike shape;
FIG. 4 is an end view of FIG. 3;
FIG. 5 is a cross section of another embodiment of a bushinglike friction member;
FIG. 6 is an end view of FIG. 5; and
FIG. 7 is a cross section of a further embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the embodiment according to FIGS. 1 and 2, a bushing 1 is contemplated as a friction element having on the inside a perforation 3 flaring toward the collar 2, whereby said perforation 3 represents the surface in contact with the yarn. Longitudinal grooves 4 are arranged in this surface which extend parallel with the axis of rotation. These longitudinal grooves are designed semicircularly, for example, and arched toward the axis of rotation. Thus, the surface is so designed that a low friction coefficient is present in an axial direction, while in a direction tangential to the rotary movement, a high friction coefficient exists. The radius of these longitudinal grooves 4 may be 8 microns, for example.
In the additional embodiment in FIGS. 3 and 4, a disk 5' is used as friction member with corresponding grooves 4' applied externally at the rounded disk body.
Here, too, these grooves 4' may be semicircular in design and terminate into each other, whereby, for example, a radius of about 8 microns may be provided. In this case the grooves 4' are arched externally, that is away from the axis of rotation. In both cases (FIGS. 1 to 4) the circular arches of the grooves 4' may be rounded at their points of intersection, that is they may altogether have a sine form.
In the embodiment according to FIGS. 1 to 4, the friction member is made of hard materials, for example agate, glass, ceramic, spinell, saphire, oxide ceramic, carbides or surface-coated materials, like steel with aluminum oxide coating, for example.
In order to utilize the advantages of an elastic polyurethane or of elastic rubber and plastic masses, it is possible, according to another embodiment shown in FIGS. 5 and 6, to embed into the surface 3" in contact with the yarn molded bodies 6" of hard materials according to the substances mentioned above, whereby these bodies are distributed linearly, that is in lines distributed parallel to the axis of rotation of the friction elements 1" and then they extend radially. For example, balls may be embedded as such bodies 6" with a diameter of 0.2 mm. The arrangement of these spherelets 6" also may be such that varying entrainment coefficients are produced in axial and tangential direction, that is to say a static distribution takes place.
In a dislike friction member 5" according to FIG. 7 the bodies 6' are arranged externally at the circumference in tiers or randomly distributed.
While a preferred form and several variations have been set forth above, it should be understood that suitable additional modifications, changes, alterations and substitutions may be made without departing from the invention's fundamental theme. | This is concerned with a friction element for a false twisting apparatus for yarns, whereby a friction element consisting of a hard material has a longitudinal groovelike composition on the surface thereof extending parallel with the axis of rotation of the element. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Italian Patent Application No. TO2005A000788, filed Nov. 9, 2005, the disclosure of which is incorporated by reference in its entirety.
[0002] This application contains subject matter which is related to the subject matter of co-owned U.S. patent application Ser. No. 11/553,553, filed Oct. 27, 2006, by Veronica Bolari, entitled “SOFTENING COMPOSITION” (Attorney Docket No. 2177.077 (BUS8317-CF/sr), which is assigned to the same assignee as this application, and which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0003] The present invention concerns a method for treating textiles in the bolt and made-up articles of clothing.
[0004] The method object of the present invention lies within the sphere of finishing procedures for a textile or for a made-up article of clothing, where by the term finishing is meant the operations of dressing the textile or garment to be performed as the last phase of a washing or dyeing process.
[0005] Finishing procedures include the operations of dressing textiles or articles of clothing, among which may be mentioned as examples teasing, cropping, calandering, steaming and delustering. The purpose of finishing procedures is to give the textile or article of clothing characteristics that improve their appearance, presentation and drape, and make them more suitable for the purposes for which they are destined. Again part of the phase of finishing procedures are treatments of high-grade nobilitation capable of improving the characteristics of use and upkeep of the textiles and of garments made with chemical fibres in general and cellulose fibres in particular.
[0006] Procedures that tend to give textiles a particular feel or hand and, in consequence, that add greater comfort for the end-user who wears the garment, thus belong to this latter category of treatments.
[0007] Treatments of this type have been described in numerous patent and other documents. As an example, documents EP-A-0 436 729 and EP-A-1 152 080 may be cited; these documents describe procedures and compositions to apply to textiles to improve the physiological condition of the skin or simply the ease and comfort of wearing articles of clothing made up from these textiles. In particular, patent document EP-A-1 152 080 provides for the application to textiles of a functional film, resistant to water, containing micro-capsules based on polymers or rubbers and aloe vera. Such micro-capsules release their content of aloe vera as a result of the mechanical destruction of their outer wall.
[0008] The use of micro-capsules containing aloe vera nevertheless presents some drawbacks; the first is that of releasing a very large quantity of aloe vera onto the skin of whoever wears the article of clothing, the second is that, instead of the fabric, for example, cotton or linen, being next to the skin, there is a film resistant to water, and thus substantially impermeable and not appropriate for the correct transpiration of the skin such as to enable whoever wears the fabric or garment to transpire.
[0009] Object of the invention is providing a finishing or high-grade nobilitation procedure that does not present the drawbacks of the known technology.
SUMMARY OF THE INVENTION
[0010] According to the present invention, this object is achieved thanks to the solution described in detail in the attached claims. The claims form an integral part of the technical instruction provided here in regard to the invention.
[0011] In an embodiment at present preferred the invention concerns a procedure for treating a textile or an article of clothing to be performed at the end of the washing or dyeing process, where such treatment provides for the application of a water bath containing aloe vera.
[0012] Application of aloe vera, and thus its penetration into the fibres of the textile or article of clothing, gives to the treated product a particular hand, softness and slipperiness that improves its characteristics of use. More specifically, once it is worn the fabric releases a part of the absorbed aloe with a consequent sensation of well-being on the skin of whoever wears the garment, such as, for example, a sensation of a smooth and velvety skin.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The invention will now be described in detail, as a simple example without limiting intent.
[0014] The finishing treatment with aloe vera is a procedure that is preferably performed as the last phase of the washing or dyeing process.
[0015] More specifically, the aloe vera is applied in a water bath with a “bath ratio”, understood as the ratio between the quantity of liquid used in the treatment and the quantity of textile treated, of 1:10. The application of this water bath may for example take place in a washing machine.
[0016] The aloe vera preferably used in the sphere of the present invention comprises a water-based silicon emulsion with Aloe Vera, in which the siloxane component presents aminoalkyl groups and is indexed in Chemical Abstracts under reference number CAS N. 75718-16-0 15-25% Xi R36. Nevertheless, it should be understood that in the sphere of the present invention aloe vera may be used in any other form or in combination with any other chemical compound.
[0017] The quantity of aloe vera contained in the water bath is related to the weight/quantity of textile/garments to be treated and varies in the range between 4 and 10% by weight.
[0018] The treatment lasts for approximately 6-10 minutes and is performed hot, preferably at a temperature of 30-40° C.
[0019] The textile or the articles of clothing are then centrifuged and dried.
[0020] In a particularly preferred embodiment, the textile or articles of clothing are subsequently sprayed with a perfume aerosol; specifically, the composition of perfume contains amber and lavender as fragrances and water. Application of the perfume aerosol comes about in a tumbler (machine that imparts a circular movement fitted with a window through which the garments may be sprayed) for approximately 30 seconds, which is followed by a period of five minutes to equalise the perfume.
[0021] From tests carried out by the applicant it is clear that the effect of treatment with aloe vera is resistant to approximately three household washes at a temperature of about 40° C.
[0022] Naturally, details of performance and embodiments may be widely varied with regard to what is described and illustrated without thereby departing from the sphere of protection of the present invention, as defined by the attached claims. | A method to treat a textile and/or article of clothing including the application of aloe vera to the textile/article of clothing, preferably in a water bath. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to separation systems, and more particularly to separation systems having bolt ejecting separation nut assemblies combined with bolt catcher assemblies.
2. Description of the Prior Art
To provide separation of two planes, such as for staging in spacecraft and in missiles, various types of separation devices, including separation nuts, explosive bolts, pin pullers and separation joints to name a few, have been used. These devices are generally initiated by explosive devices called squibs which generate a large volume of gas to perform the work. In aerospace applications a certain amount of redundancy is desired since there is generally no way to repair a malfunction during flight. Although squibs are highly reliable, some separation devices have used two squibs per device to achieve the desired redundancy at the cost of the added weight and added electrical power required for initiation.
Additionally, testing of the separation devices prior to actual use is desired to demonstrate performance reliability. Presently this cannot be done without complete disassembly and reassembly after testing prior to actual use, resulting in added man-hours with the chance for error in reassembly which would invalidate the test.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a separation nut system which provides performance redundancy without a second squib, and which can be tested to demonstrate performance reliability without disassembly and reassembly of the system prior to actual use. At least two separation nut assemblies with their respective bolt catcher assemblies are connected by a manifold tube so that, should the squib initiator of one separation nut assembly fail, the manifold tube will transfer and redistribute the gas generated from one squib to both separation nut assemblies to provide performance redundancy. Also, each separation nut assembly is provided with a restoring device to return the separation nut assembly to its initial configuration after the bolt has been ejected so that the separation nut system can be tested using cold gas instead of a squib for actuation to demonstrate performance reliability without disassembly and reassembly prior to actual use.
Therefore, it is an object of the present invention to provide a separation nut system having performance redundancy.
A further object of the present invention is to provide a separation nut system capable of being tested to demonstrate performance reliability without complete disassembly and reassembly prior to actual use.
Yet another object of the present invention is to provide a separation nut system which is extremely lightweight.
Additional objects and advantages of the present invention will become apparent from the following description when read in view of the accompanying drawing and claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view, partly in cross-section, of a separation nut assembly and bolt catcher assembly.
FIG. 2 is a perspective view of the separation nut system.
FIG. 3 is a cross-sectional view of one embodiment of a separation nut assembly according to the present invention.
FIG. 4 a, b, c are cross-sectional views of the separation nut assembly of FIG. 3 showing the release-ejection sequence including (a) piston release, (b) segment release and (c) bolt ejection.
FIG. 5 is a cross-sectional view of another embodiment of a separation nut assembly according to the present invention.
FIG. 6 a, b, c are cross-sectional views of the separation nut assembly of FIG. 5 showing the release-ejection sequence including (a) piston release, (b) segment release and (c) bolt ejection.
FIG. 7 is a cross-sectional view of the bolt catcher assembly showing the head of the bolt.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2 a separation nut system is shown connecting two planes 10, 12 together, such planes being two stages of a missile for example. A bolt catcher assembly 14 is attached to one plane 10 by any suitable means such as rivets, screws or the like, and a separation nut assembly 16 is attached to the second plane 12 in a like manner. A conical seat 18 is attached to the second plane 12 with a washer 20 between the separation nut assembly 16 and the plane 12. The conical seat 18 has a recess 22 shaped to fit closely the end 24 of the body 26 of the bolt catcher assembly 14 to provide alignment of the bolt catcher assembly with the separation nut assembly 16. A bolt 28 extends from the end 24 of the bolt catcher assembly 14 into the separation nut assembly 16 where it is tightly gripped to assure connection of one plane 10 to the second plane 12.
A manifold 30 is attached to the separation nut assembly 16 in which an initiator port 32 is located. An initiator 34, such as an explosive squib or gas generator, is located in the initiator port 32. A manifold tube 35 connects the manifold 30 of one separation nut assembly 16 to the manifold of at least one other separation nut assembly.
FIG. 3 shows the details of one embodiment of the separation nut assembly 16. A case 36, approximately cylindrical in shape, has a head end 38, a base end 40, a central cavity 42 open at the base end and a central ejector post 44 extending from the head end into the cavity. A base assembly 46 is attached to the base end 40 of the case 36 having a central hole 48 to partially close the cavity 42, and having a peripheral lip 50. A flange 52 surrounds the base assembly 46, engaging the lip 50, and is secured to the second plane 12 to hold the separation nut assembly 16 in place.
A piston assembly 54 in the form of an inverted cup fits snugly about the ejector post 44 and against the interior wall of the case 36. The piston assembly 54 has a beveled lip 56. A separator 58 is slidably situated within the piston assembly 54 and has a central hole through which an ejector 60 protrudes. The ejector tip 62 rests against the bolt 28 and the ejector head 64 is located in an expanded chamber 66 within the ejector post 44 which is the base leg of a T-shaped port 68, the cross portion of the T-shaped port being within the head 38 and connecting to an exterior circumferential groove 70 in the head. A spring 72 is situated within the cavity 42 about the ejector post 44 between the piston assembly 54 and the head 38. A plurality of segments 74 grip the bolt 28 and are held in position by the separator 58 at the top, a beveled upward base projection 76 at the bottom and the inner walls of the piston lip 56 on the sides. The upper section 78 of the segment 74 has a smaller outside radius than the lower section 80, and the bevel between the two sections matches in angle the bevel of the piston lip 56.
The manifold 30 is situated about the head 38 and encloses the groove 70. The case 36 is allowed to slide within the manifold 30 so that the separation nut assembly 16 can be tightened to the bolt 28 without disturbing the relative position of the manifold which, as shown in FIG. 2, is connected to another manifold by the manifold tube 35. O-rings are used to provide a gas-tight seal between the various components so that gas generated by the squib initiator 34 is contained within the groove 70, the T-shaped port 68, the expanded chamber 66 and the pressure area 83 defined by the upper surface of the separator 58, the upper interior surface of the piston assembly 54 and the ejector post 44. The head 38 may have a nut inset 84 or a hexagonal nut external shape for ease of tightening the separation nut assembly 16 to the bolt 28.
As shown in FIGS. 4 a, b, c when gas is introduced at the initiator port 32 it flows around the groove 70 into the T-shaped port 68, and then out the expanded chamber 66 into the pressure area 83. The gas pressure in the pressure area 83 causes the piston assembly 54 to move upward, compressing the spring 72, until the piston lip 56 clears the lower section 80 of the segments 74. At this point the separator 58 moves downward causing the segments 74 to move outward until the upper section 78 contacts the piston lip 56, releasing the bolt 28. The ejector 60 now moves downward, propelling the bolt 28 out of the separation nut assembly 16 into the bolt catcher assembly 14 completing separation of the planes 10, 12.
In cold gas testing of the separation nut system, after the gas pressure has dissipated itself the restoring force of the spring 72 forces the piston assembly 54 down which forces the segments 74 together again, restoring the separation nut assembly 16 to its initial state. Connection of another bolt 28 restores the ejector 60 to its initial position so that the separation nut system is again ready for use. Total actuation time is on the order of 6 milliseconds.
A second embodiment is shown in FIG. 5. The separation nut assembly 16 has a case 136 with a head end 138, a base end 140, a central cavity 142 open at the base end, and a peripheral lip 150. A base assembly 146 is attached interior to the base end 140 of the case 136 having a central hole 148 to partially close the cavity 142. A flange 152 surrounds the base end 140, engaging the lip 150, and is secured to the second plane 12 to hold the separation nut assembly 16.
A separator 158 is slidably situated within the upper portion of cavity 142 and has a central hole through which an ejector 160 protrudes. A piston assembly 154 in the form of an inverted cup fits snugly about the lower portion of the separator 158 and against the interior wall of the case 136. The piston assembly 154 has one or more beveled interior annular protrusions 156. The ejector head 164 is located snugly in an expanded chamber 166 within the separator 158. The expanded chamber 166 connects to a quadri-port 168 located in the head 138 which in turn connects to an exterior circumferential groove 170. A spring 172 is situated within the cavity 142 about the lower portion of the separator 158 interior to the piston assembly 154. A plurality of segments 174 grip the bolt 28 and have external annular protrusions 180. The segments 174 are held in position by the spring 172 at the top and a beveled upward base projection 176 at the bottom and the piston protrusions 156 against the segment protrusions 180 on the sides. O-rings provide a seal to contain the gas generated by the squib initiator 34 within the quadri-port 168 and the pressure region 183 between the head 138, and the separator 158 and ejector head 164.
As shown in FIGS. 6a, b, c gas introduced at initiator port 32 exerts downward pressure on separator 158 and ejector 160 causing piston 154 to also move downward, compressing spring 172. When the piston protrusions 156 clear the segment protrusions 180 the separator 158 forces the segments 174 radially outward, releasing bolt 28. The ejector 160 continues its downward movement to eject the bolt 28 into the bolt catcher assembly 14.
In cold gas testing of the separation nut system, after the gas pressure has dissipated itself the restoring force of the spring 172 forces the piston 154 and separator 158 upward, which in turn due to the interaction between the piston protrusions 156 and segment protrusions 180 cause the segments 174 to return to their original position. Connection of another bolt 28 again places the separation nut system in its initial condition ready for use.
Referring now to FIG. 7 the bolt catcher assembly 14 has a body 90 having a catcher cavity 92 and a bolt hole 94 of diameter smaller than that of the catcher cavity. A flange 96 integral with the body 90 provides means for attaching the bolt catcher assembly 14 to one plane 10 by any suitable means such as screws, rivets, bolts or the like. The bolt head 98 is situated within the catcher cavity 92 with the bolt shaft 100 protruding through the bolt hole 94. A catcher 102 lines the catcher cavity 92 and has a plurality of resilient fingers 104 which are bent inwardly toward the center of the cavity. A conical ring 106 of a soft malleable material such as aluminum has inwardly sloping sides and is situated within the catcher cavity 92 above the catcher 102. A cap 108 seals the open end of the catcher cavity 92 and holds the conical ring 106 and catcher 102 securely in place.
The bolt head 98 is tapered and has a series of circumferential grooves 110. When the bolt 28 is forcibly ejected by the separation nut assembly 16, the bolt head 98 passes between the fingers 104 and embeds itself in the conical ring 106, the material of which fills the bolt head grooves 110 to prevent the bolt 28 from rebounding back to its initial position. Although the fingers 104 should catch the bolt head 98 as it rebounds, in practice without more than the fingers to catch the bolt the bolt 28 would vibrate back and forth once or twice before the resilience of the fingers would react fast enough to catch the bolt. Thus, the fluid deformation of the conical ring 106 about the bolt head grooves 110 prevents this undesirable vibratory action due to bolt 28 rebound.
Referring back to FIG. 2 the manifold tube 35 connecting the manifolds 30 of two or more separation nut assemblies 16 allows the gas generated by one initiator 34 to actuate all the separation nut assemblies connected to the manifold tube. For weight considerations the manifold tube. 35 should be as small as possible, but it must be large enough to provide virtual simultaneity of action of all the separation nut assemblies 16 connected to it by the action of a single initiator 34. The manifold tube 35 should also be sized to handle the pressure of all the initiators 34 to which it is connected.
Thus, the present invention provides a separation nut system with performance redundancy to avoid squib malfunction without using additional squibs, with automatic resetting so it can be cold gas tested for reliability without disassembly and reassembly after each use, and with positive bolt catching to avoid vibration disturbances caused by bolt rebound. | A separation nut system having bolt ejecting separation nut assemblies coned with bolt catcher assemblies. At least two separation nut assemblies with their respective bolt catcher assemblies are connected by a manifold tube so that, should the squib initiator of one separation nut assembly fail, the manifold tube will transfer and redistribute the gas generated from one squib to both separation nut assemblies to provide performance redundancy. Also, each separation nut assembly is capable of being tested for performance integrity prior to actual usage without the need for disassembly and subsequent reassembly and inspection after each use. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to gas-bearing structures and more particularly to an integral vacuum sealed gas-bearing housing assemblies.
2. Description of the Prior Art
In certain technical fields, development tends towards large vacuum housings wherein some elements forming the vacuum chamber are movable relative to other elements forming the vacuum chamber in very precisely, controlled, minute increments. As an example, in the electronic semiconductor industry, electronic beam devices are frequently used for performing functions on silicon devices to form circuits, etc. This requires continuous and/or repeated movement of the device relative to the beam. As such, frequently it is necessary to have continuous, minute, precise, control of the position of the beam relative to the silicon devices within a vacuum environment. This in turn requires finite control of the positioning of the housing enclosing the beam relative to the position of the housing enclosing the silicon devices while maintaining the vacuum environment. With structures heretofore available, it has been necessary to use complex structures and very finely machined parts in order to achieve finite positioning control. Such units are very expensive and delicate to manufacture and maintain.
SUMMARY OF THE PRESENT INVENTION
An object of the present invention is to provide an integral vacuum-sealed gas-bearing housing assembly wherein a high vacuum seal is established between the interior of two relatively movable sub-assemblies and the exterior of the sub-assemblies to allow two sub-assemblies to move relative to one another without friction.
Another object of the present invention is to provide an integral vacuum sealed gas-bearing housing assembly which may be utilized in applications wherein an evacuated vessel need be moved relative to a fixed structure which structure establishes one interfacing wall with such vessel and wherein such motion requires the precision and low friction afforded by gas-bearings, and wherein a vacuum seal need be maintained at the interface.
A further object of the present invention is to provide an integral vacuum sealed gas-bearing housing assembly in which precise rectilinear or rotational motion within a vacuum environment may be communicated through an interface to a pressurized environment.
Briefly, this invention pertains to an integral vacuum sealed air-bearing housing assembly having at least two aligned chamber housings. The housings are movable relative to one another in a common plane. At least one of the housings comprises a combination of gas-bearing elements, compensated or uncompensated, with vacuum plenums or grooves about the common plane such that a gas seal is maintained across the bearing at the planar interface of the two chambers.
A "gas seal" implies that an air pressure differential may be maintained across the bearing interface such that ambient atmospheric pressure (or higher) may be present on one side of the interface while a very low pressure, approaching that of a complete vacuum, may be maintained on the opposite side of the interface without leakage of gas across the bearing interface into the vacuum chamber environment. Gas normally dispelled from the bearing is likewise prevented from entering the vacuum environment.
A "gas bearing" implies a noncontacting interface between fixed and moving elements with a film of flowing gas between the elements and physically separating the elements. Such a film provides a force opposing the gravitational and weight forces which otherwise tend to cause mechanical and frictional interface contact between the two relative moving elements. The gas bearing offers a virtually frictionless interface between the two members while in motion relative to one another. The scope of the present invention includes various geometrical arrangements of the gas-bearing elements and vacuum plenums as well as numerous applications of such mechanisms.
Other objects and advantages of the present invention will become apparent to those skilled in the art after having read the following detailed description of the preferred embodiment as illustrated in the figures of the drawing.
IN THE DRAWING
FIG. 1 is a perspective view of a vacuum-sealed, gas-bearing assembly having a chamber for housing an electronic beam and a chamber for receiving silicon devices on which the electronic beam is to operate;
FIG. 2 is a cross-sectional view of the assembly of FIG. 1 taken along the line 2--2; and
FIG. 3 is a cross-sectional view of the structure of FIG. 2 taken along the line 3--3 illustrating the interface wall of one chamber housing with the other chamber housing removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings illustrate an integral vacuum-sealed, gas-bearing housing assembly referred to by the general reference character 10. The assembly 10 includes a stationary sub-assembly, referred to by the general reference character 12, and a movable sub-assembly referred to by the general reference character 14. In application, the sub-assembly 12 may house an electron beam and the sub-assembly 14 may house silicon devices on which electronic circuits are formed. A planar interface 16 is established intermediate the stationary sub-assembly 12 and the movable sub-assembly 14. The vacuum-sealed, gas-bearing is established about the interface 16 to allow the sub-assembly 14 to move relative to the sub-assembly 12.
A support base 18, e.g. granite table, supports the stationary sub-assembly 12 and movable sub-assembly 14. A circular manifold 20 with vacuum ports 22 is supported on and above the base 18. The manifold 20 is hermetically sealed to the base 18 by a plurality of anchor bolts 23 and O-ring seal 23A. The stationary sub-assembly 12 forms a first chamber 24 which is an extension of a second vacuum chamber 25 formed about the interior of the manifold 20. The chamber 24 may be evacuated of gases by means of high vacuum pumps operating through the pump-port interconnects 26 and the ports 22 of the manifold 20. The chamber 24 is formed about the interior of a bearing block 27. The top surface of block 27 forms the interface with the sub-assembly 14. The block 27 contains geometry to coact with a plurality interconnecting internal ducts 28, 30, 32, 34 and 36. The ducts 28-36 interconnect with a set of eight gas manifold blocks 38 positioned about the periphery of the block 27. The block 27 is bolted and sealed to the manifold 20 by means of a plurality of bolts 39 and an O-ring seal 40. As such, the sub-assembly 12 and manifolds 38 are fixed in place, i.e. stationary with the base 18. Interconnections of the ducts 28 and 30 with the manifold blocks 38 permit interconnection with air pumps to permit pressurization of a gas-bearing about the interface 16. Interconnections of ducts 32, 34 and 36 with the manifolds 38 allow connection of external vacuum pumps to the vacuum sweeper and differential vacuum plenums. The eight manifolds 38 are spaced with two manifolds at each corner so as to retain the air bearing substantially uniform and the pressure at the vacuum plenum relatively uniform.
The sub-assembly includes a rectangular housing 41 adapted for coordinate X-Y displacements as well as rotational movement relative to the axis 42 of the vacuum chamber 24. The housing 41 has a planar smooth surface 43 facing the interface 16. Sub-assembly 14 is driven by a driver 44 to control the axial and radial position of the housing 41 relative to the chamber 24. Sub-assembly 14 has a central chamber 45 formed by the interior walls of the housing 41. The housing 41 communicates directly with the chamber 24. A cover 46 establishes the top wall of the chamber 45 and is attached to the housing 41 by the use of O-ring seals 47 and bolt seals 48 to provide a vacuum seal about the cover 46 and housing 41.
FIG. 3 illustrates in further detail the top plan view of the bearing block 27 and the interior of the chamber 24. As illustrated, the duct 32, 34 and 36 provide a multiple-plenum vacuum seal which is interposed between the vacuum environment within the chamber 24 and a gas-bearing geometry 48 established intermediate the air ducts 28 and 30.
As illustrated, a plurality of parallel cylindrical bores 52 communicate intermediate the duct 34 and a groove 53. Likewise, a plurality of parallel cylindrical bores 54 which communicate intermediate a groove 55 about the interface 16 and the duct 36. A land 56 is formed intermediate the chamber 24 and the groove 55. A land 58 is established intermediate the groove 55 and the groove 53. Likewise, a land 60 is established intermediate the groove 53 and a groove 61 communicating to the duct 32. The lands 56, 58 and 60 have a minute clearance to the moving stage vessel 14 as it is moved about the axis 40 and/or in the X-Y direction. The grooves 61, 53 and 55 establish a multiple-plenum vacuum seal which communicates to the interconnecting ducts 32, 34 and 36, respectively, connected to a vacuum pump connection 62 and thence to a vacuum system to form an inboard sweeping plenum. A pair of narrow air grooves 64 and 66, respectively, are separated by a gas film space 68 which constitutes the air-bearing geometry. The grooves 64 and 66 communicate by holes 69 and 70 to the ducts 30 and 28, respectively. The ducts 28 and 30 are connected to a pair of air pump connections 72 and 74, respectively. The connections 72 and 74 are coupled to air pumps (not shown) to provide the supporting film of gas for the air bearing.
Thus, the vacuum sealed gas-bearing housing assembly 10 is viewed as an integral mechanism, i.e., the operation of the vacuum seal about the chamber is dependent upon the presence of the air bearing about the film space 68, and the vacuum seal cannot be utilized separately from it. The vacuum seal portion of the structure, which may consist of one or several vacuum plenums delineated by adjacent lands, is effective as a seal only when a constant small gap is maintained above the isolation lands about the interface. This gap is produced by the gas-bearing lift created through the grooves 64 and 66 interconnected to air pumps through connections 72 and 74. The precision of the gap at the interface 16 is related to the stiffness of the gas-bearing, i.e., the change in air-film thickness is a function of vertical (compressive) force applied to the gas-bearing. In some applications, compensated gas-bearings may be required to maintain sufficient accuracy of the gap under conditions of varying load while other applications may not require such compensation.
Generally, as illustrated in the preferred embodiment of housing 10, the housing is designed to situate the gas-bearing to that side of the interface which intersects ambient pressure. Escape of gas at this interface is usually of no consequence. However, gas which is expelled at the low-pressure side of the gas-bearing must be swept up at a low-pressure plenum so as to avoid its escaping to the intended vacuum chamber. Thus, as the spacing intermediate the air grooves and vacuum chamber interface progresses, plenums of progressively lower air pressure are required. Each plenum and its isolating land acts to remove residual gas until the required degree of isolation is achieved at the vacuum interface. The necessary number of such vacuum plenum stages depend upon the ultimate level of vacuum required and the pumping rate of the vacuum environment together with the precision of the gas-bearing gap. Thus, the total interface consists of a pressurized area filled by a flowing gas film (which provides the bearing lift) with an inboard sweeper plenum, followed by progressively lower pressure areas on the side toward the vacuum interface.
While this invention has been particularly shown and described with reference to a preferred embodiment thereof, 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. | An integral vacuum-sealed gas-bearing assembly comprising a combination of gas-bearing elements and vacuum plenums such that a gas seal is maintained across the bearing separating two assemblies to allow one assembly to be moved relative to the other in finite increments while maintaining an internal vacuum environment. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/347,321 filed Dec. 31, 2008, by Souhel Khanania, entitled “Oven,” which claims priority to U.S. Provisional Patent Application No. 61/018,830 which was filed on Jan. 3, 2008, which are incorporated by reference herein as if reproduced in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] Large quantities of energy are used in the manufacture of modern food products. Systems and methods that can reduce the total energy consumption of manufacturing plants that create, package, and prepare the food would be beneficial. Therefore systems and methods that provide for the efficient manufacture of food products are desirable.
SUMMARY OF THE DISCLOSURE
[0005] In some embodiments, an oven is provided that comprises a first conveyor. In that oven, a first burner directs heat toward the first conveyor from above the first conveyor and a second burner directs heat toward the first conveyor from below the first conveyor.
[0006] In other embodiments, a method is provided for cooking foodstuff that comprises providing foodstuff on a conveyor, exposing the foodstuff to heat directed toward the foodstuff from above the conveyor, and exposing the foodstuff to heat directed toward the foodstuff from below the conveyor.
[0007] In still other embodiments, an oven is provided that comprises a first conveyor. In that oven, first conveyor insulators substantially surround the first conveyor and thereby define a first zone.
[0008] In still other embodiments, a method of cooking foodstuff is provided that comprises introducing foodstuff to a first conveyor belt within a first insulated zone. The method further comprises introducing heat into the first insulated zone and retaining a portion of the heat within the first insulated zone.
[0009] In still other embodiments, an oven is provided that comprises a substantially insulated cooking zone that closely envelopes a cooking path and a substantially insulated oven zone that substantially envelopes the cooking zone.
[0010] The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments of the disclosure, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
[0012] FIG. 1 is an oblique view of an oven according to the present disclosure;
[0013] FIG. 2 is a front view of the oven of FIG. 1 ;
[0014] FIG. 3 is an enlarged oblique view of a portion of the upper right side of the oven of FIG. 1 ;
[0015] FIG. 4 is an enlarged oblique view of a portion of the lower left side of the oven of FIG. 1 ;
[0016] FIG. 5 is an oblique view of the belts and IR burners of the oven of FIG. 1 ;
[0017] FIG. 6 is an upper oblique view of the belts and cooking zone of the oven of FIG. 1 ;
[0018] FIG. 7 is a lower oblique view of the belts and cooking zone of the oven of FIG. 1 ;
[0019] FIG. 8 is an enlarged oblique view of the left side of the belts and cooking zone of the oven of FIG. 1 ;
[0020] FIG. 9 is an enlarged oblique view of the right side of the belts and cooking zone of the oven of FIG. 1 ;
[0021] FIG. 10 is a front oblique view the frame and air delivery system of the oven of FIG. 1 ;
[0022] FIG. 11 is an oblique view of a mixer of the oven of FIG. 1 ;
[0023] FIG. 12 is an oblique view of an IR burner of the oven of FIG. 1 ;
[0024] FIG. 13 is an oblique upper view of a belt guide of the oven of FIG. 1 ;
[0025] FIG. 14 is an oblique front view of two belt tensioners of the oven of FIG. 1 ;
[0026] FIG. 15 is an oblique view of a motor, gearbox, and drive shaft of the oven of FIG. 1 ;
[0027] FIG. 16 is a simplified front view of another oven according to the present disclosure; and
[0028] FIG. 17 is a simplified front view of still another oven according to the present disclosure.
DETAILED DESCRIPTION
[0029] In the preparation of food materials, such as, but not limited to, potato, corn and tortilla chips, cooking the foodstuff sometimes consumes large quantities of energy. Conventional industrial ovens lose a significant amount of heat and energy due to poor design and/or a lack of insulation. Systems and methods that could improve on the efficiency of ovens would greatly reduce the overall energy required to manufacture foodstuff. Accordingly, the present disclosure discloses systems and methods that may be implemented to reduce energy consumption in the process of cooking foodstuff.
[0030] Typical ovens comprise large enclosures having multiple conveyors within the enclosures. Sometimes the multiple conveyors work together to form a path along which foodstuff successively travels from one conveyor to the next. However, the typical ovens require that the entire enclosure be heated in order to cook foodstuff on the conveyors, thereby unnecessarily heating the contents of space that is not in close proximity or adjacent to the foodstuff. The unnecessary heating of the contents of a large volume of space accounts for a large amount of energy consumption and waste, rendering the cooking process unnecessarily energy inefficient.
[0031] The present disclosure provides for substantially enclosing each conveyor within substantially adjacent insulative barriers that generally serve to envelope the conveyors individually within zones. The present disclosure further discloses providing insulated ducts for connecting the various zones that relate to the conveyors so that heat is efficiently transferred between the various zones. The present disclosure provides a cooking zone that comprises the zones that are individually related to the conveyors and further comprises the insulated ducts that join the various zones. Generally, the insulative barriers serve to retain heat within the cooking zone, thereby allowing more efficient cooking of foodstuff within the cooking zone. The present disclosure further provides gas-fueled infrared burners positioned to emit and direct heat toward one or more conveyors from both above the conveyors and from below the conveyors. Still further, the present disclosure provides enclosing the cooking zone within an oven zone that substantially envelops the entirety of the cooking zone so that heat loss from the cooking zone is reduced. While every combination is not discussed, the present disclosure expressly contemplates combining the disclosed features in many combinations. For example, an oven according to the disclosure may comprise one or more conveyors that are enclosed by insulative barriers and one or more of those conveyors may have infrared burners associated with the conveyor to emit and direct heat on the conveyor from both above and below the conveyors.
[0032] Referring now to FIGS. 1-4 , an oven 100 is disclosed. Oven 100 comprises a supportive frame 102 having a plurality of structural components, only some of which are described in greater detail below. The frame 102 is supported by feet 104 attached to the bottom of the frame 102 . The oven has a left side shown generally leftward in FIG. 2 and a right side shown generally rightward in FIG. 2 . Further, the oven 100 has a front side that is displayed generally between the left and right sides in FIG. 2 . Accordingly, the oven 100 comprises a top side opposite the bottom side and a rear side opposite the front side. It will be appreciated that the above directional conventions apply throughout the description of oven 100 .
[0033] Most generally, the oven 100 comprises an upper conveyor system 106 , a middle conveyer system 108 , and a lower conveyor system 110 . Each of the conveyor systems 106 , 108 , 110 comprise the necessary equipment for operation of each conveyor system 106 , 108 , 110 independent of the others. In the preferred embodiment, each conveyor system 106 , 108 , 110 comprises its own motor 112 , gearbox 114 , drive shaft 116 , and belt tensioners 118 . It will be appreciated that in other embodiments, a single motor may be used to power one or more conveyors. Each conveyor system 106 , 108 , 110 further comprises the necessary drive drums 120 , tensioner drums 122 , and free drums 124 to carry conveyor belts. The conveyor systems 106 , 108 , 110 , together, generally define a cooking path along which foodstuff is carried and cooked while present on the cooking path.
[0034] At an entrance 126 formed by the frame 102 (most clearly shown in FIG. 3 ), foodstuff may be introduced to an upper surface of an upper belt 128 . The upper conveyor system 106 operates to rotate upper belt 128 in a generally counterclockwise direction as viewed in FIG. 2 so that the upper surface of upper belt 128 moves from right to left. Middle conveyor system 108 is located generally below upper conveyor system 106 so that as foodstuff reaches the left end of the upper belt 128 , the foodstuff falls from the upper belt 128 to an upper surface of a middle belt 130 of middle conveyor system 108 . The middle conveyor system 108 operates to rotate middle belt 130 in a generally clockwise direction as viewed in FIG. 2 so that the upper surface of middle belt 130 moves from left to right.
[0035] Lower conveyor system 110 is located generally below middle conveyor system 108 so that as foodstuff reaches the right end of the middle belt 130 , the foodstuff falls from the middle belt 130 to an upper surface of a lower belt 132 of lower conveyor system 110 . The lower conveyor system 110 operates to rotate lower belt 132 in a counterclockwise direction as viewed in FIG. 2 so that the upper surface of lower belt 132 moves from right to left. As foodstuff reaches the left end of the lower belt 132 the foodstuff is free to fall from lower belt 132 down through an exit 134 formed generally by the frame 102 (most clearly shown in FIG. 4 ). In some embodiments the oven 100 may be associated with other foodstuff preparation and/or packaging equipment so that once foodstuff passes through exit 134 the foodstuff is collected and further processed and/or packaged. It will be appreciated that, in this embodiment, the cooking path of foodstuff is defined as the path along which foodstuff travels within the oven 100 (i.e. along the conveyor belts 128 , 130 , 132 as described above).
[0036] The cooking path is more than a path along which foodstuff is moved. The cooking path is a path along which foodstuff is cooked by exposure to high temperatures through various forms of heat transfer as discussed below. In this embodiment, each conveyor system 106 , 108 , 110 has a plurality of gas fueled infrared burners 136 (see FIGS. 5 and 12 ) (hereinafter referred to as “IR burners”) associated therewith. The IR burners 136 are fed a mixture of air and fuel gas through mixers 138 that are described in greater detail below (see FIG. 11 ). While IR burners 136 are not shown in FIGS. 1-4 , it will be appreciated that one IR burner 136 is associated with each mixer 138 . As described in more detail below, each IR burner 136 is capable of directing radiant heat in a directional manner.
[0037] Referring now to FIG. 5 , the upper, middle, and lower belts 128 , 130 , and 132 are shown along with the IR burners 136 , but without the remainder of the components of the oven 100 . In this embodiment, the upper belt 128 is associated with six IR burners 136 that are located slightly above the upper belt 128 and that are oriented to emit radiant heat downward onto upper belt 128 . The upper belt 128 is further associated with six IR burners 136 that are located slightly below the upper belt 128 and that are oriented to emit radiant heat upward onto upper belt 128 . Similarly, middle belt 130 is associated with six IR burners 136 that are located slightly below the middle belt 130 and that are oriented to emit radiant heat upward onto middle belt 130 . Finally, lower belt 132 is associated with eight IR burners 136 that are located slightly below the lower belt 132 and that are oriented to emit radiant heat upward onto the lower belt 132 . Of course, in alternative embodiments, an upper belt may comprise IR burners only above or below the upper belt, a middle belt may comprise IR burners both above and below the middle belt or may comprise IR burners only above the middle belt, and a lower belt may comprise IR burners both above and below the middle belt or may comprise IR burners only above the lower belt. Also, burners other than IR burners may be used or used in combination with IR burners.
[0038] A feature of the oven 100 is that heat generated by IR burners 136 is not merely cast upon the belts 128 , 130 , 132 and easily allowed to pass into the general interior space of the oven 100 (where the interior space is generally defined by the left, right, bottom, top, front, and rear of the oven 100 ), but rather, the heat is retained near the foodstuff. Specifically, the oven 100 is constructed in a manner that substantially encloses the cooking path in a minimal envelope of space, thereby retaining the heat generated by the IR burners 136 in space near the foodstuff that is carried along the cooking path. Most generally, the heat is retained by constructing insulative barriers to prevent the escape of heat so that the cooking path (i.e. each conveyor belt 128 , 130 , 132 ) is substantially enclosed within an insulated cooking zone.
[0039] Referring now to FIGS. 6-9 , the insulated cooking zone is defined generally as a substantially contiguous space that is substantially bounded by insulation in close proximity to the cooking path. In this embodiment, an upper zone substantially surrounds the upper belt 128 and is defined generally by the space bounded by upper insulators 140 , lower insulators 142 , left insulators 144 , right insulators 146 , front insulators 148 , and rear insulators 150 . The various insulators 140 , 142 , 144 , 146 , 148 , 150 are generally plate-like in shape and serve to closely bound the belts 128 , 130 , 132 while being sized and/or otherwise shaped to accommodate protrusions of other portions of the oven 100 as necessary. In keeping with the goal of substantially enclosing the cooking path within a cooking zone, the insulators 140 , 142 , 144 , 146 , 148 , 150 generally form substantially continuous walls around the belts 128 , 130 , 132 . However, upper burner openings 152 and lower burner openings 154 are present to allow a passage for radiant heat to enter the cooking zone from IR burners 136 . The insulators 140 , 142 , 144 , 146 , 148 , 150 also form a middle zone that substantially surrounds the middle belt 130 and a lower zone that substantially surrounds the lower belt 132 .
[0040] It will further be appreciated that the upper, middle, and lower zones are connected to generally form the single cooking zone. Specifically, the insulators 140 , 142 , 144 , 146 , 148 , 150 form a right duct 156 that generally connects the right side of the lower zone to the right side of the middle zone. The insulators 140 , 142 , 144 , 146 , 148 , 150 also generally form a left duct 158 that generally connects the left side of the middle zone to the left side of the upper zone. The joint nature of the lower, middle, and upper zones allow heat and hot air to travel in a directed manner from left to right in the lower zone, up through the right duct 156 , from right to left in the middle zone, up through the left duct 158 , and finally from left to right in the upper zone. The heat and hot air in the cooking zone generally travels along a path opposite in direction to the direction the foodstuff is carried along the cooking path.
[0041] By directing the heat and hot air in the manner described above, the heat generated by IR burners 136 associated with the lower belt 132 that is not absorbed by foodstuff on the lower belt 132 is not lost. Instead, the unabsorbed heat encounters foodstuff along the entire length of the cooking path until the heat is ultimately fully absorbed by foodstuff along the cooking path or the heat exits the cooking zone near the right side of the upper zone. It will be appreciated that front insulators 148 that aid in forming the right duct 156 and left duct 158 are omitted from view in FIGS. 8 and 9 to allow a view inside the right duct 156 and the left duct 158 .
[0042] Referring again to FIGS. 1-4 , the oven 100 further comprises an insulated oven zone that is generally defined by outer insulators 160 that bound the oven zone. The oven zone substantially envelopes the cooking zone so that any heat escaping the cooking zone within the oven 100 is retained within the oven zone. It will be appreciated that while outer insulators 160 are mostly shown as being associated with the top and bottom sides of the oven 100 , outer insulators 160 associated with the right, left, front, and rear sides of the oven 100 are expressly contemplated by this disclosure. Some outer insulators 160 associated with the right, left, front, and rear sides of the oven 100 are not shown in order to provide clarity in view the other components of the oven 100 .
[0043] The effect of providing an insulated oven zone is that temperature gradients at the interface of the cooking zone and the oven zone are less than what the temperature gradients would be between the cooking zone and an otherwise existing adjacent ambient zone. Since the temperature gradient between the cooking zone and the next adjacent zone is lessened, a lower amount of heat transfer will occur between the cooking zone and the next adjacent zone. In other words, with the provision of the oven zone, heat will tend to transfer away from the cooking zone at a reduced rate. Further, an exhaust heat duct 160 is provided that is shown as a substantially rectangular structure and that connects the oven zone to another space. In some embodiments, the exhaust heat duct 162 may direct exhaust heat to the exterior of a building that houses the oven 100 . In other embodiments, the exhaust heat duct 162 may direct heat to another device or zone to allow recapture and/or reuse of the exhausted heat.
[0044] Referring now to FIG. 10 , a simplified view of the frame 102 is shown to illustrate that the frame 102 serves not only as a structural support system, but also as an air delivery system. Specifically, frame 102 comprises an air input manifold 164 that supplies air to top burner upper manifolds 166 that supply air to IR burners 136 that direct heat downward onto upper belt 128 . Similarly, frame 102 comprises supply air to bottom burner upper manifolds 168 that supply air to IR burners 136 that direct heat upward onto upper belt 128 . Further, frame 102 comprises middle manifolds 170 that supply air to the IR burners 136 that direct heat upward onto middle belt 130 . Finally, frame 102 comprises lower manifolds 172 that supply air to the IR burners 136 that direct heat upward onto lower belt 132 . Each manifold 166 , 168 , 170 , 172 has a plurality of mixers 138 attached thereto and the mixers 138 serve as outlets for air supplied through the manifolds 166 , 168 , 170 , 172 .
[0045] Referring now to FIG. 11 , a mixer 138 is shown. The mixer 138 comprises a latch 174 for securing mixer 138 to one of the previously described manifolds 166 , 168 , 170 , 172 . The mixer 138 further comprises a gas inlet 176 for attachment to a gas supply line. The mixer 138 also comprises a gas adjustment 178 that functions to alter the flow rate of fuel gas into the mixer 138 through the gas inlet 176 , thereby providing a convenient way to adjust a gas-air mixture that exits a mixer insert 180 . Mixer insert 180 is shaped to provide improved mixing of the air and gas as compared to the mixing of the air and gas that would otherwise occur in the tubing-shaped body 182 of the mixer 138 . The mixer 138 further comprises a mounting plate 184 for attachment to a burner manifold.
[0046] Referring now to FIG. 12 , an IR burner 136 is shown in greater detail. The IR burner 136 comprises a plurality of mixture inputs 186 that distribute the gas-air mixture along the length of a burner tube 188 . The IR burner 136 further comprises forms 190 that serve to hold ceramic reflector-emitters 192 . The reflector-emitters 192 serve the dual role of reflecting radiant heat in a concentrated manner in a direction generally away from the forms 190 while also becoming heated to emit infrared radiation. The emitted infrared radiation serves to heat foodstuff and the components that carry foodstuff along the cooking path.
[0047] Referring now to FIG. 13 , a belt guide 194 is shown. A plurality of belt guides 194 are used in oven 100 to maintain a front-to-back alignment of the belts 128 , 130 , 132 . To keep the belts 128 , 130 , 132 aligned from front to back, the belts 128 , 130 , 132 are guided between side pulleys 196 that oppose the front and rear sides of the belts 128 , 130 , 132 . To keep the belts 128 , 130 , 132 generally flat where appropriate, a support shaft 198 is provided with support gears 200 and support bearings 202 . The support shaft turns freely due to the support bearings 202 while the support gears 200 actually engage and vertically support the belts 128 , 130 , 132 . The support gears 200 have a larger diameter than the support bearings 202 . The components of the belt guide 194 are all commonly carried by a support bar 204 that is in turn supported by other structures of the oven 100 .
[0048] Referring now to FIG. 14 , belt tensioners 118 are shown that serve to provide a convenient adjustment to the tension of belts 128 , 130 , 132 . The belt tensioner 118 comprises an adjustable shaft mount 206 that allows upward or downward movement of tensioner drum 122 . As tensioner drum 122 is moved up, the tension of the belt is decreased. As the tensioner drum 122 is moved down, the tension of the belt is increased.
[0049] Referring now to FIG. 15 , an enlarged view of a motor 112 , gearbox 114 , and drive shaft 116 are shown in association with a drive drum 120 and a belt. Motor 112 is an electric motor, however, in alternative embodiments, the motor may be a pneumatic motor, hydraulic motor, or any other suitable motor. The motor 112 is connected to a gearbox 114 which is in turn connected to a drive shaft 116 that drives the drive drum 120 . When the drive drum 120 is rotated, the belt is moved.
[0050] Referring now to FIG. 16 , an alternative embodiment of an oven 400 is shown in simplified form. Oven 400 is substantially similar to oven 100 but for the choice of heat generators. Specifically, oven 400 comprises an upper belt 402 , a middle belt 404 , and a lower belt 406 that are connected and insulated to have a cooking zone substantially similar to the cooking zone of oven 100 . Oven 400 comprises a combination of slit-tube gas burners 408 , IR burners 410 , and microwave emitters 412 . Further, it will be appreciated that the slit-tube gas burners 408 and IR burners 410 associated with the middle belt 404 are oriented lengthwise with the middle belt 404 . However, the slit-tube gas burners 408 and IR burners 410 associated with the upper belt 402 are oriented generally across the upper belt 402 from front to back. Further, an oven zone 414 comprises a slit-tube gas burner 408 , an IR burner 410 , and a microwave emitter 412 within the oven zone 414 but outside the cooking zone. The oven zone 414 further comprises a forced air fan 416 for circulating air in the oven zone 414 . Of course, in alternative embodiments, the types of heat generators, the placement of the heat generators 408 , 410 , 412 and fans 416 may be different than shown and the various combinations of components and component placements may be used in combination with other embodiments disclosed herein.
[0051] Referring now to FIG. 17 , an alternative embodiment of an oven 500 is shown in simplified form. Oven 500 is substantially similar to oven 100 but for the placement of heat generators. Specifically, oven 500 comprises an upper belt 502 , a middle belt 504 , and a lower belt 506 that are connected and insulated to have a cooking zone substantially similar to the cooking zone of oven 100 . Oven 500 comprises IR burners 510 . IR burners 510 are placed continuously along both the top and bottom side of upper belt 502 . IR burners 510 are alternatingly placed along the middle belt 504 so that there is no overlap in IR burners 510 but also so that foodstuff is always directly above or directly below an IR burner 510 while on middle belt 504 . IR burners 510 are also placed substantially adjacent one another to form a series of adjacent IR burners 510 on the upper left side of the lower belt 506 . However, another series of adjacent IR burners 510 is located just to the right of the upper left series of IR burners 510 on the bottom side of the lower belt 506 . Another IR burner 510 is located near the right end of the lower belt 506 on the upper side of the lower belt 506 and is offset to the right from any IR burners 506 on the lower belt 506 . Finally, IR burners 510 are placed facing the left end of the upper belt 502 , the right end of the middle belt 504 , and the left end of the lower belt 506 . Further, it will be appreciated that while IR burners 510 are discussed in the particular layouts described above, in alternative embodiments, IR burners may be positioned along conveyor belts and positioned relative to each other in any other suitable manner.
[0052] It will be appreciated that any of the insulators 140 , 142 , 144 , 146 , 148 , 150 , 160 may be constructed of stainless steel, Stainless Steel 253 MA™, high nickel steel, Rockwool™ materials, or any other suitable material. The insulators may be placed in relative close proximity to conveyor belts in such a way to maximize heat retention in the cooking zone (i.e. near the belts). It will further be appreciated that one advantage of the of using the IR burners 136 is that the effective cooking area of the IR burners 136 is essentially the footprint of the reflector-emitters 192 as compared to the effective cooking area of a gas flame being only the area of the gas flame. It will further be appreciated that while ovens 100 , 400 , and 500 are disclosed as having three conveyor belts (i.e. a three-pass system), the principles disclosed herein can be equally applied to any oven having one, two, three, or more such conveyor systems. Specifically, for example, an oven may comprise a single conveyor within an insulated cooking zone where the cooking zone is further substantially enveloped within an insulated oven zone.
[0053] Further, in alternative embodiments, an oven may comprise multiple conveyor belts at or near the same vertical level so that foodstuff is not dropped from one belt to another. Still further, in alternative embodiments, the cooking path may not comprise substantially level conveyor belts. Instead, an alternative embodiment may comprise a cooking path that spirals up or down, slopes up or down, or follows a meandering course. All of the above-described alternative embodiments may employ the method of reducing a required amount of energy to cook foodstuff by enclosing the cooking path using insulators located in close proximity to the cooking path (i.e. close to the conveyor belts). Further, all of the above-described alternative embodiments may employ the method of conserving heat and energy by ducting hot air and heat between various conveyors that are located at different vertical levels. Still further, all of the above-described alternative embodiments may employ the method of conserving heat and energy by further substantially enclosing a cooking zone within an oven zone using outer insulators. Finally, all of the above-described alternative embodiments may employ the use of IR burners to increase an effective cooking area as compared to using conventional slit-tube gas burner systems.
[0054] At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R 1 , and an upper limit, R u , is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R 1 +k*(R u −R 1 ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention. The discussion of a reference in the disclosure is not an admission that it is prior art, especially any reference that has a publication date after the priority date of this application. | An oven has a first conveyor, a first burner that directs heat toward the first conveyor from above the first conveyor, and a second burner directs heat toward the first conveyor from below the first conveyor. A method includes providing foodstuff on a conveyor, exposing the foodstuff to heat directed toward the foodstuff from above the conveyor, and exposing the foodstuff to heat directed toward the foodstuff from below the conveyor. Another oven has a first conveyor and first conveyor insulators that surround the first conveyor and define a first zone. Another method includes introducing foodstuff to a first conveyor belt within a first insulated zone, introducing heat into the first insulated zone, and retaining a portion of the heat within the first insulated zone. Another oven has an insulated cooking zone that closely envelopes a cooking path and an insulated oven zone that substantially envelopes the cooking zone. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of powering data terminal equipment and more particularly to providing power over data communication cabling constituted of a single pair.
[0002] Ethernet communication, also known as IEEE 802.3 data communication, is typically implemented over a structured cable having 4 twisted wire pairs. Power of Ethernet (PoE), as described in IEEE 802.3af—2003 and IEEE 802.3.at—2009, as published by the Institute of Electrical and Electronics Engineers, New York, the entire contents of each document is incorporated herein by reference, is superimposed over the data utilizing phantom powering. In particular, the existing data transformers of Ethernet are center-tapped, and thus the DC current through the two halves of the transformer are of equal magnitude and opposite direction leaving no net flux in the transformer core.
[0003] Ethernet communication for speeds less than 1000 megabits per second (Mbps) is typically supplied over 2 twisted wire pairs, one of the pairs being used as a transmit pair from the hub equipment to the data terminal equipment (DTE), which when powered by PoE is also known as a powered device (PD), and a second of the pairs being used as a transmit pair from the data terminal equipment to the hub equipment. The other two pairs were typically not used, and were known as spare pairs. The term transmit is typically abbreviated TX and the term receive is typically abbreviated RX for simplicity. In such an embodiment either spare powering, or data pair powering, may be implemented.
[0004] FIG. 1A illustrates a high level block diagram of an arrangement 10 for powering a PD from a switch/hub equipment 30 using phantom powering in accordance with the above standards. Arrangement 10 comprises: switch/hub equipment 30 comprising a first and second data pair 20 , a power sourcing equipment (PSE) 40 , and a first and second data transformer 50 ; four twisted pair data connections 60 constituted in a single structured cable 65 ; and a powered end station 70 comprising a first and second data transformer 55 , a first and a second data pair 25 , and a PD 80 . Powered end station 70 is also known as the DTE.
[0005] The primary of each of first and second data transformers 50 are coupled to respective data pairs 20 . An output and return of PSE 40 are connected, respectively, to the center tap of the secondary of first and second data transformers 50 . The output leads of the secondary of first and second data transformers 50 are respectively connected to first ends of a first and a second twisted pair data connection 60 of structured cable 65 . The second ends of first and second twisted pair data connections 60 are respectively connected to the secondary of first and second data transformers 55 located within powered end station 70 . The center tap of the secondary of each of first and second transformers 55 is connected to a respective input of PD 80 . Third and fourth twisted pair data connections 60 of structure cable 65 are connected to respective inputs of PD 80 for use in an alternative powering scheme known to those skilled in the art. In another embodiment, as will be described further below, third and fourth twisted pair data connections 60 further carry data. First and second data pairs 25 are coupled to the primary winding of each of first and second data transformers 55 and represent data transmitted between powered end station 70 , particularly PD 80 , and switch/hub equipment 30 , each direction provided on a respected twisted pair data connection 60 .
[0006] In operation, PSE 40 supplies power over first and second twisted pair data connection 60 , thus supplying both power and data over first and second twisted pair data connections 60 to PD 80 . As described above, since power is transmitted and received via the center tap of the respective transformers 50 , 55 DC flux does not build up in the respective transformers 50 , 55 responsive to power from PSE 40 .
[0007] For speeds of 1000 Mbps, also known as Gigabit Ethernet, all 4 pairs are utilized for data communication, and each of the 4 pairs provide bi-directional communication. Thus, at both the hub equipment and at the DTE end, both a transmitter and a receiver are coupled to each pair. Arrangement 100 of FIG. 1B illustrates such an arrangement. Arrangement 100 is in all respects similar to arrangement 10 , with the exception that data pairs 20 are provided coupled to each of the four twisted pair data connections 60 via respective transformers 50 and similarly four data pairs 25 are coupled to respective twisted pair data connections 60 via respective transformers 55 . As indicated above each of data pairs 20 , 25 are implemented as bidirectional transmitter receiver pairs as will be described further below, responsive to a respective hybrid circuit.
[0008] FIG. 2 illustrates a high level block diagram of an arrangement 100 , known to the prior art, to provide bidirectional communication over each twisted pair data connection 60 . At each end a transmitter 110 , a receiver 120 and a hybrid circuit 130 is provided. The output of each transmitter 110 , comprising a differential pair, is coupled to a respective differential input of the respective hybrid circuit 130 and the input of each receiver 120 , comprising a differential pair, is connected to a respective differential output of the respective hybrid circuit 130 . A bi-directional port of hybrid circuit 130 at the hub side, comprising a differential pair, is coupled to the primary winding of transformer 50 and presents data pair 20 and a bi-directional port of hybrid circuit 130 at the PD side, comprising a differential pair, is coupled to the primary winding of transformer 55 and presents data pair 25 . The secondary winding of transformer 50 is coupled to a first end of a respective twisted pair data connection 60 and the secondary winding of transformer 55 is coupled to a second end of the respective twisted pair data connection 60 .
[0009] Each hybrid circuit 130 is arranged to channel data transmitted by the coupled transmitter 110 towards twisted pair data connection 60 and away from the coupled receiver 120 . Hybrid circuit 120 may be implemented electronically or magnetically, as known to those skilled in the art, although typically electronic hybrid circuits are implemented.
[0010] The arrangement of FIG. 2 thus provides bi-directional communication on each of the twisted pair data connection 60 . Data communication over a single pair, thus obviating the need for a structured cable of 4 twisted pairs, is similarly possible using arrangement 100 , has been commercially implemented, and is commonly known as single pair Ethernet.
[0011] Disadvantageously, the arrangement of FIG. 2 , when utilized for single pair Ethernet does not provide a plurality of powering paths over twisted pair data connection 60 which would result in no net flux. This is particularly true, since with a single twisted pair, the power and return paths must be provided over only the 2 wires of twisted pair data connection 60 .
[0012] U.S. Pat. No. 8,044,747 issued Oct. 25, 2011 to Yu et al., entitled “Capacitor Coupled Ethernet”, the entire contents of which is incorporated herein by reference, provides a system and method for enabling power applications over a single conductor pair. In one embodiment, data transformers are coupled to a single conductor pair using one or more direct current (DC) blocking elements that preserve an alternating current path. Power is injected onto the single conductor pair after the DC blocking elements and power is extracted from the single conductor pair before the DC blocking elements. Disadvantageously, such a solution places the one or more DC blocking elements in the data path before the detecting element, which may lead to signal degradation.
SUMMARY OF THE INVENTION
[0013] Accordingly, it is a principal object of the present invention to overcome at least some of the disadvantages of the prior art. This is provided in certain embodiments by a magnetics based hybrid circuit, comprising a receiver side transformer and a transmitter side transformer. Power is supplied via respective inductive elements coupled to respective first end of the receiver side transformer and the transmitter side transformer. A DC blocking element is further provided in series between the second end of the receiver side primary winding and the second end of the transmitter side primary winding.
[0014] Additional features and advantages of the invention will become apparent from the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding elements or sections throughout.
[0016] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
[0017] FIG. 1A illustrates a high level block diagram of an arrangement for powering a PD from a switch/hub equipment using phantom powering in accordance with the prior art;
[0018] FIG. 1B illustrates a high level block diagram of an arrangement for powering a PD from a switch/hub equipment using phantom powering appropriate for Gigabit Ethernet in accordance with the prior art;
[0019] FIG. 2 illustrates a high level block diagram of an arrangement to provide bidirectional communication over each twisted data pair connection in accordance with the prior art; and
[0020] FIG. 3 illustrates a high level schematic of an exemplary arrangement providing bidirectional data communication and powering over a single twisted pair data connection.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. The term winding is particularly meant to mean a winding of electrically conducting wire forming an inductor. The winding may form a stand alone inductor, or be magnetically coupled to another winding forming a transformer.
[0022] FIG. 3 illustrates a high level schematic of an exemplary arrangement 200 providing bidirectional data communication and powering over a single twisted pair data connection 60 . Arrangement 200 comprises: a PSE 40 ; a twisted pair data connection 60 ; a first transmitter 110 ; a first receiver 120 ; a first combination DC blocking and hybrid circuit 210 ; a first inductive element 220 ; a second inductive element 220 ; a PD 240 ; a second transmitter 110 ; a second receiver 120 ; a second combination DC blocking and hybrid circuit 210 ; a third inductive element 220 ; and a fourth inductive element 220 . Each of first and second combination DC blocking and hybrid circuit 210 comprise a first and a second transformer 250 , a first, second and a third resistor 260 and a DC blocking capacitor 270 . Each transformer 250 comprises a first and a second primary winding 252 and a first and a second secondary winding 254 , arranged about a common core and magnetically inter-coupled.
[0023] Each transformer 250 is described as having a first and a second primary winding 252 primarily for ease of understanding, it being understood that first and second primary windings 252 may be combined into a single primary winding 252 without limitation.
[0024] A first lead of the differential output of first transmitter 110 is connected via first resistor 260 of first combination DC blocking and hybrid circuit 210 to a first end of first primary winding 252 of first transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first primary winding 252 of first transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a first end of second primary winding 252 of first transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second primary winding 252 of first transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a second lead of the differential output of first transmitter 110 .
[0025] A first lead of the differential input of first receiver 110 is connected to a first end of first primary winding 252 of second transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first primary winding 252 of second transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a first end of second primary winding 252 of second transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second primary winding 252 of second transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a second lead of the differential input of first receiver 120 . Second resistor 260 of first combination DC blocking and hybrid circuit 210 is connected across the differential inputs of first receiver 120 .
[0026] A first end of first secondary winding 254 of first transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity, is connected to a first end of third resistor 260 of first combination DC blocking and hybrid circuit 210 . A second end of first secondary winding 254 of first transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a first end of first secondary winding 254 of second transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first secondary winding 254 of second transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a second end of second resistor 260 of first combination DC blocking and hybrid circuit 210 .
[0027] A first end of second secondary winding 254 of first transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity, is connected via DC blocking capacitor 270 to a first end of second secondary winding 254 of second transformer 250 of first combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second secondary winding 254 of first transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a first output of PSE 40 via first inductive element 220 , the first output of PSE 40 denoted as the positive output for clarity, without limitation, and to a first end of a first wire of twisted pair data connection 60 . A second end of second secondary winding 254 of second transformer 250 of first combination DC blocking and hybrid circuit 210 is connected to a second output of PSE 40 via second inductive element 220 , the second output of PSE 40 denoted as the return for clarity, without limitation, and to a first end of a second wire of twisted pair data connection 60 . In particular, as will be apparent, combination DC blocking and hybrid circuit 210 is polarity insensitive.
[0028] A first lead of the differential output of second transmitter 110 is connected via first resistor 260 of second combination DC blocking and hybrid circuit 210 to a first end of first primary winding 252 of first transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first primary winding 252 of first transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a first end of second primary winding 252 of first transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second primary winding 252 of first transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a second lead of the differential output of second transmitter 110 .
[0029] A first lead of the differential input of second receiver 110 is connected to a first end of first primary winding 252 of second transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first primary winding 252 of second transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a first end of second primary winding 252 of second transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second primary winding 252 of second transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a second lead of the differential input of second receiver 120 . Second resistor 260 of second combination DC blocking and hybrid circuit 210 is connected across the differential inputs of second receiver 120 .
[0030] A first end of first secondary winding 254 of first transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity, is connected to a first end of third resistor 260 of second combination DC blocking and hybrid circuit 210 . A second end of first secondary winding 254 of first transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a first end of first secondary winding 254 of second transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of first secondary winding 254 of second transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a second end of third resistor 260 of second combination DC blocking and hybrid circuit 210 .
[0031] A first end of second secondary winding 254 of first transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity, is connected via DC blocking capacitor 270 to a first end of second secondary winding 254 of second transformer 250 of second combination DC blocking and hybrid circuit 210 , denoted with a dot for polarity. A second end of second secondary winding 254 of first transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a second end of the first wire of twisted pair data connection 60 and via third inductive element 220 to a first input of PD 240 , denoted as the positive input for clarity, without limitation. A second end of second secondary winding 254 of second transformer 250 of second combination DC blocking and hybrid circuit 210 is connected to a second end of second wire of twisted pair data connection 60 and via fourth inductive element 220 to a second input of PD 240 , denoted as the return for clarity, without limitation.
[0032] In one embodiment, each of first, second, third and fourth inductive elements 220 are constituted of a stand-alone inductor. In another embodiment, each of first, second, third and fourth inductive elements 220 are constituted of ferrite beads which provide high AC resistance at data frequencies instead of reactive impedance. In one particular embodiment, the ferrite beads of first, second, third and fourth inductive elements 220 are constituted of nickel zinc which provide ohmic resistance at high frequencies, and thus do not present phase changes. In yet another embodiment first and second inductive element 220 are constituted of a pair windings on a single core arranged to offer impedance to differential signals appearing on single twisted pair data connection 60 . Additionally, or optionally, third and fourth inductive element 220 are similarly constituted of a pair windings on a single core arranged to offer impedance to differential signals appearing on single twisted pair data connection 60 . Each of first, second and third resistors 260 of the respective combination DC blocking and hybrid circuit 210 are preferably matched to provide impedance matching. DC blocking capacitor 270 is selected to pass frequencies of data transmission without appreciable impedance.
[0033] In operation, each combination DC blocking and hybrid circuit 210 provides DC blocking and echo cancellation. For clarity, operation of first combination DC blocking and hybrid circuit 210 will be detailed, it being understood by those skilled in the art that the identical explanation is to be applied to second combination DC blocking and hybrid circuit 210 . In the event that first transmitter 110 is active, the differential signal creates a current flow through first windings 252 of first transformer 250 , which is mirrored in second windings 254 of first transformer 250 . Due to the crossed connections via third resistor 260 , the current flow through first windings 252 of second transformer 250 , responsive to the differential signal from first transmitter 110 , cancel current flow responsive thereto reflected back from second combination DC blocking and hybrid circuit 210 via twisted pair data connection 60 . In some further detail, the polarity of current flow experienced by first receiver 120 responsive to the output of first transmitter 110 , received via first and second primary windings 252 and first secondary winding 254 of second transformer 250 is 180° out of phase with the polarity of current flow experienced by first receiver 120 responsive to the reflected signal received via twisted pair data connection 60 and reflected to receiver 120 via second secondary winding 254 of second transformer 250 . DC blocking capacitor 270 prevents a short circuit for current injected by PSE 40 . Inductive elements 220 prevent PSE 40 from appearing as a capacitive load to data signals traversing twisted pair data connection 60 .
[0034] Similarly, current flow caused by a differential signal received over twisted pair data connection 60 , originating in second transmitter 110 , creates a current flow through second windings 254 of first and second transformers 250 , which is mirrored in first windings 252 . Due to the crossed connections via third resistor 260 , the current flow through first windings 252 of first transformer 250 experienced by first transmitter 110 are cancelled by current flow reflected back from the current flow experienced by first receiver 120 . In some further detail, the polarity of current flow experienced by first transmitter 110 responsive to the current flow received via twisted pair data connection 60 is 180° out of phase with the polarity of current flow experienced by first transmitter 110 reflected by the cross connection.
[0035] The operation of combination DC blocking and hybrid circuit 210 , in the absence of DC blocking capacitor 270 , which as described above does not impact operation in relation to high frequency signals, is known to those skilled in the art.
[0036] Referring to PD 240 , power is received from the second ends of secondary windings 254 , and inductive elements 220 prevent PD 240 from appearing as a capacitive load to data signals traversing twisted pair data connection 60 . PD 240 typically comprises a diode bridge input circuit thus providing the above mentioned polarity insensitivity, and a under voltage lockout circuit to prevent startup of any load circuitry until sufficient voltage appears across the input leads of PD 240 . Such a PD 240 is known to those skilled in the art, and in the interest of brevity is not further detailed.
[0037] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.
[0039] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including definitions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
[0040] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not in the prior art. | A magnetics based hybrid circuit, comprising a receiver side transformer and a transmitter side transformer is described. Power is supplied via respective inductive elements coupled to respective first end of the receiver side transformer and the transmitter side transformer. A DC blocking element is further provided in series between the second end of the receiver side primary winding and the second end of the transmitter side primary winding. | 7 |
This is an application claiming the benefit under 35 USC 119(e) of U.S. Provisional Application Ser. No. 60/447,025, filed Feb. 13, 2003. All of U.S. Ser. No. 60/447,025 is incorporated herein by this reference to it.
FIELD OF THE INVENTION
This invention relates to wastewater treatment and, more particularly, to a method and system for the treatment of wastewater, for example industrial or municipal wastewater.
BACKGROUND OF THE INVENTION
Currently, most wastewater treatment plants use an activated sludge process, based on biological oxidation of organic contaminants in a suspended growth medium. Oxygen is supplied from air using bubble type aerators. Efficiency of these systems is poor resulting in very high energy use. Tank size is large as chemical oxygen demand loadings are low because of low biomass concentration. The result is high capital and operating cost.
A second type of established biological oxidation process uses biofilms grown on a media. The wastewater is circulated to the top of the reactor and trickles down. Air is supplied at the bottom. The rate of oxygen transfer is limited by the biofilm surface area, and the operating cost is high because of wastewater pumping requirements. Other versions of this process are also available, but all of these result in high operating costs.
Recently, development work has been done on a membrane supported bioreactor concept. This process involves growing biofilm on the surface of a permeable membrane. Oxygen containing gas is supplied on one side of the membrane and the biofilm is grown on the other side, which is exposed to the substrate. Oxygen transferred through the membrane is absorbed by the biofilm as it is available in the form of very fine bubbles. This type of process has not become commercially viable.
SUMMARY OF THE INVENTION
It is an object of this invention to improve on the prior art. It is another object of this invention to provide methods and apparatus suitable for treating water, for example industrial and municipal wastewater, using membrane supported bioreactor technology. It is another object of this invention to provide a hollow fibre membrane and module and to use them in a membrane supported biofilm reactor. The inventors have observed that a membrane and module with a high gas transfer rate and adequate surface area would allow a membrane supported biofilm reactor to provide an operating cost advantage over other processes used in the art. For example, a savings in operating cost may be achieved using a membrane with an oxygen transfer efficiency (OTE) of over 50% or in the range of 50% to 70% or more. The inventors have also observed that a module of hollow fibre membranes may provide a large surface area but that commercially available hollow fibre membranes tend to wet which results in a drastic drop in their oxygen transfer rates.
In one aspect, this invention provides a very fine dense hollow fibre made from polymethyl pentene (PMP), which has a high selectivity and diffusion coefficient for oxygen. Use of very small diameter fibre helps reduce module cost as established textile fine fibre technology can be used. A very large surface area can be provided to achieve high OTE.
In another aspect, this invention provides a fabric with a very large number of PMP hollow fibres providing sufficient surface area so that oxygen transfer does not become a limiting factor in controlling biological kinetics. The fabric is made with the PMP fibre as weft and an inert fibre as warp to minimize the damage to the fibre while weaving. The fabric provides strength to the fine fibre to permit biofilm growth on its surface with minimal fibre breakage.
In another aspect, the invention provides a module built from this fabric with very high packing density to permit good substrate velocities across the surface without recirculation of a large volume of liquid. The modules enable oxygen containing gas to be supplied to the lumen of the hollow fibre without exposing it to the wastewater. Long fibre elements are used and potted in the module header to provide a low cost configuration.
In another aspect, this invention uses air as a means of controlling the biofilm thickness to an optimum level. Other methods of biofilm control include in-situ digestion, periodic ozonation followed by digestion, and use of a higher life form, such as worms, to digest the biofilm periodically. To speed up the biological digestion reactions, the air is preheated to raise the temperature of the bioreactor.
In another aspect, this invention provides a plug flow, or multistage continuously stirred tank reactors to conduct biological reactions at high substrate concentrations. This maximizes mass transfer of organic carbon compounds and ammonia in the biofilm, eliminating this process as a potential limitation to reaction rates.
In another aspect, this invention uses oxygen enrichment as a means of dealing with peak flows. Such oxygen enrichment may be determine by on-line COD monitors, or set according to time of day for municipal applications where diurnal flow and strength variations are well known.
In another aspect, this invention uses the module and bioreactor design to conduct other biological reactions on the surface of the fabric. An example is biological reduction of compounds such as sulphates in water using hydrogen gas supplied to the lumen of the hollow fibre.
In another aspect, this invention uses either air or enriched air to supply oxygen. Selection of enriched air and level of oxygen present in such air is determined by the wastewater strength.
In another aspect, this invention uses one or more of the apparatuses described above to digest primary and secondary sludge.
The features of these various embodiments may be combined together in various combinations or sub-combinations. The description above is intended to introduce the reader to aspects of the invention, embodiments of which will be discussed below. In addition to various combinations of features described above, the invention may also involve combinations or sub-combinations of features or steps described above with features or steps described below.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described below with reference to the following figures.
FIG. 1 presents a picture of a fibre.
FIG. 2 presents a drawing of a fabric made from the fibre of FIG. 1 .
FIG. 3 is a drawing of a module made from the fabric of FIG. 2 .
FIG. 4 presents a picture of the module of FIG. 3 .
FIG. 5 is a graph of results of tests on the module of FIG. 4 .
FIGS. 8 and 9 are drawings of reactors excerpted from U.S. Ser. No. 09/799,524.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a textile polymethyl pentene fibre with 45 micron outside diameter and 15 to 30 micron inside diameter. The fibre is made by a melt extrusion process in which the PMP is melted and drawn through an annular spinnerette. The raw polymer used was MX-001, produced by Mitsui Petrochemical. Outside diameters of 30–50 microns may be used. The fibres are hollow inside but non-porous. Oxygen travels through the fibre walls by molecular diffusion.
In FIG. 2 , the fibre is woven in a fabric, with PMP fibre running horizontally, and an inert fibre running vertically to provide support to the fine PMP fibre. FIG. 3 shows a module, in which a bundle or stack of sheets of fabric are potted at both ends in a header using potting materials such as polyurethane, hot melt or epoxy. A large sheet of the fabric may also be rolled or folded to produce a module rather than using separate sheets. The bundle is assembled together with spacers between the sheets of fabric which provide a gap between the sheets for aeration and substrate flow. These spacers may be plastic strips or hot melt layers. The gap between sheets may range from 3 mm to 15 mm depending on the nature of the wastewater. The length of the module may range from 1 m to 5 m. To produce the module of FIG. 3 , a sheet of fibres is laid onto strips of adhesive located to cross the ends of the fibres. Spacing strips were then placed over the sheet, followed by additional strips of adhesive and an additional sheet of fabric. These steps were repeated several times. The resulting assembly was then sealed into a pair of opposed headers such that the lumens of the fibres would be in communication with a port in one or both headers.
Gas containing oxygen flows into at least one of the headers. The module may be operated in a dead end mode, with no outlet other than through the fibres. Alternately, the module may be operated in a cross flow manner with gas entering through one header, flowing through the membranes then exiting from the other header. The oxygen content and flow rate of the gas may be set to produce an oxygen transfer that provides aerobic conditions near the membranes and anoxic conditions near the substrate being treated. Multiple reactions, including carbon based organics, ammonia and total nitrogen reduction, may be performed in the biofilm,
FIG. 4 shows a picture of a module assembled as described above. The headers were about 2 metres apart. Additional spacers were used mid way between the headers to better preserve the sheet separation. A thin steel rod was attached to the edges of the fabric sheet in the right half of the module to address the folding which can be seen in the left half of the Figure.
Reactors similar to those describes in U.S. patent application Ser. No. 09/799,524, filed Mar. 7, 2001, may be used. For example the reactors discussed in an excerpt from U.S. Ser. No. 09/799,524 reproduced below may be used with the present invention. The entire text of U.S. patent application Ser. No. 09/799,524, filed Mar. 7, 2001, is incorporated herein by this reference to it.
In another embodiment of the invention, a biofilm is grown on a fabric woven from textile PMP dense wall hollow fibre. Oxygen bearing gas is introduced into the lumen of the fibre. Aerobic reactions take place at the surface of the fibre, where the highest levels of oxygen exists. These reactions include conversion of organic carbon compounds to carbon dioxide and water, and ammonia to nitrates. The surface of the biofilm is maintained under anoxic conditions such that conversion of nitrates to nitrogen can take place. The result is simultaneous reduction of organic carbon, ammonia and total nitrogen.
In another embodiment, all the above features are used, except that high aeration velocity of 2–8 feet/second is used at the surface of the fabric to reduce the thickness of the biofilm. This is done once every day to once every week. Also, air may be used to periodically mix the contents of the bioreactor.
In another embodiment of the invention, a number of bioreactors are installed in series to provide flow patterns approaching plug flow. This results in higher reaction rates and better utilization of oxygen.
In another embodiment, ozone gas, introduced in the fibre lumen, is used to oxidize a part of the biofilm to make it digestible. Oxygen is then provided to digest the oxidized organics, thereby reducing the total amounts of solids generated.
In another embodiment of the invention, worms are used in an isolated section of the reactor to digest excess biofilm to reduce bio-solids generation. The worms are grown in a separate bioreactor.
In another embodiment of the invention, different oxygen levels are used in different stages of the bioreactor by oxygen spiking to meet different levels of oxygen demand and to achieve high bioreactor loadings.
In another embodiment of the invention, the elements are stacked in a vertical configuration, with flow taking place from top to bottom or bottom to top. This reduces the capital required for aeration and the operating cost of air. Numerous other embodiments may also be made according to the invention.
EXAMPLE
Example 1
Chemical Oxygen Demand (COD) Reduction in a Membrane Supported Bioreactor
A bench scale bioreactor was designed using the experimental module presented in FIG. 4 . Wastewater with a COD level of 1000 mg/l was introduced in a batch manner at daily intervals. A series of batch reactions were conducted to determine the rate of reaction and oxygen transfer efficiency. FIG. 5 presents the results. It can be seen that 80–90% reduction of COD was obtained. Oxygen transfer efficiency during these series of tests ranged from 50 to 70%, as measured by the exit concentration of air.
Excerpt Form U.S. Ser. No. 09/799,524
Membrane Supported Biofilm Reactors for Wastewater Treatment
FIG. 8 shows a reactor 80 having a tank 82 , a feed inlet 84 to the tank 82 , an effluent outlet 86 from the tank 82 , a flow path 88 between the feed inlet 84 and effluent outlet 86 and a plurality of the third apparatus 210 . The third apparatus 210 is shown as an example only and the second apparatus 110 or first apparatus 10 may also be used with suitable modifications to the reactor 80 .
The planar elements 226 are sized to fit the tank 82 and fill a substantial amount of its volume. The planar elements 226 have no pre-manufactured or rigid frame and thus are preferably custom made to provide efficient use of the available space in the tank 82 . For example, planar elements 226 may range from 0.5 m to 2 m wide and 2 to 10 m deep. The planar elements 226 are preferably arranged in the tank 82 in a number of rows, one such row being shown in FIG. 8 . The planar elements 226 may range from 0.5 to 2 mm in thickness and adjacent rows are placed in the tank 82 side by side at a distance of 5 to 15 mm to allow for biofilm growth and wastewater flow between adjacent planar elements 226 .
The tank 82 is longer than it is deep and it is preferred to encourage a generally horizontal flow path 88 with minimal mixing. This is done by leaving some space near the ends (ie. near the inlet 84 and outlet 86 ) of the tank 82 for vertical movement of water and leaving minimal free space at the top, bottom and sides of the tank 82 . A baffle 90 may also be placed upstream of the effluent outlet 86 to force the flow path 88 to go under it. A sludge outlet 92 is provided to remove excess sludge.
The flow path 88 is generally straight over a substantial portion of the tank 82 between the feed inlet 84 and effluent outlet 86 . Each third apparatus 210 is held in the tank 82 by its headers 52 attached to a frame 90 and by its weight 68 . The headers 52 , frame 90 and weights 68 restrain each third apparatus 210 in positions in the reactor 80 whereby the planar element 226 of each third apparatus 210 are generally parallel to the flow path 88 . Preferably, a plurality of planar elements 226 are spaced in series along the flow path 88 so that the reactor 80 will more nearly have plug flow characteristics. Wastewater to be treated may be partially recycled from the effluent outlet 86 to the feed inlet 84 . Such a recycle can increase the rate of gas transfer by increasing the velocity of wastewater along the flow path 88 , but it is preferred if the recycle ratio is small so as to not provide more nearly mixed flow characteristics in the reactor 80 .
Oxygen containing gas is provided to each third apparatus 210 through its inlet conduit 216 connected to an inlet manifold 94 located above the water to be treated. With the inlet manifold 94 located above the water, a leak in any third apparatus 210 will not admit water into the manifold nor any other third apparatus 210 . Gas leaves each third apparatus 210 through its outlet conduit 218 which is connected to an exhaust manifold 95 . Although it is not strictly necessary to collect the gases leaving each third apparatus 210 , it does provide some advantages. For example, the gas in the exhaust manifold 95 may have become rich in volatile organic compounds which may create odour or health problems within a building containing the reactor 80 . These gases are preferably treated further or at least vented outside of the building.
Preferably, the gas is provided at a pressure such that no bubbles are formed in the water to be treated and, more preferably, at a pressure of less than 10 kPa. This pressure is exceeded by the pressure of the water to be treated from one meter of depth and beyond. Preferably at least half of the area of the third planar elements 226 is below that depth. The water pressure thus prevents at least one half of the surface of the membranes 12 from ballooning.
Oxygen diffuses through the membranes 12 . The amount of oxygen so diffused is preferably such that an aerobic biofilm is cultured adjacent the planar elements 226 , an anoxic biofilm is cultivated adjacent the aerobic biofilm and the wastewater to be treated is maintained in an anaerobic state. Such a biofilm provides for simultaneous nitrification and denitrification. A source of agitation 96 is operated from time to time to agitate the planar elements 226 to release accumulated biofilm. A suitable source of agitation is a series of coarse bubble aerators 98 which do not provide sufficient oxygen to the water to be treated to make it non-anaerobic.
FIG. 9 shows a second reactor 180 having a tank 182 , a feed inlet 184 , an effluent outlet 186 , a flow path 188 and a plurality of the first apparatus 10 . The first apparatus 10 is shown as an example only and the second apparatus 110 or third apparatus 210 may also be used with suitable modifications to the second reactor 180 .
Each first apparatus 10 is held by its loops 30 wrapped around wires 100 or ropes attached to the tank 182 . The loops 30 and wires 100 restrain each first apparatus 10 in a position in the second reactor 180 whereby the planar element 26 of each first apparatus 10 is generally parallel to the flow path 188 .
The first planar elements 26 are sized to fit the tank 182 and fill a substantial amount of its volume. Like the third planar elements 226 , the first planar elements 26 have no pre-manufactured or rigid frame and are preferably custom made to provide efficient use of the available space in the tank 182 . The first planar elements 26 may range from 0.25 to 1 mm in thickness and are placed side by side at a distance of 5 to 15 mm to allow for biofilm growth and wastewater flow between adjacent first planar elements 26 .
The tank 182 is deeper than it is long and it is preferred to encourage a straight and generally vertical flow path 188 over a substantial portion of the tank 182 with minimal mixing. This is done by leaving minimal space near the ends and sides of the tank 82 but a substantial amount of space near the top and bottom of the tank 82 . Water to be treated may be partially recycled from the effluent outlet 186 to the feed inlet 184 but it is preferred that the recycle rate be small.
Oxygen containing gas is provided to each first apparatus 10 through its inlet conduit 16 connected to a manifold 94 located above the water to be treated. With the inlet manifold 94 located above the water, a leak in any first apparatus 10 will not admit water into the manifold nor any other first apparatus 210 . The outlet conduits 18 are clipped in a convenient place, for example to the inlet manifold 94 , above the surface of the water to be treated. Preferably, the gas is provided at a pressure of less than 10 kPa and the planar elements 26 are located more than 1 m deep in the tank 182 . In this way, the gas pressure is exceeded by the pressure of the water to be treated which prevents the membranes 12 from ballooning. Glue lines (not shown), preferably not effecting more than one half of the area of the planar elements 26 , can be used to reinforce part of the planar elements 26 if they can not be mounted deep enough.
Alternatively, gas flow through the first element 10 is produced by applying a suction, preferably of not more than 10 kPa less than atmospheric pressure, to the outlet conduits 18 . The inlet conduits 16 are placed in fluid communication with the atmosphere. By this method, the rate of gas diffusion across the membrane 12 is slightly reduced, but no reinforcement of the membrane 12 (for example, by glue lines) is required regardless of the depth of the first element 10 .
Oxygen diffuses through the membranes 12 preferably such that an aerobic biofilm is cultured adjacent the planar elements 26 , an anoxic biofilm is cultivated adjacent the aerobic biofilm and the wastewater to be treated is maintained in an anaerobic state. A second source of agitation 196 is operated from time to time to agitate the first planar elements 26 to release accumulated biofilm. A suitable source of agitation is a series of mechanical mixers 102 . | A membrane supported biofilm reactor uses modules having fine, dense, non-porous hollow fibers made from Polymethyl pentene (PMP) formed into a fabric with the PMP as the weft. One or more sheets of the fabric are potted into a module to enable oxygen containing gas to be supplied to the lumens of the hollow fibers. Various reactors using such modules are described. | 2 |
TECHNICAL FIELD
This invention relates to the manufacture and processing of automotive vehicle wheels fabricated from cast magnesium alloys, especially wheels having radial spokes connecting the rim and hub portions of the wheels. More specifically this invention relates to the use of friction stir processing on predetermined portions of the cast wheels to improve their physical properties.
BACKGROUND OF THE INVENTION
Both for appearance and to maximize air flow to the brakes, automobile wheel styling has tended to emphasize open designs in which the tire-bearing rim is supported on slender spokes or columns connecting the rim to the hub. This is particularly true for alloy (aluminum or magnesium) wheels and is beneficial in reducing wheel mass but results in the imposition of higher stresses than obtain in a wheel designed with a more traditional, generally disc-shaped, spider.
In vehicle use, wheels experience repeated cyclic loads and operate under adverse corrosion conditions. Despite this, wheels are required to exhibit a suitable service lifetime and to achieve this goal current magnesium wheels are forged, primarily to improve their performance under cyclic loading. However magnesium is a difficult material to forge and only a few magnesium alloys are forgeable, which limits the number of magnesium alloys which may be selected. Further it limits the range of wheel designs which may be economically produced, since complex wheel designs cannot be substantially realized by forging alone but they require a combination of forging and extensive machining.
However, tests and simulations demonstrate that wheels are not uniformly stressed but rather experience high stresses only in local regions. This suggests that rather than improving the fatigue performance of the entire wheel, through forging, selective improvement in fatigue performance of a cast magnesium wheel in high stress areas would be equally beneficial in meeting performance goals. Thus a procedure capable of identifying the highly stressed regions and imparting selective fatigue performance improvement would enable the application of reduced cost cast magnesium wheels with performance at least equivalent to that of current forged wheels.
SUMMARY OF THE INVENTION
This invention provides a method for making cast vehicle wheels of a magnesium alloy selected for a wheel application. In many embodiments a selected magnesium alloy will be cast by die casting, either high pressure or low pressure die casting, or by squeeze casting to reduce porosity in the cast wheel. The method is applicable to many wheel designs (solid and open) but is particularly useful where the wheel uses spokes to connect the rim with the wheel hub.
The shape of the wheel is analyzed in consideration of the physical properties of the cast magnesium alloy material. A goal of the structural analysis may be to determine regions of the cast wheel in which an improvement in fatigue strength may be required. In accordance with embodiments of this invention, surfaces of such cast wheel regions may be subjected to friction stir processing conducted to thermoplastically work the surface in a solid-state mode to improve its mechanical properties, such as its fatigue strength.
An engineering analysis of structural loading of a prospective light metal alloy cast wheel design is a first step to determining whether friction stir processing may be useful. In use, loads applied at the tire-road contact patch are transferred through the wheel to the axle. When the wheel design uses spokes, the tire load passes to the wheel rim and is then conveyed by the spokes to the hub. The response of the wheel rim to this loading is generally less important than the response of the spokes. A particular loading condition of concern to wheel designers is the loading resulting from cornering which applies a rotating bending moment to the hub which will cause the spokes to flex out of the plane of the wheel. The wheel spokes, for purposes of analysis, may be treated as columns extending from the rim to the hub of the wheel. Thus cornering forces applied at the tire contact patch will manifest themselves as a load applied at the end of a cantilevered beam and will generate high stresses at the connection of the spoke (beam) and hub.
Thus, the fatigue strength of the wheel may be increased if it is possible to selectively improve the capabilities of the material in those high stress regions which are most prone to failure, such as the region where the spoke joins the hub. A technology for doing this is friction stir processing.
Friction stir processing is a process derivative of friction stir welding and involves the interaction between a workpiece and a generally cylindrical, rotating tool with a pin protruding from one of its planar bounding surfaces thereby creating a shoulder on the tool. The pin is generally aligned with the axis of tool rotation. As the tool is rotated and pressed against a predetermined surface region of a cast wheel, the rotating pin commences heating of the contacted surface. The rotating pin locally heats the contacted material, lowering its flow strength, and enabling significant plastic flow which permits the pin to penetrate into the softened metal to its full length. Thus the length of the pin should be determined to penetrate to a desired depth below the surface of a cast wheel. At full tool penetration, the shoulder of the tool substantially contacts the surface of the workpiece over a region based on the diameter of the shoulder.
The rubbing of the shoulder on the workpiece due to tool rotation will also generate frictional heating and locally raise the workpiece temperature. The combined effects of pin and shoulder are employed to successively work and strengthen regions of the cast wheel workpiece. The rotating tool may engage the wheel surface at one or more fixed spots such as at the rim ends of spokes of the wheel. Or the tool may be moved while penetrating a treated wheel surface to process an area of the workpiece that is larger than the contacting surfaces of the tool.
Friction stir processing imparts significant loads to the part. In many applications where the workpieces may be supported by an external structure it is possible to process the workpiece to a depth substantially equal to its thickness. The complex geometry of wheels will generally preclude introducing a support structure in the rear except for relatively simple designs. Thus much of the processing will result from pin penetrations of less than the full wheel thickness. This may be sufficient to enable the desired durability improvement or it may be necessary to make two passes with the friction stir processing tool—one pass on the front wheel surface and a second on the opposing surface on the reverse surface of the wheel.
The local workpiece temperature is less than the melting point of the workpiece but sufficient to reduce its strength and render it more malleable. Hence the heated, softened region under the tool shoulder will be deformed as the rotating pin induces a stirring action in the workpiece leading to local deformation and transport of workpiece material about its axis of rotation. The combination of these complex metal flows and the elevated temperature will result in both grain refinement and porosity elimination or reduction. Thus friction stir processing may confer, locally, many of the advantages obtained globally through forging. Specifically addressing fatigue life improvements in magnesium alloys, fatigue life improvements in excess of a factor of 10 in the long-life regime have been reported.
The fatigue life of metal components is also strongly affected by the surface condition of the component, with smoother surfaces promoting longer fatigue lives than rougher surfaces. While friction stir processing will generate an improved microstructure with more fatigue-resistant properties the surface finish of a friction stir processed component is not smooth. Thus the surface of the wheel will generally be machined after friction stir processing to improve its durability under fatigue load as well as to impart a more pleasing appearance to the wheel.
A further advantage of friction stir processing, however, is that a much wider range of alloys may be friction stir processed than may be forged. This affords the opportunity to select cast alloys with other desirable attributes, for example corrosion resistance, with the assurance that, by selective friction stir processing, acceptable fatigue life may be achieved.
Thus this invention seeks to selectively friction stir process cast magnesium alloy wheels with good corrosion resistance to impart superior fatigue resistance to those regions of the wheel which are subject to the highest in-service stresses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an alloy wheel for a passenger vehicle representative of those to which this invention may be applied.
FIG. 2 shows a representative wheel design onto which have been mapped contour lines showing the magnitudes of the largest tensile values of the major principal stresses developed during a specific evaluation procedure for wheel response to in-service loading—a Cornering Fatigue Test. It will be appreciated that as the wheel rotates only a portion of the tire (wheel) will be in contact with the road so that the applied loads will be localized and directional. The stresses shown are instantaneous stresses which will rotate around the wheel as the wheel rotates and the stresses shown in the lower spokes in FIG. 2 will be experienced by all spokes in sequence as the wheel rotates.
FIG. 3 shows experimental test data on the fatigue life of magnesium AZ91 test coupons produced by high pressure die casting. The conditions of the test coupons include: as-cast; heat treated; friction stir processed; and heat treated and friction stir processed.
FIG. 4 is a schematic illustration of friction stir processing, showing the general tool geometry, the stirred or processed zone and the roughened surface left after the passage of the tool.
FIG. 5 shows the wheel design of FIG. 2 further illustrating the regions of preferred friction stir processing, which by reference to FIG. 2 are shown to be the regions where the highest major principal stresses are developed under the Cornering Fatigue Test. As noted in conjunction with FIG. 2 , all spokes experience similar loading and thus will require similar processing.
FIG. 6 shows the as-cast geometry of the wheel design of FIG. 2 on which a representative path for friction stir processing has been overlaid and also illustrating material additions to facilitate friction stir processing. In most applications these material additions will be subsequently machined off.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a wheel 100 suitable for the practice of this invention, which exhibits the spoke-like configuration which will generate high stresses at the hub under cornering loads. Specifically FIG. 1 indicates a wheel with a hub 112 including bolt holes 118 for attachment of the wheel to the wheel hub (not shown) of the vehicle. Hub 112 is connected to rims 114 and 124 by columnar spokes 116 . In service a tire (not shown) will be mounted on and sealed against wheel rims 114 and 124 to create a sealed air volume between the interior of the wheel cavity and the tire when opening 122 is sealed with a valve suitable for controlled removal and addition of air.
FIG. 2 shows a second, but similar, representative wheel 200 which has been analyzed to determine the stresses throughout the wheel under a test intended to simulate the loading occurring on hard cornering. Clearly, consistent with the simple beam analogy described above, the highest tensile stresses, which can be significant, develop where the columnar-like spokes 216 and hub 212 join. Note that in this design the bolt holes 218 are not aligned with spokes 216
FIG. 3 shows experimental fatigue data on a high pressure die cast AZ91 magnesium alloy (nominal composition by weight: 8.3-9.1% aluminum; 0.4-1.0% Zn; balance magnesium) tested under four conditions: as-cast; as cast and heat treated (indicated as AZ91 H. T.); as-cast and friction stir processed (indicated as AZ91 FSP); and as-cast and heat treated and then friction stir processed (indicated as AZ91 H. T. FSP). It is clear that while heat treating the casting offers some modest advantage in fatigue life, the major enhancement in fatigue life is obtained by friction stir processing, which raises the stress at which a fatigue life of 1×10 7 cycles is obtained from around 55 MPa to around 75 MPa. Although not relied upon, this improvement was attributed to reduction in grain size and the essential elimination of (micro) porosity in the stirred zone.
Thus significant advantage in fatigue lifetime may be achieved through friction stir processing. Friction stir processing is schematically depicted in FIG. 4 which shows a tool 10 , with shoulder 18 and pin 20 , rotating about its axis 15 as indicated by arrow 12 and advancing in a direction indicated by arrow 14 . The underside of shoulder 18 is in contact with upper surface 30 of workpiece 28 and pin 20 is embedded in workpiece 28 where it has generated a stirred region 24 . Shoulder 18 is maintained in contact with surface 30 of the workpiece 28 by a force directed substantially along axis 15 and the motion of tool 10 along surface 30 has led to some surface roughening 26 in the wake of the advancing tool.
From review of FIG. 4 several points may be appreciated. First, it may be noted that the rotation of the tool transports workpiece material around the tool. However, although the workpiece has been heated by frictional heating it does not reach its melting point and therefore remains solid. Thus, the stirring action results in large plastic strains and the combination of the large plastic strain and elevated temperature induces thermoplastic processing in the solid state which is beneficial in refining the grains size reducing or eliminating porosity.
Note that the stirring action is entirely associated with the pin and thus the width of the stirred zone will be directly related to the pin diameter. Conversely if it is desired to confer the benefits of friction stir processing on a large area it is necessary either to employ a large diameter pin 20 or to make repeated passes over the area, offsetting the pin position with each pass. A second point is that the function of the shoulder is two-fold: to enforce the stirring action of the pin by acting as a barrier to any up-flow of material; and to generally heat the stirred zone through frictional interaction with the surface 30 . It may be noted that to be effective in controlling the up-flow of material the underside of shoulder 18 should closely conform to surface 30 . This is easily accomplished for flat surfaces like that depicted in the figure but is more challenging on contoured surfaces such as would be encountered on a wheel. Thus it may be necessary to impose design restrictions on the shape of the wheel where friction stir processing is contemplated to ensure good entrainment of the stirred material.
A specific point which should be comprehended in the design is to control the transition from the spoke to the hub since the maximum stresses, as FIG. 2 makes clear, will occur in that region. Thus the transition should be gradual to enable use of simple friction stir processing tools. Alternatively, since some machining will be required after friction stir processing to render a smooth surface, it may be more practical to design the casting to facilitate friction stir processing and generate any desired product features through machining. For example by casting a flat surface all along the desired friction stir processing path, and only after friction stir processing introduce the desired contour in this region by machining. Or start with a flat as-cast surface all along the desired friction stir processing path, and after FSP machine the surface to give the desired contour. This machining may not be an extra step, since the rough friction stir processed surface will require machining anyway as discussed below.
Through analysis of FIG. 2 it is clear that the maximum tensile stresses occur on the edges of the wheel spokes. Thus these regions are the obvious candidate regions for friction stir processing as indicated by X in FIG. 5 . It will be appreciated however that since the goal is to improve fatigue life and since fatigue life is adversely affected by surface imperfections, the surface roughness left by the tool shoulder ( 26 in FIG. 4 ) should be removed before the wheel is placed in service.
Issues not addressed in the discussion to this point relate to the insertion and extraction of the tool 10 corresponding to the initiation and termination of friction stir processing. Since the pin 20 extends beyond shoulder 18 , it is clear that on initial insertion of the pin into the workpiece the portion of the workpiece displaced by the pin will be unconstrained by the shoulder. Thus on first workpiece-pin contact, material will be displaced upward out of the stirred region so that this material will be lost to the stirred zone and if the pin were extracted a cavity corresponding to the displaced material would remain on the surface. Similarly at the end of the process, extraction of the pin will leave a cavity in the surface. Obviously these cavities may be detrimental to fatigue life and thus may not be tolerated in the finished wheel. Various suggestions have been put forward for more complex tools, for example incorporating retractable pins, or for modifying tools to enable addition of filler metal, to overcome this general deficiency of friction stir welding and processing. However it is not clear that the benefits of these tooling approaches offset their additional complexity.
An alternative and more direct approach is to cast a wheel blank incorporating dispensable features to serve as locations for the entrance and exit of the friction stir tool from the wheel, and, after serving that purpose, to be machined off. An example is shown in FIG. 6 . Here the casting geometry has been modified to form an additional cast section 225 which partially spans the gap between spokes 216 and 216 ′. Friction stir process tool path 260 is shown as a dotted line which traverses all of the spokes and particularly traverses those regions previously identified as subject to high stresses. Friction stir tool path 260 however originates and terminates at location A in the additional cast section 225 , thus enabling all critical wheel regions to be traversed without need of tool insertion or withdrawal. Hence the undesirable surface features resulting from tool insertion or withdrawal are confined to additional cast section 225 which may be machined off after friction stir processing has been conducted.
An alternative approach is to use the bolt hole locations 218 . If cast as solid, they may be used to provide entry and/or exit locations for the friction stir tool. In this case the cavity left behind on withdrawal of the tool could simply be used as a pilot hole for a drill to facilitate creating an initial hole.
The overall process may best be understood by consideration of an example.
EXAMPLE
Suitable materials for wheels are die cast magnesium alloys AZ91D (nominal composition by weight: Aluminum 9%, zinc 1%, balance magnesium and AM50A (nominal composition by weight: Aluminum 5%, manganese 0.26-0.60%, balance magnesium). AZ91D has slightly higher strength but AM50A has better ductility and toughness.
The alloys should be melted under protective atmosphere. Traditionally this has usually been air with small additions (typically less than 0.2%) of sulfur hexafluoride, SF 6 . However, for die casting the holding temperature may be held to below 700° C. which enables the use of alternate shielding gases such as Argon-CO 2 —N 2 mixtures.
Typical section sizes for wheels range from as little as 3 to 4 mm at the wheel rim to up to 35 mm at the hub, with the spokes exhibiting thicknesses intermediate between these values, generally from about 15 mm to 25 mm. Although several processes, including Squeeze Casting and Modified High Pressure Die Casting, are believed suitable for cast magnesium wheel manufacture, current practice favors Low Pressure Die Casting techniques with mold temperatures in the range of 220° C. to 240° C. and typical fill times of between 20 and 30 seconds. Also it is generally beneficial apply a pressure of between 40 and 100 MPa during solidification to minimize porosity and gas inclusions. These may also be suppressed by partial evacuation of the mold prior to casting. To avoid sticking of the part to the mold wall a mold lubricant should be applied but since mold lubricants are typically diluted with water they should be applied sparingly to avoid heat loss in the die through vaporization of the water.
Wheel performance will typically have been subject to preliminary assessment through modeling and these results may be relied upon to identify the high stress regions. Alternatively or additionally, the high stress regions may be identified or confirmed by conducting a cyclic fatigue test following the procedures outlined in the Society of Automotive Engineer's SAE J328 standard which describes two basic test procedures: a cornering fatigue test directed toward the wheel disc and a radial fatigue test directed toward the wheel rim and attachment portion of the wheel.
However achieved, once the highly stressed regions of the wheel have been identified, suitable friction stir processing path(s), with appropriate entry and exit locations and embracing all of the highly stressed regions should be identified and friction stir processing initiated. Preferably, as depicted at 260 on FIG. 6 , all high stress regions may be processed using a single continuous path, but a series of shorter paths which treat the high stress regions individually or in small groups is also acceptable. There is some flexibility in the choice of tool geometry and operating conditions but a tool with a shoulder diameter of 20 mm, pin diameter 6 mm and pin length 4 mm operated at 400 rpm and a traverse rate of 100 mm/min produces acceptable results. It may be necessary or preferred to make more than one circuit with the tool if the extent of the highly stressed regions exceeds the size of the processed zone. It may also be necessary or preferred to make circuits on the visible and hidden surfaces of the wheel to more completely propagate the effects of processing through the entire thickness of the wheel.
When friction stir processing is complete, the wheel may be machined, typically by end-milling to remove surface features resulting from friction stir processing and, if necessary, impart final shape to the wheel.
While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. 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. | A method of imparting superior fatigue performance to a vehicle wheel cast from a magnesium alloy by selective application of friction stir processing to regions of the casting known to be subject to high in-service stresses is described. The method may be particularly applicable to open wheel designs in which a plurality of spokes is used to connect the hub and rim portions of the wheel. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a restaurant service request system, more particularly to a system which utilizes a bi-directional wireless radio frequency data link to communicate a variety of service requests from table units to a server or master unit and to acknowledge the reception of a request back to the table unit which originated the request.
While various hard-wired annunciator systems have been utilized in the past for communicating a simple request for service from restaurant customers to a central location, such systems have not found widespread acceptance because of the high cost of installing wiring and the limited utility and reliability of such systems. While radio frequency data link systems have been used in various high technology and security environments, the technologies utilized have not been suitable for, and have therefore not suggested themselves for, utilization in the context of restaurant service request communications.
Among the several objects of the present invention may be noted the provision of a service request communications system for use in a restaurant environment; the provision of such a system which permits the communication of a variety of requests to a server unit or station, the provision of such a system which acknowledges to the restaurant customer that his request was received by the server unit; the provision of such a communication system which does not require the installation of wiring to individual restaurant tables, the provision of such a system which is highly reliable and which is yet of relatively simple and inexpensive construction. Other objects and features will be in part apparent and in part pointed out hereinafter.
SUMMARY OF THE INVENTION
Briefly, the present invention relates to a restaurant service request communications system utilizing a plurality of remote units and at least one server/master units. The remote units communicate with server/master units by means of microprocessor controlled radio frequency transceivers. The remote units are battery powered and the microprocessor in each remote is normally maintained in a lower "sleep" state. Each remote includes a plurality of manually actuable switch elements by means of which a patron can enter his request. A display is provided for indicating that a request has been received and acknowledged by a server/master. The actuation of any switch element triggers initial operation or "powering up" of the remote unit microcomputer, the reading of the switch status and transmission of a coded request identifying the particular remote unit/switch element combination. Following the transmission, the transceiver is controlled to listen for an acknowledgement code and, if a predetermined acknowledgement code is received, the display is correspondingly energized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, and 1C are top, side and front views, rspectively, showing the physical arrangement of a remote or table unit employed in a restaurant service request communication system constructed in accordance with the present invention;
FIG. 2 is an illustration of the physical arrangement of a server unit which cooperates with a plurality of table units such as that illustrated in FIG. 1;
FIG. 3 is a schematic circuit diagram of a table unit of the type illustrated in FIG. 1;
FIG. 4 is a schematic circuit diagram of a server unit of the type illustrated in FIG. 2;
FIG. 5 is a schematic circuit diagram of a master unit which coordinates the operation of a plurality of remote and server units of the type illustrated in FIGS. 3 and 4 respectively in the operation of an overall restaurant service request communications system in accordance with the present invention;
FIG. 6 is a flow chart of software employed in the circuitry of the table unit of FIGS. 1 and 3;
FIGS. 7A and 7B are a flow chart of software employed in the server unit of FIGS. 2 and 4; and
FIG. 8 is a flow chart of software employed in the master unit of FIG. 5.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the individual remote or table unit illustrated there comprises a relatively compact case 11 which houses the transceiver and microcomputer circuitry described hereinafter, together with a rechargeable battery. The top of the case may include recesses, as indicated at 12 and 14, for holding restaurant accoutrements such as salt and pepper. On the sloped face of the unit are a series of push-button switch elements S1-S3 each of which is labeled to designate a respective service function, e.g. waiter service, check request and do not disturb. As will be understood, additional or different types of service request can be straightforwardly provided. A fourth push-button switch S4 is provided to implement a cancel function as described hereinafter. The face of the case also carries a display D1 which can be operated, as described hereinafter, to indicate to the restaurant patron that a particular service request signal has been received and acknowledged by a central service or master unit. While more complex displays can be utilized, a simple array of lamps or LEDs (light emitting diodes), one for each of the three service request switches, is presently preferred.
An appropriate physical arrangement for a server unit or situation display is illustrated in FIG. 2. The server unit comprises a relatively large wall-mountable case 15, the face of which comprises an array of display regions, one for each table which is to be served from that server unit. Each display region includes three lamps SL1-SL3, i.e. corresponding to the lamps at the respective table units, a pushbutton display cancel switch PBC, and a thumbwheel type selector switch, these selector switches being designated by reference characters SS1-SS10 in FIG. 2. Each server unit includes a radio frequency transceiver, similar to those in each of the table units, together with microcomputer circuitry for controlling the transceiver, for monitoring the state of the switches PBC and SS1-SS10, and for operating the display lamps.
As indicated previously, the present invention contemplates a restaurant service request communication system in which a plurality of table units send coded service requests by a wireless r.f. data link to a central master or server unit and the central unit sends back an acknowledgement signal which activates a display at the table unit so that the patron knows that his request has been received.
In a relatively simple implementation of the invention, a single server/master unit may accommodate a number of table units sufficient for a small establishment. However, in the preferred embodiment of the invention, a plurality of server display stations are provided and these table units and the server units are linked by a master unit through which communications are routed. In one sense, a master unit together with several server display stations can be thought of as a large master/server unit. The use of multiple server units or situation displays is advantageous in larger establishments since each request can be displayed at a server location appropriate to the nature of the request. For example, different server displays can be provided for different groups of tables and requests for cocktail service can be routed to the cocktail waitresses if they are different from the food servers.
In that the average level of data transmission is not particularly high, data communications among the various units is advantageously provided using a polled, time-slotted r.f. data link. Before describing the detailed construction of the system, it is useful to set forth the basic communications protocol. All of the various units, whether remote, server or master, use crystal controlled oscillators to establish an accurate time base so that time division utilization or "time-slotting" of a single channel r.f. data link is straightforwardly implemented. To synchronize the time bases of the various units, the master unit periodically transmits a coded "start" signal. This, in effect, initiates the "polling" of the various units making up the overall system. No unit other than the master initiates any transmission until it has received the "start" signal and has timed out the required interval between the "start" signal and the respective time slot in which it is allowed to transmit.
A typical restaurant service request scenario is as follows. The customer activates a request button at one of the remote or table units. This "wakes up" the remote unit which locks on its power and reads the request into memory. The remote unit then listens for the poll start code, and, after timing from the start code, transmits the message in its time slot to the master indicating the remote unit number, the nature of the request, and a checksum. The master, in the next poll cycle, sends an acknowledgement to the remote, and also sends messages to all of the situation display or server units indicating the table number and the request. If the remote does not receive an acknowledgement, it will re-transmit the original message until it does so. Only when the remote receives an acknowledgement from the master does it operate its display in correspondence to the activated request switch.
The situation display or server units, after they have been sent a message, individually acknowledge the message back to the master in the poll sequence. After having received a valid service request message from the master, each of the situation display units scan its table number switches SS1-SS10 and, if that table number is dialed in to any one or more of the switches, the corresponding status lamp is lit. Otherwise the message is ignored by that server unit, except for sending back its acknowledgement that the message was received.
When a service person has fulfilled a request, the request may be cancelled in two ways. From the remote, by a process essentially identical to the entering of a service request or from a server unit by activating the cancel switch (PBC) associated with the appropriate table number. This causes the server unit to insert a "cancel" message into the next poll. This message contains the table number and a checksum in addition to the cancel code. The master, on the following poll, acknowledges the message to the situation display unit, and sends a message to the remote to cancel pending requests.
Referring now to FIG. 3, the transceiver which is provided in each remote unit is indicated generally by reference character 21 and the microcomputer which is utilized for controlling the transceiver and the remote unit display is indicated generally by reference character 23. A suitable type of transceiver is that employed in the Model 49-SA communicator sold by Maxon Systems, Inc. of Kansas City, MO.
The microcomputer in the illustrated embodiment comprises a microprocessor 24 together with a separate read only memory 26 (ROM) for holding resident software (firmware). A preferred microprocessor for this application is the model 8OC31 available from the Intel Corporation of Sunnyvale, Calif. since it consumes relatively little power and provides an adequate number of input/output lines to directly implement the control functions required by the remote units of the system of the present invention. Since the 8OC31 microprocessor utilizes multiplexed addressing, a latch 28 is provided for retaining address information for the memory 26. The frequency of the timing oscillator internal to the 8OC31 microprocessor is controlled by the crystal Y1 as shown in the drawing.
One output lead of the microprocessor is used to select between the transmit and receive functions of the transceiver 21 by controlling conduction through a transistor Q4. A series of resistors having binary weighted resistances values are connected to four microcomputer output leads to implement a digital-to-analog (D/A) conversion function. This group or resistors together with the usual load resistor is indicated generally by reference character 27. The D/A function is used in generating a wave form which modulates the transmitter. The form of modulation employed is an essentially conventional frequency shift keying (FSK) modulation technique.
Tone signals picked up by the transceiver in its receive mode are converted to digital logic levels by a hysteresis type level trigger 22 and the logic level signal is applied to a narrow band tone detector indicated generally be reference character 29. Detector 29 provides a logical "true" output only when the modulation frequency of the received signal is within a preselected band. The output of the detector 29 is applied to one of the microprocessor input leads. One of the microprocessor output leads is used to reset the particular tone detector circuit used at the start of each listening session.
The state of the input switches S1-S4 are sensed by individual input leads of the microprocessor 24 in a one-to-one fashion, though it should be understood that, for more complex request systems, a matrix scanning arrangement might also be used. The display lamps are controlled from respective microprocessor output leads through respective driver transistors Q1-Q3.
As indicated previously, the transceiver 21 and microprocessor circuitry are powered by a battery, preferably rechargeable, which is self-contained within the table unit, such a battery being indicated at B1 in FIG. 3. The battery B1 is connected to the microprocessor circuitry through a transistor Q5 so that power to the microcomputer can be shut off when not needed. The transceiver and the other circuits ancillary to the microprocessor are also powered from the switched power lead though these connections are not shown in FIG. 3. Once the microcomputer is in operation, conduction through transistor Q5 is controlled by one of the microcomputer output leads through a diode D5 and a driver transistor Q6.
Initial powering-up of the microcomputer is provided by an array of diodes D1-D4 which are connected to the switch elements S1-S4. One side of each switch S1-S4 is connected to the positive side of the battery. The diodes acts as an OR gate so that when any one of the switches is actuated, power will be applied at least momentarily to the microcomputer. As part of the initial power-up routine of the microcomputer program, the lead controlling the power gating transistor is operated to latch up the supply by turning the transistor on. Similarly, when the remote unit has completed its communication and display tasks, the program can turn the transistor Q5 off, putting the microcomputer into its "sleep" mode. While the power-down or "sleep" function has been shown as being implemented by discrete separate circuitry, it should be understood that certain microprocessors incorporate within themselves circuitry for implementing essentially the same function and that such an integrated function should be understood to be equivalent to the implementation disclosed herein by way of example.
As indicated previously, the microcomputer incorporates read-only memory (ROM) for storing programs, so that the operating software can be understood to be inbedded or always resident in the system. The flow chart of FIG. 6 illustrates operating system software for the table unit of FIGS. 1 and 3. When power is first turned on, i.e. by the actuation of any one of the switch elements S1-S4, the first task of the program is to read the status of the switches to determine which switch was operated. The unit number, i.e. a number uniquely identifying the particular table unit so as to distinguish it from other units in the system, is then read from the appropriate location in the read-only memory. This information might also be obtained by reading a unit number selection switch. From this combination of data, a cyclic redundancy checksum (CRC) is calculated.
At this point the program operates the transceiver in the receive mode to listen for a coded "start" message which indicated the beginning of a poll sequence as noted previously. Once the "start" code is received, the microprocessor starts timing a preselected interval to reach the time slot corresponding to the respective remote unit. The remote unit also listens for messages from the master, the master being assigned the first time slot. Relevant messages from the master include acknowledgements and cancel messages. However, assuming that no such message was received, the microcomputer operates the transmitter to send a coded message which comprises the data representing the unit number, the data representing the switch which was activated, and the cyclic redundancy checksum. As is understood by those skilled in the art, the inclusion of a cyclic redundancy checksum allows the receiving unit, i.e. the master unit, to determine if a valid message has been received.
After the message has been transmitted, the program loops back and the receiver is turned on to listen to determine if an acknowledgement message is recieved. If no acknowledgement signal is received during the next poll, the program, in effect, assumes that interference has occurred and re-transmits the request message in the appropriate time slot.
Once a proper acknowledgement is received, the computer operates the remote unit display to provide an acknowledgement indication, i.e. by lighting the appropriate lamp to indicate to the restaurant customer that the service request was in fact communicated to the host and received by it. The message pending flag is also reset.
While the display is on, the remote unit continues to monitor the respective time slot with the receiver listening for a coded cancel message. Once the coded cancel message is received, the microcomputer resets the power latch 33 causing the table unit to, in effect, shut down and stop consuming power from the battery. In addition, if a remote unit's cancel switch is operated while the microprocessor is energized and a display lamp is lit, the remote unit will transmit a cancel request to the master in the remote's time slot. The energization of the microprocessor and the display lamp, however, will continue until the corresponding acknowledgement message is received from the master.
Referring now to FIG. 4, the server unit circuitry illustrated there includes a transceiver 41 essentially similar to the transceiver 21 in each remote unit, a suitable antenna being indicated by reference character 43. A microcomputer 45 is included within the server unit for performing the various control functions as described hereinafter. To facilitate consistent programming, it is convenient that microprocessor 45 be either an 8031 or 80C31 though very low power operation is not required for the server unit since it will typically be powered by a line-operated power supply rather than batteries. Details of the microprocessor implementation are not discribed in detail herein insofar as they are essentially identical with the implementation in the remote units.
In order to read the relatively large number of switch contacts involved in the selector switches SS1-SS10 and request cancel switches PBC, and to operate the relatively large number of display lamps, the server unit microcomputer 45 is provided with decoding circuitry, as indicated by reference characters 46 and 48, so that the switch contacts and lamps can be scanned or multiplexed as is well understood in the art.
The flow chart of FIG. 7 illustrates operating system software for a server unit of the type illustrated in FIGS. 2 and 4. After powering up, the unit first listens for a "start" transmitted by the master unit to indicate the start of a poll cycle. The unit then listens, to transmissions from the master, for a message addressed to that server unit. If a service request message is received, the server unit stores the data and sets a flag to initiate transmission of an acknowledgement in the unit's time slot. In its time slot, each server unit may transmit an acknowledgement of a request received or it may initiate a cancel message as indicated previously.
Having received a message relevant to server units, each server unit then reads its selector switches (SS1-SS10) to determine if the message number which identifies the initiating remote unit, is equal to any one of the numbers set into the selector switches. If not, the message is ignored but, if there is a match, the program begins a loop which increments through its own table locations to see if there is a match between the selection switch settings and the remote which initiated the service request. If a match is found, the appropriate display lamp is set. The program assumes that the server unit may have up to 25 selector switches though only 10 have been implemented in the embodiment described. The numbers set into the selector switches may range up to 99 in the embodiment illustrated. After the last location is scanned, the program returns to the initial listening stage.
If no message directed to the server units is received, the program enters a different branch (it may be considered to be a background task) in which it reads the cancel switches PBC to determine if any one of them is being actuated. If so, the program sets a flag to initiate the transmission of a cancel message in the server units time slot. Following transmission of the cancel message, no further action is taken to actually effect cancelling of the respective display lamp until an acknowledgement from the master unit is received. If no acknowledgement is received, the cancel operation is effectively aborted for retry on another poll cycle since the pending cancel message flag is reset only after an appropriate acknowledgement is received from the master.
In terms of the actual operation of the service request communications system, the function of the master unit is essentially a message coordinator. With reference to FIG. 5, the master communications microcomputer is designated generally by reference character 61. The electrical interconnections between the microcomputer 61 and the master transceiver 63 are essentially the same as the arrangements in the remote and server units and are thus not described in detail herein. The master unit essentially comprises no circuitry not in the remote and server units except that one microcomputer input lead 71 and one microcomputer output lead 73 are used to implement in hardwired serial data link for purposes described hereinafter.
As indicated previously, the function of the master unit in the actual operation of the restaurant service request communications system of the present invention is essentially that of a central communications coordinator or clearing house. The master microcomputer keeps a table for holding pending messages, accessible by unit number. Proceeding from the top of the flow chart of FIG. 8, the first task of the master unit microcomputer program is to scan through that table and, if a message or acknowledgement is pending for any unit, transmit that message or acknowledgement. These transmissions take place in the first time slot of the poll sequence. Preferably, while most of the time only a single message will need to be transmitted by the master during a given poll sequence, it may be useful in some circumstances to allow the first slot to be expandable to accommodate multiple messages from the master. In such case, the server and remote units are programmed to time out an interval to their respective time slot beginning at the end of the master's time slot (slot 0).
At the end of its transmissions, the master unit listens in each of the successive time slots which are allocated to the various remote and server units. If a message is received, the master unit program in essence parses the message to first determine if it is an acknowledgement message. If it is, the respective pending acknowledgement flag for that slot is cleared. If the message received is not an acknowledgement, the program tests to see if it is a request cancel message. If it is, a message pending flag is set for the respective remote designated in the message. If the message received is neither an acknowledgement nor a cancel message, it is assumed to be a service request message and a message pending flag is set for all servers. As noted previously, service requests originating from any remote or table unit is sent to all server units and the server units themselves determine, from their respective selector switch settings, whether the remote unit originating with the request is one for which that server unit is responsive.
This listening and parsing continues to all possible slots until the maximum slot number is reached at which point the program loops back to begin another polling cycle.
For restaurant management purposes, it may also be useful to provide a central display which essentially duplicates the several server unit displays. It is also useful for management purposes to provide data identifying the service requests and the responses thereto to a logging system which records those events and can correlate them into meaningful management reports.
As the master unit carries the heaviest data communications load, it is presently preferred that the computational load associated with operating a central display or logging be provided by a display controller system, i.e. another microcomputer system to which the master communications microcomputer provides display data just as it does to the server units. This data communication, however, is preferably provided over a simple, hardwired serial data link. With reference to FIG. 5, the serial data link is implemented by the microprocessor leads 71 and 73.
As indicated previously, the preferred embodiment described herein provides for a plurality of server display units. However, for smaller establishments, a single server display may be sufficient and the communications functions of the master may be subsummed therein. Similarly, while the use of time slotted r.f. data communications is preferred, collision detection might also be used, particularly in a system with a limited number of remote units or server displays.
In view of the foregoing, it may be seen that several objects of the present invention are achieved and other advantageous results have been attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it should be understood that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | In the service request communication system disclosed herein, a plurality of battery-powered table units communicate a variety of service requests to a central server or master unit by a bi-directional wireless radio frequency data link. The table units remain in a low-power "sleep" state until any one of a plurality of switches is actuated by a customer to denote a corresponding service request. A transceiver is controlled by a microprocessor to transmit a coded signal identifying the request and then to receive and indicate to the customer an acknowledgment signal transmitted from the server or master station. At a server station a display is operated to identify the table unit/request combination, the display being canceled when a corresponding switch at the server unit is actuated, e.g. by the employee who will provide the service requested. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 12/496,535, filed on Jul. 1, 2009, which is incorporated in its entirety herein.
ACKNOWLEDGEMENT OF GOVERNMENT SUPPORT
This invention was made with Government support under Grant No. NFS-CHE 0645891 awarded from the United States National Science Foundation; accordingly, the United States Government has certain rights to this invention.
TECHNICAL FIELD
This invention relates generally to the polymerization of monomers, and, more particularly relates to an organocatalytic method for polymerizing monomers. The invention is applicable in numerous fields, including industrial chemistry and manufacturing processes requiring a simple and convenient method for the preparation of polymers.
BACKGROUND OF THE INVENTION
Polymers containing heteroatoms along the backbone play an ever-increasingly important role in modern society, and the variety of such polymers continues to expand at a high rate. For example, poly(ethylene terephthalate) (i.e., poly(oxy-1,2-ethanediyl-oxycarbonyl-1,4-diphenylenecarbonyl), or “PET”) is a widely used engineering thermoplastic for carpeting, clothing, tire cords, soda bottles and other containers, film, automotive applications, electronics, displays, etc. The worldwide production of PET has been growing at an annual rate of 10% per year, and with the increase in use in electronic and automotive applications, this rate is expected to increase significantly to 15% per year.
Polymers with heteroatoms along the backbone are commonly prepared using an addition-type polymerization mechanism, in which monomers react to form dimers, which can in turn react with other dimers to form tetramers. This growth process is allowed to continue until polymers with the desired molecular weight are formed. Unfortunately (and unlike the alternative chain-growth polymerization mechanism), obtaining high molecular weight polymer using this mechanism requires carrying the polymerization reaction to very high conversion.
A frequently-used method for commercial synthesis of (PET) involves a two-step transesterification process from dimethyl teraphthalate (DMT) and excess ethylene glycol (EO) in the presence of a metal alkanoates or acetates of calcium, zinc, manganese, titanium, etc. This first step generates bis(hydroxy ethylene) teraphthalate (BHET) with the elimination of methanol and the excess EO. The BHET is heated, generally in the presence of a transesterification catalyst, to generate high polymer. This process is generally accomplished in a vented extruder to remove the polycondensate (EO) and generate the desired thermoformed object from a low viscosity precursor.
Some polycondensation reactions, such as the commercial method of synthesis of PET described above, require polymerization catalysts. Such catalysts may be difficult to prepare, may be unstable to long-term storage, or may require stringent reaction conditions to provide polymer. Moreover, these catalysts are immortal, limiting the versatility of the widely used mechanical recycling, because at high temperatures the residual catalyst causes molecular weight degradation. This limits the use of these recycled products to secondary applications (i.e., carpet, playground equipment etc.).
SUMMARY OF THE INVENTION
Accordingly, there is a need in the art for improved polymerization methods that involve mild reaction conditions, non-metallic and stable catalysts, and minimal potentially problematic by-products, while allowing for the synthesis of polymers with controlled molecular weights, low polydispersities, and/or controlled architecture (e.g., end-functionalized, branched, block copolymers, etc.).
The invention provides an efficient catalytic polymerization reaction that does not employ a metallic catalyst. Because a nonmetallic catalyst is employed, the polymerization products, in a preferred embodiment, are substantially free of metal contaminants. Furthermore, in preferred embodiments, the catalysts are substantially more stable than previous non-metallic catalysts.
In some embodiments, then, the disclosure provides a method for forming a polymer. The method comprises contacting a monomer with a nucleophilic reagent in the presence of a guanidine-containing compound to form a prepolymer. The method further comprises polymerizing the prepolymer to form a polymer. The monomer comprises at least one electrophilic moiety, and in some embodiments, the monomer comprises two electrophilic moieties separated by a linker.
In further embodiments, the disclosure provides a composition comprising a monomer, a nucleophile, and a guanidine-containing compound. The monomer comprises two electrophilic moieties separated by a linker.
In still further embodiments, the disclosure provides an improved method for polymerizing a monomer having at least one electrophilic moiety. The improvement comprises contacting the monomer with a nucleophile in the presence of a guanidine-containing compound.
Preferred catalysts herein are guanidine compounds. In some embodiments, cyclic guanidines, including monocyclic and polycyclic guanidines are used. Polycyclic guanidines suitable for the methods of the disclosure include fused and non-fused polycyclic compounds. Further details of suitable guanidine catalysts are provided below.
Additional aspects and embodiments of the invention will be provided, without limitation, in the detailed description of the invention that is set forth below.
DETAILED DESCRIPTION OF THE INVENTION
Unless otherwise indicated, this invention is not limited to specific polymers, catalysts, nucleophilic reagents, or depolymerization conditions. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a polymer” encompasses a combination or mixture of different polymers as well as a single polymer, reference to “a catalyst” encompasses both a single catalyst as well as two or more catalysts used in combination, and the like.
In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:
As used herein, the phrase “having the formula” or “having the structure” is not intended to be limiting and is used in the same way that the term “comprising” is commonly used.
The term “alkyl” as used herein refers to a linear, branched, or cyclic saturated hydrocarbon group (i.e., a mono-radical) typically although not necessarily containing 1 to about 24 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, octyl, decyl, and the like, as well as cycloalkyl groups such as cyclopentyl, cyclohexyl and the like. Generally, although not necessarily, alkyl groups herein may contain 1 to about 18 carbon atoms, and such groups may contain 1 to about 12 carbon atoms. The term “lower alkyl” intends an alkyl group of 1 to 6 carbon atoms. “Substituted alkyl” refers to alkyl substituted with one or more substituent groups, and this includes instances wherein two hydrogen atoms from the same carbon atom in an alkyl substituent are replaced, such as in a carbonyl group (i.e., a substituted alkyl group may include a—C(═O)-moiety). The terms “heteroatom-containing alkyl” and “heteroalkyl” refer to an alkyl substituent in which at least one carbon atom is replaced with a heteroatom, as described in further detail infra. If not otherwise indicated, the terms “alkyl” and “lower alkyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkyl or lower alkyl, respectively.
The term “alkenyl” as used herein refers to a linear, branched or cyclic hydrocarbon group of 2 to about 24 carbon atoms containing at least one double bond, such as ethenyl, n-propenyl, isopropenyl, n-butenyl, isobutenyl, octenyl, decenyl, tetradecenyl, hexadecenyl, eicosenyl, tetracosenyl, and the like. Generally, although again not necessarily, alkenyl groups herein may contain 2 to about 18 carbon atoms, and for example may contain 2 to 12 carbon atoms. The term “lower alkenyl” intends an alkenyl group of 2 to 6 carbon atoms. The term “substituted alkenyl” refers to alkenyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkenyl” and “heteroalkenyl” refer to alkenyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkenyl” and “lower alkenyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkenyl and lower alkenyl, respectively.
The term “alkynyl” as used herein refers to a linear or branched hydrocarbon group of 2 to 24 carbon atoms containing at least one triple bond, such as ethynyl, n-propynyl, and the like. Generally, although again not necessarily, alkynyl groups herein may contain 2 to about 18 carbon atoms, and such groups may further contain 2 to 12 carbon atoms. The term “lower alkynyl” intends an alkynyl group of 2 to 6 carbon atoms. The term “substituted alkynyl” refers to alkynyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkynyl” and “heteroalkynyl” refer to alkynyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkynyl” and “lower alkynyl” include linear, branched, unsubstituted, substituted, and/or heteroatom-containing alkynyl and lower alkynyl, respectively.
The term “alkoxy” as used herein intends an alkyl group bound through a single, terminal ether linkage; that is, an “alkoxy” group may be represented as —O-alkyl where alkyl is as defined above. A “lower alkoxy” group intends an alkoxy group containing 1 to 6 carbon atoms, and includes, for example, methoxy, ethoxy, n-propoxy, isopropoxy, t-butyloxy, etc. Substituents identified as “C 1 -C 6 alkoxy” or “lower alkoxy” herein may, for example, may contain 1 to 3 carbon atoms, and as a further example, such substituents may contain 1 or 2 carbon atoms (i.e., methoxy and ethoxy). The term “alkylthio” as used herein refers to a group —S-alkyl, where “alkyl” is as defined above.
The term “aryl” as used herein, and unless otherwise specified, refers to an aromatic substituent generally, although not necessarily, containing 5 to 30 carbon atoms and containing a single aromatic ring or multiple aromatic rings that are fused together, directly linked, or indirectly linked (such that the different aromatic rings are bound to a common group such as a methylene or ethylene moiety). Aryl groups may, for example, contain 5 to 20 carbon atoms, and as a further example, aryl groups may contain 5 to 12 carbon atoms. For example, aryl groups may contain one aromatic ring or two or more fused or linked aromatic rings (i.e., biaryl, aryl-substituted aryl, etc.). Examples include phenyl, naphthyl, biphenyl, diphenylether, diphenylamine, benzophenone, and the like. “Substituted aryl” refers to an aryl moiety substituted with one or more substituent groups, and the terms “heteroatom-containing aryl” and “heteroaryl” refer to aryl substituent, in which at least one carbon atom is replaced with a heteroatom, as will be described in further detail infra. If not otherwise indicated, the term “aryl” includes unsubstituted, substituted, and/or heteroatom-containing aromatic substituents.
The term “aralkyl” refers to an alkyl group with an aryl substituent, and the term “alkaryl” refers to an aryl group with an alkyl substituent, wherein “alkyl” and “aryl” are as defined above. In general, aralkyl and alkaryl groups herein contain 6 to 30 carbon atoms. Aralkyl and alkaryl groups may, for example, contain 6 to 20 carbon atoms, and as a further example, such groups may contain 6 to 12 carbon atoms.
The term “alkylene” as used herein refers to a di-radical alkyl group. Unless otherwise indicated, such groups include saturated hydrocarbon chains containing from 1 to 24 carbon atoms, which may be substituted or unsubstituted, may contain one or more alicyclic groups, and may be heteroatom-containing “Lower alkylene” refers to alkylene linkages containing from 1 to 6 carbon atoms. Examples include, methylene (—CH 2 —), ethylene (—CH 2 CH 2 —), propylene (—CH 2 CH 2 CH 2 —), 2-methylpropylene (—CH 2 —CH(CH 3 )—CH 2 —), hexylene (—(CH 2 ) 6 —) and the like. Similarly, the terms “alkenylene,” “alkynylene,” “arylene,” “aralkylene,” and “alkarylene” as used herein refer to di-radical alkenyl, alkynyl, aryl, aralkyl, and alkaryl groups, respectively. Collectively, these and other di-radical groups are referred to herein as “linkers” or “linker groups.” By the term “functional linker group” or “functional linker” is meant di-radical moieties that contain one or more functional groups such as an oxo (—O—, such as in an ether linkage), amine (—NR—), carbonyl (—C(═O)—), carbonate, and the like.
The term “amino” is used herein to refer to the group—NZ 1 Z 2 wherein Z 1 and Z 2 are hydrogen or nonhydrogen substituents, with nonhydrogen substituents including, for example, alkyl, aryl, alkenyl, aralkyl, and substituted and/or heteroatom-containing variants thereof.
The terms “halo” and “halogen” are used in the conventional sense to refer to a chloro, bromo, fluoro or iodo substituent.
The term “heteroatom-containing” as in a “heteroatom-containing alkyl group” (also termed a “heteroalkyl” group) or a “heteroatom-containing aryl group” (also termed a “heteroaryl” group) refers to a molecule, linkage or substituent in which one or more carbon atoms are replaced with an atom other than carbon, e.g., nitrogen, oxygen, sulfur, phosphorus or silicon, typically nitrogen, oxygen or sulfur. Similarly, the term “heteroalkyl” refers to an alkyl substituent that is heteroatom-containing, the term “heterocyclic” refers to a cyclic substituent that is heteroatom-containing, the terms “heteroaryl” and “heteroaromatic” respectively refer to “aryl” and “aromatic” substituents that are heteroatom-containing, and the like. Examples of heteroalkyl groups include alkoxyaryl, alkylsulfanyl-substituted alkyl, N-alkylated amino alkyl, and the like. Examples of heteroaryl substituents include pyrrolyl, pyrrolidinyl, pyridinyl, quinolinyl, indolyl, furyl, pyrimidinyl, imidazolyl, 1,2,4-triazolyl, tetrazolyl, etc., and examples of heteroatom-containing alicyclic groups are pyrrolidino, morpholino, piperazino, piperidino, tetrahydrofuranyl, etc.
“Hydrocarbyl” refers to univalent hydrocarbyl radicals containing 1 to about 30 carbon atoms, including 1 to about 24 carbon atoms, further including 1 to about 18 carbon atoms, and further including about 1 to 12 carbon atoms, including linear, branched, cyclic, saturated and unsaturated species, such as alkyl groups, alkenyl groups, aryl groups, and the like. “Substituted hydrocarbyl” refers to hydrocarbyl substituted with one or more substituent groups, and the term “heteroatom-containing hydrocarbyl” refers to hydrocarbyl in which at least one carbon atom is replaced with a heteroatom. Unless otherwise indicated, the term “hydrocarbyl” is to be interpreted as including substituted and/or heteroatom-containing hydrocarbyl moieties. The term “hydrocarbylene” refers to a di-radical hydrocarbyl group.
By “substituted” as in “substituted hydrocarbyl,” “substituted alkyl,” “substituted aryl,” and the like, as alluded to in some of the aforementioned definitions, is meant that in the hydrocarbyl, alkyl, aryl, or other moiety, at least one hydrogen atom bound to a carbon (or other) atom is replaced with one or more non-hydrogen substituents. Examples of such substituents include, without limitation: functional groups such as halo, hydroxyl, sulfhydryl, C 1 -C 24 alkoxy, C 2 -C 24 alkenyloxy, C 2 -C 24 alkynyloxy, C 5 -C 20 aryloxy, acyl (including C 2 -C 24 alkylcarbonyl (—CO-alkyl) and C 6 -C 20 arylcarbonyl (—CO-aryl)), acyloxy (—O-acyl), C 2 -C 24 alkoxycarbonyl (—(CO)—O-alkyl), C 6 -C 20 aryloxycarbonyl (—(CO)—O-aryl), halocarbonyl (—CO)—X where X is halo), C 2 -C 24 alkylcarbonato (—O—(CO)—O-alkyl), C 6 -C 20 arylcarbonato (—O—(CO)—O-aryl), carboxy (—COOH), carboxylato (—COO − ), carbamoyl (—(CO)—NH 2 ), mono-substituted C 1 -C 24 alkylcarbamoyl (—(CO)—NH(C 1 -C 24 alkyl)), di-substituted alkylcarbamoyl (—(CO)—N(C 1 -C 24 alkyl) 2 ), mono-substituted arylcarbamoyl (—(CO)—NH-aryl), thiocarbamoyl (—(CS)—NH 2 ), carbamido (—NH—(CO)—NH 2 ), cyano (—C≡N), isocyano (—N≡C − ), cyanato (—O—C≡N), isocyanato (—O—N + ≡C − ), isothiocyanato (—S—C≡N), azido (—N═N + ═N − ), formyl (—(CO)—H), thioformyl (—(CS)—H), amino (—NH 2 ), mono- and di-(C 1 -C 24 alkyl)-substituted amino, mono- and di-(C 5 -C 20 aryl)-substituted amino, C 2 -C 24 alkylamido (—NH—(CO)-alkyl), C 5 -C 20 arylamido (—NH—(CO)-aryl), imino (—CR═NH where R=hydrogen, C 1 -C 24 alkyl, C 5 -C 20 aryl, C 6 -C 20 alkaryl, C 6 -C 20 aralkyl, etc.), alkylimino (—CR═N(alkyl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), arylimino (—CR═N(aryl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), nitro (—NO 2 ), nitroso (—NO), sulfo (—SO 2 —OH), sulfonato (—SO 2 —O − ), C 1 -C 24 alkylsulfanyl (—S-alkyl; also termed “alkylthio”), arylsulfanyl (—S-aryl; also termed “arylthio”), C 1 -C 24 alkylsulfinyl (—(SO)-alkyl), C 5 -C 20 arylsulfonyl (—(SO)-aryl), C 1 -C 24 alkylsulfonyl (—SO 2 -alkyl), C 5 -C 20 arylsulfonyl (—SO 2 -aryl), phosphono (—P(O)(OH) 2 ), phosphonato (—P(O)(O − ) 2 ), phosphinato (—P(O)(O − )), phospho (—PO 2 ), and phosphino (—PH 2 ), mono- and di-(C 1 -C 24 alkyl)-substituted phosphino, mono- and di-(C 5 -C 20 aryl)-substituted phosphino; and the hydrocarbyl moieties C 1 -C 24 alkyl (including C 1 -C 18 alkyl, further including C 1 -C 12 alkyl, and further including C 1 -C 6 alkyl), C 2 -C 24 alkenyl (including C 2 -C 18 alkenyl, further including C 2 -C 12 alkenyl, and further including C 2 -C 6 alkenyl), C 2 -C 24 alkynyl (including C 2 -C 18 alkynyl, further including C 2 -C 12 alkynyl, and further including C 2 -C 6 alkynyl), C 5 -C 30 aryl (including C 5 -C 20 aryl, and further including C 5 -C 12 aryl), and C 6 -C 30 aralkyl (including C 6 -C 20 aralkyl, and further including C 6 -C 12 aralkyl). In addition, the aforementioned functional groups may, if a particular group permits, be further substituted with one or more additional functional groups or with one or more hydrocarbyl moieties such as those specifically enumerated above. Analogously, the above-mentioned hydrocarbyl moieties may be further substituted with one or more functional groups or additional hydrocarbyl moieties such as those specifically enumerated.
In addition, the aforementioned functional groups may, if a particular group permits, be further substituted with one or more additional functional groups or with one or more hydrocarbyl moieties such as those specifically enumerated above. Analogously, the above-mentioned hydrocarbyl moieties may be further substituted with one or more functional groups or additional hydrocarbyl moieties such as those specifically enumerated.
When the term “substituted” appears prior to a list of possible substituted groups, it is intended that the term apply to every member of that group. For example, the phrase “substituted alkyl and aryl” is to be interpreted as “substituted alkyl and substituted aryl.”
Unless otherwise specified, reference to an atom is meant to include isotopes of that atom. For example, reference to H is meant to include 1 H, 2 H (i.e., D) and 3 H (i.e., T), and reference to C is meant to include 12 C and all isotopes of carbon (such as 13 C).
By “substantially free of” a particular type of chemical compound is meant that a composition or product contains less 10 wt % of that chemical compound, for example less than 5 wt %, or less than 1 wt %, or less than 0.1 wt %, or less than 0.01 wt %, or less than 0.001 wt %. For instance, the polymerization product herein is “substantially free of” metal contaminants, including metals per se, metal salts, metallic complexes, metal alloys, and organometallic compounds.
Unless otherwise specified, the terms “guanidine compound,” “guanidine catalyst,” “guanidine-containing compound,” and the like refer to compounds containing a guanidinyl moiety, i.e., compounds containing the structure
Accordingly, the invention features a method for preparing a polymer having a backbone containing electrophilic linkages. The electrophilic linkages may be, for example, ester linkages (—(CO)—O—), carbonate linkages (—O—(CO)—O)—, urethane linkages (—O—(CO)-—NH), substituted urethane linkages (—O—(CO)—NR—, where R is a nonhydrogen substituent such as alkyl, aryl, alkaryl, or the like), amido linkages (—(CO)—NH—), substituted amido linkages (—(CO)—NR— where R is as defined previously), thioester linkages (—(CO)—S—), sulfonic ester linkages (—S(O) 2 —O—), ketone linkages (—C(═O)—), and the like. Other electrophilic linkages will be known to those of ordinary skill in the art of organic chemistry and polymer science and/or can be readily found by reference to the pertinent texts and literature.
In some embodiments, the monomer comprises two electrophilic moieties separated by a linker moiety, and has the structure X 1 -L-X 2 , wherein X 1 and X 2 are independently electrophilic moieties and L is the linker moiety. In some embodiments, L is selected from C 1 -C 30 hydrocarbylene and functional linker groups. In some embodiments, L is C 1 -C 30 hydrocarbylene. For example, L is selected from C 1 -C 30 alkylene, C 2 -C 30 alkenylene, C 2 -C 30 alkynylene, C 5 -C 30 arylene, and combinations thereof (such as C 1 -C 30 alkylene linked with a C 5 -C 30 arylene), wherein any of these groups may contain one or more heteroatoms and one or more substituents. Linker moieties may also be functional groups, such as heteroatom groups, including thioether (—S—), ether (—O—), and amino (—NR—) groups. In some embodiments, L is substituted or unsubstituted phenylene (1,4-, 1,3-, or 1,2-connectivity), or substituted or unsubstituted lower alkylene (e.g., methylene, ethylene, propylene, butylene, pentylene, hexylene, septylene, or octylene, including cyclic versions of such linkers).
In some embodiments, X 1 and X 2 are independently selected from ester moieties (—(CO)—O—R, wherein R is lower alkyl or the like), carboxylic acid or carbonic acid (—COOH or —OCOOH), carbonate moieties (—O—(CO)—O—R, wherein R is lower alkyl or the like), urethane moieties (—O—(CO)—NH—R, wherein R is H, lower alkyl, or the like), substituted urethane moieties (—O—(CO)—NR′—R, where R′ is a nonhydrogen substituent such as alkyl, aryl, alkaryl, or the like), amido moieties (—(CO)—NH—R, wherein R is H, lower alkyl, or the like), substituted amido moieties (—(CO)—NR′—R where R′ is as defined previously), thioester moieties (—(CO)—S—R, wherein R is H, lower alkyl, or the like), sulfonic ester moieties (—S(O) 2 —O—R, wherein R is H, lower alkyl, or the like), and the like. For example, X 1 and X 2 are lower alkyl esters (e.g., methyl esters or ethyl esters) or amine groups.
Examples of polymers that can be prepared using the methodology of the invention include, without limitation: poly(alkylene terephthalates) such as poly(ethylene terephthalate) (PET), fiber-grade PET (a homopolymer made from monoethylene glycol and terephthalic acid), bottle-grade PET (a copolymer made based on monoethylene glycol, terephthalic acid, and other comonomers such as isophthalic acid, cyclohexene dimethanol, etc.), poly(butylene terephthalate) (PBT), and poly(hexamethylene terephthalate); poly(alkylene adipates) such as poly(ethylene adipate), poly(1,4-butylene adipate), and poly(hexamethylene adipate); poly(alkylene suberates) such as poly(ethylene suberate); poly(alkylene sebacates) such as poly(ethylene sebacate); poly(ε-caprolactone) and poly(β-propiolactone); poly(alkylene isophthalates) such as poly(ethylene isophthalate); poly(alkylene 2,6-naphthalene-dicarboxylates) such as poly(ethylene 2,6-naphthalene-dicarboxylate); poly(alkylene sulfonyl-4,4′-dibenzoates) such as poly(ethylene sulfonyl-4,4′-dibenzoate); poly(p-phenylene alkylene dicarboxylates) such as poly(p-phenylene ethylene dicarboxylates); poly(trans-1,4-cyclohexanediyl alkylene dicarboxylates) such as poly(trans-1,4-cyclohexanediyl ethylene dicarboxylate); poly(1,4-cyclohexane-dimethylene alkylene dicarboxylates) such as poly(1,4-cyclohexane-dimethylene ethylene dicarboxylate); poly([2.2.2]-bicyclooctane-1,4-dimethylene alkylene dicarboxylates) such as poly([2.2.2]-bicyclooctane-1,4-dimethylene ethylene dicarboxylate); lactic acid polymers and copolymers such as (S)-polylactide, (R,S)-polylactide, poly(tetramethylglycolide), and poly(lactide-co-glycolide); and polycarbonates of bisphenol A, 3,3′-dimethylbisphenol A, 3,3′,5,5′-tetrachlorobisphenol A, 3,3′,5,5′-tetramethylbisphenol A; polyamides such as poly(p-phenylene terephthalamide); poly(alkylene carbonates) such as poly(propylene carbonate); polyurethanes; and polyurethane/polyester copolymers.
The monomers for polymerization may be obtained from any suitable source. In one preferred embodiment, the monomers are depolymerization products from recycled post-consumer waste. In another embodiment, the monomers are virgin feedstock.
Polymerization of the monomer is carried out, as indicated herein, in the presence of a nucleophilic reagent and a catalyst. Nucleophilic reagents are those that comprise one or more nucleophilic groups, such as hydroxyl, ether, carboxylato (e.g., —COO − ), amine, azide, sulfhydryl, and the like. Nucleophilic reagents therefore include monohydric alcohols, diols, polyols, amines, diamines, polyamines, sulfhydryls, disulfhydryls, polysulfhydryls, and combinations thereof. Thus, the nucleophilic reagents may contain a single nucleophilic moiety or two or more nucleophilic moieties, e.g., hydroxyl, sulfhydryl, and/or amino groups.
In some embodiments, the nucleophilic reagent consists of a single nucleophilic group, and has the structure R-Nu 1 , wherein R is a C 1 -C 30 hydrocarbyl group and Nu 1 is any nucleophilic group such as those previously described.
In some embodiments, nucleophilic reagents comprise two nucleophilic groups separated by a linker, and have the structure Nu 1 -L 1 -Nu 2 , wherein Nu 1 is as described previously, Nu 2 is a nucleophilic group (such as those described for Nu 1 ) and wherein L 1 is as described previously for L. Examples of such difunctional nucleophilic reagents include alkyl diols, aryl diols, alkyl diamines, aryl diamines, amino alcohols, amino thiols, and the like.
In some embodiments, the nucleophilic reagent comprises three nucleophilic groups, and has the structure
(also written Nu 1 -L 3 (Nu 2 )Nu 3 ) wherein Nu 1 and Nu 2 are as described previously, Nu 3 is a nucleophilic group (such as those described for Nu 1 ), and L 3 may be any of the linkers described previously for L 1 , provided that linker L 3 has at least three non-hydrogen substituents (i.e., Nu 1 -Nu 3 ). Such nucleophilic reagents allows cross linking reactions to occur. Any combination of nucleophilic reagents (having the same or a different number of nucleophilic groups) may be used.
In some embodiments, the nucleophilic reagent will be present in excess of the monomer, meaning that the number of nucleophilic groups exceeds the number of electrophilic groups at the beginning of the reaction. In some other embodiments, the ratio of nucleophilic groups to electrophilic groups is 1:1.
A few specific examples of suitable nucleophilic groups include methanol, ethanol, propanol, butanol, ethylene glycol, propylene glycol, methylamine, ethylamine, ethylenediamine, propylenediamine, methanethiol, ethanethiol, as well as the following:
Preferred catalysts for the polymerization reactions are organic compounds containing a guanidine moiety. In some preferred embodiments, the polymerization catalysts are organic guanidines having the structure of formula (I)
wherein R 2 , R 3 , R 4 and R 5 are independently selected from hydrogen and C 1 -C 30 hydrocarbyl, provided that any two of R 2 , R 3 , R 4 and R 5 may be linked to form a cycle. In preferred embodiments, at least two of R 2 , R 3 , R 4 and R 5 are linked to form a cycle, such that the compound is a cyclic guanidine compound.
For example, R 2 , R 3 , R 4 and R 5 are independently selected from substituted or unsubstituted C 1 -C 30 alkyl, C 2 -C 30 alkenyl, C 2 -C 30 alkynyl, C 5 -C 30 aryl, C 6 -C 30 aralkyl, and C 6 -C 30 alkaryl, any of which may be heteroatom-containing. As mentioned previously, the alkyl, alkenyl, and alkynyl groups include linear, branched, and cyclic such groups. The aryl, aralkyl, and alkaryl groups include multicyclic groups such as annulated and linked ring systems.
In some embodiments of formula (I), R 2 and R 3 are taken together to form a cycle, and R 4 and R 5 are taken together to form a cycle, such that an annulated ring system is formed. Preferred embodiments include compounds having the structure of formula (Ia)
wherein
n1 and n2 are independently selected from zero and 1; and
R 6a , R 6b , R 6c , R 6d , R 7a , R 7b , R 7c , and R 7d are independently selected from H, substituted or unsubstituted C 1 -C 30 alkyl, C 2 -C 30 alkenyl, C 2 -C 30 alkynyl, C 5 -C 30 aryl, C 6 -C 30 aralkyl, and C 6 -C 30 alkaryl, any of which may be may be heteroatom-containing, provided that any two of R 6a , R 6b , R 6c , R 6d , R 7a , R 7b , R 7c , and R 7d may be taken together to form a ring.
In some embodiments of formula (Ia), n1 is zero and n2 is 1. In some embodiments of formula (Ia), n2 is zero and n1 is 1. In some embodiments of formula (Ia), n1 and n2 are both zero. In some embodiments of formula (Ia), n1 and n2 are both 1.
In some embodiments of formula (Ia), one of R 6a and R 6b is C 5 -C 30 aryl, and the other is Hydrogen, and one of R 7a and R 7b is C 5 -C 30 aryl, and the other is H. In some such embodiments, the C 5 -C 30 aryl group is phenyl.
In some embodiments of formula (Ia), R 6c , R 6d , R 7c , and R 7d are each H. Examples of such embodiments include the following compounds:
In some embodiments of formula (I), R 3 and R 4 are taken together to form a cycle. For example, preferred embodiments include compounds having the structure of formula (Ib)
wherein
n3 is selected from 0 and 1;
X 1 and X 2 are independently selected from —NR 10 — and —C(R 11 )(R 12 )—, wherein R 10 , R 11 , and R 12 are independently selected from H and alkyl; and
R 8a , R 8b , R 9a , and R 9b are independently selected from alkyl, aryl, aralkyl, and alkaryl, provided that any two of R 8a , R 8b , R 9a , R 9b , R 10 , R 11 , and R 12 may be taken together to form a cycle.
In some embodiments of formula (Ib), R 9a and R 9b are both H, and X 1 and X 2 are both —CH 2 —, such that the compounds have the structure of formula (Ic)
Further examples of embodiments of formula (Ib) include compounds having the structures
In some embodiments of the structures shown above, R 2 and R 5 are independently selected from substituted or unsubstituted C 1 -C 30 alkyl and substituted or unsubstituted heteroatom-containing C 1 -C 30 alkyl. For example, R 2 and R 5 may be C 3 -C 30 alicyclic, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl (Cy), cycloheptyl, or cyclooctyl. Also, for example, R 2 and R 5 may be methyl, ethyl, propyl (i-propyl, n-propyl), or butyl (t-butyl, n-butyl, sec-butyl), or may be heteroatom-containing such as 3-dimethylaminopropyl or a salt thereof.
In some embodiments, the guanidine-containing compounds described herein are chemically more stable than other catalysts capable of causing depolymerization, such as N-heterocyclic carbene catalysts. In some embodiments, compared with N-heterocyclic carbene catalysts under similar conditions, the guanidine-containing compounds decompose at a substantially lower rate. Preferred catalysts are substantially stable under some or all of the depolymerization conditions described herein.
The guanidine-containing compounds described herein may be synthesized by any appropriate method, and such methods are readily ascertainable from the relevant literature. For example, cyclic guanidines may be prepared using the methods disclosed in U.S. Pat. No. 4,797,487 entitled “Production of Bicyclic Guanidines from Bis(aminoalkyl)amine.” It will be appreciated that the handling of certain guanidine-containing compounds may require precautions to avoid decomposition. For example, mixing of the reaction components may require an inert atmosphere.
The polymerization catalysts of the disclosure (i.e., guanidine-containing compounds) are typically present in the reaction mixture in an amount (i.e., a “catalyst loading”) that is less than 5 mol %, or less than 2 mol %, or less than 1 mol %, or less than 0.5 mol %, or less than 0.1 mol %, with less than 1 mol % being particularly preferred. Such catalyst loadings are measured as mol % relative to the total amount of monomer used in the reaction.
The polymerization reaction occurs by initial formation of a prepolymer comprising the product of a reaction between the monomer and nucleophilic reactant, and subsequent condensation polymerization of the prepolymer. In some embodiments, the prepolymer comprises one or more electrophilic groups and one or more nucleophilic groups; for example the prepolymer comprises two nucleophilic groups and two electrophilic groups. In such embodiments, the condensation reaction may occur as the electrophilic group of one prepolymer molecule reacts with the nucleophilic group of another prepolymer molecule. In embodiments where the condensation reaction produces non-polymeric byproducts (particularly small organic molecules such as water, H 2 , ethylene glycol, propylene glycol, etc.), such products may be removed during the reaction to help the polymerization achieve higher molecular weight polymers.
The initial formation of the prepolymer may be carried out in a suitable solvent, or without any solvent. The nucleophilic reagent may function as a solvent. When a separate solvent is used, it is preferable that the solvent is removed prior to polymerization of the prepolymer. Thus, in some embodiments, the polymerization reaction is started in a solvent for a predetermined period of time, after which time the solvent is removed (such as by applying reduced pressure and/or increased temperature), and the polymerization is allowed to continue for a period of time sufficient to provide polymer of the desired molecular weight.
The polymerization reaction may be carried out in an inert atmosphere. In carrying out the reactions, combination of the reactants may be accomplished in any order. For example, the reactants can be combined by dissolving a catalytically effective amount of the selected catalyst in a solvent, combining the monomer and the catalyst solution, and then adding the nucleophilic reagent. In a particularly preferred embodiment, the monomer, the nucleophilic reagent, and the catalyst are combined and dissolved in a suitable solvent, and polymerization thus occurs in a one-pot, one-step reaction.
The reaction mixture is typically, although not necessarily, agitated (e.g., stirred), and the progress of the reaction can be monitored by standard techniques, although visual inspection is generally sufficient. Examples of solvents that may be used in the polymerization reaction include organic, protic, or aqueous solvents that are inert under the polymerization conditions, such as aromatic hydrocarbons, chlorinated hydrocarbons, ethers, aliphatic hydrocarbons, or mixtures thereof. Preferred solvents include toluene, methylene chloride, tetrahydrofuran, methyl t-butyl ether, Isopar, gasoline, and mixtures thereof. Reaction temperatures are in the range of about 25° C. to about 300° C. The total polymerization reaction time will generally, although again not necessarily, be in the range of about 1 to 24 hours.
In some embodiments, the reactions are carried out by first combining the monomer with the nucleophilic reagent and the catalyst in a solvent. After allowing sufficient time for the monomer to react with the nucleophilic reagent to form a prepolymer, the reaction conditions are changed to encourage polymerization of the prepolymer. For example, elevated temperature and/or reduced pressure may be applied in order to force the condensation of prepolymer molecules. In some embodiments, the temperature of the reaction after formation of the prepolymer is raised to between 100° C. and 200° C., or greater than about 150° C., or greater than about 170° C. The amount of time required to form the prepolymer from the monomer and the nucleophilic reagent will vary depending upon the reactants and conditions, but may be estimated or determined by the usual analytical methods. The temperature during formation of the prepolymer may be room temperature or higher, for example between 30° C. and 100° C.
The polymerization product from reactions according to the invention contains product polymer and the guanidine-containing catalyst, which may be removed from the polymer product in the usual manner.
Because the polymerization catalysts disclosed herein do not contain metals, the methods of the disclosure allow for the polymerization of a monomer starting material to provide a polymerization product that is substantially free of metal contaminants. In particular, the concentration of metal contaminants in the polymer products is equal to or less than the concentration of metal contaminants in the starting materials prior to polymerization. For example, when a sample of dimethyl terephthalate (DMT) is polymerized according to the invention, and the sample of DMT has a certain concentration of metal contaminant (e.g., residual metals from any reaction that was used to prepare the DMT, such as a metal catalyst used in a depolymerization reaction recycling PET into DMT via depolymerization), the polymerization reaction according to the invention does not increase the total concentration of metal contaminants. The polymer products (e.g., PET) contain the same or lower concentration of metal contaminants as the starting materials. A lower concentration of metal contaminant may be observed if the polymer products are subjected to any purification steps (such as precipitation, filtration, etc.). As a further example, a sample of DMT having no metal contaminants (or an undetectable level of metal contaminants) may be polymerized according to the invention to yield polymer products having no metal contaminants (or an undetectable level of metal contaminants).
In some embodiments, the polymerization reactions of the disclosure allow preparation of polymer products having a metal contaminant concentration that is immeasurable or equal to or less than the metal contaminant concentration of the starting materials used to prepare the polymer. Such polymer products may have substantially less metal contaminant concentrations than similar polymers prepared using conventional (i.e., metal catalyzed) polymerization methods.
For example, depending on the method of manufacture, conventional PET used for drinking bottles may have a residual metal contamination level of up to 50 ppm, or up to 20 ppm, or up to 5 ppm. In some embodiments, the methods of the invention provide PET suitable for food and beverage storage since the level of metal contamination of the polymerization products will be no higher than the level of metal contamination of the original monomer. Thus, in some embodiments, the methods of the invention provide polymers having a metal contamination concentration of ≦50 ppm, or ≦20 ppm, or ≦5 ppm, or below 1 ppm.
The methods described herein find utility, for example, in the preparation of polymers and items made from polymers, the use of recycled polymer depolymerization products, and similar areas as described herein throughout.
All patents, patent applications, and publications mentioned herein are hereby incorporated by reference in their entireties. However, where a patent, patent application, or publication containing express definitions is incorporated by reference, those express definitions should be understood to apply to the incorporated patent, patent application, or publication in which they are found, and not to the remainder of the text of this application, in particular the claims of this application.
It is to be understood that while the invention has been described in conjunction with the preferred specific embodiments thereof, that the foregoing description as well as the examples that follow, are intended to illustrate and not limit the scope of the invention. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention, and further that other aspects, advantages and modifications will be apparent to those skilled in the art to which the invention pertains.
EXAMPLES
Example 1
Sample 1 is a PET that was polymerized (bulk) with 2 mol % of catalysts relative to DMT. Since the concentration of ethylene glycol tends to vary during the course of the polymerization, all catalysts loadings are relative to dimethyl terephthalate (DMT). The maximum polymerization temperature in the case was 200° C.
DMT (0.5 grams, 0.0025 mol) was added to a round bottom flask together with ethylene glycol (0.62 grams, 0.01 mol). To this slurry, TBD (0.006 grams, 0.00005 mol) was added. The reaction was heated to 40° C. under vacuum (3 hours), 100° C. (1 hour) and 200° C. for 3 hours.
Example 2
Sample 2 was also PET that was polymerized with 1.5 mol % catalyst relative to DMT. The maximum polymerization temperature in this case was 275° C.
DMT (3.0 grams, 0.015 mole) and ethylene glycol (6.5 grams, 0.01 mol) was added to a round bottom flask together with TBD (0.01 grams, 0.000075 mol). The reaction was heated to 40° C. under nitrogen (2 hours), heated to 60° C. under vacuum (30 min) and heated to 100° C. (vacuum, 1 hour). The reaction was then heated to 150° C. (vacuum, 35 min. where it became homogeneous. The reaction was then heated to 200° C. (1.5 hours) and then 275° C. (1 hour) to finish the reaction.
The product polymers were characterized by 1 H NMR.
Example 3
Combining bis(hydroxy ethylene) terephthalate (BHET) with 1,5,7-triazabicyclo[4.4.0]dec-5-ene (TBD) and heating the mixture under vacuum results in the formation of poly(ethylene terephthalate). Polymerization can also be carried out by heating dimethyl terephthalate with ethylene glycol in the presence of TBD catalysts followed by heating under vacuum. This process is shown in Scheme 1.
Example 4
Synthesis of 1,4,6-triazabicyclo[3.3.0]-oct-4-ene (TBO). With stirring at room temperature under nitrogen atmosphere, xylenes (300 mL), diethylenetriamine (20.6 g, 21.7 mL, 0.2 mol), and carbon disulfide (15.2 g, 12.0 mL, 0.2 mol) were added to a three-necked flask. A white precipitate formed immediately and the suspension was heated to reflux. Evolution of H 2 S from the reaction exhaust was monitored using filter paper soaked in a methanolic suspension of lead(II) acetate. After 10 days of reflux under nitrogen, GC/MS analysis confirmed quantitative conversion to the target compound. Upon cooling to room temperature a white solid crystallized from solution, and the supernatant was decanted. The solid was washed with 2×50 mL portions of acetone and pentane, respectively, and dried under vacuum overnight. (8.65 g, 39%). 1 H NMR 400 MHz (CDCl 3 ).differential. (ppm)=6.02 [br s, 1H, N—H], 3.79 [t, 2H, backbone CH 2 , J=7.0 Hz], 3.05 [t, 2H, backbone CH 2 , J=7.0 Hz]. 13 C NMR 100.6 MHz (CDCl 3 ).differential. (ppm)=171.18 [central sp 2 C], 52.62 [backbone CH 2 ], 49.38 [backbone CH 2 ]. LRMS (m/z): 112.1 (positive ion, M+H).
Example 5
Synthesis of Guanidine catalysts. The general procedure is shown in Scheme 2.
DCC was reacted neat (110° C.) with a secondary amine. Once the DCC melted a homogeneous solution was formed and the reaction was allowed to proceed overnight to generate a viscous oil/gel. The reaction was followed by GC/MS and quantitative conversion of starting material was accomplished in .about.12 hours. Compounds were purified either by kugelroh distillation or by column chromatography.
Synthesis of Guanidinium 1: Dicyclohexylcarbodiimide (3 g, 14.8 mmol) and pyrrolidine (10 ml, 120 mmol) were heated to reflux overnight under N 2 . The excess pyrrolidine was distilled off and the product was purified by Kugelroh distillation (265° C.) to yield a colorless oil. The product guanidine compound has the structure shown below.
Synthesis of Guanidinium 2: DCC (0.93 g, 4.52 mmol) and TBD (0.66 g, 4.76 mmol) were allowed to react for 20 (125° C. under N 2 ). The gel like product was purified by Kugelroh distillation 265° C. to yield a white crystalline solid T m =69-71° C. The product guanidine compound has the structure shown below.
Synthesis of Guanidinium 3: DCC (0.70 g, 3.39 mmol) and (s)-(−) α,α-diphenyl-2-pyrrolidinemethanol (0.86 g, 3.39 mmol) were heated (under N 2 ) at 80° C. for 20 h. Temperatures above 100° C. resulted in decomposition. The product was purified using column chromatographs (ethyl acetate/hexane (60/40)) to yield a white crystalline solid T m =104-106° C. The product guanidine compound has the structure shown below. | The disclosure relates to methods and materials useful for polymerizing a monomer. In one embodiment, for example, the disclosure provides a method for polymerizing a monomer containing a plurality of electrophilic groups, wherein the method comprises contacting the monomer with a nucleophilic reagent in the presence of a guanidine-containing catalyst. The methods and materials of the disclosure find utility, for example, in the field of materials science. | 2 |
RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 09/817,514, filed Mar. 26, 2001, now U.S. Pat. No. 6,639,129, which claims priority from United States Provisional Patent Application Ser. No. U.S. 60/191,806 filed on Mar. 24, 2000.
BACKGROUND OF THE INVENTION
As reported in WO98/08932, protein toxins from the genus Photorhabdus have been shown to have oral toxicity against insects. The toxin complex produced by Photorhabdus luminescens (W-14), for example, has been shown to contain ten to fourteen proteins, and it is known that these are produced by expression of genes from four distinct genomic regions: tca, tcb, tcc, and tcd. WO98/08932 discloses nucleotide sequences for many of the native toxin genes.
Of the separate toxins isolated from Photorhabdus luminescens (W-14), those designated Toxin A and Toxin B have been the subject of focused investigation for their activity against target insect species of interest, for example corn rootworm. Toxin A is comprised of two different subunits. The native gene tcda (SEQ ID NO:1) encodes protoxin TcdA (see SEQ ID NO:1). As determined by mass spectrometry, TcdA is processed by one or more proteases to provide Toxin A. More specifically, TcdA is an approximately 282.9 kDA protein (2516 aa) that is processed to provide TcdAii, an approximately 208.2 kDA (1849 aa) protein encoded by nucleotides 265-5811 of SEQ ID NO:1, and TcdAiii, an approximately 63.5 kDA (579 aa) protein encoded by nucleotides 5812-7551 of SEQ ID NO:1.
WO 01/11029 discloses nucleotide sequences that encode TcdA and TcbA and have base compositions that have been altered from that of the native genes to make them more similar to plant genes. Also disclosed are transgenic plants that express Toxin A and Toxin B.
We have observed that heterologous expression of Toxin A does not afford the level of oral toxicity to insects that is observed for the native toxin. It would be very valuable if means could be found to enhance the level of toxicity of heterologously expressed Toxin A.
SUMMARY OF THE INVENTION
The present invention provides nucleotide sequences for two genes, tcdB and tccC2, from the tcd genomic region of Photorhabdus luminescens W-14. These sequences were not previously known. We have discovered that coexpression of tcdB and tccC2 with tcdA in heterologous hosts results in enhanced levels of oral insect toxicity compared to that obtained when tcdA is expressed alone in such heterologous hosts. Coexpression of tcdB and tccC2 with tcdA or tcbA, or with any other functionally equivalent toxin gene in the same family as tcdA and tcbA, to provide enhanced oral insect activity falls within the scope of the invention.
Summary of the Sequences
SEQ ID NO: 1 is the DNA sequence for tcdA from Photorhabdus luminescens W-14.
SEQ ID NO: 2 is the amino acid sequence for TcdA from Photorhabdus luminescens W-14.
SEQ ID NO: 3 is the DNA sequence for tcdB from Photorhabdus luminescens W-14.
SEQ ID NO: 4 is the amino acid sequence for TcdB from Photorhabdus luminescens W-14.
SEQ ID NO: 5 is the DNA sequence for tccC2 from Photorhabdus luminescens W-14.
SEQ ID NO: 6 is the amino acid sequence for TccC2 from from Photorhabdus luminescens W-14.
SEQ ID NO: 7 is the DNA sequence for tcbA from from Photorhabdus luminescens W-14.
SEQ ID NO: 8 is the amino acid sequence for TcbA from Photorhabdus luminescens W-14.
DETAILED DESCRIPTION OF THE INVENTION
It is preferred for the nucleic acids according to the invention to comprise at least one sequence chosen from
(a) the sequences according to SEQ ID NOS: 3 and 5.
(b) at least 14 base pairs-long partial sequences of the sequences defined under (a),
(c) sequences that hybridize with the sequences defined under (a),
(d) sequences that are at least 70%, preferably 80% and even more preferred, 90% identical to the sequences defined under (a),
(e) sequences that are at least 70%, preferably 80% and even more preferred, 90% similar to the sequences defined under (a),
(f) sequences that complement the sequences defined under (a), and
(g) sequences that due to the degeneracy of the genetic code, code for the same amino acid sequence as (i.e. are “isocoding” with) the sequences defined under (a) through (e).
The expression “hybridize” as used herein refers to hybridization under the following specified conditions: 5×SSC; blocking reagent (Roche Diagnostics Inc., Mannheim, Germany), 1%; N-lauroyl-sarcosine, 0.1%; SDS (sodium-dodecyl sulfate) 0.02%; hybridization temperature: 60° C.; first wash step: 2×SSC at 60° C.; second wash step: 2×SSC at 60° C.; preferred second wash step: 0.5×SSC at 60° C.; especially preferred second wash step: 0.2×SSC at 60° C.
“Identity” and “similarity” are scored by the GAP algorithm using the Blosum 62 protein scoring matrix (Wisconsin Package Version 9.0, Genetics Computer Group (GCG), Madison, Wis.).
Expression of the Nucleotide Sequences in Heterologous Microbial Hosts
As biological insect control agents, the insecticidal toxins are produced by expression of the nucleotide sequences in heterologous host cells capable of expressing the nucleotide sequences. In a first embodiment, additional copies of one or more of the nucleotide sequences are added to Xenorhabdus nematophilus, Xenorhabdus poinarii , or Photorhabdus luminescens cells either by insertion into the chromosome or by introduction of extrachromosomally replicating molecules containing the nucleotide sequences.
In another embodiment, at least one of the nucleotide sequences of the invention is inserted into an appropriate expression cassette, comprising a promoter and termination signals. Expression of the nucleotide sequence is constitutive, or an inducible promoter responding to various types of stimuli to initiate transcription is used. In a preferred embodiment, the cell in which the toxin is expressed is a microorganism, such as a virus, a bacteria, or a fungus. In a preferred embodiment, a virus, such as a baculovirus, contains a nucleotide sequence of the invention in its genome and expresses large amounts of the corresponding insecticidal toxin after infection of appropriate eukaryotic cells that are suitable for virus replication and expression of the nucleotide sequence. The insecticidal toxin thus produced is used as an insecticidal agent. Alternatively, baculoviruses engineered to include the nucleotide sequence are used to infect insects in-vivo and kill them either by expression of the insecticidal toxin or by a combination of viral infection and expression of the insecticidal toxin.
Bacterial cells are also hosts for the expression of the nucleotide sequences of the invention. In a preferred embodiment, non-pathogenic symbiotic bacteria, which are able to live and replicate within plant tissues, so-called endophytes, or non-pathogenic symbiotic bacteria, which are capable of colonizing the phyllosphere or the rhizosphere, so-called epiphytes, are used. Such bacteria include bacteria of the genera Agrobacterium, Alcaligenes, Azospiriilum, Azotobacter, Bacillus, Ciavibacter, Enterobacter, Erwinia, Flavobacter, Klebsielia, Pseudomonas, Rhizobium, Serratia, Streptomyces and Xanthomonas . Symbiotic fungi, such as Trichoderma and Gliocladium are also possible hosts for expression of the inventive nucleotide sequences for the same purpose.
Techniques for these genetic manipulations are specific for the different available hosts and are known in the art. For example, the expression vectors pKK223-3 and pKK223-2 can be used to express heterologous genes in E. coli , either in transcriptional or translational fusion, behind the tac or trc promoter. For the expression of operons encoding multiple ORFS, the simplest procedure is to insert the operon into a vector such as pKK2233 in transcriptional fusion, allowing the cognate ribosome binding site of the heterologous genes to be used. Techniques for overexpression in gram-positive species such as Bacillus are also known in the art and can be used in the context of this invention (Quax et al. In.: Industrial Microorganisms: Basic and Applied Molecular Genetics, Eds. Baltz et al., American Society for Microbiology, Washington (1993)). Alternate systems for overexpression rely for example, on yeast vectors and include the use of Pichia, Saccharomyces and Kluyveromyces (Sreekrishna, In: industrial microorganisms: basic and applied molecular genetics, Baltz, Hegeman, and Skatrud eds., American Society for Microbiology, Washington (1993); Dequin & Barre, Biotechnology 12:173–177 (1994); van den Berg et al., Biotechnology 8:135–139 (1990)).
Expression of the Nucleotide Sequences in Plant Tissue
In a particularly preferred embodiment, at least one of the insecticidal toxins of the invention is expressed in a higher organism, e.g., a plant. In this case, transgenic plants expressing effective amounts of the toxins protect themselves from insect pests. When the insect starts feeding on such a transgenic plant, it also ingests the expressed toxins. This will deter the insect from further biting into the plant tissue or may even harm or kill the insect. A nucleotide sequence of the present invention is inserted into an expression cassette, which is then preferably stably integrated in the genome of said plant, In another preferred embodiment, the nucleotide sequence is included in a non-pathogenic self-replicating virus. Plants transformed in accordance with the present invention may be monocots or dicots and include, but are not limited to, maize, wheat, barley, rye, sweet potato, bean, pea, chicory, lettuce, cabbage, cauliflower, broccoli, turnip, radish, spinach, asparagus, onion, garlic, pepper, celery, squash, pumpkin, hemp, zucchini, apple, pear, quince, melon, plum, cherry, peach, nectarine, apricot, strawberry, grape, raspberry, blackberry, pineapple, avocado, papaya, mango, banana, soybean, tomato, sorghum, sugarcane, sugarbeet, sunflower, rapeseed, clover, tobacco, carrot, cotton, alfalfa, rice, potato, eggplant, cucumber, Arabidopsis, and woody plants such as coniferous and deciduous trees.
Once a desired nucleotide sequence has been transformed into a particular plant species, it may be propagated in that species or moved into other varieties of the same species, particularly including commercial varieties, using traditional breeding techniques.
A nucleotide sequence of this invention is preferably expressed in transgenic plants, thus causing the biosynthesis of the corresponding toxin in the transgenic plants. In this way, transgenic plants with enhanced resistance to insects are generated. For their expression in transgenic plants, the nucleotide sequences of the invention may require modification and optimization. Although in many cases genes from microbial organisms can be expressed in plants at high levels without modification, low expression in transgenic plants may result from microbial nucleotide sequences having codons that are not preferred in plants. It is known in the art that all organisms have specific preferences for codon usage, and the codons of the nucleotide sequences described in this invention can be changed to conform with plant preferences, while maintaining the amino acids encoded thereby. Furthermore, high expression in plants is best achieved from coding sequences that have at least about 35% GC content, preferably more than about 45%, more preferably more than about 50%, and most preferably more than about 60%. Microbial nucleotide sequences which have low GC contents may express poorly in plants due to the existence of ATTTA motifs which may destabilize messages, and AATAAA motifs which may cause inappropriate polyadenylation. Although preferred gene sequences may be adequately expressed in both monocotyledonous and dicotyledonous plant species, sequences can be modified to account for the specific codon preferences and GC content preferences of monocotyledons or dicotyledons as these preferences have been shown to differ (Murray et al. Nucl. Acids Res. 17:477–498 (1989)). In addition, the nucleotide sequences are screened for the existence of illegitimate splice sites that may cause message truncation. All changes required to be made within the nucleotide sequences such as those described above are made using well known techniques of site directed mutagenesis, PCR, and synthetic gene construction.
For efficient initiation of translation, sequences adjacent to the initiating methionine may require modification. For example, they can be modified by the inclusion of sequences known to be effective in plants. Joshi has suggested an appropriate consensus for plants (NAR 15:6643–6653 (1987)) and Clontech suggests a further consensus translation initiator (1993/1994 catalog, page 210). These consensuses are suitable for use with the nucleotide sequences of this invention. The sequences are incorporated into constructions comprising the nucleotide sequences, up to and including the ATG (whilst leaving the second amino acid unmodified), or alternatively up to and including the GTC subsequent to the ATG (with the possibility of modifying the second amino acid of the transgene).
Expression of the nucleotide sequences in transgenic plants is driven by promoters shown to be functional in plants. The choice of promoter will vary depending on the temporal and spatial requirements for expression, and also depending on the target species. Thus, expression of the nucleotide sequences of this invention in leaves, in ears, in inflorescences (e.g. spikes, panicles, cobs, etc.), in roots, and/or seedlings is preferred. In many cases, however, protection against more than one type of insect pest is sought, and thus expression in multiple tissues is desirable. Although many promoters from dicotyledons have been shown to be operational in monocotyledons and vice versa, ideally dicotyledonous promoters are selected for expression in dicotyledons, and monocotyledonous promoters for expression in monocotyledons. However, there is no restriction to the provenance of selected promoters; it is sufficient that they are operational in driving the expression of the nucleotide sequences in the desired cell.
Preferred promoters that are expressed constitutively include promoters from genes encoding actin or ubiquitin and the CAMV 35S and 19S promoters. The nucleotide sequences of this invention can also be expressed under the regulation of promoters that are chemically regulated. This enables the insecticidal toxins to be synthesized only when the crop plants are treated with the inducing chemicals.
A preferred category of promoters is that which is wound inducible. Numerous promoters have been described which are expressed at wound sites and also at the sites of phytopathogen infection. Ideally, such a promoter should only be active locally at the sites of infection, and in this way the insecticidal toxins only accumulate in cells which need to synthesize the insecticidal toxins to kill the invading insect pest. Preferred promoters of this kind include those described by Stanford et al. Mol. Gen. Genet. 215:200–208 (1989), Xu et al. Plant Molec. Biol. 22:573–588 (1993), Logemann et al. Plant Cell 1: 151–158 (1989), Rohrmeier & Lehle, Plant Molec. Biol. 22:783–792 (1993), Firek et al. Plant Molec. Biol. 22: 129–142 (1993), and Warner et al. Plant J. 3:191–201 (1993).
Especially preferred embodiments of the invention are transgenic plants expressing at least one of the nucleotide sequences of the invention in a root-preferred or root-specific fashion. Further preferred embodiments are transgenic plants expressing the nucleotide sequences in a wound-inducible or pathogen infection-inducible manner.
In addition to the selection of a suitable promoter, constructions for expression of an insecticidal toxin in plants require an appropriate transcription terminator to be attached downstream of the heterologous nucleotide sequence. Several such terminators are available and known in the art (e.g. tml from Agrobacterium , E9 from rbcs). Any available terminator known to function in plants can be used in the context of this invention.
Numerous other sequences can be incorporated into expression cassettes described in this invention. These include sequences which have been shown to enhance expression such as intron sequences (e.g. from Adhl and bronzel) and viral leader sequences (e.g. from TMV, MCMV and AMV).
It may be preferable to target expression of the nucleotide sequences of the present invention to different cellular localizations in the plant. In some cases, localization in the cytosol may be desirable, whereas in other cases, localization in some subcellular organelle may be preferred. Subcellular localization of transgene encoded enzymes is undertaken using techniques well known in the art Typically, the DNA encoding the target peptide from a known organelle-targeted gene product is manipulated and fused upstream of the nucleotide sequence. Many such target sequences are known for the chloroplast and their functioning in heterologous constructions has been shown. The expression of the nucleotide sequences of the present invention is also targeted to the endoplasmic reticulum or to the vacuoles of the host cells. Techniques to achieve this are well-known in the art.
Vectors suitable for plant transformation are described elsewhere in this specification. For Agrobacterium -mediated transformation, binary vectors or vectors carrying at least one T-DNA border sequence are suitable, whereas for direct gene transfer any vector is suitable and linear DNA containing only the construction of interest may be preferred. In the case of direct gene transfer, transformation with a single DNA species or co-transformation can be used (Schocher et al. Biotechnology 4:1093–1096 (1986)). For both direct gene transfer and Agrobacterium-mediated transfer, transformation is usually (but not necessarily) undertaken with a selectable or screenable marker which may provide resistance to an antibiotic (kanamycin, hygromycin or methotrexate) or a herbicide (Basta). Examples of such markers are neomycin phosphotransferase, hygromycin phosphotransferase, dihydrofolate reductase, phosphinothricin acetyltransferase, 2,2-dichloroproprionic acid dehalogenase, acetohydroxyacid synthase, 5-enolpyruvyl-shikimate-phosphate synthase, haloarylnitrilase, protoporhyrinogen oxidase, acetyl-coenzyme A carboxylase, dihydropteroate synthase, chloramphenicol acetyl transferase, and glucuronidase. The choice of selectable or screenable marker for plant transformation is not, however, critical to the invention.
The recombinant DNA described above can be introduced into the plant cell in a number of art-recognized ways. Those skilled in the art will appreciate that the choice of method might depend on the type of plant targeted for transformation. Suitable methods of transforming plant cells include microinjection (Crossway et al., BioTechniques 4.,320–334 (1986)), electroporation (Riggs et al., Proc. Natl. Acad, Sci. USA 83.,5602–5606 (1986), Agrobacterium -mediated transformation (Hinchee et al., Biotechnology 6:915–921 (1988); See also, lshida et al., Nature Biotechnology 14:745–750 (June 1996) (for maize transformation), direct gene transfer (Paszkowski et al., EMBO J. 3.2717–2722 (1984); Hayashimoto et al., Plant Physiol 93.857–863 (1990) (rice), and ballistic particle acceleration using devices available from Agracetus, Inc., Madison, Wis. and Dupont, Inc., Wilmington, Del. (see, for example, Sanford et al., U.S. Pat. No. 4,945,050; and McCabe et al., Biotechnology 6.923–926 (1988)). See also, Weissinger et al., Annual Rev Genet. 22.–421–477 (1988); Sanford et al., Particulate Science and Technology 5.27–37 (1987)(onion); Svab et al., Proc. Natl. Acad. Sci. USA 87.- 8526–8530 (1990) (tobacco chloroplast); Christou et al., Plant Physiol 87,671–674 (1988) (soybean); McCabe et al., BioTechnology 6.923–926 (1988)(soybean); Klein et al., Proc. Natl. Acad. Sci. USA, 85:4305–4309 (1988) (maize); Klein et al., BioTechnology 6.,559–563 (1988) (maize); Klein et al., Plant PhysioL 91.,440–444 (1988) (maize); Fromm et al., BioTechnology 8:833–839 (1990); and Gordon-Kamm et al., Plant Cell 2: 603–618 (1990) (maize); Koziel et al., Biotechnology 1 1: 194–200 (1993) (maize); Shimamoto et al., Nature 338: 274–277 (1989) (rice); Christou et al., Biotechnology 9: 957–962 (1991) (rice); Datta et al., BioTechnology 8.736–740 (1990) (rice); European Patent Application EP 0 332 581 (orchardgrass and other Pooideae); Vasil et al., Biotechnology 1 1: 1553–1558 (1993) (wheat); Weeks et al., Plant Physiol. 102:1077–1084 (1993) (wheat); wan et al., Plant Physiol. 104:37–48 (1994) (barley); Jahne et al., Theor. Appl. Genet. 89:525–533 (1994) (barley); Umbeck et al., BioTechnology 5:263–266 (1987) (cotton); Casas et al., Proc. Natl. Acad. Sci. USA 90:11212–11216 (December 1993) (sorghum); Somers et al., BioTechnology 10:1 589–1594 (December 1992) (oat); Torbert et al., Plant Cell Reports 14:635–640 (1995) (oat); Weeks et al., Plant Physiol. 102:1077–1084 (1993) (wheat); Chang et al., WO 94/13822 (wheat) and Nehra et al., The Plant Journal 5:285–297 (1994) (wheat). A particularly preferred set of embodiments for the introduction of recombinant DNA molecules into maize by microprojectile bombardment can be found in Koziel et al., Biotechnology 11: 194–200(1993), Hill et al., Euphytica 85:119–123 (1995) and Koziel et al., Annals of the New York Academy of Sciences 792:164–171 (1996). An additional preferred embodiment is the protoplast transformation method for maize as disclosed in EP 0 292 435. Transformation of plants can be undertaken with a single DNA species or multiple DNA species (i.e. co-transformation).
In another preferred embodiment, a nucleotide sequence of the present invention is directly transformed into the plastid genome. A major advantage of plastid transformation is that plastids are generally capable of expressing bacterial genes without substantial modification, and plastids are capable of expressing multiple open reading frames under control of a single promoter. Plastid transformation technology is extensively described in U.S. Pat. Nos. 5,451,513, 5,545,817, and 5,545,818, in PCT application no. WO 95/16783, and in McBride et al. (1994) Proc. Natl. Acad. Sci. USA 91, 7301–7305. The basic technique for chloroplast transformation involves introducing regions of cloned plastid DNA flanking a selectable marker together with the gene of interest into a suitable target tissue, e.g., using biolistics or protoplast transformation (e.g., calcium chloride or PEG mediated transformation). The 1 to 1.5 kb flanking regions, termed targeting sequences, facilitate homologous recombination with the plastid genome and thus allow the replacement or modification of specific regions of the plastome. Initially, point mutations in the chloroplast 16S rRNA and rpsl2 genes conferring resistance to spectinomycin and/or streptomycin are utilized as selectable markers for transformation (Svab, Z., Hajdukiewicz, P., and Maliga, P. (1990) Proc. Nati. Acad. Sci. USA 87, 8526–8530; Staub, J. M., and Maliga, P. (1992) Plant Cell 4, 39–45). This resulted in stable homoplasmic transformants at a frequency of approximately one per 100 bombardments of target leaves. The presence of cloning sites between these markers allowed creation of a plastid targeting vector for introduction of foreign genes (Staub, J. M., and Maliga, P. (1993) EMBO J. 12, 601–606). Substantial increases in transformation frequency are obtained by replacement of the recessive RRNA or r-protein antibiotic resistance genes with a dominant selectable marker, the bacterial aada gene encoding the spectinomycin-detoxifying enzyme aminoglycoside-3′ adenyltransferase (Svab, Z., and Maliga, P. (1993) Proc. Natl. Acad. Sci. USA 90, 913–917). Previously, this marker had been used successfully for high-frequency transformation of the plastid genome of the green alga Chlamydomonas reinhardtii (Goldschmidt-Clermont, M. (1991) Nucl. Acids Res. 19: 4083–4089). Other selectable markers useful for plastid transformation are known in the art and encompassed within the scope of the invention. Typically, approximately 15–20 cell division cycles following transformation are required to reach a homoplastidic state. Plastid expression, in which genes are inserted by homologous recombination into all of the several thousand copies of the circular plastid genome present in each plant cell, takes advantage of the enormous copy number advantage over nuclear-expressed genes to permit expression levels that can readily exceed 10% of the total soluble plant protein. In a preferred embodiment, a nucleotide sequence of the present invention is inserted into a plastid targeting vector and transformed into the plastid genome of a desired plant host. Plants homoplastic for plastid genomes containing a nucleotide sequence of the present invention are obtained, and are preferentially capable of high expression of the nucleotide sequence.
Provisional Patent Application Ser. No. U.S. 60/191,806 filed Mar. 24, 2000, is hereby incorporated by reference. | Nucleotide sequences for two genes, tcdB and tccC2, from the tcd genomic region of Photorhabdus luminescens W-14 are useful in heterologous expression of orally active insect toxins. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. § 119(e) of provisional application U.S. Serial No. 60/348,762 filed Jan. 14, 2002. The contents of this application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to compositions and methods for use in treating skeletal system disorders in a vertebrate at risk for bone loss, and in treating conditions that are characterized by the need for bone growth, in treating fractures, and in treating cartilage disorders. More specifically, the invention concerns the use of inhibitors of microtubule assembly, e.g., a microtubule inhibitor compound, for enhancing bone growth.
BACKGROUND OF THE INVENTION
[0003] Bone is subject to constant breakdown and resynthesis in a complex process mediated by osteoblasts, which produce new bone, and osteoclasts, which destroy bone. The activities of these cells are regulated by a large number of cytokines and growth factors, many of which have now been identified and cloned.
[0004] There is a plethora of conditions which are characterized by the need to enhance bone formation or to inhibit bone resorption. Perhaps the most obvious is the case of bone fractures, where it would be desirable to stimulate bone growth and to hasten and complete bone repair. Agents that enhance bone formation would also be useful in facial reconstruction procedures. Other bone deficit conditions include bone segmental defects, periodontal disease, metastatic bone disease, osteolytic bone disease and conditions where connective tissue repair would be beneficial, such as healing or regeneration of cartilage defects or injury. Also of great significance is the chronic condition of osteoporosis, including age-related osteoporosis and osteoporosis associated with post-menopausal hormone status. Other conditions characterized by the need for bone growth include primary and secondary hyperparathyroidism, disuse osteoporosis, diabetes-related osteoporosis, and glucocorticoid-related osteoporosis.
[0005] Bone fractures are still treated exclusively using casts, braces, anchoring devices and other strictly mechanical means. Further bone deterioration associated with post-menopausal osteoporosis has been treated with estrogens or bisphosphonates, which may have drawbacks for some individuals. Treatment of bone or other skeletal disorders, such as those associated with cartilage, can be achieved either by enhancing bone formation or inhibiting bone resorption or both.
[0006] Bone tissue is an excellent source for factors which have the capacity for stimulating bone cells. Thus, extracts of bovine bone tissue obtained from slaughterhouses contain not only structural proteins which are responsible for maintaining the structural integrity of bone, but also biologically active bone growth factors which can stimulate bone cells to proliferate. Among these latter factors are transforming growth factor β, the heparin-binding growth factors (e.g., acidic and basic fibroblast growth factor), the insulin-like growth factors (e.g., insulin-like growth factor I and insulin-like growth factor II), and a recently described family of proteins called bone morphogenetic proteins (BMPs). All of these growth factors have effects on other types of cells, as well as on bone cells.
[0007] The BMPs are novel factors in the extended transforming growth factor β superfamily. Recombinant BMP2 and BMP4 can induce new bone formation when they are injected locally into the subcutaneous tissues of rats (Wozney, J., Molec Reprod Dev (1992) 32:160-67). These factors are expressed by normal osteoblasts as they differentiate, and have been shown to stimulate osteoblast differentiation and bone nodule formation in vitro as well as bone formation in vivo (Harris S., et al., J Bone Miner Res (1994) 9:855-63).
[0008] The cells which are responsible for forming bone are osteoblasts. As osteoblasts differentiate from precursors to mature bone-forming cells, they express and secrete a number of enzymes and structural proteins of the bone matrix, including Type-1 collagen, osteocalcin, osteopontin and alkaline phosphatase. They also synthesize a number of growth regulatory peptides which are stored in the bone matrix, and are presumably responsible for normal bone formation. These growth regulatory peptides include the BMPs (Harris S., et al. (1994), supra). In studies of primary cultures of fetal rat calvarial osteoblasts, BMPs 1, 2, 3, 4, and 6 are expressed by cultured cells prior to the formation of mineralized bone nodules (Harris S., et al. (1994), supra). Like alkaline phosphatase, osteocalcin and osteopontin, the BMPs are expressed by cultured osteoblasts as they proliferate and differentiate.
[0009] Other agents appear to operate by preventing the resorption of bone. Thus, U.S. Pat. No. 5,280,040 discloses compounds described as useful in the treatment of osteoporosis. These compounds putatively achieve this result by preventing bone resorption.
[0010] Wang, G.-J., et al., J Formos Med Assoc (1995) 94:589-592 report that certain lipid clearing agents, exemplified by lovastatin and bezafibrate, were able to inhibit the bone resorption resulting from steroid administration in rabbits. There was no effect on bone formation by these two compounds in the absence of steroid treatment. The mechanism of the inhibition in bone resorption observed in the presence of steroids (and the mechanism of the effect of steroid on bone, per se) is said to be unknown.
[0011] An abstract entitled “Lovastatin Prevents Steroid-Induced Adipogenesis and Osteoporosis” by Cui, Q., et al., appeared in the Reports of the ASBMR 18th Annual Meeting (September 1996) J Bone Mineral Res. (1996) 11(S1):S510 which reports that lovastatin diminished triglyceride vesicles that accumulated when osteoprogenitor cells cloned from bone marrow stroma of chickens were treated in culture with dexamethasone. Lovastatin was reported to diminish the expression of certain mRNAs and to allow the cells to maintain the osteogenic phenotype after dexamethasone treatment, and chickens that had undergone bone loss in the femoral head as a result of dexamethasone treatment were improved by treatment with lovastatin.
[0012] These data are, however, contrary to reports that dexamethasone and other inducers, such as BMPs, induce osteoblastic differentiation and stimulate osteocalcin mRNA (Bellows, C. G., et al., Develop Biol (1990) 140:132-38; Rickard, D. J., et al., Develop Biol (1994) 161:218-28). In addition, Ducy, P., et al., Nature (1996) 382:448-52 have recently reported that osteocalcin deficient mice exhibit a phenotype marked by increased bone formation and bones of improved functional quality, without impairment of bone resorption. Ducy, et al., state that their data suggest that osteocalcin antagonists may be of therapeutic use in conjunction with estrogen replacement therapy (for prevention or treatment of osteoporosis). However, there continues to be a need for additional treatments to stimulate bone growth or to mitigate bone loss.
[0013] In order to maintain their shape and integrity, it is critical that all types of cells contain a structural scaffold. This structure is known as the cytoskeleton and is composed of a framework of interlocking proteins such as microtubules, actin and intermediate filaments. It is currently believed that the controlled regulation of the assembly and disassembly of the cytoskeleton is critical to the survival of the cell and many cellular processes are mediated by the cytoskeleton, especially those involving the interaction of the cell with the surrounding environment. These processes include, but are not limited to, cell adhesion, motility, and polarity. Cell division or mitosis also is dependent on concerted structural changes in the cytoskeleton.
[0014] There are several proteins that, in conjunction with the primary components of the cytoskeleton, act as regulators of cytoskeletal architecture. Microtubules are members of an array of fibrous cytoskeleton proteins that control cell strength and molecular movement within the cell. In particular, microtubules are critical to chromosomal movement during cell division and are comprised of tubulin subunits, which form a diverse array of both permanent and transient structures. The processes of microtubule assembly and disassembly are dynamic and can be affected by various factors.
SUMMARY OF THE INVENTION
[0015] In one aspect, the present invention is directed to a method to enhance bone formation or bone mineral density, or to treat a pathological bone condition or to treat a degenerative joint condition in a vertebrate subject, which method comprises administering to a vertebrate subject in need of such treatment an effective amount of a microtubule inhibitor, whereby bone formation or bone mineral density is enhanced, or said pathological bone condition or degenerative joint condition is treated, in said vertebrate subject. The microtubule inhibitor can be used alone, in combinations, or can be used in conjunction with an additional or secondary agent that promotes bone growth or inhibits bone resorption.
[0016] In another aspect, the present invention is directed to a combination, preferably in the form a pharmaceutical composition, which combination comprises a microtubule inhibitor compound and a non-microtubule inhibitor compound that promotes bone growth or inhibits bone resorption. Any suitable bone enhancer or bone resorption inhibitor can be used in the combination. Exemplary of such agents that can be used in the combination include bone morphogenetic factors, anti-resorptive agents, osteogenic factors, cartilage-derived morphogenetic proteins, growth hormones, estrogens, bisphosphonates, statins, differentiating factors, compounds that inhibit activity of NF-κB, e.g., 1-Pyrrolidinecarbodithioic Acid (PDTC), compounds that inhibit production of NF-κB, e.g., anti-NF-κB antisense oligos, compounds that inhibit activity of proteasomal activity, e.g., antibodies that specifically bind to proteasomal proteins, and compounds that inhibits production of a proteasome protein, e.g., antisense oligos that are complementary to genes or RNAs that encode proteasomal proteins. For clinical uses, the antibodies are preferably monoclonal or humanized antibodies.
[0017] Also provided are methods to stimulate osteoblast proliferation and/or differentiation in a vertebrate animal, which methods comprise administering to the vertebrate in need of such stimulation and/or differentiation, a therapeutically-effective amount of a microtubule inhibitor. Further provided by the present invention are methods to decrease bone resorption in a vertebrate animal, which methods comprise administering to the vertebrate in need of such decrease, a therapeutically-effective amount of a microtubule inhibitor.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In accordance with the present invention, there are provided methods of treating bone defects (including osteoporosis, fractures, osteolytic lesions and bone segmental defects) in subjects suffering therefrom said method comprising administering to said subject, in an amount sufficient to stimulate bone growth, a microtubular inhibitor.
[0019] For clarity of disclosure, and not by way of limitation, the detailed description of the invention is divided into the subsections that follow.
[0020] A. Definitions
[0021] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this invention belongs. All patents, applications, published applications and other publications and sequences from GenBank and other databases referred to herein are incorporated by reference in their entirety. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in applications, published applications and other publications and sequences from GenBank and other data bases that are herein incorporated by reference, the definition set forth in this section prevails.
[0022] As used herein, “a” or “an” means “at least one” or “one or more.” As used herein, “or” means in the alternative as well as in combination.
[0023] As used herein, “enhance” means to promote, increase, or stimulate bone formation or growth, or bone mineral density, in a vertebrate animal.
[0024] As used herein, “an effective amount” of a compound for treating a particular disease is an amount that is sufficient to ameliorate, or in some manner reduce the symptoms associated with the disease. Such amount may be administered as a single dosage or may be administered according to a regimen, whereby it is effective. The amount may cure the disease but, typically, is administered in order to ameliorate the symptoms of the disease. Repeated administration may be required to achieve the desired amelioration of symptoms. Within the present invention, an “effective amount” of a composition is that amount which produces a statistically significant effect. For example, an “effective amount” for therapeutic uses is the amount of the composition comprising an active compound herein required to provide a clinically significant increase in healing rates in fracture repair; reversal of bone loss in osteoporosis; reversal of cartilage defects or disorders; prevention or delay of onset of osteoporosis; stimulation and/or augmentation of bone formation in fracture non-unions and distraction osteogenesis; increase and/or acceleration of bone growth into prosthetic devices; and repair of dental defects. Such effective amounts will be determined using routine optimization techniques and are dependent on the particular condition to be treated, the condition of the patient, the route of administration, the formulation, and the judgment of the practitioner and other factors evident to those skilled in the art.
[0025] As used herein, “pharmaceutically acceptable salts, esters or other derivatives” include any salts, esters or derivatives that may be readily prepared by those of skill in this art using known methods for such derivatization and that produce compounds that may be administered to animals or humans without substantial toxic effects and that either are pharmaceutically active or are prodrugs.
[0026] As used herein, “treatment” means any manner in which the symptoms of a conditions, disorder or disease are ameliorated or otherwise beneficially altered. Treatment also encompasses any pharmaceutical use of the compositions herein.
[0027] As used herein, “amelioration” of the symptoms of a particular disorder by administration of a particular pharmaceutical composition refers to any lessening, whether permanent or temporary, lasting or transient that can be attributed to or associated with administration of the composition.
[0028] As used herein, “substantially pure” means sufficiently homogeneous to appear free of readily detectable impurities as determined by standard methods of analysis, such as thin layer chromatography (TLC), gel electrophoresis and high performance liquid chromatography (HPLC), used by those of skill in the art to assess such purity, or sufficiently pure such that further purification would not detectably alter the physical and chemical properties, such as enzymatic and biological activities, of the substance. Methods for purification of the compounds to produce substantially chemically pure compounds are known to those of skill in the art. A substantially chemically pure compound may, however, be a mixture of stereoisomers or isomers. In such instances, further purification might increase the specific activity of the compound.
[0029] As used herein, a “prodrug” is a compound that, upon in vivo administration, is metabolized or otherwise converted to the biologically, pharmaceutically or therapeutically active form of the compound. To produce a prodrug, the pharmaceutically active compound is modified such that the active compound will be regenerated by metabolic processes. The prodrug may be designed to alter the metabolic stability or the transport characteristics of a drug, to mask side effects or toxicity, to improve the flavor of a drug or to alter other characteristics or properties of a drug. By virtue of knowledge of pharmacodynamic processes and drug metabolism in vivo, those of skill in this art, once a pharmaceutically active compound is known, can design prodrugs of the compound (see, e.g., Nogrady (1985) Medicinal Chemistry A Biochemical Approach, Oxford University Press, New York, pages 388-392).
[0030] As used herein, “antibody” includes antibody fragments, such as Fab fragments, which are composed of a light chain and the variable region of a heavy chain.
[0031] As used herein, “humanized antibodies” refer to antibodies that are modified to include “human” sequences of amino acids so that administration to a human will not provoke an immune response. Methods for preparation of such antibodies are known. For example, the hybridoma that expresses the monoclonal antibody is altered by recombinant DNA techniques to express an antibody in which the amino acid composition of the non-variable regions is based on human antibodies. Computer programs have been designed to identify such regions.
[0032] The term “substantially” identical or homologous or similar varies with the context as understood by those skilled in the relevant art and generally means at least 70%, preferably means at least 80%, more preferably at least 90%, and most preferably at least 95% identity.
[0033] As used herein, a “composition” refers to any mixture. It may be a solution, a suspension, liquid, powder, paste, aqueous, non-aqueous or any combination thereof.
[0034] As used herein, a “combination” refers to any association between two or among more items.
[0035] As employed herein, the term “subject” embraces human as well as other animal vertebrate species, such as, for example, canine, feline, bovine, porcine, rodent, and the like. It will be understood by the skilled practitioner that the subject is one appropriate to the desirability of enhancing bone formation or bone mineral density. Preferably the subject is a mammal, more preferably a primate, and most preferably a human.
[0036] As used herein, “treat” or “treatment,” as related to bone growth defects, include a postponement of development of bone deficit symptoms and/or a reduction in the severity of such symptoms that will or are expected to develop. These terms further include ameliorating existing bone or cartilage deficit symptoms, preventing additional symptoms, ameliorating or preventing the underlying metabolic causes of symptoms, preventing or reversing bone resorption and/or encouraging bone growth. Thus, the terms denote that a beneficial result has been conferred on a vertebrate subject with a cartilage, bone or skeletal deficit, or with the potential to develop such deficit.
[0037] By “bone deficit” is meant an imbalance in the ratio of bone formation to bone resorption, such that, if unmodified, the subject will exhibit less bone than desirable, or the subject's bones will be less intact and coherent than desired. Bone deficit may also result from fracture, from surgical intervention or from dental or periodontal disease. By “cartilage defect” is meant damaged cartilage, less cartilage than desired, or cartilage that is less intact and coherent than desired. “Bone disorders” includes both bone deficits and cartilage defects.
[0038] As used herein, the abbreviations for any protective groups, amino acids and other compounds, are, unless indicated otherwise, in accord with their common usage, recognized abbreviations, or the IUPAC-IUB Commission on Biochemical Nomenclature (see, (1972) Biochem. 11:1726).
[0039] B. Methods for Enhancing Bone Formation and Uses Thereof
[0040] In one aspect, the present invention is directed to a method to enhance bone formation or bone mineral density, or to treat a pathological bone condition or to treat a degenerative joint condition in a vertebrate subject, such as a mammal, preferably a human, which method comprises administering to a vertebrate subject in need of such treatment an effective amount of a microtubule inhibitor, whereby bone formation or bone mineral density is enhanced, or said pathological bone condition or degenerative joint condition is treated, in said vertebrate subject. The inhibitor can be used alone or can be used in conjunction with an additional or secondary agent that promotes bone growth or inhibits bone resorption.
[0041] Any microtubule inhibitor that enhances bone formation can be used in the present method. For example, microtubule inhibitors for this invention include, but are not limited to, one or more of the following: 3-(1-Anilinoethylidene)-5-benzylpyrrolidine-2,4-dione (TN-16); N-(5,6,7,9-Tetrahydro-1,2,3,10-tetra-methoxy-9-oxobenzo[a]heptalen-7-yl) acetamide (Colchicine); Methyl-[5-(2-thienylcarbonyl)-1 H-benzimidazole-2-yl]-carbamate (Nocodazole); and 2-Methoxy-estradiol (2-ME), and analogs, such as paclitaxel and docetaxel. Also included are allocolchine, taxane, other benzimidazole carbamates, ansamitocin, and the like.
[0042] The present method can be used for treating any diseases, disorders or conditions that are associated with bone formation defects, whether caused by defective bone growth, over-active bone resorption or both. Any pathological dental conditions or degenerative joint conditions can be treated with the present method. Exemplary conditions that can be treated by the present method include osteoporosis, bone fracture or deficiency, bone segmental defects, primary or secondary hyperparathyroidism, periodontal disease or defect, metastatic bone disease, osteolytic bone disease, post-plastic surgery, post-prosthetic surgery, and post-dental implantation.
[0043] Other uses of the present method include, but are not limited to, repair of bone defects and deficiencies, such as those occurring in closed, open and non-union fractures; prophylactic use in closed and open fracture reduction; promotion of bone healing in plastic surgery; stimulation of bone in-growth into non-cemented prosthetic joints and dental implants; elevation of peak bone mass in pre-menopausal women; treatment of growth deficiencies; treatment of periodontal disease and defects, and other tooth repair processes; increase in bone formation during distraction osteogenesis; and treatment of other skeletal disorders, such as age-related osteoporosis, post-menopausal osteoporosis, diabetes-related osteoporosis, glucocorticoid-induced or related osteoporosis, or disuse osteoporosis and arthritis, or any condition that benefits from stimulation of bone formation; repair of congenital, trauma-induced or surgical resection of bone (for instance, for cancer treatment) and in cosmetic surgery; limiting or treating cartilage defects, injuries or disorders; and may be useful in wound healing or tissue repair.
[0044] C. Combinations
[0045] In a specific embodiment, the present method can further comprise administering to the subject an additional agent that promotes bone growth or inhibits bone resorption. The microtubule inhibitor and the secondary agent can be administered simultaneously or sequentially.
[0046] Any suitable bone enhancer or bone resorption inhibitor can be used in this combination therapy as the additional agent. Exemplary compounds that can be used in the combination therapy include steroids, bone growth stimulating compounds, bone morphogenetic factors, anti-resorptive agents, osteogenic factors, cartilage-derived morphogenetic proteins, growth hormones, estrogens, bisphosphonates, statin, differentiating factors, compounds that inhibit activity of NF-κB, compounds that inhibit production of NF-κB, compounds that inhibit activity of proteasomal activity and compounds that inhibits production of a proteasome protein. Preferably, these compounds used for enhancing bone formation or treating pathological dental conditions or degenerative joint conditions are disclosed below and those that are disclosed in the following published PCT International Patent Applications also can be used: PCT/US 00/41360, filed Oct. 20, 2000; and WO 00/02548.
[0047] Small molecules which are able to stimulate bone formation have been disclosed in PCT applications WO98/17267 published Apr. 30, 1998, WO97/15308 published May 1, 1997 and WO97/48694 published Dec. 24, 1997. These agents generally comprise two aromatic systems spatially separated by a linker. In addition, PCT application WO98/25460 published Jun. 18, 1998, discloses the use of the class of compounds known as statins in enhancing bone formation.
[0048] The microtubule inhibitor and additional agent can be formulated in a single pharmaceutical composition. Alternatively, they can be formulated as separate pharmaceutical compositions.
[0049] Other known inhibitors of proteasomal activity, NF-κB or both can be ascertained from the literature or compounds can be tested for these activities using assays known in the art. In addition, inhibitors, e.g., antisense polynucleotides, which lower the level of effective expression of the nucleotide sequence encoding the enzymes that have proteasomal activity or of the nucleotide sequence encoding NF-κB can be assessed and used in the invention methods. Also provided are compounds such as sulfasalazine, sulfasalazine (Liptay, et al., Br. J. Pharmacol., 128(7):1361-9 (1999)); and Wahl, et al., J. Clin. Invest., 101(5):1163-74 (1998)) and calpain inhibitor II.
[0050] E. Assays for Microtubule Inhibitors
[0051] Numerous assays can be used to identify and/or assess the efficacy of compounds that can be used in the present methods and combinations or pharmaceutical compositions.
[0052] Screening Assays—Bone
[0053] The osteogenic activity of the compounds used in the methods of the invention can be verified using in vitro screening techniques, such as the assessment of transcription of a reporter gene coupled to a bone morphogenetic protein-associated promoter or in alternative assays.
[0054] ABA Screening Assay
[0055] A rapid throughput screening test for compounds that stimulate bone formation by demonstration that they are capable of stimulating expression of a reporter gene linked to a BMP promoter (a surrogate for the production of bone morphogenetic factors that are endogenously produced) is described in U.S. application Ser. No. 08/458,434, filed Jun. 2, 1995, the entire contents of which are incorporated herein by reference. This assay is also described as a portion of a study of immortalized murine osteoblasts (derived from a mouse expressing a transgene composed of a BMP2 promoter driving expression of T-antigen) in Ghosh-Choudhery, N., et al., Endocrinology (1996) 137:331-39. In this study, the immortalized cells were stably transfected with a plasmid containing a luciferase reporter gene driven by a mouse BMP2 promoter (˜2736/114 bp), and responded in a dose-dependent manner to recombinant human BMP2.
[0056] Briefly, the assay utilizes cells transformed permanently or transiently with constructs in which the promoter of a bone morphogenetic protein, specifically BMP2 or BMP4, is coupled to a reporter gene, typically luciferase. These transformed cells are then evaluated for the production of the reporter gene product; compounds that activate the BMP promoter will drive production of the reporter protein, which can be readily assayed. Many thousands of compounds have been subjected to this rapid screening technique, and only a very small percentage are able to elicit a level of expression of reporter gene 5-fold greater than that produced by vehicle. Compounds that activate the BMP promoter fall into groups, where members of each group share certain structural characteristics not present in inactive compounds. The active compounds (“BMP promoter-active compounds” or “active compounds”) are useful in promoting bone or cartilage growth, and thus in the treatment of vertebrates in need of bone or cartilage growth.
[0057] BMP promoter-active compounds can be examined in a variety of other assays that test specificity and toxicity. For instance, non-BMP promoters or response elements can be linked to a reporter gene and inserted into an appropriate host cell. Cytotoxicity can be determined by visual or microscopic examination of BMP promoter- and/or non-BMP promoter-reporter gene-containing cells, for instance. Alternatively, nucleic acid and/or protein synthesis by the cells can be monitored. For in vivo assays, tissues may be removed and examined visually or microscopically, and optionally examined in conjunction with dyes or stains that facilitate histologic examination. In assessing in vivo assay results, it may also be useful to examine biodistribution of the test compound, using conventional medicinal chemistry/animal model techniques.
[0058] Neonatal Mouse Calvaria Assay (In Vitro)
[0059] An assay for bone resorption or bone formation is similar to that described by Gowen M. & Mundy G., J Immunol (1986) 136:2478-82. Briefly, four days after birth, the front and parietal bones of ICR Swiss white mouse pups are removed by microdissection and split along the sagittal suture. In an assay for resorption, the bones are incubated in BGJb medium (Irvine Scientific, Santa Ana, Calif.) plus 0.02% (or lower concentration) β-methylcyclodextrin, wherein the medium also contains test or control substances. The medium used when the assay is conducted to assess bone formation is Fitton and Jackson Modified BGJ Medium (Sigma) supplemented with 6 μg/ml insulin, 6 μg/ml transferrin, 6 ng/ml selenous acid, calcium and phosphate concentrations of 1.25 and 3.0 mM, respectively, and ascorbic acid to a concentration of 100 μg/ml is added every two days. The incubation is conducted at 37° C. in a humidified atmosphere of 5% CO 2 and 95% air for 96 hours.
[0060] Following this, the bones are removed from the incubation media and fixed in 10% buffered formalin for 24-48 hours, decalcified in 14% EDTA for 1 week, processed through graded alcohols; and embedded in paraffin wax. Three μm sections of the calvaria are prepared. Representative sections are selected for histomorphometric assessment of bone formation or bone resorption. Bone changes are measured on sections cut 200 μm apart. Osteoblasts and osteoclasts are identified by their distinctive morphology.
[0061] Other auxiliary assays can be used as controls to determine non-BMP promoter-mediated effects of test compounds. For example, mitogenic activity can be measured using screening assays featuring a serum-response element (SRE) as a promoter and a luciferase reporter gene. More specifically, these screening assays can detect signaling through SRE-mediated pathways, such as the protein kinase C pathway. For instance, an osteoblast activator SRE-luciferase screen and an insulin mimetic SRE-luciferase screen are useful for this purpose. Similarly, test compound stimulation of cAMP response element (CRE)-mediated pathways can also be assayed. For instance, cells transfected with receptors for PTH and calcitonin (two bone-active agents) can be used in CRE-luciferase screens to detect elevated cAMP levels. Thus, the BMP promoter specificity of a test compound can be examined through use of these types of auxiliary assays.
[0062] In vivo Assay of Effects of Compounds on Murine Calvarial Bone Growth
[0063] Male ICR Swiss white mice, aged 4-6 weeks and weighing 13-26 gm, are employed, using 4-5 mice per group. The calvarial bone growth assay is performed as described in PCT application WO95/24211, incorporated by reference. Briefly, the test compound or appropriate control vehicle is injected into the subcutaneous tissue over the right calvaria of normal mice. Typically, the control vehicle is the vehicle in which the compound was solubilized, and is PBS containing 5% DMSO or is PBS containing Tween (2 μl/10 ml). The animals are sacrificed on day 14 and bone growth measured by histomorphometry. Bone samples for quantitation are cleaned from adjacent tissues and fixed in 10% buffered formalin for 24-48 hours, decalcified in 14% EDTA for 1-3 weeks, processed through graded alcohols; and embedded in paraffin wax. Three to five μm sections of the calvaria are prepared, and representative sections are selected for histomorphometric assessment of the effects on bone formation and bone resorption. Sections are measured by using a camera lucida attachment to trace directly the microscopic image onto a digitizing plate. Bone changes are measured on sections cut 200 μm apart, over 4 adjacent 1×1 mm fields on both the injected and noninjected sides of the calvaria. New bone is identified by its characteristic woven structure, and osteoclasts and osteoblasts are identified by their distinctive morphology. Histomorphometry software (OsteoMeasure, Osteometrix, Inc., Atlanta) is used to process digitizer input to determine cell counts and measure areas or perimeters.
[0064] Typical treatment regimens for testing utilize application of the compound to be tested over several days of repeated administration.
[0065] Additional In Vivo Assays—Bone
[0066] Lead compounds can be further tested in intact animals using an in vivo, dosing assay. Prototypical dosing may be accomplished by subcutaneous, intraperitoneal or oral administration, and may be performed by injection, sustained release or other delivery techniques. The time period for administration of test compound may vary (for instance, 28 days as well as 35 days may be appropriate). An exemplary, in vivo oral or subcutaneous dosing assay may be conducted as follows:
[0067] In a typical study, 70 three-month-old female Sprague-Dawley rats are weight-matched and divided into seven groups, with ten animals in each group. This includes a baseline control group of animals sacrificed at the initiation of the study; a control group administered vehicle only; a PBS-treated control group; and a positive control group administered a compound (non-protein or protein) known to promote bone growth. Three dosage levels of the compound to be tested are administered to the remaining three groups.
[0068] Briefly, test compound, positive control compound, PBS, or vehicle alone is administered subcutaneously once per day for 35 days. All animals are injected with calcein nine days and two days before sacrifice (two injections of calcein administered each designated day). Weekly body weights are determined. At the end of the 35-day cycle, the animals are weighed and bled by orbital or cardiac puncture. Serum calcium, phosphate, osteocalcin, and CBCs are determined. Both leg bones (femur and tibia) and lumbar vertebrae are removed, cleaned of adhering soft tissue, and stored in 70% ethanol for evaluation, as performed by peripheral quantitative computed tomography (pQCT; Ferretti, J., Bone (1995) 17:353S-64S), dual energy X-ray absorptiometry (DEXA; Laval-Jeantet A., et al., Calcif Tissue Intl (1995) 56:14-18; J. Casez, et al., Bone and Mineral (1994) 26:61-68) and/or histomorphometry. The effect of test compounds on bone remodeling can thus be evaluated.
[0069] Lead compounds can also be tested in acute ovariectomized animals (prevention model) using an in vivo dosing assay. Such assays may also include an estrogen-treated group as a control. An exemplary subcutaneous dosing assay is performed as follows:
[0070] In a typical study, 80 three-month-old female Sprague-Dawley rats are weight-matched and divided into eight groups, with ten animals in each group. This includes a baseline control group of animals sacrificed at the initiation of the study; three control groups (sham ovariectomized (sham OVX)+vehicle only; ovariectomized (OVX)+vehicle only; PBS-treated OVX); and a control OVX group that is administered a compound known to promote bone growth. Three dosage levels of the compound to be tested are administered to the remaining three groups of OVX animals.
[0071] Since ovariectomy (OVX) induces hyperphagia, all OVX animals are pair-fed with sham OVX animals throughout the 35 day study. Briefly, test compound, positive control compound, PBS, or vehicle alone is administered orally or subcutaneously once per day for 35 days. Alternatively, test compound can be formulated in implantable pellets that are implanted for 35 days, or may be administered orally, such as by gastric gavage. All animals, including sham OVX/vehicle and OVX/vehicle groups, are injected intraperitoneally with calcein nine days and two days before sacrifice (two injections of calcein administered each designated day, to ensure proper labeling of newly formed bone). Weekly body weights are determined. At the end of the 35-day cycle, the animals' blood and tissues are processed as described above.
[0072] Lead compounds may also be tested in chronic OVX animals (treatment model). An exemplary protocol for treatment of established bone loss in ovariectomized animals that can be used to assess efficacy of anabolic agents may be performed as follows. Briefly, 80 to 100 six month old female, Sprague-Dawley rats are subjected to sham surgery (sham OVX) or ovariectomy (OVX) at time 0, and 10 rats are sacrificed to serve as baseline controls. Body weights are recorded weekly during the experiment. After approximately 6 weeks (42 days) or more of bone depletion, 10 sham OVX and 10 OVX rats are randomly selected for sacrifice as depletion period controls. Of the remaining animals, 10 sham OVX and 10 OVX rats are used as placebo-treated controls. The remaining OVX animals are treated with 3 to 5 doses of test drug for a period of 5 weeks (35 days). As a positive control, a group of OVX rats can be treated with an agent such as PTH, a known anabolic agent in this model (Kimmel, et al., Endocrinology (1993) 132:1577-84). To determine effects on bone formation, the following procedure can be followed. The femurs, tibiae and lumbar vertebrae 1 to 4 are excised and collected. The proximal left and right tibiae are used for PIXIMUS bone mineral density (BMD) measurements, and histology, while the midshaft of each tibiae is subjected to cortical BMD or histology. The femurs are prepared for pQCT scanning of the midshaft prior to biomechanical testing. With respect to lumbar vertebrae (LV), LV2 are processed for BMD; LV3 are prepared for undecalcified bone histology; and LV4 are processed for mechanical testing.
[0073] In more detail, male ICR Swiss white mice, aged 4-6 weeks and weighing 13-26 gm, are employed, using 4-5 mice per group. The calvarial bone growth assay is performed as described above. Briefly, the test compound or appropriate control vehicle is injected into the subcutaneous tissue over the right calvaria of normal mice. Typically, the control vehicle is the vehicle in which the compound was solubilized, and is PBS containing 5% DMSO or is PBS containing Tween (2 μl/10 ml). The animals are sacrificed on day 14 and bone growth measured by histomorphometry. Bone samples for quantitation are cleaned from adjacent tissues and fixed in 10% buffered formalin for 24-48 hours, decalcified in 14% EDTA for 1-3 weeks, processed through graded alcohols; and embedded in paraffin wax. Three to five μm sections of the calvaria are prepared, and representative sections are selected for histomorphometric assessment of the effects on bone formation and bone resorption. Sections are measured by using a camera lucida attachment to trace directly the microscopic image onto a digitizing plate. Bone changes are measured on sections cut 200 μm apart, over 4 adjacent 1×1 mm fields on both the injected and noninjected sides of the calvaria. New bone is identified by its characteristic woven structure, and osteoclasts and osteoblasts are identified by their distinctive morphology. Histomorphometry software (OsteoMeasure, Osteometrix, Inc., Atlanta) is used to process digitizer input to determine cell counts and measure areas or perimeters.
[0074] Typical treatment regimens for testing utilize application of the compound to be tested over several days of repeated administration.
[0075] F. Formulations and Administrations
[0076] The microtubule inhibitor, whether alone or in combination with an additional agent that promotes bone, may be administered systemically or locally. For systemic use, the compounds herein are formulated for parenteral (e.g., intravenous, subcutaneous, intramuscular, intraperitoneal, intranasal or transdermal) or enteral (e.g., oral or rectal) delivery according to conventional methods. Intravenous administration can be by a series of injections or by continuous infusion over an extended period. Administration by injection or other routes of discretely spaced administration can be performed at intervals ranging from weekly to once to three times daily. Alternatively, the compounds disclosed herein may be administered in a cyclical manner (administration of disclosed compound; followed by no administration; followed by administration of disclosed compound, and the like). Treatment will continue until the desired outcome is achieved. In general, pharmaceutical formulations will include a compound of the present invention in combination with a pharmaceutically acceptable vehicle, such as saline, buffered saline, 5% dextrose in water, borate-buffered saline containing trace metals or the like. Formulations may further include one or more excipients, preservatives, solubilizers, buffering agents, albumin to prevent protein loss on vial surfaces, lubricants, fillers, stabilizers, etc. Methods of formulation are well known in the art and are disclosed, for example, in Remington's Pharmaceutical Sciences, latest edition, Mack Publishing Co., Easton Pa., which is incorporated herein by reference. Pharmaceutical compositions for use within the present invention can be in the form of sterile, non-pyrogenic liquid solutions or suspensions, coated capsules, suppositories, lyophilized powders, transdermal patches or other forms known in the art. Local administration may be by injection at the site of injury or defect, or by insertion or attachment of a solid carrier at the site, or by direct, topical application of a viscous liquid, or the like. For local administration, the delivery vehicle preferably provides a matrix for the growing bone or cartilage, and more preferably is a vehicle that can be absorbed by the subject without adverse effects.
[0077] Delivery of compounds herein to wound sites may be enhanced by the use of controlled-release compositions, such as those described in PCT publication WO 93/20859, which is incorporated herein by reference. Films of this type are particularly useful as coatings for prosthetic devices and surgical implants. The films may, for example, be wrapped around the outer surfaces of surgical screws, rods, pins, plates and the like. Implantable devices of this type are routinely used in orthopedic surgery. The films can also be used to coat bone filling materials, such as hydroxyapatite blocks, demineralized bone matrix plugs, collagen matrices and the like. In general, a film or device as described herein is applied to the bone at the fracture site. Application is generally by implantation into the bone or attachment to the surface using standard surgical procedures.
[0078] In addition to the copolymers and carriers noted above, the biodegradable films and matrices may include other active or inert components. Of particular interest are those agents that promote tissue growth or infiltration, such as growth factors. Exemplary growth factors for this purpose include epidermal growth factor (EGF), fibroblast growth factor (FGF), platelet-derived growth factor (PDGF), transforming growth factors (TGFs), parathyroid hormone (PTH), leukemia inhibitory factor (LIF), insulin-like growth factors (IGFs) and the like. Agents that promote bone growth, such as bone morphogenetic proteins (U.S. Pat. No. 4,761,471; PCT Publication WO90/11366), osteogenin (Sampath, et al., Proc. Natl. Acad. Sci. USA (1987) 84:7109-13) and NaF (Tencer, et al., J. Biomed. Mat. Res. (1989) 23: 571-89) are also preferred. Biodegradable films or matrices include calcium sulfate, tricalcium phosphate, hydroxyapatite, polylactic acid, polyanhydrides, bone or dermal collagen, pure proteins, extracellular matrix components and the like and combinations thereof. Such biodegradable materials may be used in combination with non-biodegradable materials, to provide desired mechanical, cosmetic or tissue or matrix interface properties.
[0079] Alternative methods for delivery of compounds of the present invention include use of ALZET™ osmotic minipumps (Alza Corp., Palo Alto, Calif.); sustained release matrix materials such as those disclosed in Wang, et al. (PCT Publication WO 90/11366); electrically charged dextran beads, as disclosed in Bao, et al. (PCT Publication WO 92/03125); collagen-based delivery systems, for example, as disclosed in Ksander, et al., Ann. Surg. (1990) 211(3):288-94; methylcellulose gel systems, as disclosed in Beck, et al., J. Bone Min. Res. (1991) 6(11):1257-65; alginate-based systems, as disclosed in Edelman, et al., Biomaterials (1991) 12:619-26 and the like. Other methods well known in the art for sustained local delivery in bone include porous coated metal prostheses that can be impregnated and solid plastic rods with therapeutic compositions incorporated within them.
[0080] The compounds of the present invention may also be used in conjunction with agents that inhibit bone resorption. Antiresorptive agents, such as estrogen, bisphosphonates and calcitonin, are preferred for this purpose. More specifically, the compounds disclosed herein may be administered for a period of time (for instance, months to years) sufficient to obtain correction of a bone deficit condition. Once the bone deficit condition has been corrected, the vertebrate can be administered an anti-resorptive compound to maintain the corrected bone condition. Alternatively, the compounds disclosed herein may be administered with an anti-resorptive compound in a cyclical manner (administration of disclosed compound, followed by anti-resorptive, followed by disclosed compound, and the like).
[0081] In additional formulations, conventional preparations such as those described below may be used.
[0082] Aqueous suspensions may contain the active ingredient in admixture with pharmacologically-acceptable carriers or excipients, comprising suspending agents, such as methyl cellulose; and wetting agents, such as lecithin, lysolecithin or long-chain fatty alcohols. The said aqueous suspensions may also contain preservatives, coloring agents, flavoring agents, sweetening agents and the like in accordance with industry standards.
[0083] Preparations for topical and local application comprise aerosol sprays, lotions, gels and ointments in pharmaceutically appropriate vehicles which may comprise lower aliphatic alcohols, polyglycols such as glycerol, polyethylene glycol, esters of fatty acids, oils and fats, and silicones. The preparations may further comprise antioxidants, such as ascorbic acid or tocopherol, and preservatives, such as p-hydroxybenzoic acid esters.
[0084] Parenteral preparations comprise particularly sterile or sterilized products. Injectable compositions may be provided containing the active compound and any of the well known injectable carriers. These may contain salts for regulating the osmotic pressure.
[0085] If desired, the osteogenic agents can be incorporated into liposomes by any of the reported methods of preparing liposomes for use in treating various pathogenic conditions. The present compositions may utilize the compounds noted above incorporated in liposomes in order to direct these compounds to macrophages, monocytes, as well as other cells and tissues and organs which take up the liposomal composition. The liposome-incorporated compounds of the invention can be utilized by parenteral administration, to allow for the efficacious use of lower doses of the compounds. Ligands may also be incorporated to further focus the specificity of the liposomes.
[0086] Suitable conventional methods of liposome preparation include, but are not limited to, those disclosed by Bangham, A. D., et al., J Mol Biol (1965) 23:238-252, Olson, F., et al., Biochim Biophys Acta (1979) 557:9-23, Szoka, F., et al., Proc Natl Acad Sci USA (1978) 75:4194-4198, Kim, S., et al., Biochim Biophys Acta (1983) 728:339:348, and Mayer, et al., Biochim Biophys Acta (1986) 858:161-168.
[0087] The liposomes may be made from the present compounds in combination with any of the conventional synthetic or natural phospholipid liposome materials including phospholipids from natural sources such as egg, plant or animal sources such as phosphatidylcholine, phosphatidylethanolamine, phosphatidylglycerol, sphingomyelin, phosphatidylserine, or phosphatidylinositol and the like. Synthetic phospholipids that may also be used, include, but are not limited to: dimyristoylphosphatidylcholine, dioleoylphosphatidylcholine, dipalmitoylphosphatidylcholine and distearoylphosphatidycholine, and the corresponding synthetic phosphatidylethanolamines and phosphatidylglycerols. Cholesterol or other sterols, cholesterol hemisuccinate, glycolipids, cerebrosides, fatty acids, gangliosides, sphingolipids, 1,2-bis(oleoyloxy)-3-(trimethyl ammonio) propane (DOTAP), N-[1-(2,3-dioleoyl) propyl-N,N,N-trimethylammonium chloride (DOTMA), and other cationic lipids may be incorporated into the liposomes, as is known to those skilled in the art. The relative amounts of phospholipid and additives used in the liposomes may be varied if desired. The preferred ranges are from about 60 to 90 mole percent of the phospholipid; cholesterol, cholesterol hemisuccinate, fatty acids or cationic lipids may be used in amounts ranging from 0 to 50 mole percent. The amounts of the present compounds incorporated into the lipid layer of liposomes can be varied with the concentration of the lipids ranging from about 0.01 to about 50 mole percent.
[0088] The liposomes with the above formulations may be made still more specific for their intended targets with the incorporation of monoclonal antibodies or other ligands specific for a target. For example, monoclonal antibodies to the BMP receptor may be incorporated into the liposome by linkage to phosphatidylethanolamine (PE) incorporated into the liposome by the method of Leserman, L., et al., Nature (1980) 288:602-604.
[0089] The compounds of the present invention may be used to stimulate growth of bone-forming cells or their precursors, or to induce differentiation of bone-forming cell precursors, either in vitro or ex vivo. The compounds described herein may also modify a target tissue or organ environment, so as to attract bone-forming cells to an environment in need of such cells. As used herein, the term “precursor cell” refers to a cell that is committed to a differentiation pathway, but that generally does not express markers or function as a mature, fully differentiated cell. As used herein, the term “mesenchymal cells” or “mesenchymal stem cells” refers to pluripotent progenitor cells that are capable of dividing many times, and whose progeny will give rise to skeletal tissues, including cartilage, bone, tendon, ligament, marrow stroma and connective tissue (see A. Caplan, J. Orthop. Res. (1991) 9:641-50). As used herein, the term “osteogenic cells” includes osteoblasts and osteoblast precursor cells. More particularly, the disclosed compounds are useful for stimulating a cell population containing marrow mesenchymal cells, thereby increasing the number of osteogenic cells in that cell population. In a preferred method, hematopoietic cells are removed from the cell population, either before or after stimulation with the disclosed compounds. Through practice of such methods, osteogenic cells may be expanded. The expanded osteogenic cells can be infused (or reinfused) into a vertebrate subject in need thereof. For instance, a subject's own mesenchymal stem cells can be exposed to compounds of the present invention ex vivo, and the resultant osteogenic cells could be infused or directed to a desired site within the subject, where further proliferation and/or differentiation of the osteogenic cells can occur without immunorejection. Alternatively, the cell population exposed to the disclosed compounds may be immortalized human fetal osteoblastic or osteogenic cells. If such cells are infused or implanted in a vertebrate subject, it may be advantageous to “immunoprotect” these non-self cells, or to immunosuppress (preferably locally) the recipient to enhance transplantation and bone or cartilage repair.
[0090] The dosage required for the microtubule inhibitor, whether alone or in combination with an additional agent that promotes bone (for example, in osteoporosis where an increase in bone formation is desired), is manifested as a statistically significant difference or increase in bone mass between treatment and control groups. This difference in bone mass may be seen, for example, as a 5-20% or more significant increase in bone mass in the treatment group. Other measurements of clinically significant increases in healing may include, for example, tests for breaking strength and tension, breaking strength and torsion, 4-point bending, increased connectivity in bone biopsies and other biomechanical tests well known to those skilled in the art. General guidance for treatment regimens is obtained from experiments carried out in animal models of the disease of interest.
[0091] The dosage of the microtubule inhibitor, whether alone or in combination with the secondary agent that promotes bone, will vary according to the extent and severity of the need for treatment, the activity of the administered compound, the general health of the subject, and other considerations well known to the skilled artisan. Generally, they can be administered to a typical human on a daily basis as an oral dose of about 0.1 mg/kg-1000 mg/kg, and more preferably from about 1 mg/kg to about 200 mg/kg. The parenteral dose will appropriately be 20-100% of the oral dose. While oral administration may be preferable in most instances where the condition is a bone deficit (for reasons of ease, patient acceptability, and the like), alternative methods of administration may be appropriate for selected compounds and selected defects or diseases. The compound levels can be monitored by any suitable methods known in the art (See, e.g., Bouley et al., Ther. Drug. Monit., 23(1):56-60 (2001); and Langmann et al., J. Chromatogr. B. Biomed. Sci. Appl., 735(1):41-50 (1999)).
[0092] G. Examples
[0093] The following examples are intended to illustrate but not to limit the invention.
EXAMPLE 1
High Throughput Screening
[0094] In this screen, the standard positive control was the compound 59-0008 (also denoted “OS8”), which is of the formula:
[0095] In more detail, the 2T3-BMP-2-LUC cells, a stably transformed osteoblast cell line described in Ghosh-Choudhury et al. Endocrinology (1996) 137:331-39, referenced above, was employed. The cells were cultured using α-MEM, 10% FCS with 1% penicillin/streptomycin and 1% glutamine (“plating medium”), and were split 1:5 once per week. For the assay, the cells were resuspended in a plating medium containing 4% FCS, plated in microtiter plates at a concentration of 5×10 3 cells (in 50 μl)/well, and incubated for 24 hours at 37° C. in 5% CO 2 . To initiate the assay, 50 μl of the test compound or the control in DMSO was added at 2× concentration to each well, so that the final volume was 100 μl. The final serum concentration was 2% FCS, and the final DMSO concentration was 1%. Compound 59-0008 (10 μM) was used as a positive control.
[0096] The treated cells were incubated for 24 hours at 37° C. and 5% CO 2 . The medium was then removed, and the cells were rinsed three times with PBS. After removal of excess PBS, 25 μl of 1× cell culture lysing reagent (Promega #E153A) was added to each well and incubated for at least ten minutes. Optionally, the plates/samples could be frozen at this point. To each well was added 50 μl of luciferase substrate (Promega #E152A; 10 ml Promega luciferase assay buffer per 7 mg Promega luciferase assay substrate). Luminescence was measured on an automated 96-well luminometer, and was expressed as either picograms of luciferase activity per well or as picograms of luciferase activity per microgram of protein, as provided below, using TN-16 as the test compound.
[0097] Microtubule Inhibitor TN-16 Stimulates BMP-2 Gene Transcription and Activates BMP Signaling in Osteoblast Precursor 2T3 Cells.
TABLE 1 TN-16 Luciferase Activity (Fold Change) (μM) (BMP2 promoter-Luc) 0 1.0 ± 0.1 0.16 2.4 ± 0.40* 0.31 4.0 ± 0.09* 0.61 4.8 ± 0.50* 1.25 5.6 ± 0.12* 2.5 6.2 ± 0.30*
[0098] The numbers represent the mean ± standard error (n=4). *p<0.05, one-way analysis of variance (ANOVA) followed by Dunnett's test.
EXAMPLE 2
In vitro Bone Formation
[0099] Selected compounds and appropriate controls were assayed in vitro (ex vivo) for bone formation activity (described above in “Techniques for Neonatal Mouse Calvaria Assay (in vitro)). Histomorphometrical assessments of ex vivo calvaria were carried out using an OsteoMetrics bone morphometry measurement program, according to the manufacturer's instructions. Measurements were determined using either a 10- or 20-fold objective with a standard point counting eyepiece graticule.
[0100] New bone formation was determined (using a 10× objective) by measuring the new bone area formed in one field in 3 representative sections of each bone (4 bones per group). Each measurement was carried out ½ field distance from the end of the suture. Both total bone and old bone area were measured. Data were expressed as new bone width in mm.
[0101] Osteoblast numbers are determined by point counting. The number of osteoblast cells lining the bone surface on both sides of the bone are counted in one field using a 20× objective. Data are expressed as osteoblast numbers/mm of bone surface.
[0102] Alkaline phosphatase activity is measured in the conditioned media of the murine organ cultures, using the method described by Majeska, R. J., et al., Exp Cell Res (1978) 111:465-465. Conditional media are incubated at 37° C. for 20 minutes with phosphatase substrate 104 (Sigma) and the reaction stopped with 2 ml of 0.1 M NaOH. Alkaline phosphatase activity is calculated by measuring cleaved substrate at an optical density of 410 nm in a Beckman dual beam spectrophotometer from the OD410 and corrected for protein concentration.
[0103] The results of new bone width are shown below utilizing TN-16, colchicine, and nocodazole.
[0104] Microtubule Inhibitor TN-16, Colchicine and Nocodazole Stimulate New Bone Formation on Calvariae of One-Month-Old ICR Swiss Mice.
TABLE 2 TN-16 New Bone (mg/kg/d, x2d) Width (mm) 0 0.035 ± 0.002 2 0.120 ± 0.016* 4 0.376 ± 0.029* 8 0.525 ± 0.035*
[0105] [0105] TABLE 3 Colchicine New Bone (mg/kg/d, x2d) Width (mm) 0 0.024 ± 0.002 0.1 0.225 ± 0.013* 1.0 0.305 ± 0.020*
[0106] [0106] TABLE 4 Nocodazole New Bone (mg/kg/d, x2d) Width (mm) 0 0.025 ± 0.002* 1.5 0.231 ± 0.027*
[0107] The numbers represent the mean ± standard error (n=5). *p<0.05, t-test or one-way analysis of variance (ANOVA) followed by Dunnett's test.
EXAMPLE 3
In vivo Bone Data
[0108] TN-16 was utilized in the in vivo assay for bone mineral density according to the procedures described previously, and the results are provided below.
[0109] Microtubule Inhibitor TN-16 Increases Bone Mineral Density.
TABLE 5 Calvariae (1-month-old mice) TN-16 BMD (mg/kg/d, x2d) (mg/cm 2 ) 0 21.5 ± 0.8 4 26.0 ± 0.7* 8 31.3 ± 0.5*
[0110] [0110] TABLE 6 Tibiae (3-month-old mice) TN-16 BMD (mg/kg/d, x2d) (mg/cm 2 ) 0 72.5 ± 1.3* 2 78.0 ± 2.2* 4 84.5 ± 1.0* 8 85.5 ± 0.8*
[0111] [0111] TABLE 7 Femora (3-month-old mice) TN-16 BMD (mg/kg/d, x2d) (mg/cm 2 ) 0 87.2 ± 2.1 2 90.1 ± 2.2 4 100.9 ± 1.6* 8 102.1 ± 1.5*
[0112] The numbers represent the mean ± standard error (n=10). *p<0.05, one-way analysis of variance (ANOVA) followed by Dunnett's test.
[0113] TN-16 was shown to increase bone volume as a percentage of total volume and to increase bone formation rates as provided below.
[0114] Microtubule Inhibitor TN-16 Increases Bone Volume and Bone Formation Rates in ICR Swiss Mice.
Table 8
[0115] Bone Volume:
Group Bone Volume (%, BV/TV) Control 18.66 ± 2.41 Ps-1 (1 mg/kg/d, x5) 27.13 ± 1.51* TN-16 (2 mg/kg/d, x2) 23.42 ± 3.13* TN-16 (4 mg/kg/d, x2) 27.21 ± 2.14* TN-16 (8 mg/kg/d, x2) 25.44 ± 1.29*
[0116] The numbers represent the mean ± standard error (n=10). *p<0.05, one-way analysis of variance (ANOVA) followed by Dunnett's test. PS-1 is proteosome inhibitor-1.
TABLE 9 Bone Formation Rate: Group BFR/BS (μm 3 /μm 2 /day) Control 0.460 ± 0.075 Ps-1 (1 mg/kg/d, x5) 1.766 ± 0.425* TN-16 (2 mg/kg/d, x2) 0.815 ± 0.129* TN-16 (4 mg/kg/d, x2) 1.130 ± 0.293* TN-16 (8 mg/kg/d, x2) 1.231 ± 0.181**
[0117] The number represent the mean ± standard error (n=10). *p<0.05, **p<0.01, one-way analysis of variance (ANOVA) followed by Dunnett's test.
[0118] It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be incorporated within the spirit and purview of this application and scope of the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated herein by reference for all purposes.
[0119] Citation of the above documents is not intended as an admission that any of the foregoing is pertinent prior art, nor does it constitute any admission as to the contents or date of these documents. | The invention relates to compositions and methods for use in treating skeletal system disorders in a vertebrate at risk for bone loss, and in treating conditions that are characterized by the need for bone growth, in treating fractures, and in treating cartilage disorders. More specifically, the invention concerns the use of inhibitors of microtubule assembly for enhancing bone growth. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is in the area of equipment and methods for creating post holes, and pertains more particularly to making square holes of a size for square fence posts.
[0003] 2. Discussion of the State of the Art
[0004] It is well known that there exist at the time of this application a number of alternative tools and methods for digging post holes. A well known tool is the two-handed post-hole spade that has long handles and opposed spades connected at a pivot, such that the spades may be opened by pulling the handle apart and closed by closing the handles. A worker uses both hands to drive the opposed spades into the earth, closes the spades to collect loose earth, and raises the tool out of the developing hole to set the loose earth aside; then repeats the process until the desired depth is attained. It is also well-known that this tool and method is clumsy, tiring, and generally results in a rather large round hole.
[0005] Other than hand tools there exists a number of power tools, such as drills and augers of various sorts for making post holes. These are invariably rotary devices that produce round holes, but typically the holes produced by these power tools are more uniform and close to desired size than those produced by hand tools.
[0006] Although there are round posts that certainly may be used in round post holes, many people prefer square posts, and for the purpose of this specification four-inch square posts will be considered.
[0007] To set a four-by-four post in a post hole, one must produce a round post hole of a diameter great enough to insert the post. For a four-by-four post the diameter needed is the length of the corner-to-corner diagonal of the post, which is 5.67 inches to the nearest one-hundredth of a inch. There needs to be some clearance, so the smallest workable hole diameter is about six inches.
[0008] Once one has made a six-inch diameter hole to a desired depth, the post is placed in the hole to the bottom of the hole, leaving relatively large spaces all around the post. Now it is necessary to add loose earth back into the spaces, which are typically rodded to compact the loose soil to better hold the post. This is a difficult process.
[0009] What is clearly needed is an apparatus and method for forming a square post hole of very close to the size of the post, with sides that are formed closely compacted in the process, so the post can be driven into the square hole completing the process.
SUMMARY OF THE INVENTION
[0010] In one embodiment of the invention a tool for expanding a hole having a vertical axis in the earth is provided, comprising at least one set of two opposed compactor units constrained to separate and retract in a direction at a right angle to the axis of the hole, and a drive mechanism coupled to the set of compactor units providing force to separate the compactor units, urging the units against a wall or walls of the hole, compacting the earth and enlarging the hole.
[0011] Also in an embodiment of the invention the compactor units comprise lengths of angle iron that when fully retracted form together a substantially square shape, and the direction of separation and retraction is along the diagonal through the apex corners of the two angle irons. Also in an embodiment the drive mechanism comprises a linear actuator constrained to travel vertically, the actuator and individual compactor units joined by links pivoted both at the actuator and the individual compactor units. The drive mechanism may also have a fluid cylinder coupled to the linear actuator, the fluid cylinder driving the linear actuator vertically to the limits of the cylinder action. In still other embodiments there may be two or more sets of opposed compactor units.
[0012] In another aspect of the invention a method for producing a hole in the earth for setting a post having a cross section of a particular shape and area is provided, comprising the steps of (a) making a hole of a cross section less in area than the area of the cross section of the post to be set; (b) placing in the hole an expansion tool; and (c) activating the expansion tool to expand and shape the cross section of the hole.
[0013] In one embodiment of the method the expansion tool comprises at least one set of two opposed compactor units constrained to separate and retract in a direction at a right angle to the axis of the hole, and a drive mechanism coupled to the set of compactor units providing force to separate the compactor units, urging the units against a wall or walls of the hole, compacting the earth and enlarging the hole.
[0014] Also in one embodiment of the method in step (a) the original cross section of the hole is round, and in step (c) the hole is expanded to a square cross section shape of an area greater than the original cross section area. In some cases in step (c) two or more operations are employed with the expansion tool rotated on the axis of the hole between operations, and in some of these embodiments the final shape of the hole is substantially square.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0015] FIG. 1 is a perspective view of an expander tool according to an embodiment of the present invention for making a round hole into a larger square hole.
[0016] FIG. 2 is a vertical elevation section view of a portion of the height from the bottom of the expander tool of FIG. 1 .
[0017] FIG. 3 is a partial section taken along section line 3 - 3 of FIG. 1 showing attachment of a drive cylinder to the tubing assembly.
[0018] FIG. 4 a is a cross-section view taken along line 4 a - 4 a of FIGS. 1 and 2 .
[0019] FIG. 5 a indicates relocation of the expander for a second operation according to an embodiment of the present invention.
[0020] FIG. 5 b shows the result after a second extension of the expander from the position shown in FIG. 4 a.
[0021] FIG. 6 is an elevation view of a manual tool 120 for creating an undercut at the bottom of the square hole developed using the expander described above.
[0022] FIG. 7 a is a section taken along line 7 a - 7 a of FIG. 6 showing a plan view of an adjustable cutting head for the tool of FIG. 6 .
[0023] FIG. 7 b is a view of one end of the cutting head of FIG. 7 a.
[0024] FIG. 8 illustrates a square hole formed by an expander according to an embodiment of the present invention, with a manual undercut tool according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 is a perspective view of an expander tool 101 according to an embodiment of the present invention for expanding a round hole into a larger square hole. Expander tool 101 comprises in this embodiment two angle iron assemblies 102 having two-inch legs engaged in a mechanism described in detail below. The mechanism, driven in this example by a pneumatic cylinder 105 through a tubing assembly 104 mounted to a round base plate 103 , causes angle irons 102 to separate when the cylinder is activated with sufficient force to push a small diameter hole into a larger square hole while also compacting the soil around the resulting square post hole.
[0026] FIG. 2 is a vertical elevation section view of a portion of the height from the bottom of expander tool 101 of FIG. 1 taken along the section line 2 - 2 . An activator rod 106 engaged to and driven vertically by cylinder 105 operates within tubing assembly 104 , which is welded into base plate 103 along region 107 in this embodiment. Pusher blocks 108 are affixed to rod 106 through slots in tubing assembly 104 , the slots being of sufficient length to accommodate the full necessary stroke of rod 106 to fully open and close the two angle iron assemblies 102 . Two sets of slots and pusher blocks are shown, but there may be several more, depending on the overall height of the expander tool, which determines the depth of a hole that may be expanded.
[0027] Pusher blocks 108 are pivotally connected to pusher links 109 with pivot pins 110 , and at the opposite ends the pusher links are pivotally connected by pivot pins 111 to brackets 112 which are welded in this embodiment at strategic locations along each angle iron assembly 102 . The angle iron assemblies are closed at the lower end by welded plates 113 , such that when cylinder 105 is activated and drives rod 106 downward, the angle iron assemblies are constrained by these plates against base plate 103 to travel outward horizontally. A spring mechanism (not shown) retracts the angle iron assemblies horizontally when the cylinder is retracted.
[0028] FIG. 3 is a partial section taken along section line 3 - 3 of FIG. 1 showing attachment of cylinder 105 to tubing assembly 104 . In the tubing assembly, the main vertical tube is welded in this embodiment to base pate 103 , as described above, and as shown in FIG. 3 is welded to an upper plate 119 , which is machined to match the mounting interface for the cylinder. The cylinder is mounted to plate 119 with conventional fasteners (not shown). The active shaft of the cylinder in this embodiment has a male thread, is threaded into a female thread in rod 106 , and is secured with a standard locking nut.
[0029] FIG. 4 a is a cross-section view taken along line 4 a - 4 a of FIGS. 1 and 2 , and shows the mechanism of the expander in closed position with rod 106 retracted and the angle iron assemblies drawn together presenting the smallest cross-sectional area. Dotted circle 115 indicates diameter of a hole that has to be produced to insert the expander mechanism of the invention. The diameter of this hole is about 3.25 inches, as opposed to a hole of nearly six inches diameter required for setting a 4×4 fence post in the conventional way. Since the volume of earth to be removed to make a hole in the ground is directly related to the area of the hole, for the conventional method more than three times the volume of earth has to be removed.
[0030] FIG. 4 b is along the same section line as FIG. 4 a, but shows the expander expanded to full range by driving rod 106 downward with cylinder 105 . The length of pusher links 109 is made to cause the diagonal distance from corner-to-corner in this position to be just a bit greater than the diagonal measurement of a 4×4 post section. Dotted boundary 116 illustrates the extent of the expanded hole in the earth at this point. It is to be noted (see also FIG. 2 ) that in the first portion of a downstroke the mechanism produces the least thrust in the direction of the movement of the angle iron assemblies that move and compact the earth, but in this portion the resistance of the earth is also least. In the last portion of the downstroke, when more thrust will be needed, the mechanism produces a great mechanical advantage, and the thrust is maximized.
[0031] After the action shown in FIG. 4 b, producing the shape for the developing hole shown by dotted line 116 , the expander is retracted and rotated ninety degrees as shown in FIG. 5 a. Now activating the expander again will cause the angle iron assemblies to travel in the direction of arrows 117 .
[0032] FIG. 5 b shows the result after the second extension of the expander from the position of FIG. 4 a. Now the developed hole is as shown by dotted line 118 , which is square, of a size to accommodate a 4×4 post, and the sides of the hole are very solidly compacted. No fill or rodding is necessary.
[0033] A method then, using the apparatus in the embodiment of the invention shown, is to create a hole in the earth of diameter about 3.25 inches, insert the expander, extend and retract the expander, rotate the expander ninety degrees, and then extend and retract the expander again, creating a compacted square hole in the earth of a size to accommodate a 4×4 fence post.
[0034] FIG. 6 is an elevation view of a manual tool 120 for creating an undercut at the bottom of the square hole developed using the expander described above. Tool 120 has a vertical hollow tubing 121 that can be rotated by a t-bar 122 mounted at the upper end. The tubing is shown in broken view because the height may be much greater than shown in the view. The t-bar in this example has added hand grips. An adjustable cutter head 123 is mounted at the bottom end, and is adjustable by rotation of a gear 126 by a shaft 124 passing within tubing 121 . Shaft 124 has a handle 125 at the upper end for easy adjustment.
[0035] FIG. 7 a is a section view taken along line 7 a - 7 a of FIG. 6 , providing a plan view of cutting head 123 . Head 123 comprises main body portion 127 and two adjustable cutting units 129 , one on each side of the body. The extended portion of each adjustable cutting unit has a curved scraping edge directed for clockwise rotation. Further each cutting unit has a linear gear face 130 that engages a gear 126 driven by shaft 124 . By rotating shaft 124 clockwise (in this view) the cutting units may be extended equally.
[0036] FIG. 7 b is a view of one end of the cutting head in the direction of arrow 7 b of FIG. 7 a, which indicates how each cutting unit is restrained and guided. A portion of body 127 is machined to provide channels for panels 131 and 132 which are fastened together and to cutting unit 129 to guide the cutting unit relative to the body. In this view the curved end of the cutting unit has been cut off to be able to see the guide arrangement in full view.
[0037] FIG. 8 illustrates a square hole 134 that has been formed by an expander according to an embodiment of the present invention. Manual tool 120 is shown extended to the bottom of hole 134 with the cutting units fully retracted, so the overall width of the cutting head is a bit less than four inches, so it may be introduced into hole 134 without interference. Once in position the operator turns handle 125 (which could also be a knob) clockwise to extend the cutting heads, and also turns the manual tool clockwise using handle 122 . The cutting heads scrape earth at the bottom of the hole providing an undercut, the diameter of which is made greater by further turning handle 125 , and turning the tool with handle 122 .
[0038] When the cutting units are fully extended a significant undercut is accomplished, and a quantity of loose earth is left in the bottom of the hole. The cutting units are then retracted and the tool removed. The loose earth may be easily removed by a vacuum hose extended into the bottom of the hole from a shop vacuum apparatus.
[0039] Now the user may add concrete or other material into the hole which will flow into the undercut. The material may be, for example, an epoxy thermosetting material. After adding the concrete or plastic the post needs to be set before the added material hardens.
[0040] A post set without the undercut will be very secure, because the sides of the square hole are compacted very efficiently in the process of forming the hole. A post set with the undercut and a setting material will be even more secure, and very difficult to remove.
[0041] It will be apparent to the skilled artisan that many alterations might be made in the embodiments of the invention described above without departing from the spirit and scope of the invention. For example, the devices described might be sized to produce square holes of much different dimension than 4×4 inches. The devices described in embodiments of the invention might also be used to produce holes in the earth with much different cross-sections than square, including rectangular, polygonal, and even round. To produce a hole for a round post one might drill or auger a hole of considerably smaller diameter than the round post, and use an expander according to an embodiment of this invention, but with “pushers” with the form of circular arcs instead of the angle irons described to urge the earth in the walls of the smaller holes into a larger round hole with the walls greatly compacted. The method of undercutting and filling may be used with a hole of any shape as well.
[0042] Further to the above there may be many alterations in the materials used, and in the design to produce the desired effects. There are similarly many other alterations within the spirit and scope of the invention, so the invention is entitled to the scope of the claims that follow: | A tool for expanding a hole having a vertical axis in the earth has at least one set of two opposed compactor units constrained to separate and retract in a direction at a right angle to the axis of the hole, and a drive mechanism coupled to the set of compactor units providing force to separate the compactor units, urging the units against a wall or walls of the hole, compacting the earth and enlarging the hole. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a vehicle with a fuel cell device and a combustion arrangement.
[0002] In modern vehicles, in particular in passenger cars or non passenger cars, it has a relatively great importance whether the fuel cell devices operate with or without a preliminary reforming. It is desired to use the fuel cells for the electrical power supply in a vehicle as so-called APU.
[0003] In order to satisfy the combustion motor requirements and requirements for reforming as well as for fuel cells, an optimal integration of both systems in view of efficiency and system simplification is desired.
[0004] For the electrical power supply of modern vehicles with combustion motors, in particular with hydrogen, gasoline or diesel motors, the reforming of hydrocarbons in combination with a fuel cell is discussed. As a method for the reforming, the autothermal reforming or in other words the reforming without additional heat demand, or the steam reforming or in other words with heat supply, are considered. As for the fuel cells for the mobile use based on the cycle resistance, the PEM fuel cells are preferable when compared with a SOFC. Both the reforming reaction and the fuel cells require water in this system, for conducting the energy conversion steps as efficient as possible.
[0005] Water is produced in the fuel cell by the recombination of hydrogen and oxygen, but however escapes to a greater part as a waste gas from the system. For these reasons under extreme operational conditions, for example high outer temperature, low air moisture, operation of the APU in standing condition, wherein no cooling is possible by a wind ring, a sufficient supply of the system with water can be provided often only with significant expenses or cooling power and system complexity. In particular, in stand-by-operation the water content of a fuel cell in general is not compensated.
[0006] Moreover, systems are known which in vehicles with conventional combustion motors without APU or fuel cells, require certain quantities of water for efficiency improvement or emission reduction, as disclosed for example in the patent documents DE 196 22 836 A1 and EP 0 643 801 B1.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide a vehicle with a combustion arrangement, in particular for producing the drive energy or as standing heating etc., and in some cases with a fuel cell device, wherein the combustion arrangement has a waste gas device for withdrawing a waste gas stream, which provides an improved water management when compared with the prior art.
[0008] In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a vehicle, comprising a combustion arrangement formed as a motor selected from the group consisting of a gasoline motor and a diesel motor; a waste gas device associated with said combustion arrangement for withdrawal of a waste gas stream, said waste gas device having at least one precipitating unit for precipitation of water from the waste gas stream.
[0009] When the vehicle is designed in accordance with the present invention, the waste gas device has at least one precipitating unit for recovery or precipitation of water from the waste gas stream. Preferably the precipitator has at least one separating element for separation of the precipitated water from the waste gas stream and/or a withdrawal element for withdrawal of the precipitated water, in particular a water conduit and the like.
[0010] By means of the precipitating unit in accordance with the present invention, in an advantageous manner the water or the water stream which is contained in the waste gas stream can be provided for different applications in the vehicle or made available “on board”. Thereby a tank for operating water in the vehicle can be completely dispensed with or at least the frequency of the water storage can be significantly reduced.
[0011] During the combustion of hydrogen and/or hydrocarbons, such as for example natural gas, kerosene, gasoline or diesel, with air, for example in addition to intermediate/byproducts such as CO or NO s , substantially CO 2 and water are produced which leave the system or the vehicle in accordance with the prior through the waste gas device. From one liter of fuel, for example gasoline or diesel, approximately 0.8 kg of water and 2.3 kg of carbon dioxide are produced. The rest of the waste gas of substantially 70 volume percent is composed of nitrogen or nitrogen compounds. In the starting phase of the combustion arrangement or the combustion motor for example approximately 50 ml of gasoline are burned in the first two minutes. This means that in these two minutes approximately 40 ml of water vapor leaves the vehicle with the waste gas stream.
[0012] In the prior art during a very short period at the beginning of the starting phase, a part of the water is uncontrollably suppressed on the relatively cold waste gas device or exhaust. This water deposits uncontrollably and leave the vehicle unused together with the waste gas stream. This leads to development of the corrosion of the waste gas device or the exhaust. In accordance with the present invention, this is reduced or completely eliminated so that the service life of the waste gas device or the exhaust is considerably increased.
[0013] In accordance with the present invention the water contained in the waste gas stream is separated by means of the precipitator or the separating unit from the waste gas stream and supplied to a corresponding consumer. The precipitation with the inventive precipitator can be performed both in the starting phase and also under normal operational conditions of the combustion arrangement, or in other words at reaching from of its operational temperature with the waste gas temperatures of approximately for example 600° C. or 1000° C.
[0014] The water recovered or precipitated with the inventive precipitation unit can be made available to any water consumers in the vehicle. Generally, at least one substantial part of the waste gas device is arranged in a relatively wide lower region of the vehicle. In contrast, in the vehicle the available water consumers frequently are located at a high location of the vehicle. Exactly for these reasons at least one transporting unit for transportation of the precipitated water or pressure generating unit for the precipitated water is advantageous, since thereby the precipitated water of the precipitator can be transported from a lower region of the vehicle to a higher region of the vehicle or to a correspondingly available consumer.
[0015] Moreover, by means of the transporting or pressure generating unit a pressure which is substantially higher than the atmospheric pressure can be produced. In some cases, a correspondingly high pressure of the precipitated water can be used advantageously for a application cases. For example water in window and/or windshield wiper devices is provided with an increased pressure. It is recommended to use a precipitation unit in accordance with the present invention also in a vehicle without the fuel cell device.
[0016] Advantageously, at least one water storage for intermediate storage of the precipitated water is provided. By means of this feature in particular an advantageous time uncoupling of the water precipitation from the water consumption can be realized. For example the water during the operation, in particular during the travel of the vehicle is precipitated with the inventive precipitator and possibly simultaneously or at a later time point, for example during standing of the vehicle and/of the combustion device, can be utilized.
[0017] The water storage can be advantageously used as a buffer element. Advantageously, by means of the correspondingly then mentioned water storage, an operation of the water consumer in the stopping phase of the combustion arrangement is possible over a relatively long time.
[0018] In some cases, at least one purification unit for purification of the precipitated water can be provided. It is recommended to preliminarily purify the precipitated water by components of the waste gas stream. Thereby the corresponding preliminarily purified, precipitated water can not affect the water consumer of the vehicle or its operation or damage it. By means of the inventive purification unit in an elegant fashion a corresponding influence or damage of the water consumer is efficiently prevented. For example, the purification unit can be formed as an ion exchange device, a hydrocarbon separating unit, a membrane purification unit or the like.
[0019] Preferably, the precipitated water is utilized for the fuel cell device, so that the fuel cell system has a relatively compensated water balance and thereby a relatively frequent post filling of water for the vehicle is avoided. For this purpose between the precipitating unit and the fuel cell device, at least one connecting device for supplying the precipitated water to the separating unit is provided.
[0020] In a special embodiment of the present invention, the connecting device between the precipitating unit and the fuel cell unit is arranged. Frequently, the fuel cell unit is formed also as a so-called fuel cell-stack, wherein several individual fuel cells are assembled to form a single assembly. Each fuel cell generally has a membrane, which for its operation as a proton conductor must have a certain moisture. Frequently for this purpose an anode and/or cathode stream before the fuel cell unit is moisturized with water. This water can be made available by means of the inventive precipitator of the fuel cell unit.
[0021] Alternatively, or in combination with the previous embodiments, in a further inventive area, the connection device can be arranged between the precipitating unit and a conversion unit for chemical conversion of a fuel into a combustion substance of the fuel cell unit. Conventional conversion units or reformers frequently require water for their objectionable operation, which is made available by means of the inventive precipitator. Also, with this feature the water balance of the fuel cell system is improved in an advantageous manner.
[0022] In accordance with the present invention it is possible that the total waste gas stream passes through the precipitation unit to a special further embodiment of the invention, the precipitation unit is arranged at least on a bypass of the waste gas device for producing a waste gas stream. Thereby it is possible that a part of the total waste gas stream flows through the precipitating unit, so that the precipitation unit can be dimensioned as small as possible. Correspondingly both the space consumption and also the financial cost for producing of the precipitation unit are reduced.
[0023] Moreover, the energy quantity which is required for the precipitation or liquification, in some cases is reduced, which improves the operation of the precipitation unit. With the use of a partial waste gas stream, in an advantageous manner a reduction of the flow speed of the waste gas can be provided, so that the precipitation or liquification of the water available in the waste gas is further improved.
[0024] Generally, the fuel stream quantity which is available with the precipitation unit can be changed by an advantageous regulating or control unit. For example an adaptation to the filling height of the water storage and/or to the (actual) consumption of water in the vehicle is provided. For this purpose different sensors, such as filling, throughflow, moisture, temperature sensors and the like can be utilized in an advantageous manner.
[0025] The precipitating unit can recover the water of the waste gas stream by means of different physical or chemical processes. For example it is recommended that the water is recovered by a hydroscopic material in a precipitation phase from the waste gas stream. In a regeneration phase of the precipitation unit, water which is intermediately stored in the hydroscopic material is released and in some cases supplied to the water storage for intermediate storage of the flowing water.
[0026] Preferably, the precipitation unit can be formed as a condensation unit for condensation of water. With this feature at least a part of the water steam contained in the waste gas of the combustion arrangement is condensed by means of temperature lowering. The temperatures at the output of a combustion engine amounts to 1000° C. for Otto motors and approximately 600° C. for diesel motors. In the partial load operating pumps, however the waste gas temperatures can be substantially lower. In the output of a waste gas catalyst the temperatures of approximately 200° C. can be provided. Also, in the motor starting phase the waste gasses are significantly colder than in the normal operation. For the liquid separation of water from the waste gas of a combustion motor which typically contains between 7 and 11 volume percent of water steam, for the lowering of the dew point the temperatures under 50° C. are generally required. The further the temperature can be lowered by means of the inventive precipitator, the more water can be withdrawn from the waste gas.
[0027] Advantageously, the separating unit includes at least one cooling device for cooling the waste gas stream or the waste gas partial stream. Thereby it is guaranteed that the waste gas or the waste gas partial steam is coolable under the dew point of the water steam. The corresponding cooling device thereby increases the operational safety of the precipitating unit in accordance with the present invention.
[0028] For example, the cooling device contains a cooling medium, in particular a cooling gas and/or a cooling fluid. It is recommended for example that the air conditioning devices which are generally used in modern vehicles can include the precipitation unit in accordance with the present invention, or a cooling loop of the air conditioning device is arranged at least partially on or around the waste gas device. Relatively cool air or a cooling medium of the air conditioning device can pass through the cooling loop of the air conditioning device.
[0029] Preferably the cooling device includes a blower unit and/or an air deviating device, so that in particular atmospheric air can be flown or supplied to the precipitation unit in a defined or controllable fashion. In general the atmospheric air is significantly cooler than the waste gas stream of the combustion arrangement, so that thereby a significant temperature lowering of the waste gas steam or the waste gas partial steam can be realized.
[0030] By means of the deviating and/or guiding devices, a purposeful, local air supply can be produced for example in the lower bottom region of the vehicle at cold location in the waste gas path or in the waste gas device, so that the water steam of the waste gas stream at least partially is condensated. Advantageously this effect can be further improved by thermal bridging or the like.
[0031] In a preferable further embodiment of the invention, the cooling device includes at least one cooling element which increases an outer surface. For example, cooling ribs, cooling foam, etc. composed of metal and/or ceramics can lead to a significant increase of the cooling surface of the condensation unit, so that the invention provides local temperature lowering or further improves the condensation.
[0032] In a special further embodiment of the present invention, the precipitation unit can be designed in form of a cooled baffle plate or the like, on which the precipitated water is dropped off or guided off and thereby can be separated from the waste gas stream. Thereby in some cases it should be mentioned that a pressure drop in the waste gas line, and/or the noise generation is insignificantly increased.
[0033] In an advantageous embodiment of the invention, the precipitating unit is arranged between a catalytically active waste gas element for catalytic conversion of the waste gas stream and an outflow opening of the waste gas device. In general, an arrangement close to the motor is less desirable, since a great temperature lowering must be realized. In other words, the difference between the waste gas temperature and the condensation temperature is greater for condensation of significant quantities of water from the waste gas stream.
[0034] Preferably, the precipitation unit is arranged in a flow direction of the waste gas stream behind the last catalyst of the waste gas line or the waste gas device. Partially several catalysts for different waste gas treatment functions can be utilized. An arrangement of a precipitation unit formed as a condensation unit before a corresponding catalyst conventionally would lead to the situation that in some cases the so-called “light-off” temperature of the catalyst is reached later or only conditionally, which affects the waste gas treatment by means of this catalyst. It is recommended during a utilization of another physical or chemical principle for the precipitation of the water, that the precipitation unit is arranged relatively close to the combustion unit or in the flow direction of the waste gas stream before or between one or several waste gas catalysts.
[0035] In general, the inventive application of the precipitation unit for the fuel cell device leads to the situation that on the one hand the water balance of the fuel cell system is compensated. On the other hand, the system efficiency for the electrical supply on board is increased, since the peak cooling power for the fuel cell system and in particular a precipitator of the fuel cell, or in other words a second precipitator which is integrated in the fuel cell device, is significantly lowered. For example the cooling system of the fuel cell-APU can be dimensioned smaller and produced less expensive, since the water quantity integrated in the fuel cell device or in other words water produced by the fuel cell device, can be significantly smaller. This can result in the smaller water pumps, coolers of the fuel cell device, etc. Correspondingly, the parasitic powers of the system connected therewith are lower.
[0036] Moreover, by the additional water source “on board” of the vehicle, the service life for the pure APU operation is significantly increased.
[0037] Basically, the inventive water source can be used also for conventional combustion engine vehicles, possibly also without fuel cells for motor applications or the like, for example comfort applications and, among others, for emission reduction and/or efficiency increase, etc.
[0038] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a view showing a principal diagram of a vehicle in accordance with the present invention; and
[0040] FIG. 2 is a view schematically showing a relationship between a temperature in a precipitator in accordance with the present invention and a water content in a waste gas stream.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] In a principal diagram shown in FIG. 1 , a combustion motor is identified with reference numeral 1 . In a waste-gas stream 10 from the combustion motor 1 an oxidation catalyst 2 a and an optionally provided catalyst NO x catalyst 2 b are arranged. Behind the catalysts 2 a, 2 b in a flow direction, a precipitator 3 is provided in accordance with the present invention.
[0042] The precipitator 3 can be formed as a passive water precipitator which precipitates water 12 under suitable conditions. For this purpose the complexity and the structural and regulatory expenses of the total system can be maintained relatively low. For example, the precipitator 3 has a baffle plate or the like, on which the condensed water flows off or drops off. The baffle plate can lead to an advantageous whirling of the waste gas stream, so that the precipitation of the water 2 is improved.
[0043] In a relatively simple variant of the invention, the precipitator 3 can be formed as a heat exchanger which gives out the heat of the waste gas 10 , for example to the environment. A cooling 11 is schematically shown in FIG. 1 by several arrows. The cooling 11 can be improved by special cooling elements such as for example air guiding elements, cooling ribs, cooling coils of an air conditioning device or the like.
[0044] The relatively cold, demoisturized waste gas stream 10 is expelled from the vehicle by means of a conventional exhaust device.
[0045] The water 12 which is recovered by the precipitator 3 is supplied by a withdrawal conduit or an optionally provided pump 8 a to a fuel cell system 13 . The fuel cell system 13 includes a fuel cell 14 which has an anode 5 a and a cathode 5 b. In the variant shown in FIG. 1 a gas generating device 4 is provided, which is formed in particular as a reformer.
[0046] The fuel cell 14 is operated with air and with a water containing fuel stream 16 produced by the reformer 4 . Water vapor is supplied from the cathode 5 b of the fuel cell 14 , which is partially withdrawn by a second precipitator 6 from the gas stream. The water 17 recovered by the precipitator 6 is supplied to a water container 7 of the fuel cell device 13 . The water container 7 is used simultaneously as a water storage of the precipitator 3 in accordance with the present invention. The water 12 , 13 which is stored in it can be supplied by a pump 8 to an optionally provided cleaning unit, in particular an ion exchanger 9 .
[0047] Frequently the ion exchanger 9 is already available in the fuel cell systems 13 . It lowers the conductivity of the water 12 , 13 , so that a possible short circuiting in the fuel cell 14 is substantially prevented. For this purpose the water 12 , 13 is adjusted by the purifier 9 to a conductive value of smaller than 5 μs/cm. The purifier unit 9 can be formed alternatively or additionally for cleaning or removal of hydrocarbon particles, soot particles, etc., so that the impurities which are sometimes available can be efficiently eliminated from the waste gas water 12 .
[0048] Moreover, a not shown purification unit can purify the water outside the fuel cell system 13 at least partially. This means that for example the water 12 , when considered in a flow direction of the water 12 , is purified before the container 7 . Thereby a removal of hydrocarbon-containing or carbon-containing impurities is of special advantage.
[0049] The water 12 , 13 which is purified in some cases is supplied possibly to one or both fuel flows 15 , 16 of the fuel cell 14 for moisturizing and/or to the reformer 4 .
[0050] FIG. 2 schematically shows a relationship between a water component in the waste gas and a temperature in the precipitator 3 . From the curve 18 the course of the condensated water recovered by means of the precipitator 3 can be seen. The curve 19 shows the course of the water remaining in the waste gas stream. In FIG. 2 a mol stream of the water is shown over the temperature in the precipitator 3 in degrees Celsius. FIG. 2 clearly shows that with a water content in the waste gas of substantially 10%, water is condensated at temperatures under 50° C.
[0051] Generally, with the precipitator 3 the precipitator 6 must precipitate less water 17 , so that advantageously it consumes less (cooling) energy. The precipitator 3 can operate without energy use, for example by means travel wind or available cooling ribs, etc., or with very low energy consumption, for example for a relatively small feed pump 8 a. This leads first of all to the situation that the total efficiency of the system is increased or the so-called parasitic powers of the fuel cell system 13 are significantly reduced.
[0052] Basically, a precipitation unit 3 for precipitation of the water 12 from the waste gas stream in a vehicle with a combustion arrangement 1 , in particular a combustion motor 1 , is advantageous for producing the drive energy of the vehicle. For example the separated water 12 can be used for the windshield wiper device, for cooling purposes or further applications, for example in the combustion motor for gas cooling. Correspondingly, in FIG. 1 , for example optionally provided conduits 20 a, 20 b or branches for further application in the vehicle are shown. These conduits 20 a, 20 b can be arranged at any points of the system, at which an advantageous branching of the precipitated water 12 is possible.
[0053] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0054] While the invention has been illustrated and described as embodied in vehicle with a combustion arrangement and a fuel cell device, 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.
[0055] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A vehicle includes a combustion arrangement formed as a motor selected from the group consisting of a gasoline motor and a diesel motor, a waste gas device associated with same combustion arrangement for withdrawal of a waste gas stream, the waste gas device having at least one precipitating unit for precipitation of water from the waste gas stream. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a field converting method for generating new field data from arbitrary field data of television signals at a special playback (variable speed playback) by a magnetic recording reproducing device, e.g., a video tape recorder (hereinbelow abbreviated to VTR), a laser disk player, etc. and device for realizing same.
When image signals recorded in a VTR, etc. are reproduced, in order to regulate playback time or to achieve special effects such as slow playback, still picture playback, fast playback, the special playback is effected, by which images are skipped (jumped) or same images are reproduced repeatedly. At this time, in order to satisfy an interlace condition of image signals or a continuity condition for subcarrier, i.e., in order to keep the continuity of field numbers, an interpolation filter technique is adopted for the purpose of preventing displacements of the center of gravity of images, i.e., the position of images, at the variable speed playback, by which image signals of a field having a different field number are generated, starting from reproduced image signals, and reducing lowering of the vertical resolution. An example of such an interpolation filter device is disclosed in JP-A-2-132984.
Further, a processing technique, in the case where the processing described above is effected by means of a digital VTR, is indicated in an article entitled "Reproduced Video Signal Processing For Composite Digital VTR", ITEJ Technical Report, Vol. 14, No. 47, pp. 13-18, Sep. 1990.
FIG. 1 indicates the interpolation filter device indicated in JP-A-2-132984.
In FIG. 1, reference numerals 401 and 402 are input and output terminals for reproduced image signals; 411 is a delay line having a delay time corresponding to a horizontal scanning period (hereinbelow called simply 1 H); 412 and 413 are delay lines having delay times of 2 H and 3 H, respectively; 421 and 428 are coefficient multipliers having a coefficient of (-α/4); 422 and 427 are coefficient multipliers having a coefficient of (1/4-α/4); 423 and 426 are coefficient multipliers having a coefficient of (3/4+5α/4); 424 and 425 are coefficient multipliers having a coefficient of (-3α/4); 431 and 432 are adders; and 441 is a switch. In this device a composite signal is separated into a luminance signal and a chrominance signal by a Y/C separating circuit and the luminance signal thus separated is inputted in the delay lines 411, 412, 413, etc. through the input terminal 401. The input signal from the input terminal 401 and the output signals of the delay lines 411, 412, 413 are inputted in the coefficient multipliers 421 and 422, 423, 424 as well as 425 and 426, 427, 428, respectively. The outputs of the coefficient multipliers 421, 422, 423 and 424 are inputted in the adder 431, while the outputs of the coefficient multipliers 425, 426, 427 and 428 are inputted in the adder 432. The outputs of the adders 431 and 432 are inputted in the switch 441. The switch 441 selects the output of the adder 432 on the H side, in the case where both the field number of the reproduced image, which is to be field-converted, and the field number of the field converted output image signal are odd or even (hereinbelow called odd or even number accordance) and the output of the adder 431 on the L side, in the case where one of them is odd and the other is even (hereinbelow called odd or even number disaccordance). Since the signal outputted by the adder 431 and the signal outputted by the adder 432 have same frequency-amplitude characteristics, there is no difference in the vertical resolution.
Therefore, even in the case where the switch is turned-over in field unit at the variable speed playback, good images can be obtained. The odd or even number accordance for the field number corresponds to a case where one of them is 1 (2) and the other is 1 or 3 (2 or 4).
Further, U.S. Pat. No. 4,641,202 corresponding to JP-A-60-545580 discloses a field converting method, by which arbitrary field data are converted into new field data, and a device for realizing same.
SUMMARY OF THE INVENTION
The device disclosed in JP-A-2-132984 has a problem in that displacements are produced in images at so-called vertical transistions of the luminance signal, where the level of the luminance signal varies rapidly in the vertical direction. This will be explained, referring to FIGS. 2A to 2C, (z) and (a) to (e) in FIG. 2A indicate data of vertical rows of pixels in fields, which are consecutive in time. 501 to 503, 511 to 513, 521 to 523, 531 to 533, 541 to 543, and 551 to 553 represent pixels having high luminances, while 515, 524, 525, 534, 535, 544, 545, 554 and 555 represent pixels having low luminances. FIG. 2B shows an image signal, in the case where data, from which the field (c) in FIG. 2A is skipped, are projected on a screen without being subjected to the interpolation filter processing. Since particularly for the fields (d) and (e) not only the start line of effective data but also all the data appear, displaced upward by a distance corresponding to 0.5 H (H being one horizontal scanning period) from the original position indicated in FIG. 2A, the center of gravity of the whole image is displaced. In order to prevent this displacement of the center of gravity, the data of the different fields in FIG. 2B are input to the image input terminal 401 of the interpolation filter device indicated in FIG. 1 to be subjected to the interpolation filter processing. FIG. 2C shows data after the conversion, in the case where the field conversion is effected by means of the interpolation filter device indicated in FIG. 1. In particular, the fields (a) and (b) show cases where both the field number of the reproduced image signal and the field number of the output image signal are odd or even, which are data outputted by the adder 432 in FIG. 1. Data 563 in FIG. 2C are obtained by calculations from data 511, 512, 513 and 514. On the other hand, the fields (d) and (e) in FIG. 2C represent cases where either one of the field number of the reproduced image signal and the field number of the output image signal is odd and the other is even, which are data outputted by the adder 431. In this case, the data 583 in FIG. 2C are obtained, starting from the data 541, 542, 543 and 544 in FIG. 2A, by calculations different from those described previously. At the usual playback, a part where the luminance level varies strongly (transition of the luminance signal) exists between the data 523, 543 and the data 514, 534, 554 indicated in FIG. 2A. On the contrary, at the variable speed playback (special playback), when the field conversion is effected by means of a prior art interpolation filter, in the case indicated by the fields (a) and (b) in FIG. 2C, where the field number of the reproduced image signal and the field number of the output image signal are in odd or even number accordance, the transition of the luminance signal exists between the data 564 and the data 573, and in the case indicated by the fields (d) and (e) in FIG. 2C, where they are in odd or even number disaccordance, it exists between the data 584 and the data 593. Consequently, in the case where variable speed reproduction data (FIG. 2B) of the image signal as indicated in FIG. 2A are inputted in the image input terminal 401 in FIG. 1 and the field number of the reproduced image signal and the field number of the output image signal are in odd or even number accordance, the switch 441 in FIG. 1 selects the H side, then image signals such as the fields (a) and (b) in FIG. 2C are outputted. On the contrary, in the case where the field number of the reproduced image signal and the field number of the output image signal are in odd or even number disaccordance and the switch 441 in FIG. 1 selects the L side, image signals such as the fields (d) and (e) in FIG. 2C are outputted. For this reason, in the case where a still picture or an image where there are almost no movements is reproduced in the variable speed playback, when this switch is turned over, transitions of the luminance signal are displaced in the vertical direction. In particular, in the case where the playback speed is slightly regulated, when the switch is turned-over for every several fields, displacements in the vertical direction are easily observed by sight, which causes significant worsening in the image quality.
That is, as indicated by the literatures described above, by these methods displacements of the center of gravity in the image are produced, accompanied by the field conversion. The displacements of the center of gravity in the image give feeling of instability by sight, which gives rise to significant worsening in the image quality. Further, as described in the literature described above, if the band of a comb-shaped filter for separating the luminance signal from the carrier chrominance signal is narrow, the carrier chrominance signal remains in the luminance signal. In this way, the band of the carrier chrominance signal is varied by the phase inversion processing of the carrier chrominance signal accompanied by the field conversion, which gives rise to color flicker and significant worsening in the image quality. In order to prevent this, if the band of the comb-shaped filter is widened, resolution in the diagonal direction of the luminance signal is lowered, which gives rise to so-called foggy images. As described above, prevention of occurrence of the color flicker and reduction in the lowering in the resolution in the diagonal direction can be effected under two contractory conditions. Therefore, these methods have a problem that the image quality is worsened, because these two conditions cannot be satisfied simultaneously.
On the other hand, according to U.S. Pat. No. 4,641,202 stated above, at a variable speed playback, which was a still picture playback, the field conversion was effected by using either one of field signals delayed by one field and two fields, while at a variable speed playback, which was a moving picture (moving image or time-varying image) playback (in which images moved), the field conversion was effected by using signals on a plurality of lines within a same field. Since control was effected so as to forcibly select the interline signal processing particularly at portions, where field jump (field skip) or field repetition was effected, it was difficult to satisfactorily prevent displacements of the images in the vertical direction. Further, in the case where the field conversion was effected by using signals within a same field at moving picture portions, it was difficult to make the position thereof be in accordance with the position of images in still picture portions without significantly worsening the vertical resolution.
Therefore, an object of the present invention is to provide a field converting method for television signals and a device for realizing same capable of removing the drawbacks of the prior art techniques described previously.
Another object of the present invention is to provide a field converting method for television signals and a device for realizing same capable of removing displacements of transitions of the luminance signal, having almost no variations in the resolution even at a variable speed playback.
Still another object of the present invention is to provide a field converting method for television signals and a device for realizing same, which can eliminate displacements of the center of gravity of the images accompanied by the signal processing at the variable speed playback described above, has no color flicker, and further can improve the image quality at the variable speed playback by removing worsening in the resolution in the diagonal direction of the luminance signal and eliminating lowering in the resolution of the chrominance signal.
According to an aspect of the present invention, a field converting device for generating data of new fields from data of an arbitrary field in an interlaced television signal, is comprised of a portion for generating data of a first field by using data of a field to be field-converted and data of a field, which is in an interlaced relation therewith a portion for generating data of a second field by using data of a plurality of lines in the field to be field-converted described above; a movement detection portion for detecting movements of images represented by the data of the field to be field-converted described above; and a portion for outputting selectively the data of the first field and the data of the second field as the data of the new field described above, according to a detection result by the movement detection portion.
According to another aspect of the present invention, a field conversion device for generating data of new fields from data of an arbitrary field in an interlaced composite television signal is comprised of a portion for separating an inputted composite signal of the field at that time; a portion for obtaining a luminance signal of a field, which is in an interlaced relation with the signal of the field at that time, from the inputted composite signal; a portion for obtaining a first luminance signal of the new field by using the luminance signal of the field at that time separated by the separating portion described above and the luminance signal thus obtained of the field, which is in the interlaced relation therewith; a portion for obtaining a second luminance signal of a new field by using the luminance signal of a plurality of lines of the field at that time; a movement detection portion for detecting movements of images represented by the inputted composite signal; a portion for outputting selectively the first luminance signal and the second luminance signal described above according to a detection result by the movement detecting portion; a portion for obtaining a chrominance signal of a new field by using the chrominance signal of the field at that time separated by the separating portion; and an adding portion for adding the luminance signal selectively outputted by the movement detecting portion and the chrominance signal of the new field thus obtained to output a signal obtained by the addition as a signal of the new field described above.
In an example of the present invention, an interpolation filter portion is used, which portion utilizes inter-field signals, i.e. data of a field to be converted and data of a field, which is in an interlaced relation with the data of that field.
A reproduced image signal is inputted in a Y/C separation circuit, which Y/C-separates it into a luminance signal C. Y and a carrier chrominance signal. The separated luminance signal Y is stored in a line memory portion, which delays it appropriately, and a field memory portion, while the chrominance signal C is stored in the line memory portion. By means of the movement detection portion, which distinguishes whether the image is a moving picture or a still picture, starting from the field memory, in which the luminance signal is stored, and the separated luminance signal, in the case where the reproduced image signal is a still picture, the output of the interpolation filter signal using the inter-field signal is selected and to the contrary, in the case where it is recognized that it is a moving picture, the output is switched-over so as to select the output of the interpolation filter signal using the interline signal. The signal used for the movement detection, and the portion and signal used for the interpolation filter using the inter-field signal are switched-over, depending on the field continuity in the neighborhood of the reproduced image signal, which is to be converted. On the other hand, the separated chrominance signal C controls the presence or absence of inversion of the sign of the chrominance signal after having been delayed by a predetermined time so as to satisfy the continuity of the carrier chrominance signal of the outputted field and adds the chrominance signal, which has been subjected to the processing, to the luminance signal, which has been subjected to the interpolation filter processing to output them.
The reproduced composite signal is separated into the luminance signal Y and the carrier chrominance signal C, and the luminance signal Y is stored in the line memory portion and the field memory portion. Since the data to be field-converted and the data, which are in the interlaced relation with that field, are inputted in the interpolation filter using the inter-field signal, the field conversion without displacements at the vertical transitions of the luminance signal is effected. On the other hand, the data, which are to be field-converted, and data corresponding to several lines before and after them are inputted in the interpolation filter using the interline signal and the field conversion is effected so that no residual images remain when the reproduced image data represent a moving picture.
Taking into account that the sign of the chrominance signal is inverted for every frame, the movement detection portion compares preceding and succeeding luminance signal data by one frame or preceding and succeeding composite signal or luminance signal data by two frames. If there are no differences between these data sets or the differences are small, the movement detection portion regards the reproduced image as a still picture and selects the interpolation filter using the inter-field signal. On the contrary, if the differences are great, it regards the reproduced image as a moving picture and selects the interpolation filter using the interline signal to effect the field conversion. In this way it is possible to eliminate residual images in the moving picture portion and displacements at the vertical transitions of the luminance signal in the still picture portion.
Further, in the case where some disorder is produced in the continuity of the reproduced image data by skipping or repeating some field data, the movement detection portion detects movements by using preceding and succeeding data by 1 field (corresponding to preceding and succeeding data by 1 frame, taking the skipping processing into account) or preceding and succeeding data by 3 fields (likewise, corresponding to preceding and succeeding data by 2 frames), etc., when the reproduced image is skipped, and preceding and succeeding data sets by 3 fields (corresponding to preceding and succeeding data by 1 frame, taking the repetition processing into account), etc. Similarly, in the interpolation using the interfield data, in the case where the reproduced image is skipped or repeated, the interpolation filter processing is effected by using preceding and succeeding data by 2 fields (corresponding to preceding and succeeding data by 3 fields, taking the skipping processing into account, and to preceding and succeeding data by 1 field, taking the repetition processing into account, which are the data of the field, which is to be converted, and the data of the field, which is in the interlaced relation with that field, which fields are necessary for the inter-field conversion). In this way the processing can be effected, independently from presence or absence of the skipping or the repetition of the field data at the variable speed playback by using data necessary for the respective processing in the movement detection and the conversion using the inter-field data, i.e. the data, which are to be subjected to the field conversion, and the data preceding them by 525 H in the movement detection and the data, which are to be subjected to the field conversion, and the data of the field, which is in the interlaced relation with that field, in the inter-field conversion. Therefore it is possible to prevent worsening in the image quality both in the case where the reproduced image is a moving picture and in the case where it is a still picture.
Further, the center of gravity of the separated chrominance signal C can be made in accordance with the center of gravity of the luminance signal subjected to the interpolation processing by delaying it by means of a line memory or by subjecting it to an interpolation signal. Still further it is possible to maintain the continuity the subcarrier, depending on the presence or absence of the sign inverting processing.
Not only residual images but also displacements at the vertical transitions of the luminance signal can be eliminated by adding the luminance signal and the chrominance signal which have been subjected to these signal processings. Furthermore it is possible to realize the field conversion, by which the continuity of the subcarrier is maintained.
In another example of the present invention, the luminance signal Y and the carrier chrominance signal C are separated (Y/C separation) by using the correlation of signals between different frames for the still picture portion and the correlation of signals between different lines for the moving picture portion. Further, an interpolation filter portion is used, by which the inter-field signal is used for the still picture portion and the inter-field signal is used for the moving picture portion. Further movements in the image are detected by the movement detection portion and the inter-field signal processing and the interline signal processing by the interpolation filter are added while varying the mixing ratio, on the basis of the output signal of this detection portion. Furthermore the luminance signal and the chrominance signal are added to be outputted.
In addition, in the case where a field is repeated by the variable speed playback (special playback), the repeated field is not written in the memory. When a field is skipped and the Y/C separation using the inter-field correlation cannot be effected, the Y/C separation using the interline correlation is forcibly effected. Similarly, in the case where the movement detection using the inter-field correlation cannot be effected, it is supposed that that movement does not exist and movements are detected by using the correlation between other frames.
The reproduced composite image signal is separated into a luminance signal Y and a carrier chrominance signal C by a frame Y/C separation circuit and a line Y/C separation circuit. Further also, a composite image signal delayed by 1 field is separated into a luminance signal and a chrominance signal by the frame Y/C separation circuit. In a scanning line conversion filter using an inter-field signal, since data, which is to be interlaced, are inputted therein, the field conversion is effected without displacements at the vertical transitions of the luminance signal. In addition, the data, which are to be field-converted, and the data of the lines preceding and succeeding the relevant line are inputted appropriately in a scanning line conversion filter using an interline signal and such a field conversion that no residual images remain, when the reproduced image data represent a moving picture.
The movement detection portion compares data preceding and succeeding by 1 frame and data preceding and succeeding by 2 frames. If there are no differences therebetween, the reproduced image can be regarded as a still picture and the field conversion is effected by selecting the scanning line conversion filter using an inter-field signal. If not, the field conversion is effected by selecting the scanning line conversion filter using an interline signal. In this way it is possible to eliminate residual images and displacements at the vertical transitions of the luminance signal for still picture portions.
Further, the separated carrier chrominance signal C can maintain the continuity of the color sub-carrier by controlling the presence or absence of the phase inversion.
By adding the luminance signal and the chrominance signal subjected to these signal processings, it is possible to eliminate both residual images and displacements at the vertical transitions of the luminance signal and to realize the field conversion, keeping the continuity of the color subcarrier. Further, since in the frame Y/C separation circuit, it is possible to construct comb-shaped filters over the whole region of the image signal without lowering the resolution, it is possible to remove lowering in the resolution of the chrominance signal, residual carrier chrominance signal in the luminance signal and color flicker.
Further, for portions where fields are repeated, a same signal processing can be effected repeatedly by interrupting to write the signals in the memories.
In the case where fields are skipped, when the interframe comb-shaped signal processing cannot be effected, the separation of the luminance signal from the carrier chrominance signal is made possible by forcibly selecting the interline Y/C separation. Furthermore, in the case where no difference between the signals preceding and succeeding by 1 frame can be formed, they are treated, supposing that there are no differences between the signals, and movements are detected by differences between the signals preceding and succeeding by 2 frames. Similarly, in the case where no difference between the signals preceding and succeeding by 2 frames can be formed, they are treated, supposing that there are no differences between the signals, and movements are detected by differences between the signals preceding and succeeding by 1 frame. In this way, also in the case where the fields are skipped, the inter-field scanning line interpolation can be effected similarly to a usual case.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a scheme showing the construction of an example of the interpolation filter in a prior art field conversion device;
FIGS. 2A to 2C are schemes representing images for explaining field converting characteristics at the variable speed playback of the prior art field conversion device at the variable speed playback;
FIG. 2D is a scheme representing an image for explaining field converting characteristics at the variable speed playback by the field converting method according to the present invention;
FIG. 3 is a scheme showing the construction indicating the conception of the field conversion device according to the present invention;
FIG. 4 is a scheme showing the construction indicating a first embodiment of the field conversion device according to the present invention;
FIG. 5 is a scheme for explaining the control operation of switch control circuits in FIG. 4;
FIG. 6 is a scheme showing the construction indicating an example of the inter-field conversion circuit indicated in FIG. 4;
FIG. 7 is a scheme representing an image for explaining the processing in the present embodiment, when field data are skipped at the variable speed playback;
FIG. 8 is a block diagram showing an example of the Y/C separation circuit indicated in FIG. 4;
FIGS. 9A to 9C shows waveforms for explaining leakage of the chrominance signal to the luminance signal in the Y/C separation circuit indicated in FIG. 8;
FIG. 10 is a block diagram showing a modified example of the embodiment indicated in FIG. 4;
FIG. 11 is a scheme showing the construction indicating a second embodiment of the field conversion device according to the present invention;
FIG. 12 is a block diagram showing the construction or an example of an image movement detection circuit indicated in FIG. 11;
FIG. 13 is a scheme showing the construction indicating an example of a signal output timing converter indicated in FIG. 11;
FIG. 14 is a scheme indicating a norm for the effective start line of different fields for a D2-type digital VTR;
FIG. 15 is a scheme indicating a conversion rule for the effective start line, depending on the field number of the reproduced image signal and the output image signal at the variable speed playback;
FIGS. 16A and 16B are block diagrams showing the construction of an example of different track jump detecting circuits indicated in FIG. 11;
FIG. 17 is a block diagram showing the construction of an example of an inter-field conversion circuit indicated in FIG. 11;
FIG. 18 is a block diagram showing the construction of an example of a switching circuit 194 indicated in FIG. 11;
FIG. 19 is a block diagram showing a modified example of the embodiment indicated in FIG. 11;
FIG. 20 is a block diagram showing the construction of a third embodiment of the field conversion device according to the present invention;
FIG. 21 is a block diagram showing the construction of an example of the inter-field conversion circuit indicated in FIG. 20;
FIG. 22 is a block diagram showing the construction of another example of the inter-field conversion circuit indicated in FIG. 20;
FIG. 23 is a block diagram showing the construction of a modified example of the embodiment indicated in FIG. 20;
FIG. 24 is a block diagram showing the construction of a fourth embodiment of the field conversion device according to the present invention;
FIG. 25 is a scheme representing an image for explaining a signal processing operation of the field conversion device indicated in FIG. 24;
FIG. 26 is a scheme for explaining the converting operation of the field conversion device indicated in FIG. 24;
FIG. 27 is a scheme representing an image for explaining the signal processing, in the case where fields are skipped, in the field conversion device indicated in FIG. 24;
FIGS. 28 to 30 are schemes representing different images for explaining the signal processing operation of the field conversion device indicated in FIG. 24;
FIGS. 31 and 32 are schemes for explaining the converting operation of the field conversion device indicated in FIG. 24;
FIG. 33 is a scheme representing an image for explaining the signal processing in the case of slow playback in the field conversion device indicated in FIG. 24;
FIG. 34 is a scheme showing the construction of an example of a tapped delay circuit indicated in FIG. 24; and
FIG. 35 is a block diagram showing a modified example of the field conversion device indicated in FIG. 24.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Several embodiments of the field conversion device for television signals according to the present invention will be explained, referring to the attached drawings.
Before the explanation of the embodiments, the conception of the field conversion device according to the present invention will be explained, referring to a conceptual construction scheme indicated in FIG. 3. In the figure, a reproduced image signal for television signal given to an input terminal 4 is sent to a delay circuit 2. The delay circuit 2 outputs an image signal C, which is displaced by 1 or 2 frames with respect to image signals A of the field at that time, i.e. A 1 to A p , and image signals B, which are in an interlaced relation with the signals A, i.e. signals B 1 to B q for scanning lines different from those of the signals A. The image signals A 2 to A q are signals, which are delayed by predetermined different amounts with respect to the signal A 1 of the field at that time, while the image signals B 2 to B 1 are signals, which are delayed by predetermined different amounts with respect to the signal B 1 .
A movement detection circuit 14 detects movements in the image on the basis of the image signals A and C. Results of this detection are given to a scanning line conversion circuit 12 as a signal k. Here k is a value indicating the degree of the movements. For example, 0≦k≦1 and it is supposed that k=1 represents a moving picture, in which movements in the image are great, and k=0 represents a still picture, the movements in the image being greater with k closer to 1.
A signal indicating the field No. of the reproduced image signal (reproduced field No.) inputted in the input terminal 8 and a signal indicating the field No. of the output image signal (output field No.) inputted in the input terminal 10 are given in a control circuit 6. This control circuit selects values from groups of coefficients l 1 to l p , m ll to m lp and m 21 to m 2q indicated below of the scanning line conversion circuit 12, depending on e.g. whether both the field Nos. are odd or even (odd or even number accordance) or one of the field Nos. is odd and the other of them is even (odd or even number disaccordance).
The scanning line conversion circuit 12 includes an intra-field interpolation circuit and an inter-field interpolation circuit, which output signals L and F, respectively, indicated below; ##EQU1##
The output signal X of the scanning line convertion circuit 12 is expressed by X=k L +(l-k)F. Consequently ##EQU2## is valid, where hs are functions of k.
Now several embodiments of the present invention will be explained, referring to the attached drawings. In the following description items having a same reference numeral have a same function and explanation thereof will be omitted. FIG. 4 is a block diagram indicating the construction of the first embodiment of the present invention. In FIG. 4, reference numeral 101 is an input terminal for a reduced image signal (composite signal); 102 is an output terminal for an image signal (output image signal), which has been subjected to the field conversion; 171 to 178 are delay lines, each of which effects a delay of one horizontal scanning period (hereinbelow denoted by 1 H); 179 and 180 are delay lines effecting delays of 260 H and 261 H, respectively; 103 is a field conversion circuit, which effects a field conversion, producing no flickers due to variations in the resolution by using data within only one field (intra-field conversion circuit); 104 is an inter-field conversion circuit, which effects a field conversion, in which displacements at the transitions of the luminance signal are eliminated, by using data in a plurality of fields; 14 is a movement detection circuit, which detects movements in the image; 151 and 152 are adders; 153 and 154 are absolute circuits, which output absolute values of inputted numerical values having plus or minus signs; 155 and 156 are comparators, which compare inputted values with predetermined values in the magnitude; 157 is an AND gate; 106 is a Y/C separation circuit, which separates a composite signal into a luminance signal Y and a chrominance signal C, i.e. effecting the Y/C separation; 191 is a sign inversion circuit, which inverts a plus or minus sign of an inputted chrominance signal; 192 is a switching circuit, which selects a sign inverted chrominance signal and a sign not-inverted chrominance signal; 193 is a switching circuit, which selects a signal obtained by delaying the separated chrominance signal by 1 H and a signal obtained by delaying further the signal thus obtained by 1 H; 194 is a switching circuit, which switches-over an output signal of the intra-field conversion circuit 103 and an output signal of the inter-field conversion circuit 104 according to an output of the movement detection circuit 14; and 195 is an adder, which adds the luminance signal and the chrominance signal, which have been subjected to the field converting processing. A switch control circuit 196 detects the odd and even number accordance or disaccordance of the reproduced field No. and the output field No. inputted in the terminals 8 and 10, respectively, to control the switching circuit 193 according to the control operation indicated in FIG. 5, on the basis of a result of detection, and further to control the intrafield conversion circuit 103 and the inter-field conversion circuit 104.
Further, a switch control circuit 199 controls the switching circuit 192 according to the reproduced field No. and the output field No., as indicated in FIG. 5. The delay lines 171-176, 179 and 180 in FIG. 4 correspond to the delay circuit 2 in FIG. 3; the switch control circuits 196 and 199 to the control circuit 6; and the conversion circuit 103 and 104 to the scanning line conversion circuit 12.
FIG. 6 is a block diagram showing the construction of an example of the inter-field conversion circuit indicated in FIG. 4.
In this figure, reference numerals 211 to 215 are input terminals, through which the luminance signal after the Y/C separation of the reproduced image signal is inputted, among which data obtained by delaying the output signal of the Y/C separation circuit 106 indicated in FIG. 1 by 1 H are inputted in the terminal 211; data obtained by delaying same by 2 H are inputted in the terminal 212; data obtained by delaying same by 263 H are inputted in the terminal 213; data obtained by delaying same by 264 H are inputted in the terminal 211; and data obtained by delaying same by 265 H are inputted in the terminal 215.
221, 223 and 226 are coefficient multipliers having a coefficient m while 222, 224, 225 and 227 are coefficient multipliers having a coefficient n. The coefficients m and n have a relationship of 2(m+n)=1. Further, 23 and 24 are adders; 25 is a switch, which switches-over the outputs of the adders 23 and 24; and 26 is an output terminal of the data, which has been subjected to the inter-field conversion, the output thereof being inputted in the H input of the switch 194 in FIG. 4.
A reproduced composite signal inputted through the reproduced signal input terminal 101 in FIG. 4 is inputted at first in the Y/C separation circuit 106 and separated into a luminance signal and a chrominance signal. The luminance signal is delayed successively by delay lines 171 to 176, 179 and 180. The output luminance signal of the Y/C separation circuit 106, the 1 H delayed data; the 2 H delayed data; and the 3 H delayed data; the 2 H delayed data; and the 3 H delayed data of the luminance signal outputted by the Y/C separation circuit 106 are inputted in an intra-field conversion circuit 103. From these four kinds of the inputted luminance signal data, lines necessary for the fields, which are converted by the interpolation filter device as indicated in FIG. 1, described e.g. in JP-A-2-132984, are formed and the output data thus formed are inputted in the L input of the switch 194. A switch 441 in the intra-field conversion circuit 103 is controlled by an output of the switch control circuit 196 so as to select an output of an adder 432 by the odd or even number accordance and an output of an adder 431, if they are in odd or even number disaccordance. Further outputs of the delay lines 171, 172, 179, 174 and 175, i.e., the 1 H delayed data, the 2 H delayed data, the 263 H delayed data, the 264 H delayed data and the 265 H delayed data are inputted in the inter-field conversion circuit 104 through the input terminals 211, 212, 213, 214 and 215, respectively. The data inputted through the input terminals 213, 214 and 215 are data preceding the data inputted through the input terminals 211 and 212 by 1 field. The luminance signal inputted through the input terminal 211 is inputted in the coefficient multipliers 221 and 222; the signal inputted through the input terminal 212 is inputted in the coefficient multipliers 223 and 224; the signal inputted through the input terminal 213 is inputted in the coefficient multiplier 225; the signal inputted through the input terminal 214 is inputted in the coefficient multiplier 226; and the signal inputted through the input terminal 215 is inputted in the coefficient multiplier 227. As described previously, the values of the different coefficient multipliers m and n are in a relationship of 2(m+n)=1 and it is possible to vary frequency characteristics of the filters in the inter-field conversion circuit by varying the values of these m and n. In the present embodiment, e.g. m=5/8 and n=-1/8, and it is a matter of course that the frequency characteristics of the filter selected, if the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, i.e. filter consisting of the coefficient multipliers 221, 224, 225 and 226 are identical to the frequency characteristics of the filter selected, if they are in odd or even number disaccordance, i.e. filter consisting of the coefficient multipliers 222, 223, 226 and 227. The outputs of the coefficient multipliers 221, 224, 225 and 226 are inputted in the adder 23 to form the field conversion data, when the field numbers of the reproduced image signal and the output image signal are in odd or even number accordance, while the outputs of the coefficient multipliers 222, 223, 226 and 227 are inputted in the adder 24 to form the field conversion data, when the field numbers of the reproduced image signal and the output image signal are in odd or even number disaccordance. The switch 25 selects the L input, i.e. the output of the adder 23, responding to a signal from the switch control circuit 196 indicating the odd or even number accordance, and the H input, i.e. the output of the adder 24, responding to a signal therefrom, responding to a signal indicating the odd or even number disaccordance. In FIG. 2A, the reproduced image signal and the luminance signal reproduced in the order of (z), (a) to (e) are outputted as the luminance signal Y of the Y/C separation circuit 106 in FIG. 4. (a) and (b) in FIG. 2D are field conversion data in the case where the field Nos. of the reproduced signal and the output signal are in odd or even number accordance. For example, data 1564 are data outputted, when data 513, 503, 514 and 504 in FIG. 2A are inputted in the input terminals 212, 214, 211 and 213 in FIG. 6, respectively, and the switch 25 selects the L input. (c) and (d) in FIG. 2D are field conversion data in the case where the field Nos. of the reproduced signal and the output signal are in odd or even number disaccordance. For example, data 1593 are data outputted, when data 542, 553, 543 and 554 are inputted in the input terminals 215, 212, 214 and 211 in FIG. 6, respectively, and the switch 25 selects the H input. In these data formed by the inter-field conversion circuit, not only the frequency characteristics but also the transitions of the luminance signal remain identical, both in the case of the odd or even number accordance and in the case of the odd or even number disaccordance and therefore it is possible to eliminate displacements of the vertical transitions of the luminance signal due to the field converting processing. The outputs of the adders in FIG. 6 are inputted in the switch 25, which selects the output of the adder connected with the L input, in the case where the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and the output of the adder connected with the H input, in the case where they are in odd or even number disaccordance. The output of this switch 25 is inputted in the H input terminal of the switching circuit 194 in FIG. 4.
Further, the data, which are to be field-converted, and the data obtained by delaying them by 525 H, i.e. the output signal of the 1 H delay line 171 and the output signal of the 261 H delay line 180 in FIG. 4 are given to adder 151 in FIG. 4 to be subjected to an adding processing. On the other hand, the data preceding the data, which are to be field-converted, by 1 H and the data obtained by delaying them by 525 H, i.e. the output signal of the 1 H delay line and the output signal of the 1 H delay line 176 are inputted in an adder 152 to be subjected to an adding processing. The outputs of the different adders 151 and 152 are compared with predetermined values by comparators 155 and 156 after having formed absolute values by means of absolute circuits 153 and 154, respectively. In the case where the outputs of both the absolute circuits 153 and 154 are smaller than the predetermined values, it is supposed that there are no movements in the image in the neighborhood of the data, which are to be field-converted, and the switching circuit 194 is controlled so as to select the output signal of the inter-field conversion circuit 104 at the H input thereof and if not, it is judged that the image is a moving picture and it is controlled so as to select the output signal of the intra-field conversion circuit 103 at the L input.
On the other hand, the chrominance signal C separated by the Y/C separation circuit 106 is delayed by a delay line 177 by 1 H and is inputted in the switching circuit 193 together with the signal delayed further by a delay line 178 by 1 H and and either one of them is selected. The luminance signal Y is subjected to an interpolation processing in the intra-field conversion circuit 103 and the inter-field conversion circuit 104, which gives rise to a delay, accompanied by this interpolation processing. The delay lines 177 and 178 are disposed for compensating this delay. In the case where the field No. of the reproduced image signal inputted through the input terminal 101 and the field No. of the output image signal outputted through the output terminal 102, delayed by the interpolation processing, are in odd or even number accordance, since the delay of the luminance signal after the interpolation processing with respect to the inputted image signal is 1.25 H, the switching circuit 193 selects the signal delayed by 1 H by the delay 177 as the chrominance signal to output it. In the case where the two field Nos. are in odd or even number disaccordance, the delay of the luminance signal after the interpolation processing is 175 H with respect to the image signal inputted through the terminal 101, the switching circuit 193 selects the signal delayed by 2 H in total by the delay lines 177 and 178 to output it. The chrominance signal obtained by inverting the sign of the output signal of the switching circuit 193 by the sign inversion circuit 191 and the output chrominance signal of the switching circuit 193 are inputted in the switching circuit 192. Thus, a chrominance signal having a sign, which is in accordance with the field No. of the output image signal according to FIG. 5, is selected and outputted. In other words, in the case where the conversion is effected from the first field into the second field on the third field, the chrominance signal, whose sign is inverted by the sign inversion circuit 191, is selected. To the contrary, in the case where the conversion is effected from the first field into the fourth field or the first field, the output of the switching circuit 193 is selected without inverting the sign to be outputted.
The chrominance signal processing circuit described above is simplified one and although it has an advantage that the circuit scale is small, the delay times of the luminance signal and the chrominance signal are not completely in accordance. Consequently, if the chrominance signal is not subjected to the signal processing as described above, but the same field converting processing as that effected for the luminance signal is effected therefor and thereafter the control of the presence or absence of the chrominance signal inverting processing is effected so as to satisfy the continuity of the subcarrier of the output image signal, a processing of the chrominance signal producing no difference in the delay amount thereof from the luminance signal at all is made possible.
An adder 195 adds the chrominance signal outputted from the switching circuit 194, which has been subjected to the field conversion, and the chrominance signal, for which the control of the presence or absence of the sign inverting processing is effected so as to satisfy the continuity of the subcarrier outputted from the switching circuit 192, to output the sum of them as a composite signal. As the result, whatever image is inputted in the input terminal 101 as the reproduced image signal, the field conversion is effected by using the intra-field conversion circuit using interline data for an image, in which there are many movements, and the inter-field conversion circuit using data of a plurality of field, from which an output image, where displacements of the transitions of the luminance signal are removed, is outputted, for an image, in which there are few movements, and in this way it is possible to output image data having a target field No. in a good state.
A case where deviations are produced in the correlation between different fields by the fact that skipping or repetition of data is effected in field unit at the variable speed playback, will be explained, referring to FIG. 7. FIG. 7 indicates a state, where one field between (b) and (c) is skipped and (a), (b), (c) and (d) are outputted in this order as luminance signals Y of the Y/C separation circuit in FIG. 4. In FIG. 7, 1901 to 1903, 1911, 1912, 1922 and 1931 to 1933 are pixels having high luminances, while 1904, 1913, 1914, 1923, 1924 and 1934 are pixels having low luminances. In this case, when field conversion data of the data 1923 indicated at (c) in FIG. 7 are formed, the data 1923 and the data 1903 at (c) in FIG. 7 are inputted in the adder 151 in the movement detection circuit 14 indicated in FIG. 4 and further the data 1922 and the data 1902 indicated at (c) in FIG. 7 are inputted in the adder 152 indicated in FIG. 4. The movement detection circuit 14 indicated in FIG. 4 regards the part, where field data have been skipped, at this variable speed playback as a moving picture and the switching circuit 194 selects the intra-field conversion circuit 103 for the field conversion circuit. Consequently, in the case where the variable speed playback image is a moving picture, there are no problems at all, and even for a still picture, since the field conversion circuit using no inter-field data is selected only for the part, where field data have been skipped, no significant worsening in the image quality takes place. This is true also in the case where field data are repeatedly inputted.
The performance of the field conversion device indicated in FIG. 4, which is the embodiment of the present invention described above, depends on the performance of the Y/C separation circuit indicated in FIG. 4.
FIG. 8 shows an example of the Y/C separation circuit, in which 701 is an input terminal for the composite signal; 702 is an output terminal of the separated luminance signal Y;703 is similarly an output terminal for the carrier chrominance signal C; 704 is a band path filter (BPF); 705 is a 1 H delay line, 706 and 707 are subtracters; and 708 an attenuation circuit attenuating the amplitude to 1/2. A composite signal inputted through the input terminal 701 is inputted in the band pass filter 704. An output of the band pass filter 704 and a signal obtained by delaying that signal by 1 H by the delay line 705 are inputted in the subtracter 707 to be subjected there to a subtracting processing. The attenuation circuit 708 decreases the amplitude to 1/2 and thus a C-type comb filter for separating the C signal is formed. On the other hand, the input composite signal from the input terminal 701 and the C signal outputted by the subtracter 707 are inputted in the subtracter 706 to be subjected there to a subtracting processing so that the Y signal is separated.
FIGS. 9A to 9C show an example of the waveform of the reproduced image signal. FIG. 9A indicates the waveform of the composite signal inputted in the Y/C separation circuit indicated in FIG. 8, in which 801 and 802 are colored signals are 803 and 804 are not-colored signals. On the other hand, FIGS. 9A and 9B and 9C show chrominance signals C and luminance signals Y separated by the Y/C separation circuit indicated in FIG. 8. For example, the composite signal 801 is separated into a chrominance signal 811 and a luminance signal 821. In the case where a fixed type Y/C separation circuit as indicated in FIG. 8 is used, at a part, where color disappears in the vertical direction, an erroneous operation in the Y/C separation as a chrominance signal 813 and a luminance signal 823 takes place.
In the movement detection circuit in the field conversion device according to the present embodiment, since it is driven by the luminance signal of the data of the field, which are to be field-converted, and the luminance signal of the data preceding them by 1 frame, leakage of the chrominance signal to the luminance signal as described previously gives rise to erroneous operations in the field converting processing and the movement detection. Therefore, it is necessary to dispose an adaptive Y/C separation circuit, in which the separating processing is adaptively varied, depending on a pattern (image), differently from the Y/C separation circuit indicated in FIG. 8. If a Y/C separation circuit described e.g. in IEEE transactions on Consumer Electronics, Vol. CE-31, No. 3, August 1985, pp. 240-254, "FLICKER-FREE NON INTERLACED RECEIVING SYSTEM FOR STANDARD COLOR TV SIGNALS" is used, no erroneous separation takes place even at the vertical transitions of the chrominance signal as described previously, and consequently no erroneous operation in the movement detection is produced. The Y/C separation circuit described in the literature stated above is constructed by using a line delay line. The Y/C separation circuit constructed by using a line delay line cannot distinguish essentially the chrominance signal from an inclined line of the luminance signal, but it regards all inclined lines as chrominance signals. In order to avoid this, it is necessary to use a three-dimensional comb-shaped filter utilizing a frame memory.
Therefore, it is preferable to use a so-called three-dimensional Y/C separation circuit for the Y/C separation circuit 106 in FIG. 4, which works according to a system, which switches-over the line Y/C separation, the frame Y/C separation, etc., depending on whether the reproduced image is a moving or still picture. In this case, a movement detection circuit for determining, which should be selected, the frame Y/C separation or the line Y/C separation, in necessary. A circuit used for selecting the intra-field conversion circuit and the inter-field conversion circuit in the field conversion circuit can be used in common for this purpose. Further, since the continuity of the field number can become discontinuous by skipping or repetition of some fields at the variable speed playback in a VTR, a circuit, which detects the discontinuity of the field number and varies the processing, depending thereon, i.e. a circuit, which varies the processing in such a manner that, at a usual playback, if the Y/C separation is effected by using the data of the field, which are to be Y/C-separated, and the data preceding them by 2 fields (corresponding to the data preceding them by 1 frame, if skipping processing is taken into account), the data of the field, which are to be Y/C-separated, and the data preceding them by 1 field are used in the case where fields are skipped (e.g., 1.1 times faster playback, etc., (normally 1.0 to 1.2 times)) and the data of the field, which are to be Y/C-separated, and the data preceding them by 3 fields (corresponding to the data preceding them by 1 frame, if the case where data of 1 field are outputted repeatedly twice) are used in the case where fields are repeated (e.g. slow playback).
By using the adaptive Y/C separation circuit for the Y/C separation circuit 106 in FIG. 4, even at a place, where color disappears abruptly in a reproduced image, as indicated in FIG. 9A, it is possible to correctly separate the luminance signal from the chrominance signal and to detect movements correctly. As the result, the field conversion can be effected by selecting a circuit suitable for the reproduced image from the intra-field conversion circuit and the inter-field conversion circuit also in the field conversion circuit. Further, by using the three-dimensional Y/C separation circuit for the Y/C separating circuit 106, no erroneous separation takes place even at a part of an inclined line, and thus it is possible to remove worsening in the image quality by the inclined line.
FIG. 10 shows a modified example of the embodiment indicated in FIG. 4. Contrarily to the fact that the field conversion processing is effected by giving the composite signal to the input terminal 101, in the present embodiment, component signals, e.g. a luminance signal and color difference signals (R-Y) and (B-Y) of the reproduced image signal are inputted in input terminals 101Y, 101R and 101B in field conversion portions 200Y, 200R and 200B, respectively, and a luminance signal and color difference signals, which have been field-converted, are obtained from output terminals 102Y, 102R and 102B, respectively.
The field conversion portions 200Y, 200R and 200B for the luminance signal and the color difference signals have the same construction and the construction of each of the field conversion portions is identical to that of the field conversion device for the luminance signal indicated in FIG. 4. In the present embodiment, not only the luminance signals but also the color difference signals are subjected to the field converting processing and the effects similar to those obtained by the embodiment indicated in FIG. 4 can be obtained.
FIG. 11 shows the construction of the second embodiment of the present invention. In FIG. 11, reference numeral 101 is an input terminal for the reproduced image signal (composite signal); 102 is an output terminal for an image signal, which has been subjected to the field conversion; 100 is a signal output timing converter, which varies the start line of effective data, depending of the field Nos. of the reproduced image signal and the output image signal at the variable speed playback; 8 is an input terminal for the field No. of the reproduced image signal; 111 to 117 are delay lines of one horizontal scanning period (1 H); 121 is a delay line of 260H; 122 and 123 are delay lines of 261 H; 108 and 107 are track jump detection circuits, which examine the presence or absence of the skipping or repetition of the reproduced image signal; 131, 132 and 133 are switches for selecting data used for the inter-field conversion according to an output of the track jump detection circuit 108, e.g. multiplexers (MPX); and 134 is a switch for selecting data used for the movement detection according to an output of the track jump detection circuit 107, e.g. an MPX.
FIG. 12 is a block diagram showing in detail an example of the movement detection circuit 14 in the present embodiment. In this figure, 301 and 302 are input terminals, through which luminance signals obtained by Y/C-separating the reproduced image signal. Data obtained by delaying the output signal of the Y/C separation circuit 106 indicated in FIG. 11 by 1 H are inputted through the terminal 301, while data similarly obtained by delaying it by 526 H or an output of the switch 134 corresponding thereto are inputted to the terminal 302. 303 is an output terminal, through which the magnitude of the movements detected by this movement detections circuit is outputted. 311 and 312 are delay lines corresponding to 1 clock, when the image signal is sampled with a frequency, which is 4 times as high as that of the subcarrier; 313 is a 1 H delay line; 314 is a 262 H delay line; 321 and 322 are coefficient multipliers having a coefficient α; 323 is a coefficient multiplier having a coefficient β; 331, 332 and 333 are switches for outputting the greatest value in a plurality of inputted data sets; 341 is a subtracter; 351 is a low pass filter (hereinbelow abbreviated to LPF), which makes only signals in a frequency region lower than a predetermined frequency; 361 is an absolute circuit, which outputs the absolute value of the inputted data; and 371 is a converter for converting 8 bit data into 4 bit data.
The reproduced composite signal inputted through the reproduced signal input terminal 101 in FIG. 11 is inputted at first in the signal output timing converter 100, for which an example of the construction is indicated in FIG. 13. For example, for a D2-type digital VTR, the start line of effective data for each of the fields is determined, as indicated in FIG. 14, according to a norm. At the usual playback, this signal output timing converter 104 outputs signals according to FIG. 14. At the variable speed playback, this signal output timing converter 100 outputs effective data after having changed the start line thereof so as to satisfy the interlace condition for the output image signal, depending on the relation between the field Nos. of the reproduced image signal and the output image signal. FIG. 15 shows an example of the converting method therefor. For example, in the case where the reproduced signal of field No. 1 is converted into a signal of field No. 2 to be outputted, the start line for the effective data is the 9th line and the data representing originally the 10th line are outputted as the data of 9th line.
In FIG. 13, the signal output timing converter 100 includes a line memory 380 storing several lines of composite signals inputted through a terminal 101 one after another and a writing-in and reading-out timing control circuit 382 controlling the writing of the composite signals to the line memory and the reading-out of the same therefrom. The circuit 382 controls the line memory so as to read-out the start line of the effective data for every field on the basis of FIGS. 14 and 15, reproducing to a signal indicating the usual/variable speed playback inputted through a terminal 384 at the reading-out and the reproduced field No. and the outputted field No. inputted through the terminals 8 and 10.
The data outputted from the signal output timing converter 100 are inputted to the Y/C separation circuit 106 and separated into the luminance signal and the chrominance signal. Thereafter, the luminance signal is delayed by delay lines 111 to 117 and 121 to 123 one after another. The output luminance signal of the Y/C separation circuit 106 and the outputs of the delay lines 111, 112 and 113, i.e. the 1 H delayed data, the 2 H delayed data and the 3 H delayed data of the luminance signal outputted by the Y/C separation circuit 106, are inputted to the intra-field conversion circuit 103. Data necessary for the field, which is to be converted, are formed by means of an interpolation filter device described e.g. in JP-A-2-132984 stated previously, starting from 4 kinds of inputted luminance signal data and the output data are inputted to the switching circuit 194.
The outputs of the delay lines 121 and 122, i.e. the 263 H delayed data and the 526 H delayed data of the luminance signal outputted from the Y/C separation circuit 106, are inputted to the switch 131. In the case where the track jump detection circuit 108 judges that neither skipping nor repetition is effected just before the field including data, which are to be field-converted, this switch selects the output data of the delay line 121 to output them. To the contrary, in the case where the track jump detection circuit 108 judges that skipping or repetition is effected just before the field including data, which are to be field-converted, the switch selects the output data of the delay line 122 to output them.
FIG. 16A shows an example of the track jump detection circuit 108. In FIG. 16A, 601 is a terminal, through which the least significant bit of the field No. of the reproduced image signal inputted through the reproduced image signal field No. input terminal 8 in FIG. 11 is inputted; 602 is a terminal, through which results of detection are outputted; 611 is a delay line of one vertical scanning period (hereinbelow abbreviated to 1 FLD); and 621 is an exclusive OR (EOR) gate. At the usual playback, e.g. for the NTSC system, the field Nos. of the image signal are reptitions of 1, 2, 3 and 4 (or 0, 1, 2 and 3). When these field Nos. are converted into binary codes, the lower bit is a repetition of the low (L) level and the high (H) level. Consequently, in this example, the lower bit of the field No. of the reproduced image signal, which is to be field-converted, inputted through the input terminal 601 is compared with the lower bit of the field No. of the field preceding by 1 field stored in the delay line 611 and it is judged that neither skipping nor repetition of fields has been effected just before the field, which is to be field-converted, if they are different, and that skipping or repetition has been effected, if they are identical. A result thus obtained is outputted through the output terminal 602. The track jump detection circuit 107 is also a similar circuit, as indicated in FIG. 16B, which detects the presence or absence of the skipping or repetition of field data. However, since the movement detection circuit 14 detects movements by using the data of the field, which are to be field-converted, and the data of the field preceding it by 2 fields, the used data should be switched-over not only in the case where the skipping or repetition is effected just before the field including the data, which are to be field-converted, but also in the case where the skipping or repetition is effected just before the field preceding the field including the data, which are to be field-converted, by 1 field. Consequently, in the track jump detection circuit 107, it is necessary to form a logical product of the output of the track jump detection circuit 108 and a signal obtained by delaying the output by one field by means of a delay line 613 in an AND gate 623 to output it through an output terminal 603.
Similar to the switch 131, outputs of the delay lines 114, 122 and 116, i.e. the 264 H delayed data, the 526H delayed data and the 527 H delayed data of the luminance signal outputted from the Y/C separation circuit 106, are inputted to the switch 132. In the case where the track jump detection circuit 108 judges that the skipping or repetition of field data has not been effected just before the field including the data which are to be field-converted, this switch 132 selects the output data of the delay line 114 to output them. The the contrary, in the case where the skipping or repetition of field data has been effected just before the field including the data which are to be field-converted, and in addition the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance before the track jump, but they are in odd or even disaccordance after the track jump, the switch 132 selects the output data of the delay line 122 and in the reverse case it selects the output data of the delay line 116 to output them. Further, outputs of the delay line 115 and 116, i.e. the 265 H delayed data and the 527 H delayed data of the luminance signal outputted from the Y/C separation circuit 106, are inputted to the switch 133. In the case where the track jump detection circuit 108 judges that the skipping or repetition of field data has not been effected just before the field including the data, which are to be field-converted, this switch 133 selects the output data of the delay line 115 to output them. Conversely, in the case where the track jump detection circuit 108 judges that the skipping or repetition of field data just before the field including the data, which are to be field-converted, this switch 133 selects the output data of the delay line 116.
The construction of the inter-field conversion circuit 104 indicated in FIG. 17 is identical to that indicated in FIG. 6. The outputs of the delay lines 111 and 112, i.e. the 1 H delayed data and the 2 H delayed data of the luminance signal outputted from the Y/C separation circuit 106; the output data of the switches 131, 132 and 133 corresponding to the 263 H delayed data, the 264 delayed data and the 265 H delayed data are inputted in input terminals 211, 212, 213, 214 and 215, respectively. Since the data sets inputted in the input terminals 213, 214 and 215 are selected, taking the presence or absence of the skipping or repetition of field data into account by the switches 131, 132 and 133 in FIG. 11, they are the data of the fields, which are in the interlaced relation with the fields including the data inputted through the input terminals 211 and 212. As described previously, for the fields, for which the field Nos. of the reproduced image signal and the output image are in odd or even number disaccordance, the data appears, displayed upward by 0.5 H with respect to the original position thereof. However, if the conversion rule of the effective data start line for each field at the variable speed playback is defined as indicated in FIG. 15, in the process, in which the data sets inputted in the input terminals 211 to 215 in FIG. 6 are subjected to the inter-field converting processing by selecting the data by means of the track jump detection circuit 106 and the switches 131 to 133 in FIG. 11, taking the skipping or repetition of field data into account, the field converting processing can be effected always by a same processing without taking the skipping or repetition of field data into account. A case where the conversion rule at the variable speed playback is so defined that the data are displaced by an amount smaller than 0.5 H for the fields, for which the field Nos. of the reproduced image signal and the output image signal are in odd or even number disaccordance, can be dealt with in a similar way.
In the inter-field conversion circuit 104 indicated in FIG. 17, the luminance signal inputted through the input terminal 211 is inputted in coefficient multipliers 1222 and 1225, the signal inputted through the input terminal 212 is inputted in coefficient multipliers 1224 and 1227; the signal inputted through the input terminal 213 is inputted in a coefficient multiplier 1221; the signal inputted through the input terminal 215 is inputted in a coefficient multiplier 1228. Here the values m and n of the different coefficient multipliers satisfy 2(m+n)=1, as described previously, and it is possible to vary frequency characteristics of the filters in the inter-field conversion circuit by varying m and n. In the present embodiment, it is presumed that m=5/8 and n=-1/8 and it is a matter of course that the frequency characteristics of the filter selected when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, i.e. filter consisting of the coefficient multipliers 1221, 1222, 1223 and 1224 are identical to the frequency characteristics of the filter selected when they are in odd or even number disaccordance, i.e. filter consisting of the multipliers 1225, 1226, 1227 and 1228. Also in the case where the values of the different coefficient multipliers are varied, e.g. putting m=1/2 and n=0, the frequency characteristics of the filter selected when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance are identical to the frequency characteristics of the filter selected when they are in odd or even number disaccordance. Furthermore, in this case, the input terminals 213 and 215, the coefficient multipliers 1221, 1224, 1225 and 1228, etc. are unnecessary, and the adders 231 and 232 can be simpler circuits. Therefore an advantage can be obtained that the circuit scale is smaller. The outputs of the coefficient multipliers 1221, 1222, 1223 and 1224 are inputted in the adder 231 to form the field conversion data, when the field Nos. of the reproduced image signal and the output image data are in odd or even number accordance. On the other hand, the outputs of the coefficient multipliers 1225, 1226, 1227 and 1228 are inputted in the adder 232 to form the field conversion data when the field Nos. of the reproduced image signal and the output image data are in odd or even number disaccordance.
FIG. 2D shows the data after having been subjected to the field conversion by means of the interfield conversion circuit 104 indicated in FIG. 11 described previously. In particular, the fields (a) and (b) are data after the field conversion, in the case where the field Nos. of the reproduced signal and the output signal are in odd or even number accordance. For example, the data 1573 in FIG. 2D are data outputted when the data sets 513, 514, 522 and 523 in FIG. 2B are inputted in the input terminals 214, 213, 212 and 211, respectively, (the data set inputted in the input terminal 215 being not used) and the switch 241 selects the H input. Further the fields (d) and (e) in FIG. 2D represent data after the field conversion, in the case where the field Nos. of the reproduced signal and the output signal are in odd or even number disaccordance. For example, the data 1593 in FIG. 2D are data outputted when the data sets 542, 543, 553 and 554 in FIG. 2B are inputted in the input terminals 215, 214, 212 and 211, respectively, (the data set inputted in the input terminal 213 not being used) and the switch 241 selects the L input. Further, just after field data have been skipped or repeated, e.g. in the case where the data 1584 of the field (d) in FIG. 2D just after the data of the field (c) have been skipped, and where the state, in which the field Nos. of the reproduced image signal and the output image signal is in odd or even number accordance, is changed into the state in which they are in odd or even number disaccordance, the data sets 543 and 544 in FIG. 2B are similarly inputted to the input terminals 212 and 211 in FIG. 17. On the other hand, if it is not taken into account that the field (c) has been skipped, the data sets 522, 523 and 524 of the field (b) are inputted in the input terminals 215, 214 and 213 in FIG. 17. However, since originally the data set of the field (b) are not data of the field necessary for field-converting the data of the field (d), i.e. data of the field, which is in the interlaced relation with the field (d), the outputs of the switches 133, 132 and 131, which have selected the data of the field (a), the field which is in the interlaced relation with the field (d) according to the output of the track jump detection circuit 108 in FIG. 11, are inputted in the input terminals 215, 214 and 213, respectively, in FIG. 17. The output of the adder 232, which has been field-converted by the coefficient multipliers 1225 to 1228 in FIG. 17, is outputted by the output terminal 251 and inputted in the switching circuit 194 in FIG. 11. Immediately after field data have been skipped and in the case where the state where the field Nos. of the reproduced image signal and the output image signal is in odd or even number disaccordance is changed into the state where they are in odd or even number accordance and also in the case where field data are repeated, this inter-field conversion circuit is driven similarly. Both in the case where the field Nos. of the reproduced signal and the output signal are in odd or even number accordance and in the case where they are in odd on even number disaccordance, the data formed by this inter-field conversion circuit have not only identical frequency characteristics but also transitions of the luminance signal at same places, as indicated in FIG. 2D, and therefore it is possible to remove displacements of the vertical transitions due to the field converting processing. The outputs of the adders 231 and 232 are inputted in the switch 241. This switch selects the output of the adder connected with the H input in the case where the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance and the output of the adder connected with the L input in the case where they are in odd or even number disaccordance. The output of this switch is inputted in the switching circuit 194 in FIG. 11.
Further the outputs of the delay lines 122, 123 and 117, i.e. the 526 H delayed data, the 788 H delayed data and the 789 H delayed data of the luminance signal outputted by the Y/C separation circuit 106, are inputted in the switch 134. In the case where the track jump detection circuit 107 judges that neither skipping nor repetition of the field data has been effected immediately before the field including the data, which are to be field-converted, or immediately before the field which immediately precedes data field, this switch 134 selects the output data of the delay line 122 to output them. To the contrary, in the case where the track jump detection circuit 107 judges that either skipping or repetition of the field data has been effected immediately before the field including the data, which are to be field-converted, or immediately before the field which immediately precedes the field including the data, and further in the case where the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance before the track jump and they are in odd or even number disaccordance after the track jump, the switch 134 selects the output data of the delay line 123 and, in the reverse case, the output data of the delay line 117 to output them. The output data of the delay line 111, i.e. the 1 H delayed data of the luminance signal outputted by the Y/C separation circuit 106, which are to be field-converted, and the output data of the switch 134, i.e. the 525 H delayed data of the data, which are to be field-converted, or the data corresponding to the 525 H delay, in the case where the skipping and the repetition of field data are taken into account, are inputted in the input terminals 301 and 302, respectively, which are the input terminals of the movement detection circuit 14. The data inputted through the input terminals 301 and 302 are subjected to a subtracting processing in the subtracter 341. The output of the adder 341 is inputted in the LPF 351 and in the case where the chrominance signal component cannot be separated completely by the Y/C separation circuit 106 in FIG. 11, but it remains in the luminance signal, it is removed therein. The absolute value thereof is formed in the absolute circuit 361 and converted into a 4-bit positive number by the converter 371 to be inputted in the switch 331. The data inputted into this switch 331 represent the magnitude of the image signal data, which are to be field-converted. The greatest data selected by the switch 332 from 3 kinds of data, which are the data obtained by multiplying the data outputted before about 1 FLD by this switch 331 by an arbitrary coefficient by means of the coefficient multiplier 321, the data obtained by delaying the data outputted by the switch 331 by means of the delay line 311, and the data obtained by delaying the data outputted by the switch 331 by means of the delay lines 311 and 312 and multiplying the value thus obtained by an arbitrary coefficient by means of the coefficient multiplier 322 and the data obtained by delaying them by 1 H by means of the delay line 313 are compared by the switch 333 so as to select the greater data. The output thereof is multiplied by an arbitrary coefficient by means of the coefficient multiplier 323 and delayed by 262 H by means of the delay line 314. Of the data thus obtained, the greatest data selected by the switches 332 and 333 from the data sets obtained by multiplying the magnitudes of movements of the data sets stored in the delay lines 311, 312, 313, 314, etc., which are in the environment in the image of the data to be field-converted by the coefficients of the coefficient multipliers 321, 322, 323, etc. to attenuate them in some degree, are inputted in the other input terminal of this switch. The switch 331 further compares these data with the output of the converter 371 to output the greater data thus obtained as the magnitude representing the movements in the data, which are to be field-converted. In this way it is possible to reduce detection omission and to further smooth in time and in space transitions between the still picture processing and the moving picture processing so that the transitions between the different processings are hardly recognized. Data outputted by the switch having a greater numerical value means greater movements in the image in the environment of the data, which are to be field-converted. These data are outputted by the output terminal 303 and inputted in the switching circuit 194 in FIG. 11.
The switching circuit 194 adds the output of the intra-field conversion circuit 103 and the output of the inter-field conversion circuit 104 with a ratio, which is e.g. k:(1-k), according to the output of the movement detection circuit 14, to output it. Here k is a coefficient, which varies at arbitrary steps between 0 and 1, according to the magnitude of the movements detected by the movement detection circuit 14, and k=0 for a perfect still picture and k=1 for a perfect moving picture, taking a numerical value depending on the magnitude of the other movements. That is, as indicated in FIG. 18, the outputs from the conversion circuits 103 and 104, which are given to the input terminals 390 and 392, are given to the coefficient multiplier 394 having a coefficient of k and the coefficient multiplier 396 having a coefficient of (1-k), respectively. The outputs of the multipliers are added by the adder 398 to be outputted through the output terminal 393. The value of k is determined by a signal k depending on the magnitude of the movements given to the terminal 391, coming from the movement detection circuit 14. As described above, since by constituting the switch 135 by a soft switch, it is possible to vary the ratio used for the addition of the two signals described above, depending on the degree of movements, and influences of erroneous operations due to noise, etc. can be reduced. Further, it may be a coefficient taking only two values, which is 0, if the movement detected by the movement detection circuit 14 is smaller than an arbitrary numerical value previously determined, the image being regarded as a still picture, and 1, if the former is greater than the latter, the image being regarded as a moving picture. In this case, the device can be constructed by a simpler circuit than that required for the case where the switching circuit 194 is a soft switch.
Similarly to FIG. 4, the adder 195 adds the luminance signal outputted by the switching circuit 194, which has been subjected to the field conversion, and the chrominance signal outputted by the switching circuit 192, for sign inverting processing so as to satisfy the continuity of the subcarrier, to output them in the form of a composite signal.
FIG. 19 shows a modification of the embodiment indicated in FIG. 11. The field conversion portions 300Y, 300R and 300B process the component signals inputted in the input terminals 101Y, 101R and 101B, respectively, i.e. the luminance signal and the color difference signals (R-Y) and (B-Y) of the reproduced image signal so as to field-convert them and output them to the output terminals 102Y, 102R and 102B. The construction of the field conversion portions 300R and 300B is identical to the construction of the field conversion portion 300Y.
Next the third embodiment of the present invention is indicated in FIG. 20. In the figure, the parts identical to those used in the embodiment indicated in FIG. 11 are represented by identical reference numerals and explanation thereof in detail will be omitted. In addition, 901 and 902 are a first and a second adaptive Y/C separation circuit, in which data corresponding to 3 lines are inputted and which change the processing, depending on the state of the image signal; 903 is an inter-field conversion circuit similar to that used in the first embodiment; 909 is an intra-field conversion circuit similar to that used in the first embodiment; 911 to 918 are 1 H delay lines; 921 is a 261 H delay line; and 922 and 923 are 262 H delay lines.
A reproduced composite signal inputted through the reproduced image signal input terminal 101 and converted by a signal output timing converter 100 in FIG. 20 is inputted in the Y/C separation circuit 901 together with a signal delayed by 1 H by means of a delay line 911 and a signal delayed further by 1 H by means of a delay line 912 to be separated there into a luminance signal Y and a chrominance signal C. Y/C separation circuits 901 and 902 are adaptive Y/C separation circuits, which change the processing, depending on the inputted image signal. For example, if it is supposed that, in FIG. 9A, all the signals above the composite signal 802 are colored signal and all the signals under the signal 803 are not-colored signals, when a signal above the composite signal 801 or a signal under the composite signal 804 is Y/C-separated, a comb-shaped filter using 3 lines, which are signals to be separated, a signal higher than it by 1 and a signal lower by 1 than it, is selected. On the other hand, when the Y/C composite signal 803 is Y/C-separated, a comb-shaped filter using 2 lines which are signals to be separated. When the signal higher than it by 1 is selected. When the composite signal 803 is Y/C separated, a comb-shaped filter using 2 lines, which are signals to be separated, a signal lower than it by 1 is selected to effect the Y/C separating processing. Thus this is an adaptive Y/C separation circuit, by which no erroneous separations take place. The luminance signal Y and the chrominance signal C separated by the Y/C separation circuit are inputted in the intra-field conversion circuit 903 together with the luminance signal and the chrominance signal, which are delayed by 1 H by means of the delay circuits 915 and 916, respectively.
FIG. 21 is a block diagram showing an example of the intra-field conversion circuit 903 used in this embodiment in detail, in which 1001 and 1003 are input terminals for the luminance signal Y and the chrominance signal C separated by the Y/C separation circuit 901; 1002 and 1004 are input terminals for signals obtained by delaying by 1 H the luminance signal Y and the chrominance signal C separated by the Y/C separation circuit 901 by means of the delay lines 916 and 915, respectively; 1011, 1014, 1015 and 1018 are coefficient multipliers having a coefficient r, 1012, 1013, 1016 and 1017 are coefficient multipliers having a coefficients;, 1021 to 1025 are adders; 1031 and 1032 are switches, which select the H input side, when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and the L input side, when they are in odd or even number disaccordance; 1041 is a phase inversion circuit, which inverts the phase of the chrominance signal; 1033 is a switch for selecting the chrominance signal, which has been subjected to the phase inverting processing, and the chrominance signal, which has not been subjected to the phase inverting processing; and 1005 is an output terminal for the image signal. The luminance signal Y and the chrominance signal C separated by the Y/C separation circuit 901 are inputted in the input terminals 1001 and 1003, respectively. The luminance signal and the chrominance signal obtained by delaying the luminance signal Y and the chrominance signal C separated by the Y/C separation circuit 901 by the delay lines 916 and 915 are inputted in the input terminals 1002 and 1004, respectively. The signal inputted through the input terminal 1002 is inputted in the coefficient multipliers 1012 and 1014. The outputs of the coefficient multipliers 1011 and 1012 are added in the adder 1021, while the outputs of the coefficient multipliers 1013 and 1014 are added in the adder 1022. The outputs of the adders 1021 and 1022 are inputted in the switch 1031, which selects the output of the adder 1021 on the H side, when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance and the output of the adder 1022 on the L side, when they are in odd or even number disaccordance. Here the values r and s of the different coefficient multipliers satisfy a relationship r+s=1 and in this embodiment r=3/4 and s=1/4. In this way, since the frequency characteristics of the filter consisting of the coefficient multipliers 1011 and 1012 are identical to the frequency characteristics of the filter consisting of the coefficient multipliers 1013 and 1014, even if the switch 1031 is switched-over in field unit, no flickers accompanied by variations in the vertical resolution are produced.
On the other hand, concerning the chrominance signal, the chrominance signals inputted through the input terminals 1003 and 1004 are subjected to a completely same processing as the chrominance signal up to the output of the switch 1032. That is, the switch 1032 selects the output of the filter on the H side consisting of the adder 1023, the coefficient multipliers 1015 and 1016, when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and the output of the filter on the L side consisting of the adder 1024, the coefficient multipliers 1017 and 1018, when they are in odd or even number disaccordance, to output it. The output of the switch is inputted in the switch 1033 together with the signal, which has been subjected to the phase inverting processing by means of the phase invention circuit 1041 and the chrominance signal, for which the presence or absence of the phase inverting processing is controlled so that the continuity of the subcarrier is satisfied, is outputted by the switch 1033. The luminance signal outputted by the switch 1031, which has been subjected to the field converting processing, and the chrominance signal outputted by the switch 1033, which has been subjected to the field converting processing and for which the presence or absence of the phase inverting processing is controlled, are added in the adder 1025 and outputted through the output terminal 1005 to be inputted in the switching circuit 194 in FIG. 20.
Further, 3 kinds of signals including a signal obtained by delaying the signal inputted through the composite signal input terminal 101 and converted by the converter 109 by means of the delay lines 911, 912 and 921, a signal obtained by delaying further the signal thus obtained by means of the delay line 922 and a signal obtained by delaying further the signal thus obtained by means of the delay line 913, that is the 263 H delayed signal, the 525 H delayed signal and the 526 H delayed signal of the composite signal inputted through the input terminal 101 are inputted in the switch 132. In the case where the track jump detection circuit 108 judges that no skipping or repetition of field data has been effected just before the field including the data, which are to be field-converted, this switch 132 selects the output signal of the delay line 921. To the contrary, in the case where skipping or repetition of field data has been effected just before the field including the data, which are to be field-converted, it selects the output signal of the delay line 922, when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance before the track jump and they are in odd or even number disaccordance after the track jump, and the output signal of the delay line 913 in the reverse case to output it. The composite signal outputted by the switch 132 is inputted in the adaptive Y/C separation circuit 902 together with the signal obtained by delaying it by 1 H by means of the delay line 917 and the signal obtained by delaying it further by 1 H by means of the delay line 918 to be separated into the luminance signal Y and the chrominance signal C. The luminance signal Y and the chrominance signal C outputted by the adaptive Y/C separation circuit 902 are inputted in the inter-field conversion circuit 904 together with the luminance signal Y and the chrominance signal C outputted by the adaptive Y/C separation circuit 901 and the data obtained by delaying the luminance signal Y and the chrominance signal C outputted by the adaptive Y/C separation circuit by 1 H by means of the delay lines 916 and 915.
FIG. 22 is a block diagram of the inter-field conversion circuit 904 used in the present embodiment, in which 1101 to 1103 are input terminals for the luminance signal Y; 1104 to 1106 are input terminals for the chrominance signal C; 1107 is an output terminal for the image signal after having been subjected to the inter-field converting processing; 1111 to 1116 are coefficient multipliers having a coefficient m; 1121 to 1125 are adders; 1131 and 1132 are switches, which select the H side when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and select the L side when they are in odd on even number disaccordance. 1141 is a phase inversion circuit, which inverts the phase of the chrominance signal and 1133 is a switch, which selects the chrominance signal C, which has been subjected to the phase, inverting processing, and the chrominance signal Y, which has not been subjected to the phase inverting processing. The luminance signal Y outputted by the Y/C separation circuit 901, a signal obtained by delaying that signal by 1 H by means of the delay line 916, and the luminance signal Y outputted by the Y/C separation circuit 902 are inputted in the input terminals 1101 to 1103, respectively. The inputted different luminance signals are inputted in the coefficient multipliers 1111, 1113 and 1112, respectively. The outputs of the coefficient multipliers 1111 and 1112 are inputted in the adder 1121, while the outputs of the coefficient multipliers 1112 and 1113 are inputted in the adder 1122 to be subjected to an adding processing. Thereafter the output signals of the adders 1121 and 1122 are inputted in the switch 1131. The switch 1131 selects the output of the adder 1121 on the H side when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and selects the output of the adder 1122 on the L side when they are in odd or even number disaccordance. Here also, of course, the frequency characteristics of the filter consisting of the coefficient multipliers 1111 and 1112 are identical to the frequency characteristics of the filter consisting of the coefficient multipliers 1112 and 1113. Therefore, even if the switch 1131 is switched-over in field unit, no flickers accompanied by variations in the vertical resolution are produced.
On the other hand, the chrominance signal C outputted by the Y/C separation circuit 901, a signal obtained by delaying that signal by 1 H by means of the delay line 915, and the chrominance signal C outputted by the Y/C separation circuit 902 are inputted in the input terminals 1104 to 1106, respectively, and subjected to virtually the same processing as the luminance signal up to the output of the switch 1132. That is, the switch 1132 selects the output of the filter on the H side consisting of the adder 1123 and the coefficient multipliers 1114 and 1115 when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance, and selects the output of the filter on the L side consisting of the adder 1124 and the coefficient multipliers 1115 and 1116 when they are in odd or even number disaccordance, to output it. The output of the switch 1132 is inputted in the switch 1133 together with a signal, which has been subjected to the sign inverting processing by the sign inversion circuit 1141 and the chrominance signal, for which the presence or absence of the phase inverting processing is controlled so that the continuity of the subcarrier is satisfied, is outputted by the switch 1133. The luminance signal outputted by the switch 1131, which has been subjected to the field converting processing, and the chrominance signal outputted by the switch 1133, which has been subjected to the field converting processing and for which the presence or absence of the phase inverting processing is controlled, are added in the adder 1125 and outputted through the output terminal 1107 to be inputted in the switching circuit 194 in FIG. 20. The input terminals 1103 and 1106 correspond to the inter-field conversion circuit described in the second embodiment and the input terminal 214 in FIG. 17. Further, by putting the coefficients m=1/2 and n=0 and removing the coefficient multipliers 221, 224, 225 and 228 as well as the input terminals 213 and 215, the inter-field conversion circuit is used for processing each of the luminance signal and the chrominance signal, and in addition, the presence or absence of the phase inverting processing is controlled in the processing of the chrominance signal.
Further, 3 kinds of signals, i.e. the output signal of the delay line 913, a signal obtained by delaying that signal further by means of the delay line 923 and a signal obtained by delaying that delayed signal further by means of the delay line 914, i.e. the 526 H delayed signal, the 788 H delayed signal and the 789 H delayed signal of the reproduced image signal inputted through the composite signal input terminal 101, are inputted in the switch 134.
The switch 134 selects the output of the delay line 913, in the case where the track jump detection circuit 107 judges that neither skipping nor repetition of field data has been effected just before the field including data, which are to be field-converted, or just before the field preceding that field by 1. On the contrary, in the case where the track jump detection circuit 107 judges that skipping or repetition of field data has been effected just before the field, which is to be field-converted, or just before the field preceding that field by 1 field, it selects the output of the delay line 923, when the field Nos. of the reproduced image signal and the output image signal are in odd or even number accordance before the track jump and they are in odd or even number disaccordance after the track jump, and the output of the delay line 914 in the reverse case. The output signal of the switch 134 is inputted in the movement detection circuit 14 together with the output signal of the delay line 911. The output signal from the switch 134 is a signal delayed by 525 H from the output of the delay line 911, i.e. the signal, which is to be field-converted, or a signal corresponding to the 525 H delayed signal, taking the skipping or the repetition into account. The output signal of the delay line 911 and the output signal of the switch 134 are inputted in the movement detection circuit 14 and the movement detection is effected by using a circuit similar to that used in the second embodiment. However, in the present embodiment, the signals inputted in the movement detection circuit 14, i.e. the output signal of the delay line 911 and the output signal of the switch 134, are composite signals and the movement detection is effected by using the signals preceding and succeeding that signal by 2 fields or signals corresponding thereto. That is, since it is effected by using only luminance signals of the reproduced image signal, an LPF for eliminating the chrominance signal is necessary just after the input terminal of the movement detection circuit 14. This LPF is unnecessary, if this movement detection circuit is driven by using signals preceding and succeeding that field by 4 fields or signals corresponding thereto.
The switching circuit 194, in which the outputs of the intra-field conversion circuit 903 and the inter-field conversion circuit 904 are inputted, selects one of them according to the output of the movement detection circuit 14. Or it adds the outputs of the intra-field conversion circuit 903 and the interfield conversion circuit 904 with an arbitrary ratio according to the output of the movement detection circuit 14 to output the sum of them. That is, the switching circuit 194 may be constructed in the same way as the switching circuit 194 described in the second embodiment and the output of the switching circuit 194 is outputted through the output terminal 102 as the field conversion data.
In the present embodiment, too, the performance of the field conversion device depends on the separation characteristics of the Y/C separation circuits 901 and 902 similar to the second embodiment and it is possible to realize a field converting processing without worsening the resolution in the diagonal direction by using three-dimensional separation circuits provided with movement detection circuits similar to the movement detection circuit 105 indicated in FIG. 20 for these Y/C separation circuits and selecting the line Y/C separation in the case where there are movements between different fields and the frame Y/C separation in the case where there are no movements between different fields, to use it.
By using the circuit construction as described in the present third embodiment, an advantage can be obtained that displacements in the vertical direction are removed not only for the luminance signal but also for the chrominance signal and the number of uses of memories can be reduced.
Further the intra-field conversion circuit 903 and the inter-field conversion circuit 904 in FIG. 20, described in the third embodiment, can be applied also to the embodiment indicated in FIG. 11. Also in this case the number of uses of memories can be reduced.
Furthermore, the intra-field conversion circuit 103 and the inter-field conversion circuit 104 in FIG. 11, described in the second embodiment, can be applied also to the circuit for the embodiment indicated in FIG. 20. In this case it is possible to prevent the lowering in the resolution in the vertical direction.
FIG. 23 shows a modified example of the embodiment indicated in FIG. 11. The field conversion portions 400Y, 400R and 400B field-conversion-process component signals, i.e. the luminance signal, the color difference signals (R-Y) and (B-Y) of the reproduced image signal, inputted through the input terminals 101Y, 101R and 101B, respectively, and outputs them to the output terminals 102Y, 102R and 102B. The construction of the field conversion portions 400R and 400B is identical to the construction of the field conversion portion 400Y. By this modification it is possible to obtain effects similar to those obtained by the embodiment indicated in FIG. 20.
FIG. 24 is a block diagram showing the fourth embodiment of the present invention and FIG. 25 is a scheme for explaining the operation thereof, in which the position of scanning lines for signals in different portions are indicated and the time axis is set in the horizontal direction, i.e. now fields appear one after another in this direction. Marks A, B, C, . . . in FIG. 25 indicate the position of scanning lines and suffixes represent the field number. In the case where it is necessary to indicate the kind of signals, in particular the composite image signal, the luminance signal, the carrier chrominance signal, etc. for each position of signal, A1, B2, . . . , etc., marks V, Y, C, etc. are added after each of the marks. Further arrows indicate the phase of the color subcarrier in the case of the NTSC signal.
In FIG. 24, 101 is an input terminal for the composite reproduced image signal; 102 is an output terminal for the composite image signal after the field conversion; 8 is an input terminal for a signal indicating the field number of the reproduced image signal; 10 is an input terminal for a signal indicating the field number of the output image signal after the signal processing; 105 is an input terminal for a mode signal indicating the reverse playback; 2010 and 2011 are line C-type comb filter outputting the carrier chrominance signal; 2020 is a tapped delay circuit for delaying signals in field unit; 2030 to 2032 are subtracting and averaging circuits, each of which reduces the signal level to a half after subtraction; 2033 and 2034 are subtracters; 2040 and 2041 are soft switch circuits; 2050 and 2051 are line delay circuits; 2060 is a C adaptive line conversion circuit line-converting the carrier chrominance signal; 2070 is a Y adaptive line conversion circuit line-converting the luminance signal; 2080 is an adding circuit; and 2100 is a signal control circuit for controlling the delay time of the tapped delay circuit 2020, signal processing of the C adaptive control circuit 2060 and the Y adaptive control circuit 2070, etc. Here the line C-type comb filter 2010, the subtracting and averaging circuit 2030; the subtraction circuit 2033; the soft switching circuit 2040; and the movement detection circuit 14 constitute a first motion adaptive Y/C separation circuit, which separates the composite signal of the field at that time into the luminance signal and the chrominance signal. On the other hand, the line C-type comb filter 2011, the subtracting and averaging circuit 2031, the subtraction circuit 2034; the soft switch circuit 2041; and the movement detection circuit 14 are means for separating the signal of the field, which is in the interlaced relation with the signal of the field at that time, into the luminance signal and the chrominance signal and constitute a motion adaptive Y/C separation circuit.
The composite image signal A1V inputted through the terminal 101 is inputted in the line C-type comb filter 2010 and the carrier chrominance signal is separated to be outputted. Here, as an example, it is a so-called three lines adaptive C-type comb filter, which uses three lines contiguous to each other to separate and process them adaptively, depending on the pattern. The composite image signal inputted at that time through the terminal 101 is denoted in FIG. 25 by A1V. The carrier chrominance signal C1C separated by the line C-type comb filter 2010 is at a position delayed by one line with respect to the composite image signal A1V. The carrier chrominance signal C1C thus separated is inputted in the soft switch circuit 2040. Further a composite image signal C1V having a same delay time as the separated carrier chrominance signal C1C, which is at a position indicated by C1 in FIG. 25, is outputted by the filter 2010. The composite image signal C1V is inputted in the tapped delay line 2020 and the subtracting and averaging circuit 2030.
A composite image signal B2V, which is delayed by 1 field with respect to the inputted composite image signal C1V so as to be at a position indicated by B2 in FIG. 25, is outputted from the first tap of the tapped delay line 2020. The composite image signal B2V outputted from the first tap is inputted in the line C-type comb filter 2011 and a carrier chrominance signal D2C corresponding to a position indicated by D2 in FIG. 25 is outputted in the same way as indicated above. Then it is inputted in the soft switch circuit 2041. Further a composite image signal D2V having a same delay time as the separated carrier chrominance signal D2C, so as to be at the position D2 in FIG. 25, is outputted to be inputted in the subtracting and averaging circuit 2031 and the subtracting circuit 2034.
A composite image signal C3V, which is delayed by 2 fields with respect to the signal C1V inputted in the tapped delay line 2020 so as to be at a position C3 in FIG. 25, is outputted from the second tap of the tapped delay line 2020. The composite image signal C3V is inputted in the subtracting and averaging circuit 2030 to be subtracted from the composite image signal C1V and averaged. In this way a frame C-type comb filter is constructed. The carrier chrominance signal outputted from the subtracting and averaging circuit 2030 is inputted in the soft switch circuit 2040.
The soft switch circuit 2040 has a construction identical to that indicated in FIG. 18, in which the carrier chrominance signal C1C separated by the line C-type comb filter 2010 and the carrier chrominance signal separated by the frame C-type comb filter composed of the tapped delay line 2020 and the subtracting and averaging circuit 2030 are inputted. When there is no movement in the picture, the output signal of the frame C-type comb filter is selected, and in the case where movements are significant, the output signal of the line C-type comb filter is selected. The selection of this signal is controlled by a control signal k outputted by the movement detection circuit 14. That is, the two signals are mixed with a mixing ratio determined by an amount of this movement k to be outputted. Demoting the value of the output signal LC of the line C-type comb filter by LC, the value of the output signal of the frame C-type comb filter by FC and the coefficient indicating the magnitude of the amount of movements by k, the output signal SC of the soft switch circuit 2040 is given by a following formula;
SC=k·LC+(1-k)·FC
An output signal ClSC of the soft switch circuit 2040 at a position C1 is inputted in the C adaptive line conversion circuit 2060; the line delay circuit 2050 and the subtracting circuit 2033. A one-horizontal scanning period signal is delayed by the line delay circuit 2050 and a signal E1SC at a position of E1 in FIG. 25 is inputted in the C adaptive line conversion circuit 2060.
A composite image signal D4V, which is delayed by 3 fields with respect to the composite image signal C1V inputted in a tapped delay circuit 2020 so as to correspond to a position D4 in FIG. 25, is outputted from the third tap of the tapped delay circuit 2020 to be inputted in the subtractive and average circuit 2031. This composite image signal D4V is subtracted from the composite image signal D2V inputted in the subtractive and average circuit 2031 and averaged. In this way a frame C-type comb filter is constructed.
The output signal of the subtracting and averaging circuit 2031 is inputted in the soft switch circuit 2041. The soft switch circuit 2041 is operated in the same way as the soft switch circuit 2040 and the control signal from the movement detection circuit 14 is inputted therein. In this way the output signal D2C of the line C-type comb filter 2011 and the output signal of the frame C-type comb filter are mixed and added, depending on the amount of movements, to be outputted. The output signal D2SC corresponding to the position D2 of the soft switch circuit 2041 is inputted in the C adaptive line conversion circuit 2060 and the subtracting circuit 2034.
On the other hand, the composite image signal C1V inputted in the tapped delay circuit 2020 is inputted in the subtracting circuit 2033. The carrier chrominance signal C1SC outputted by the soft switch circuit 2040 is also inputted in the subtracting circuit 2033 to be subtracted from the composite image signal C1V. The luminance signal C1Y corresponding to the position C1 in FIG. 25 is outputted from the subtracting circuit 2033 and inputted in the line delay circuit 2051 and the Y adaptive line conversion circuit 2070. The one horizontal scanning period luminance signal C1Y is delayed by the line delay circuit 2051, which outputs the luminance signal E1Y corresponding to the position E1 in FIG. 25. Further the composite image signal D2V and the carrier chrominance signal D2SC corresponding to the position D2 in FIG. 25 are inputted in the subtracting circuit 2334, which outputs the luminance signal D2Y, which is inputted in the Y adaptive line conversion circuit 2070.
This means that the luminance signals corresponding to the positions C1, D2 and E1 indicated in FIG. 25 are inputted in the Y adaptive line conversion circuit 2070. The control signal from the movement detection circuit 14 is inputted in the Y adaptive line conversion circuit 2070. The field conversion is effected by using inter-field signals when there are no movements, and inter-line signals when there are movements. In the case where the field conversion is effected from an odd number field to an even number field or in the reverse direction, the scanning line conversion is effected so as to have a signal between the positions C1 and D2 in FIG. 25. Denoting the value of that signal in the case where there are no movements, a following equation is valid;
Y3S=m·D2Y+(1-m)·E1Y,
where D2Y and E1Y represent values of the amplitude of the luminance signals at the positions D2 and El, respectively (this being valid for the other marks), and m is a coefficient determining characteristics of the scanning line conversion filter and taken values from 0 to 1. Denoting the value of that signal in the case where there are significant movements by Y3M,
Y3M=(C1Y+3·E1Y)/4
is obtained/ 10 Denoting the coefficient indicating the magnitude of the amount of movements by k and supposing that the value of the signal is Y3,
Y3=k⃡Y3M+(1-k)·Y3S
is obtained.
In the case where the conversion is effected from an odd number field to an odd number field on from an even number field to an even number field, the scanning line conversion is effected so as to have a signal between the positions C1 and D2 in FIG. 25. Denoting the values of that signal in the case where there are no movements by Y1S,
Y1S=m·C1Y+(1-m)·D2Y
is valid. Denoting the values of that signal in the case where there are significant movements
Y1M=(3·C1Y+E1Y)/4
is obtained. Denoting the coefficient indicating the magnitude of the amount of movements by k and supposing that the value of the signal is Y1,
Y1=k·Y1M+(1-k)·Y1S
is obtained.
This means that the carrier chrominance signal corresponding to the positions C1, D2 and E1 indicated in FIG. 25 are inputted in the C adaptive line conversion circuit 2060. The control signal from the movement detection circuit 14 is inputted in the C adaptive line conversion circuit 2060. The field conversion is effected by using inter-field signals for a still picture, where there are no movements, and inter-line signals for a moving picture, where there are movements. The C adaptive line conversion circuit 2060 is operated in the same way as the Y adaptive line conversion circuit 2070. In the case of the NTSC signal, since the frequency of the color subcarrier is a half of an odd number times as high as the frequency of the horizontal scanning, the phase of the color subcarrier is inverted at the position C1 as well as the positions D2 and E1. Consequently the conversion can be effected by the same processing as the Y adaptive line conversion circuit 2070 by inverting the phase of the signal at the positions D2 and E1 with respect to the signal at the position C1.
A phase inversion circuit and a control circuit therefor are necessary further after the scanning line conversion in the C adaptive line conversion circuit 2060. In the case of the NTSC signal, since the frequency of the color subcarrier is selected so as to be a half of an odd number times as high as the frequency of the horizontal scanning, as described above, the phase of the carrier chrominance signal is inverted between lines in a part, where the hue is not varied. Based on this relation, the control is effected to invert the phase of the carrier chrominance signal or to interrupt the inversion so that the phase thereof is in accordance with the phase of the color subcarrier of the converted field.
These controls are effected on the basis of the control signal from the signal control circuit 2100. The field No. of the reproduced image signal inputted through the terminal 8 is compared with the field No. of the output image signal inputted through the terminal 10 and the conversion control is effected on the basis of this relation. FIG. 26 shows a table, in which this control is summarized.
In FIG. 26, 1/4 represents a scanning line conversion to a same scanning line and 3/4 indicates a scanning line conversion to a different scanning line.
The luminance signal and the carrier chrominance signal converted as described above are inputted in the adding circuit 2080 to be added there to form a field-converted composite image signal, which is outputted through the terminal 102.
Further the output of the subtracting and averaging circuit 2030 is inputted in the movement detection circuit 14. For a signal, where there are no movements, contrarily to the fact that the phase of the carrier chrominance signal is inverted between frames, the amplitude of the luminance signal is not varied. Therefore the luminance signal is removed by subtraction so that only the carrier chrominance signal is outputted. Consequently, by removing carrier chrominance signal components from the output of the frame C-type comb filter, it is possible to detect movements in the luminance signal. Concretely speaking, it is possible to obtain movement signals in the luminance signal by making the output of the frame comb filter pass through a low pass filter.
Further the composite image signal C1V is inputted in the subtracting and averaging circuit 2032. Another composite image signal C5V delayed by 4 fields with respect to the composite image signal C1V and corresponding to the position C5 in FIG. 25 is outputted from the fourth tap of the tapped delay circuit 2020 and inputted in the subtracting and averaging circuit 2032. A difference signal between the composite image signals C1V and C5V inputted in the subtracting and averaging circuit 2032 is outputted therefrom and inputted in the movement detection circuit 14. For a signal, in which there are no movements, since carrier chrominance signals are in accordance in the phase between different two frames and luminance signals are in accordance with each other in the amplitude, it is possible to detect the movements by forming the difference.
According to the present embodiment, since the field converting processing is effected by using inter-field signals for a part of a still picture, there are no variations of the center of gravity both in the case of a conversion from an odd number field to an even number field or a conversion of reverse direction and in the case of a conversion from an odd number field to an odd number field or from an even number field to an even number field, the field converting processing can be visually stabilized.
On the other hand, since contrary to the fact that the level of signal remains unchanged for different frames in a luminance signal, where there are no movements, the phase of a carrier chrominance signal, where there are no movements is inverted between different frames, it is possible to separate the carrier chrominance signal from a composite signal by forming the average of signal differences between different frames. In this way, it is not necessary to restrict the band, which should have comb-shaped filter characteristics. Therefore it is possible to separate the luminance signal and the carrier chrominance signal without worsening in the resolution in the diagonal direction as produced by a line Y/C separation comb-shaped filter.
Furthermore, by using a frame comb-shaped filter, since it is not necessary to restrict the band having comb-shaped characteristics, it is possible to separate surely the luminance signal and the carrier chrominance signal even at a horizontal transient part of the chrominance signal. In addition, since no carrier chrominance signal components remain in the luminance signal, it is possible to eliminate color flicker.
Next, the signal processing in the case where one field is skipped for several fields in order to shorten the playback time will be explained. FIG. 27 is a scheme indicating the position of signals for explaining the operation in this case.
In FIG. 27, it is supposed that the number of the field, which is reproduced at present, is designated by 1, that the playback is effected by skipping field 2, and that at least fields 3, 4 and 5 preceding them are reproduced successively. In this case, since the playback is effected, skipping field 2, the Y/C separating processing by means of a frame comb-shaped filter using field 2 and field 4. In this case, the inteline Y/C separating processing using only field 4 is not possible. Further, similarly, it is not possible also to detect movements by using field 2 and field 4. In this case, the signal processing is effected, supposing that there are no movements between field 2 and field 4. Or the processing is effected, using a signal obtained by multiplying a movement signal of the preceding field by a coefficient for a signal representing movements in this field.
Concretely speaking, the signal processing is effected as described below. A composite image signal B4V at a position B4 in FIG. 27 delayed by 2 fields (since the playback is effected by skipping originally field 2, this corresponds to a delay of substantially 3 fields) with respect to the inputted image signal C1V, which are in the interlaced relation with each other, is outputted from the first tap of the tapped delay line 2020 in FIG. 24. Similarly to the case indicated in FIG. 25, a composite image signal C3V at a position C3, a composite image signal D4V at a position D4 and a composite image signal C5V at a position C5 are outputted from the second, the third and the fourth tap, respectively. In this way a carrier chrominance signal D4C at the position D4 is outputted from the line C-type comb filter 2011. The continuity of the reproduced field number inputted through the terminal 8 is examined in the signal control circuit 2100 and for the field immediately after the field jump the movement detection circuit 14 controls the soft switch circuit 2041 so as to be forcedly turned-over to the movement mode. Further, since the signal D4V is inputted in the two input terminals of the subtracting and averaging circuit 2031 constituting the frame comb-shaped filter, the processing is effected, supposing that there are movements. Since the control signal from the signal control circuit 2100 is inputted in the movement detection circuit 14, the control may be effected so that the signal from the subtracting and averaging circuit 2032 is forcibly set at 0. In this case the output signal from the third tap of the tapped delay line 2020 is indifferent.
FIG. 28 is a scheme indicating the signal processing for the case succeeding the field indicated in FIG. 27 by 1 field. This means that the playback is effected, skipping the signal preceding the field at that time by two fields. In this case, since there is no signal of field 3, the signal processing effected by using signals of field 1 and field 3 is not possible. The Y/C separating processing is effected between different times by using only the signal of field 1. The movement detection is effected by using field 1 and field 5. The signal processing is effected, supposing that there are no movements between field 1 and field 3.
Concretely speaking, the signal processing is effected, as described below. Similar to the case indicated in FIG. 25, signals B2V, D4V and C5V are outputted from the first, the third and the fourth tap of the tapped delay line 2020 in FIG. 24, respectively, responding to the inputted image signal C1V. The movement detection circuit 14 controls the soft switch circuit 2040 so as to be turned-over forcedly to the movement mode, on the basis of the control signal from. the signal control circuit 2100. The output signal of the subtractive and average circuit 2030 is controlled by the movement detection circuit 14 so as to be forcibly set at 0.
FIG. 29 is a scheme indicating the signal processing for the case succeeding the field indicated in FIG. 28 further by 1 field. This means that the playback is effected, skipping the signal preceding the field at that time by three fields. In this case, since there is no signal of field 4, the signal processing effected by using signals of field 2 and field 4 is not possible. The Y/C separating processing is effected between different lines by using only the signal of field 2.
Concretely speaking, the signal processing is effected, as described below. Similar to the case indicated in FIG. 25, signals B2V, C3V and C5V are outputted from the first, the second and the fourth tap of the tapped delay line 2020 in FIG. 24, respectively, responding to the inputted image signal C1V. The movement detection circuit 14 controls the soft switch circuit 2041 so as to be turned-over forcedly to the movement mode, on the basis of the control signal from the signal control circuit 2100. The output signal of the subtracting and averaging circuit 2031 is controlled by the movement detection circuit 14 so as to be set forcedly at 0.
FIG. 30 is a scheme indicating the signal processing for the case succeeding the field indicated in FIG. 29 further by 1 field. This means that the playback is effected, skipping the signal preceding the field at that time by four fields. In this case, since there is no signal of field 5, the signal processing effected by using signals of field 1 and field 5 is not possible. The signal processing is effected, supposing that there are no movements between two frames.
Concretely speaking, the signal processing is effected, as described below. Similarly to the case indicated in FIG. 25, signals B2V, C3V and D4V are outputted from the first, the second and the third tap of the tapped delay line 2020 in FIG. 24, respectively, responding to the inputted image signal C1V. The movement detection circuit 14 controls the output signal of the subtracting and averaging circuit 2032 so as to be set forcedly at 0, on the basis of the control signal from the signal control circuit 2100.
If succeeding fields are successively reproduced, the playback returns to the normal state indicated in FIG. 25. In the case where the immediately succeeding field is skipped, the state indicated in FIG. 27 takes place and the signal processing described above is repeated. If the skipping (jumping) of fields is less frequent than once for every 5 fields, the signal processing described above can be effected.
FIG. 31 is a table, in which the signal processing described above is summarized.
FIG. 32 is a table indicating the output signals from the different taps of the tapped delay line.
Next the signal processing for the slow playback, in which same fields are repeated, will be explained. FIG. 33 is a scheme for explaining this signal processing, in which one field is repeatedly reproduced.
In FIG. 33, signals A1 and A1', C1 and C1', and E1 and E1' are signals belonging to different same lines in a same field, respectively. In this case, signals B2V, C3V, D4V and C5V are outputted from the first, the second, the third and the fourth tap of the tapped delay line 2020 indicated in FIG. 24, respectively. At this time, the signal A1', etc. of the field, which is being reproduced at that time, are not written in the tapped delay line 2020 and the signals, which have been already written-in (signals of fields 1 to 5), are maintained, as they are.
After one field, in the case where the signal of a same field is reproduced again, the signal processing is effected in the same way as explained, referring to FIG. 33. As far as the same field is repeated, the same signal processing is effected. That is, also in the case of the signal processing of a freeze mode, the same signal processing can be effected.
When the succeeding field is reproduced, similarly to the case indicated in FIG. 25, the usual signal processing is effected. That is, a slow playback is realized. In particular, in the case of a slow playback, since signals of a new field are produced by using signals of two fields, which are in the interlaced relation with each other, not only there are no displacements of the center of gravity of images, but also there is no worsening in the vertical resolution. For example, any inclined line is never stepwise, which improves remarkably the image quality.
Now the case of the reverse playback will be explained. In the case of the reverse playback the phase of the color subcarrier in the carrier chrominance signal is different from that for the usual playback. In FIG. 24, the phase of the color subcarrier in the signal D2SC outputted by the soft switch 2041 is inverted. In FIG. 24, a mode signal is taken-in through the terminal 105 from a system controller, etc. and at the reverse playback the signal processing is effected by inverting the phase of the signal D2SC. The signal processing other than the phase inversion of the signal D2SC is identical to that used for the usual playback.
FIG. 34 is a block diagram showing an example of the tapped delay circuit 2020. In FIG. 34, parts identical to those indicated in FIG. 24 are denoted by same reference numerals and explanation thereof will be omitted. 2110 is an image signal input terminal of the tapped delay circuit 2020; 2111 to 2114 are output terminals from the first to the fourth tap; 2120 to 2124 are field memories; 2131 to 2134 are switching circuits; 2140 to 2144 are input terminals for write control signals for controlling the timing to write signals in the field memories 2120 to 2124, respectively; 2150 to 2154 are similarly input terminals for read control signals for controlling to read-out data therefrom; 2161 to 2164 are input terminals for switching control signals for controlling the switching circuits 2131 to 2134, respectively, to switch-over them; and 2170 is a control signal input terminal for controlling the field memories 2120 to 2124 to interrupt writing image signals therein.
The continuity of the field number of the reproduced image signal inputted through the terminal 8 is examined. At a point where the field number becomes discontinuous, a delay control signal for controlling the device so as to output the signals indicated in FIG. 32 through the different taps is outputted. This control signal is inputted in the terminals 2140 to 2144 as a write-in control signal, in the terminals 2150 to 2154 as a read-out control signal, and in the terminals 2161 to 2164 as a switch-over control signal.
The field memory has a memory capacity of about 1 field. For example, for the case where the image signal B4V outputted from the first tap 2111, delayed by 2 fields, can be obtained from the first tap 2111 by selecting the signal inputted from the field memory 2121 in the switching circuit 2131 by means of the switching circuit 2131 to output it.
Applying the same procedure correspondingly to the following, it is possible to output the image signals indicated in FIG. 32 through the respective taps by controlling the switching circuits 2131 to 2134.
Next, a case where a field in consecutive image signals is repeatedly reproduced at least two times in order to adjust the playback time or to effect a slow playback will be explained.
In the case where field 1 is reproduced successively twice, it is recognized by the signal control circuit 2100 indicated in FIG. 24 that a same field is inputted successively twice by using reproduced field numbers inputted through the terminal 8. A control signal from the signal control circuit 2100 is inputted in the tapped delay line 202) and then inputted in the terminal 2170 indicated in FIG. 34. In this way it is interrupted to write signals in the field memories 2120 to 2124.
At this time, as explained above, referring to FIG. 33, the switching circuit 2131 to 2134 select the signals B2V, C3V, D4V and C5V to output them.
The procedure remains same also in the case where a same field is reproduced over more than 2 fields. The signal processing is possible by interrupting to write signals in the field memories 2120 to 2124 as far as a same field continues.
Although, in the embodiment indicated in FIG. 24, the case where the composite image signal is reproduced is indicated, the separation into the luminance signal and the carrier chrominance signal is unnecessary, in the case where component signals such as the luminance signal, the chrominance signal, etc. are reproduced. Furthermore, for the output, it is sufficient to output the luminance signal and the color difference signal and the adding circuit is also no more necessary. Also in this case, it is obvious that it is possible to use the scanning line conversion circuit according to the present invention.
According to the present embodiment, since the inter-field converting processing is effected for a still picture portion of the reproduced image signal, also at a part, where the field skipping has been effected or in the case where a same field is successively reproduced, it is possible to remove displacements of the center of gravity by the field converting processing. Further, for a still picture portion of the reproduced image signal, since the inter-frame Y/C separating processing can be effected, it is possible to remove worsening in the resolution in the diagonal direction by the field converting processing. Furthermore, it is not necessary to restrict the separation band of the luminance signal and the carrier chrominance signal for the inter-frame Y/C separation, the carrier chrominance signal never remains in the luminance signal and color flicker, which was produced heretofore by color signals remaining in the luminance signal, can be eliminated. Although the procedure is identical to that used heretofore for a moving picture portion, since the resolution is lowered originally by residual images, etc., lowering in the resolution for the luminance signal, etc. give rise to almost no problem. Further, horizontal transient portions of the chrominance signal are not abrupt owing to the effects of the residual images and chrominance signals remaining in the luminance signal are almost perfectly eliminated. Consequently almost no color flickers take place.
Owing to the effects described above, it is possible to improve the image quality at the variable speed playback.
FIG. 35 shows a modified example of the embodiment indicated in FIG. 24. Field conversion portions 500Y, 500R and 500B field-conversion-process component signals, i.e. the luminance signal, and the color difference signals (R-Y) and (B-Y), inputted in input terminals 101Y, 101R and 101B, respectively, and output them to output terminals 102Y, 102R and 102B. The construction of the field conversion portions 500R and 500B is identical to the construction of the field conversion portion 500Y. Also in the present embodiment, effects similar to those obtained in the embodiment indicated in FIG. 24 can be obtained. | A field conversion device for forming data of a new field, comprising luminance and chrominance signals, respectively, by combining data of an arbitrary field of an interlaced television signal and field data of a television signal in an interlaced relationship therewith, and method thereof. Field signal data extracted from the arbitrary field is combined with data from the field in an interlaced relationship therewith. Furthermore, a second new field data is obtained using field data of a plurality of lines in the arbitrary field. Field data, comprising luminance and chrominance signals, respectively, are selectively chosen and output from the new first and second field data according to movement detected within an input signal, to comprise the new field data. | 7 |
CLAIM TO PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional U.S. patent applications 62/335,981, filed May 13, 2016, and 62/375,543, filed Aug. 16, 2016, the entire contents of which are incorporated here by reference. This application is related to U.S. patent application Ser. No. 15/373,541, filed Dec. 9, 2016, the entire contents of which are incorporated here by reference. This application is related to U.S. patent application ______, titled “Processing Speech from Distributed Microphones,” and ______, titled “Handling Responses to Speech Processing,” both filed at the same time as this application.
BACKGROUND
[0002] This disclosure relates to processing speech from distributed microphones.
[0003] Current speech recognition systems assume one microphone or microphone array is listening to a user speak and taking action based on the speech. The action may include local speech recognition and response, cloud-based recognition and response, or a combination of these. In some cases, a “wake-up word” is identified locally, and further processing is provided remotely based on the wake-up word.
[0004] Distributed speaker systems may coordinate the playback of audio at multiple speakers, located around a home, so that the sound playback is synchronized between locations.
SUMMARY
[0005] In general, in one aspect, a system includes a plurality of microphones positioned at different locations, and a dispatch system in communication with the microphones. The dispatch system derives a plurality of audio signals from the plurality of microphones, computes a confidence score for each derived audio signal, and compares the computed confidence scores. Based on the comparison, the dispatch system selects at least one of the derived audio signals for further handling.
[0006] Implementations may include one or more of the following, in any combination. The dispatch system may include a plurality of local processors each connected to at least one of the microphones. The dispatch system may include at least a first local processor and at least a second processor available to the first processor over a network. Computing the confidence score for each derived audio signal may include computing a confidence in one or more of whether the signal may include speech, whether a wakeup word may be included in the signal, what wakeup word may be included in the signal, a quality of speech contained in the signal, an identity of a user whose voice may be recorded in the signal, and a location of the user relative to the microphone locations. Computing the confidence score for each derived audio signal may also include determining that the audio signal appears to contain an utterance and whether the utterance includes a wakeup word. Computing the confidence score for each derived audio signal may also include identifying which wakeup word from a plurality of wakeup words is included in the speech. Computing the confidence score for each derived audio signal further may include determining a degree of confidence that the speech includes the wakeup word.
[0007] Computing the confidence score for each derived audio signal may include comparing one or more of a timing between when the microphones detected sounds corresponding to each of the audio signals, signal strength of the derived audio signals, signal-to-noise ratio of the derived audio signals, spectral content of the derived audio signals, and reverberation within the derived audio signals. Computing the confidence score for each derived audio signal may include, for each audio signal, computing a distance between an apparent source of the audio signal and at least one of the microphones. Computing the confidence score for each derived audio signal may include computing a location of the source of each audio signal relative to the locations of the microphones. Computing the location of the source of each audio signal may include triangulating the location based on computed distances distance between each source and at least two of the microphones.
[0008] The dispatch system may transmit at least a portion of the selected signal or signals to a speech processing system to provide the further handling. Transmitting the selected audio signal or signals may include selecting at least one speech processing system from a plurality of speech processing systems. At least one speech processing system of the plurality of speech processing systems may include a speech recognition service provided over a wide-area network. At least one speech processing system of the plurality of speech processing systems may include a speech recognition process executing on the same processor on which the dispatch system is executing. The selection of the speech processing system may be based on one or more of preferences associated with a user, the computed confidence scores, or context in which the audio signals are derived. The context may include one or more of an identification of a user that may be speaking, which microphones of the plurality of microphones produced the selected derived audio signals, a location of the user relative to the microphone locations, operating state of other devices in the system, and time of day. The selection of the speech processing system may be based on resources available to the speech processing systems.
[0009] Comparing the computed confidence scores may include determining that at least two selected audio signals appear to contain utterances from at least two different users. The determining that the selected audio signals appear to contain utterances from at least two different users may be based on one or more of voice identification, location of the users relative to the locations of the microphones, which of the microphones produced each of the selected audio signals, use of different wakeup words in the two selected audio signals and visual identification of the users. The dispatch system may also send the selected audio signals corresponding to the two different users to two different selected speech processing systems. The selected audio signals may be assigned to the selected speech processing systems based on one or more of preferences of the users, load balancing of the speech processing systems, context of the selected audio signals, and use of different wakeup words in the two selected audio signals. The dispatch system may also send the selected audio signals corresponding to the two different users to the same speech processing system as two separate processing requests.
[0010] Comparing the computed confidence scores may include determining that at least two received audio signals appear to represent the same utterance. The determining that the selected audio signals represent the same utterance may be based on one or more of voice identification, location of the source of the audio signals relative to the locations of the microphones, which of the microphones produced each of the selected audio signals, time of arrival of the audio signals, correlations between the audio signals or between outputs of microphone array elements, pattern matching, and visual identification of the person speaking. The dispatch system may also send only one of the audio signals appearing to represent the same utterance to the speech processing system. The dispatch system may also send both of the audio signals appearing to represent the same utterance to the speech processing system. The dispatch system may also transmit at least one selected audio signal to each of at least two speech processing systems, receive responses from each of the speech processing systems, and determine an order in which to output the responses.
[0011] The dispatch system may also transmit at least two selected audio signals to at least one speech processing system, receive responses from the speech processing system corresponding to each of the transmitted signals, and determine an order in which to output the responses. The dispatch system may be further configured to receive a response to the further processing, and output the response using an output device. The output device may not correspond to the microphone that captured the audio. The output device may not be located at any of the locations where the microphones are located. The output device may include one or more of a loudspeaker, headphones, a wearable audio device, a display, a video screen, or an appliance. Upon receiving multiple responses to the further processing, the dispatch system may determine an order in which to output the responses by combining the responses into a single output. Upon receiving multiple responses to the further processing, the dispatch system may determine an order in which to output the responses by selecting fewer than all of the responses to output, or sending different responses to different output devices. The number of derived audio signals may be not equal to the number of microphones. At least one of the microphones may include a microphone array. The system may also include non-audio input devices. The non-audio input devices may include one or more of accelerometers, presence detectors, cameras, wearable sensors, or user interface devices.
[0012] In general, in one aspect, a system includes a plurality of devices positioned at different locations, and a dispatch system in communication with the devices receives a response from a speech processing system in response to a previously-communicated request, determines a relevance of the response to each of the devices, and forwards the response to at least one of the devices based on the determination.
[0013] Implementations may include one or more of the following, in any combination. The at least one of the devices may include an audio output device, and forwarding the response may cause that device to output audio signals corresponding to the response. The audio output device may include one or more of a loudspeaker, headphones, or a wearable audio device. The at least one of the devices may include a display, a video screen, or an appliance. The previously-communicated request may have been communicated from a third location not associated with any of the plurality of locations of the devices. The response may be a first response, and the dispatch system may also receive a response from a second speech processing system. The dispatch system may also forward the first response to a first one of the devices, and forward the second response to a second one of the devices. The dispatch system may also forward both the first response and the second response to a first one of the devices. The dispatch system may also forward only one of the first response and the second response to any of the devices.
[0014] Determining the relevance of the response may include determining which of the devices were associated with the previously-communicated request. Determining the relevance of the response may include determining which of the devices may be closest to a user associated with the previously-communicated request. Determining the relevance of the response may be based on preferences associated with a user of the claimed system. Determining the relevance of the response may include determining a context of the previously-communicated request. The context may include one or more of an identification of a user that may have been associated with the request, which microphone of a plurality of microphones may have been associated with the request, a location of the user relative to the device locations, operating state of other devices in the system, and time of day. Determining the relevance of the response may include determining capabilities or resource availability of the devices.
[0015] A plurality of output devices may be positioned at different output device locations, and the dispatch system may also receive a response from the speech processing system in response to the transmitted request, determine a relevance of the response to each of the output devices, and forward the response to at least one of the output devices based on the determination. The at least one the output devices may include an audio output device, and forwarding the response causes that device to output audio signals corresponding to the response. The audio output device may include one or more of a loudspeaker, headphones, or a wearable audio device. The at least one of the output devices may include a display, a video screen, or an appliance. Determining the relevance of the response may include determining a relationship between the output devices and the microphones associated with the selected audio signals. Determining the relevance of the response may include determining which of the output devices may be closest to a source of the selected audio signal. Determining the relevance of the response may include determining a context in which the audio signals were derived. The context may include one or more of an identification of a user that may have been speaking, which microphone of the plurality of microphones produced the selected derived audio signals, a location of the user relative to the microphone locations and the device locations, operating state of other devices in the system, and time of day. Determining the relevance of the response may include determining capabilities or resource availability of the output devices.
[0016] In general, in one aspect, a system includes a plurality of microphones positioned at different microphone locations, a plurality of loudspeakers positioned at different loudspeaker locations, and a dispatch system in communication with the microphones and loudspeakers. The dispatch system derives a plurality of voice signals from the plurality of microphones, computes a confidence score about the inclusion of a wakeup word for each derived voice signal, compares the computed confidence scores, and based on the comparison, selects at least one of the derived voice signals and transmits at least a portion of the selected signal or signals to a speech processing system. The dispatch system receives a response from a speech processing system in response to the transmission, determines a relevance of the response to each of the loudspeakers, and forwards the response to at least one of the loudspeakers for output based on the determination.
[0017] Advantages include detecting a spoken command at multiple locations and providing a single response to the command. Advantages also include providing a response to a spoken command at a location more relevant to the user than the location where the command was detected.
[0018] All examples and features mentioned above can be combined in any technically possible way. Other features and advantages will be apparent from the description and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a system layout of microphones and devices that may respond to voice commands received by the microphones.
DESCRIPTION
[0020] As more and more devices implement voice-controlled user interfaces (VUIs), a problem arises that multiple devices may detect the same spoken command and attempt to handle it, resulting in problems ranging from redundant responses to contradictory actions being taken at different points of action. Similarly, if a spoken command can result in output or action by multiple devices, which device should take action may be ambiguous. In some VUIs, a special phrase, referred to as a “wakeup word,” “wake word,” or “keyword” is used to activate the speech recognition features of the VUI—the device implementing the VUI is always listening for the wakeup word, and when it hears it, it parses whatever spoken commands came after it. This is done to conserve processing resources, by not parsing every sound that is detected, and can help disambiguate which system was the target of the command, but if multiple systems are listening for the same wakeup word, such as because the wakeup word is associated with a service provider and not individual pieces of hardware, the problem remains of determining which device should handle the command.
[0021] FIG. 1 shows a potential environment, in which a stand-alone microphone array 102 , a smart phone 104 , a loudspeaker 106 , and a set of headphones 108 each have microphones that detect a user's speech (to avoid confusion, we refer to the person speaking as the “user” and the device 106 as a “loudspeaker;” discrete things spoken by the user are “utterances”). Each of the devices that detects the utterance 110 transmits what it heard as an audio signal to a dispatch system 112 . In the case of the devices having multiple microphones, those devices may combine the signals rendered by the individual microphones to render single combined audio signal, or they may transmit a signal rendered by each microphone.
[0022] This disclosure refers to various different types of audio and related signals. For clarity, the following conventions are used. “Acoustic signal” refers to physical signals, that is, physical sound pressure waves that are interpreted as sound by humans, such as the utterances mentioned above. “Audio signal” refers to electrical signals that represent sound. Audio signals may be generated from a microphone responding to acoustic audio, or they may be received from other electronic sources, such as recordings, computer-generated signals, or streamed data. “Audio output” refers to acoustic signals generated by a loudspeaker based on an audio signal input to the speaker.
[0023] The dispatch system 112 maybe a cloud-based service to which each of the devices is individually connected, a local service running on one of the same devices or an associated device, a distributed service running cooperatively on some or all of the devices themselves, or any combination of these or similar architectures. Due to their different microphone designs and their differing proximity to the user, each of the devices may hear the utterance 110 differently, if at all. For example, the stand-alone microphone array 102 may have a high-quality beam-forming capability that allows it to clearly hear the utterance regardless of where the user is, while the headphones 108 and the smart phone 104 have highly directional near-field microphones that only clearly pick up the user's voice if the user is wearing the headphones and holding the phone up to their face, respectively. Meanwhile, the loudspeaker 106 may have a simple omnidirectional microphone that detects the speech well if the user is close to and facing the loudspeaker, but produces a low-quality signal otherwise.
[0024] Based on these and similar factors, the dispatch system 112 computes a confidence score for each audio signal (this may include the devices themselves scoring their own detection before sending what they heard, and sending that score along with their respective audio signals). Based on a comparison of the confidence scores, to each other, to a baseline, or both, the dispatch system 112 selects one or more of the audio signals for further processing. This may include locally performing speech recognition and taking direct action, or transmitting the audio signal over a network 114 , such as the Internet or any private network, to another service provider. For example, if one of the devices produces an audio signal with a high confidence that the signal contains the wakeup word “OK Google,” that audio signal may be sent to Google's cloud-based speech recognition system for handling. In the case that the audio signal is transmitted to a remote service, the wakeup word may be included along with whatever utterance followed it, or the utterance alone may be sent.
[0025] The confidence scoring may be based on a large number of factors, and may indicate confidence in more than one parameter as well. For example, the score may indicate a degree of confidence about which wakeup word was used (including whether one was used at all), or where the user was located relative to the microphone. The score may also indicate a degree of confidence in whether the audio signal is of high quality. In one example, the dispatch system may score the audio signals from two devices as both having a high confidence score that a particular wakeup word was used, but score one of them with a low confidence in the quality of the audio signal, while the other is scored with a high confidence in the audio signal quality. The audio signal with the high confidence score for signal quality would be selected for further processing.
[0026] When more than one device transmits an audio signal, one of the critical things to determine confidence in is whether the audio signals represent the same utterance or two (or more) different utterances. The scoring itself may be based on such factors as signal level, signal-to-noise ratio (SNR), amount of reverberation in the signal, spectral content of the signal, user identification, knowledge about the user's location relative to the microphones, or relative timing of the audio signals at two or more of the devices. Location-related scoring and user identity-related scoring may be based on both the audio signals themselves and on external data such as visual systems, wearable trackers worn by users, and identity of the devices providing the signals. For example, if a smart phone is the source of the audio signal, a confidence score that the owner of that smart phone is the user whose voice was heard would be high. User location may be determined based on the strength and timing of acoustic signals received at multiple locations, or at multiple microphones in an array at a single location.
[0027] In addition to determining which wakeup word was used and which signal is best, the scoring may provide additional context that informs how the audio signal should be handled. For example, if the confidence scores indicate that the user was facing the loudspeaker, than it may be that a VUI associated with the loudspeaker should be used, over one associated with the smart phone. Context may include such things as which user was speaking, where the user was located and facing relative to the devices, what activity was the user engaged in (e.g., exercising, cooking, watching TV), what time of day it is, or what other devices are in use (including devices other than those providing the audio signals).
[0028] In some cases, the scoring indicates that more than one command was heard. For example, two devices may each have high confidence that they heard different wakeup words, or that they heard different users speaking. In that case, the dispatch system may send two requests—one request to each system for which a wakeup word was used, or two different requests to a single system that both users invoked. In other cases, more than one of the audio signals may be sent—for example, to get more than one response, to let the remote system decide which one to use, or to improve the voice recognition by combining the signals. In addition to selecting an audio signal for further handling, the scoring may also lead to other user feedback. For example, a light may be flashed on whichever device was selected, so that the user knows the command was received.
[0029] Similar considerations come into play when a response is received from whatever service or system the dispatch system sent the audio signal to for handling. In many cases, the context around the utterance will also inform the handling of the response. For example, the response may be sent to the device from which the selected audio signal was received. In other cases, the response may be sent to a different device. For example, if the audio signal from the stand-alone microphone array 102 was selected, but the response back from the VUI is to start playing an audio file, the response should be handled by the headphones 108 or the loudspeaker 106 . If the response is to display information, the smart phone 104 or some other device with a screen would be used to deliver the response. If the microphone array audio signal was selected because the scoring indicated that it had the best signal quality, additional scoring may have indicated that the user was not using the headphones 108 but was in the same room as the loudspeaker 106 , so the loudspeaker is the likely target for the response. Other capabilities of the devices would also be considered—for example, while only audio devices are shown, voice commands could address other systems, such as lighting or home automation systems. Hence, if the response to the utterance is to turn down lights, the dispatch system may conclude that it is referring to the lights in the room where the strongest audio signal was detected. Other potential output devices include displays, screens (e.g., the screen on the smart phone, or a television monitor), appliances, door locks, and the like. In some examples, the context is provided to the remote system, and the remote system specifically targets a particular output device based on a combination of the utterance and the context.
[0030] As mentioned, the dispatch system may be a single computer or a distributed system. The speech processing provided may similarly be provided by a single computer or a distributed system, coextensive with or separate from the dispatch system. They each may be located entirely locally to the devices, entirely in the cloud, or split between both. They may be integrated into one or all of the devices. The various tasks described—scoring signals, detecting wakeup words, sending a signal to another system for handling, parsing the signal for a command, handling the command, generating a response, determining which device should handle the response, etc., may be combined together or broken down into more sub-tasks. Each of the tasks and sub-tasks may be performed by a different device or combination of devices, locally or in a cloud-based or other remote system.
[0031] When we refer to microphones, we include microphone arrays without any intended restriction on particular microphone technology, topology, or signal processing. Similarly, references to loudspeakers and headphones should be understood to include any audio output devices—televisions, home theater systems, doorbells, wearable speakers, etc.
[0032] Embodiments of the systems and methods described above comprise computer components and computer-implemented steps that will be apparent to those skilled in the art. For example, it should be understood by one of skill in the art that instructions for executing the computer-implemented steps may be stored as computer-executable instructions on a computer-readable medium such as, for example, floppy disks, hard disks, optical disks, Flash ROMS, nonvolatile ROM, and RAM. Furthermore, it should be understood by one of skill in the art that the computer-executable instructions may be executed on a variety of processors such as, for example, microprocessors, digital signal processors, gate arrays, etc. For ease of exposition, not every step or element of the systems and methods described above is described herein as part of a computer system, but those skilled in the art will recognize that each step or element may have a corresponding computer system or software component. Such computer system and/or software components are therefore enabled by describing their corresponding steps or elements (that is, their functionality), and are within the scope of the disclosure.
[0033] A number of implementations have been described. Nevertheless, it will be understood that additional modifications may be made without departing from the scope of the inventive concepts described herein, and, accordingly, other embodiments are within the scope of the following claims. | A plurality of microphones positioned at different locations. A dispatch system in communication with the microphones derives a plurality of audio signals from the plurality of microphones, computes a confidence score for each derived audio signal, and compares the computed confidence scores. Based on the comparison, the dispatch system selects at least two of the derived audio signals for further handling. Comparing the computed confidence scores includes determining that at least the two selected audio signals appear to contain utterances from at least two different users. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for examining electrostatic discharge damage to semiconductor devices, and more particularly to a method and apparatus of this kind, which can accurately determine the electrostatic discharge breakdown voltages of semiconductor devices enclosed in dielectric packages.
Conventionally, in handling IC devices, there often occurred accidents of sudden discharge of electrostatic charge of the mold packages, causing damage to insulating films within the devices. MOS IC devices in general are subjected to electrostatic breakdown tests for delivery, and only those ones which are found acceptable are delivered to users. However, in actual use or handling on the user side, even MOS IC devices found acceptable sometimes had dielectric breakdown and were sent back to the maker. Therefore, the appearance of a new testing method has been desired which is capable of accurately evaluating the susceptibility of semiconductor IC devices to such electrostatic discharge damage.
Typical conventional methods for examining electrostatic discharge damage to semiconductor IC devices include "the Human Body Model" and "the Charged Device Model".
FIG. 1 is a circuit diagram of a testing circuit for electrostatic discharge damage according to the Human Body Model which is employed in general. In the figure, the testing circuit comprises a direct-current voltage supply 1, a changeover switch SW1, an equivalent human body capacitance CD (e.g. 100-200 pF), an equivalent human body resistance RE, and a MOS IC device 2. The equivalent circuit of this MOS IC device is represented by an input protective resistance Rl, an input protective diode D, and a capacitance Cox of a gate-insulating film of a MOS transistor. The MOS IC device 2 has an input or output pin terminal 2a connected to an end of the resistance RE, and a supply pin terminal 2b connected to ground.
In the testing operation, first the switch SWl is connected to the voltage supply 1 to cause charging of the capacitance CD up to 250 volts, for instance. Then, the switch SWl is switched over to the resistance RE to cause discharge currents Il and I2 to flow through the IC device 2, as shown in FIG. 2, in such a manner that initially discharge current Il takes place through the capacitance Cox, and thereafter Zener current I2 flows through the diode D. The above applied voltage from the direct current voltage supply 1 is evaluated to be a withstanding voltage of the MOS IC device 2.
This conventional testing method, however, does not give any consideration to the package capacitance Cp, and it is therefore difficult with this method to accurately determine the electrostatic breakdown voltage of the MOS IC device.
FIG. 3 shows a circuit diagram of a testing circuit for electrostatic discharge damage according to the conventional Charged Device Model which takes into account the package capacitance. In FIG. 3, a MOS IC device 2 comprises an input or output pin terminal 2a, a supply pin terminal 2b, and a metal plate 4 disposed in contact with a package surface of the device and having a ground potential level. In testing operation, the switch SW2 is closed, and at the same time the switch SW3 is opened, to thereby cause charging of the package capacitance Cp (e.g. 2-5 pF) up to a testing voltage. Next, the switch SW2 is opened, and simultaneously the switch SW3 is closed, to thereby cause discharging of the package capacitance Cp, followed by checking damage to the gate-insulating film capacitance Cox by the charged voltage of the package capacitance Cp. FIG. 4 shows transient discharge current I3 flowing through the gate-insulating film capacitance, and transient discharge current I4 flowing through the protective diode D in the circuit of FIG. 3.
According to this Charged Device method, however, since the package capacitance Cp is very small, a discharge current flow through the diode D in the forward direction, which takes place upon opening of the switch SW2 and simultaneous closing of the switch SW3, can cause a drop in the testing voltage applied to the gate-insulating film capacitance Cox. Therefore, it is difficult to accurately determine the electrostatic breakdown voltage of the IC device.
As stated above, testing results according to the conventional electrostatic discharge damage testing methods are not so accurate as to assure users of the reliability of the semiconductor devices found acceptable after testing.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a method and apparatus for examining electrostatic discharge damage to semiconductor devices, which is capable of accurately determining a breakdown voltage at which a semiconductor device can be damaged by discharge of electrostatic charge of a dielectric package thereof.
The present invention provides a method and apparatus for examining the susceptibility of a semiconductor device to damage by discharge of electrostatic charge of a dielectric package thereof. The method according to the invention comprises the following steps:
(1) electrically charging the package with an input or output pin of the semiconductor device disconnected at least from a reference potential source of the device;
(2) connecting the input or output pin of the device to the reference potential source through a load impedance means, while continuing the charging of the step (1), whereby the charge of the package is discharged to the reference potential source through the input or output pin of the device and the load impedance means; and
(3) determining a voltage value at which the device has been damaged by the discharging of the step (2).
The apparatus according to the invention comprises:
charging means connected between a surface of a package of the device and a reference potential source, for electrically charging the package;
switch means having one terminal connected to an input or output pin of the device; and
load impedance means connected between the other terminal of the switch means and the reference potential source.
The switch means is closed to discharge the charge of the package, with the charging of the package continued.
The above and other objects, features, and advantages of the invention will be more apparent from the ensuing detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of the equivalent circuit of an electrostatic discharge damage testing apparatus according to the conventional Human Body Model;
FIG. 2 shows current paths in the circuit of FIG. 1;
FIG. 3 is a circuit diagram of the equivalent circuit of an electrostatic discharge damage testing apparatus according to the conventional Charged Device Model;
FIG. 4 shows current paths in the circuit of FIG. 3;
FIG. 5 is a block diagram of an electrostatic discharge damage testing apparatus according to the present invention;
FIG. 6 is a circuit diagram of the equivalent circuit of the apparatus of FIG. 5;
FIG. 7 shows current paths in the circuit of FIG. 6;
FIG. 8 is a graph showing the relationship between number of times of friction and percentage of occurrence of electrostatic discharge damage;
FIG. 9 is a graph showing the relationship between number of times of friction and charged voltage of the package surface;
FIG. 10 is a schematic view showing a first embodiment of the apparatus according to the present invention;
FIG. 11 is a schematic view showing a second embodiment of the apparatus according to the invention;
FIG. 12 is a schematic view showing a third embodiment of the apparatus according to the invention;
FIG. 13 is a schematic view showing a fourth embodiment of the apparatus according to the invention; and
FIG. 14 is a schematic view showing a fifth embodiment of the apparatus according to the invention.
DETAILED DESCRIPTION
Referring first to FIG. 5, there is shown in block diagram an electrostatic discharge damage testing apparatus of the present invention. In the figure, the apparatus according to the invention comprises a semiconductor device 11 to be tested, such as a MOS IC device, a charging means 10 disposed in contact with a major surface 11a of a dielectric package of the semiconductor device 11, for electrically charging the dielectric package, a load impedance 13 connected to a ground potential source, and a switch 12 connected between an input or output pin 11b of the semiconductor device 11 and the load impedance 13, for causing discharging of the static electricity charged in the dielectric package.
In operation, first the output voltage from the charging means 10 is elevated up to a predetermined voltage level to charge the package surface 11a. Next, the switch 12 is closed to cause discharging of the charged static electricity through the input or output pin 11b of the semiconductor device. Thereafter, it is checked-whether or not there has occurred electrostatic discharge damage to the semiconductor device 11, by tesing electrical performance of the same device. By repeating the above charging step and discharging step at various different withstand voltages, it is possible to accurately determine the maximum withstanding voltage at which the semiconductor device can withstand electrostatic discharge. For instance, assuming that damage to the device 11 occurs immediately after an nth testing operation with a charged voltage Vn of the package surface 11a, it is decided that the maximum withstanding voltage of the semiconductor device against electrostatic discharge damage is (Vn-1+Vn)/2, wherein Vn-1 is a charged voltage of the package surface 11a obtained immediately after an (n-1)th testing operation, and Vn-Vn-1 is larger than 0. The smaller the value of difference ΔVn=Vn-Vn-1, the more accurate the withstanding voltage value obtained.
FIG. 6 is a circuit diagram of the equivalent circuit of the testing apparatus of FIG. 5. In FIG. 6, the equivalent circuit of the MOS IC device is formed of an input protective diode D and an input protective resistance RI, a capacitance Cox of a gate-insulating film of a MOS transistor in the device or of a field-insulating film of a bipolar transistor, and a capacitance Cp of a dielectric or plastic package of the device. It is an important feature of the invention that the output voltage from the charging means 10 is applied to the package surface 11a.
The value of the load impedance 13 is set at a capacitance value of 200 pF if it is assumed that the electrostatic charge of the package is discharged to the human body through the pin 11b of the semiconductor device 11, and at a resistance value of 0 ohm by making a short across the means 13 if it is assumed that the electrostatic charge of the package is discharged to a metal body through the pin 11b body.
In operation, the switch 14 is closed, and then a predetermined charging voltage from the charging means 10 is applied to the package surface 11a to electrically charge the package. Thereafter, the switch 12 is closed while the charging is continued, and then the charged static electricity is discharged through the pin 11b and the load impedance 13. On this occasion, as shown in FIG. 7, initially transient current Ill flows through the device, and thereafter transient current I12 flows therethrough. After the discharging operation, the presence of damage to the semiconductor device 11 is checked to evaluate the susceptibility of the device to electrostatic discharge damage.
According to the arrangement of the invention, the charging operation into the package is continued even when the discharging operation is carried out, thereby enabling accurate determination of the electrostatic breakdown voltage.
FIG. 8 shows the relationship between the number of times of friction of the package surfaces of MOS IC devices of a certain model and the percentage of occurrence of electrostatic discharge damage to the devices. The MOS IC devices were charged with static electricity by subjecting the package surfaces to friction by means of a rubber roller normally used in printing the model name during sealing step.
FIG. 9 shows the relationship between the number of times of friction of the package surfaces of the MOS IC devices and the charged electrostatic voltage of the package surfaces of the MOS IC devices.
It will be learned from FIGS. 8 and 9 that if the package surface voltage exceeds approximately 600 volts, a sudden increase occurs in the percentage of devices damaged by the electrostatic discharge.
Table 1 given below shows average values of the electrostatic breakdown voltage as results of tests conducted on the MOS IC devices on the same lot according to the Human Body Mode, the Charged Device Mode, and the method of the present invention.
TABLE 1______________________________________Method Breakdown Voltage (-x)______________________________________Human Body Model: 250 vCharged Device Model: 1100 vPresent Invention: 620 v______________________________________ Number of sets of sample n = 30
Referring to Table 1 above and FIGS. 8 and 9, it will be learned that the average value of 620 volts as test results according to the invention is closest to the above value of 600 volts found critical from FIGS. 8, 9. From this fact, it will be understood that the method of the present invention can most accurately determine the electrostatic breakdown voltage of semiconductor devices subjected to discharge of electrostatic charge of the package surfaces.
TABLE 2______________________________________ Maker Maker MakerIC Maker A B C______________________________________Percent of Devices 64% 2% 0%Damaged during SealingElectrostaticBreakdown VoltageHuman Body Model 350 v 220 v 300 vCharged Device Model 950 v 700 v 1000 vPresent Invention 700 v 1400 v 5000 v______________________________________ Number of sets of sample n = 30
Table 2 given above shows average values of the breakdown voltage of semiconductor devices of the same model manufactured by three makers A, B, and C, and percentage of devices damaged due to discharge of electrostatic charge of the package surfaces subjected to friction ten times, as results of breakdown tests using the aforementioned three methods. Since the percentage of damaged devices becomes smaller in the order of makers A, B and C in Table 2, properly the average value of the breakdown voltage should become larger in the order of makers A, B and C. According to Table 2, it is only the method according to the present invention that satisfies the above requirement of the order of makers. This fact also tells that the method according to the present invention is capable of most accurately determining the breakdown voltage by electrostatic discharge of the packages.
A first embodiment of the apparatus according to the invention will now be described with reference to FIG. 10. In the first embodiment, a charging means 10 comprises a metal plate 10a disposed in contact with susbtantially the whole area of the package surface 11a, and a direct current voltage supply 10b connected between the metal plate 10a and ground potential. In FIG. 10, reference numeral 11c designates a semiconductor chip.
According to this embodiment, the charging voltage from the direct current voltage supply 10b is applied to the package surface 11a to a set guaranteeable voltage, so that the package is electrically charged over substantially the whole surface area thereof, to thereby enable simulation of a state of a semiconductor device frictionally charged with static electricity.
FIG. 11 shows a second embodiment of the invention. The charging means 10 comprises a corona discharge device 10d for generating ion beams.
According to this embodiment, the potential of the package surface 11a can be positively held at a set guaranteeable value (which is checked by means of a surface potential meter 10c) by adjusting the amount of ion beams radiated against the package surface 11a.
FIG. 12 shows a third embodiment of the invention, in which the charging means 10 comprises a first metal plate 10e disposed in contact with a selected portion of the package surface 11a, and a second metal plate 10f disposed in contact with the other part of the package surface 11a, and a direct current voltage supply 10b connected between the first metal plate 10e and the second metal plate 10f. In the figure, the distance d between the first and second metal plates 10e, 10f is set at such a value that no discharge can take place between the two plates.
According to this embodiment, only the potential of the selected portion of the package surface 11a in contact with the first metal plate 10e is locally charged to a set guranteeable voltage, to thereby enable testing a phenomenon of discharge damage caused by local charging of the package surface 11a.
FIG. 13 shows a fourth embodiment of the invention, in which the charging means 10 comprises a metal plate 10a disposed in contact with substantially the whole area of the package surface 11a, a direct current voltage supply 10b, and a capacitor C X having an equivalent ground capacitance which is equal to a distributed or stray capacitance present between the major surface of the package 11 of the semiconductor device and ground, connected at one end to the metal plate 10a, and at the other end to the positive electrode of the charging supply 10b.
According to this embodiment, the quantity Q of charge of the package capacitance Cp can be calculated indirectly from the capacitance value of the capacitance Cx, thereby enabling an estimate of a phenomenon of electrostatic discharge damage to the semiconductor device depending upon the parameter Q.
FIG. 14 shows a fifth embodiment of the invention, in which the capacitor C X is interposed between the first metal electrode 10e and the charging supply 10b.
Further, in the foregoing embodiments of the invention, a thin insulating plate, not shown, may be interposed between the metal plate 10a, 10e and the package surface 11a, to prevent spark discharge between a pin of the semiconductor device 11 and the metal plate, thereby permitting a breakdown test using a high electrostatic voltage.
Still further, a dielectric breakdown test according to the invention can also be applied to determination of the dielectric package capacity Cp in an indirect manner, making it possible to estimate the electrostatic breakdown voltage in designing the package. | A method and apparatus for examining the susceptibility of a semiconductor device to damage by discharge of electrostatic charge on a dielectric package of the device. The package is electrically charged, with an input or output pin of the device disconnected at least from a reference potential of the charging source. The input or output pin is then connected to the reference potential through a load impedance with the charging continued, to effect discharging of the charge on the package. Thus, the electrostatic breakdown voltage of the device can be determined with accuracy by testing of the device after each charging and discharging operation at successively higher charging potentials. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application claims priority to U.S. Provisional Patent Application 61/653,063, filed May 30, 2012, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a tool for use in pipe fitting, carpentry, and other trades.
BACKGROUND OF THE INVENTION
[0003] A vast number of tools for measuring and leveling are used in the field of pipe fitting. Pipefitters and other tradesmen have long used levels, rulers and squares to establish exact lengths and angles in their work. Speed squares, torpedo levels, T-bevels and the like are often used to establish lengths and angles as to properly assemble joints and the like. A principle problem has been that in certain trades, each of these objects are often carried individually, and thus are burdensome to use together with one hand while holding a pipe, piece of wood, or fastening tool in the other hand. Moreover, particularly amongst pipefitters, the typical pipe fitter's square comes to an apex, which often interferes with a socket or collar at the junction of the two pipes, and thus is cumbersome for a single person to use. Often, one person holds the square and level, often awkwardly, while another person tacks or welds the pipe and joint into place. Additionally, pipefitters often need to mark parallel lines on sides of pipe for mitering at precise angles.
[0004] It is a principal object of the multi-purpose tool to provide apparatus, systems and methods for use in leveling and squaring. More particularly, the invention relates to an “all-in-one” tool which, in certain exemplary embodiments comprises a modified square and level combination for domestic and commercial use, particularly in the area of pipe fitting. Certain other examples and embodiments can incorporate a variety of other common devices which would be useful to the tradesman or craftsman.
BRIEF SUMMARY OF THE INVENTION
[0005] The present application is directed to apparatus, systems and methods for use domestically, as well as in construction, pipefitting, and other skilled trades.
[0006] In certain exemplary embodiments, these apparatus, systems and methods generally relate to a squaring and leveling tool. In further exemplary embodiments, the squaring and leveling tool is a combination square having the apex of the square removed and further comprising one or more levels, and so as to be useful in working with pipes and other objects that have obstacles at the point of the apex. In yet further exemplary embodiments, markings are added so as to be useful in making measurements. Other embodiments are possible, and are within the spirit of the present application.
[0007] While multiple embodiments are disclosed, still other embodiments of the multi-purpose tool will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the multi-purpose tool. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of one embodiment of the multi-purpose tool.
[0009] FIG. 2 is a side view of one embodiment of the multi-purpose tool.
[0010] FIG. 3 is a top view of one embodiment of the multi-purpose tool.
[0011] FIG. 4 is an endlong view of one embodiment of the multi-purpose tool.
[0012] FIG. 5 is a first side view of the multi-purpose tool against a standard 90 degree joint.
[0013] FIG. 6 is a second side view of the multi-purpose tool against a flange.
[0014] FIG. 7 is a top view of one embodiment of the multi-purpose tool resting against a pipe.
[0015] FIG. 8 is a perspective view of one embodiment of the multi-purpose tool against a standard stud.
[0016] FIG. 9 is a perspective view of one embodiment of the multi-purpose tool against a standard stud.
[0017] FIG. 10 shows a prior art square superimposed upon a 90 degree joint.
DETAILED DESCRIPTION
[0018] Turning to the figures, FIGS. 1-4 generally show certain exemplary embodiments of the squaring and leveling tool 10 . In these exemplary embodiments, the tool 10 comprises a longer first side 11 and a shorter second side 13 . The tool 10 can thus generally be shaped like a ruler, or a speed square without the apex, and features an angled first end 24 and angled second end 26 . While this embodiment features 45 degree angles for forming a generally right triangle, one of skill in the art would understand that other configurations such as 30/60, 60/60 and others could be used.
[0019] As shown best in FIGS. 1-2 , in exemplary embodiments the tool features a generally trapezoidal body 10 , having a variety of inserts. In certain exemplary embodiments the tool 10 is inset with a variety of levels 12 , 14 , 16 , which are set at opposing angles so as to provide the user with the ability to establish a level angle while using the tool 10 in a variety of positions. Although bubble levels 12 , 14 , 16 are depicted, in certain other exemplary embodiments other levels could be used, as would be apparent to one of skill in the art. The embodiments of the tool 10 depicted in FIGS. 1-2 also features a ruler 22 , while other embodiments can include other measuring devices, such as a protractor or other means of establishing angles. In some embodiments, as is best depicted in FIG. 2 , the tool 10 can further comprise a hole 60 for mounting to a peg board or attachment to a D-ring so as to attach to a lanyard to assist in OSHA compliance.
[0020] Exemplary embodiments of the tool also feature one or more straight edge posts 18 , 20 for use as a further squaring means in fitting the tool flush to straight edge studs, boards, uni-struts and other items. Although the embodiment depicted in FIGS. 3-4 has two such posts, other numbers of posts and configurations are possible. The longer post 20 is depicted to have 45 degree end portions 21 , but one of skill in the art would realize that other angles would also be appropriate for certain implementations. The posts 18 , 20 can also assist in the squaring of picture frames and other mitered boards perpendicularly or otherwise.
[0021] As best seen in FIGS. 5-6 , one of the principle advantages of the present tool 10 is that a user may fit it flush to a 90 degree L-joint 30 without interference from the joint socket 34 or other objects at the throat 32 of the joint itself, such as square flanges 36 . As such, the multi-purpose tool can achieve the same goals as a typical speed square and a torpedo level combined.
[0022] By way of example, one embodiment is approximately 10″ long on the long side, approximately 7.5″ on the shorter side and approximately 1.25″ wide with 45 degree angles on the ends and posts ¼″ to ⅜″. Other embodiments are possible. As shown in FIG. 6 , for example, in use this embodiment 10 allows a tradesman such as a pipefitter or other craftsman to tack and weld 38 pipe with one hand while holding the tool 10 in the other while leaving room to clear a typical socket or butt, for example a 3″ socket weld, on a 90 degree joint, tee, or flange 36 . Because of this exemplary size, the multi-purpose tool is capable of use in most typical pipe fitting applications. In certain other embodiments, the tool may also be sized at, for example, 16″ to allow for quick and easy determination of the required distance between wall studs, rafters, and floor joists. As would be apparent to one of skill in the art, many other uses are possible.
[0023] As best shown in FIG. 7 , in certain exemplary embodiments the straight edge posts 18 , 20 of the multi-purpose tool 10 also may be used lay the tool flat against a rounded piece of pipe 40 , so as to mark 42 the pipe with segment lines 42 for mitering the pipe to specific angles.
[0024] FIGS. 8-9 depict the use of the tool 10 as a square, fitting flush against studs 44 for marking and measuring angles as well as leveling. In FIG. 8 , the tool is shown being used endwise such that the shorter of the straight edge posts 18 is flush against a standard stud 44 , so as to allow measurement and leveling. Likewise, in FIG. 9 , the tool 10 is shown being used lengthwise such that the longer of the straight edge posts 20 is flush against a standard stud 44 , so as to allow measurement and leveling. In certain exemplary embodiments, uni-struts, boards, angle iron, steel beam, pipe and other construction materials can be used, measured or leveled, as would be apparent to one of skill in the art. In further exemplary embodiments, other numbers and configurations of edge posts can be used, so as to suit the tool most ideally for the desired task.
[0025] This trapezoidal design also overcomes the problems inherent in the prior art, and as depicted in FIG. 10 , wherein the square 46 has comes to the 90 degree angle 48 in the throat of the joint, and the socket of the pipe 50 creates an obstacle. One of skill in the art would understand that variations of the length or shape of the tool will allow the user to overcome obstacles of various sizes when measuring, leveling and squaring.
[0026] Although the multi-purpose tool has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | A multi-purpose squaring and leveling tool comprising a generally trapezoidal body, angled corners, and leveling inserts. The tool may be used for tradesman, pipe fitters, and home carpenters as a means of setting joints and other construction or repair. The shape of the tool allows for the squaring and leveling of joints around obstacles which may present barriers to traditional squaring tools. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a reagent kit for measuring freshness. The kit can easily measure freshness of, for example, fish meat in a short time and has high storage stability.
BACKGROUND ART
[0002] Recently, as an index of freshness of, for example, meat, fish meat, or chicken, K value is used. The K value is a ratio (%) of the content of inosine (HxR) and hypoxanthine (Hx) to the total content of adenosine triphosphate (ATP) and ATP decomposition products (ADP, AMP, IMP, HxR, and Hx) in the meat, that is, a numerical value (%) represented by (HxR+Hx)×100/(ATP+ADP+AMP+IMP+HxR+Hx). Herein, ADP denotes adenosine diphosphate, AMP denotes adenosine monophosphate, IMP denotes inosinic acid, HxR denotes inosine, and Hx denotes hypoxanthine.
[0003] In order to determine the K value, it is necessary to measure the contents of ATP, ADP, AMP, IMP, HxR, and Hx in meat, fish meat, or chicken. However, the measurement of the contents of these ATP and ATP decomposition products is very troublesome, and in the case of fish meat, ATP, ADP, and AMP are mostly decomposed into IMP (inosinic acid) with time after death of fish, and thereby the amounts of ATP, ADP, and AMP become very low. Accordingly, a numerical value Ki, which is represented by (HxR+Hx)×100/(IMP+HxR+Hx), is assumed as to be Ki≈K and is conveniently used instead of the K value as an index of freshness.
[0004] It is known a method for measuring the contents of HxR and Hx as described in, for example, JP-B-62-50120, by mixing a composition solution containing nucleoside phosphorylase (NP), xanthine oxidase (XOD), and a color former with meat juice to decompose HxR in the meat juice to Hx by nucleoside phosphorylase (NP), to decompose Hx to xanthine and uric acid by xanthine oxidase (XOD), and to develop a color by conjugation of the color former with decomposition of Hx, and determining the intensity of the color development.
[0005] It is known a method for measuring the contents of IMP, HxR, and Hx as described in, for example, JP-A-Hei-9-262098, by applying a sample solution containing meat juice to a reactor to which alkaline phosphatase (AP), nucleoside phosphorylase (NP), and xanthine oxidase (XOD) are fixed to decompose inosinic acid (IMP) to inosine (HxR) by alkaline phosphatase (AP), to decompose inosine (HxR) to hypoxanthine (Hx) by nucleoside phosphorylase (NP), and to decompose hypoxanthine (Hx) to xanthine and uric acid by xanthine oxidase (XOD), in the sample solution, and measuring the concentration of hypoxanthine (Hx) using a luminous reagent.
[0006] However, enzymes (AP, NP, and XOD) used in the above-described methods are very unstable, and their activities easily decrease with time. In addition, their activities further decrease under high temperature. Therefore, it is very difficult to commercialize compositions containing these enzymes.
[0007] Against unstableness of these enzymes, for example, JP-A-Hei-8-131196, JP-T-2000-51394, WO 2002/004633, and JP-A-2008-206491 propose some technologies for stabilizing an enzyme by adding sugar (e.g., trehalose or sucrose) or serum albumin (BSA) to an aqueous solution of the enzyme and lyophilizing the solution.
[0008] However, there is compatibility between the type of sugar and the type of enzyme for stabilizing the enzyme, and the degree of stabilization of enzyme differs depending on how to combine the enzyme with the sugar. Therefore, the type and concentration of sugar for stabilizing a specific enzyme are not easily determined. In a case of using a mixture of a plurality of enzymes, determination of the type and concentration of sugar for stabilizing these enzymes are further difficult.
[0009] When an enzyme is stabilized by freezing an aqueous solution containing the enzyme and then drying it, the conditions, in particular, the conditions in the process for drying the frozen product by increasing the temperature after the freezing also highly affect the stability of the enzyme, but optimum conditions are not known. In a case using a mixture of a plurality of types of enzymes, it is further difficult to determine the optimum conditions.
CITATION LIST
Patent Literature
[0000]
PTL 1: JP-A-62-50120
PTL 2: JP-A-Hei-9-262098
PTL 3: JP-A-Hei-8-131196
PTL 4: JP-T-2000-513940
PTL 6: WO 2002/004633
PTL 7: JP-A-2008-206491
SUMMARY OF INVENTION
Technical Problem
[0016] The problem to be solved is that there is not a reagent kit for measuring freshness, as means for measuring freshness of fish meat, etc., by providing an enzyme activity necessary for appropriately measuring freshness of fish meat, etc. with high storage stability in which enzyme activity is hardly decreased even after storage at high temperature for a long time.
Solution to Problem
[0017] The main characteristics of the reagent kit for measuring freshness according to the present invention are that, in order to enhance the storage stability of enzymes contained in the reagent kit for measuring freshness, an enzyme aqueous solution containing an enzyme protecting agent (sugar and/or gelatin) is quickly frozen, and the resulting frozen product is dried at a temperature not higher than the glass transition temperature (Tg) of the frozen product under reduced pressure.
[0018] That is, the reagent kit for measuring freshness according to the present invention is composed of a first reagent and a second reagent. The first reagent is a lyophilizate of a first reagent solution containing xanthine oxidase (XOD), nucleoside phosphorylase (NP), an enzyme protecting agent, and a color former, and the second reagent is a lyophilizate of a second reagent solution containing xanthine oxidase (XOD), nucleoside phosphorylase (NP), alkaline phosphatase (AP), an enzyme protecting agent, and a color former.
[0019] Herein, the first reagent solution and the second reagent solution are rapidly frozen with, for example, liquid nitrogen and are then dried under reduced pressure. In this case, since the drying time can be shortened by performing the drying while increasing sample temperature (lyophilizer shelf temperature) with elapse of time, the temperature of the solution is preferably increased with elapse of time during the drying of the solution. However, since the enzyme activity decreases if the solution temperature is increased to a temperature not lower than the glass transition temperature (Tg) of the product obtained by the drying, the sample temperature should be increased in the range not higher than the glass transition temperature (Tg) of the product obtained by the drying.
[0020] As the enzyme protecting agent, sucrose and/or gelatin can be used. The concentration of sucrose is preferably in the range of 50 to 400 mM. A sucrose concentration in this range can provide a reagent having high storage stability. The concentration of gelatin is preferably in the range of 0.1 to 2.0 (grams of gelatin/100 mL of reagent solution). A gelatin concentration in this range can provide a reagent having high storage stability.
[0021] As the color former, one that develops a color by conjugation with a reaction of decomposing hypoxanthine (Hx) into xanthine and uric acid by xanthine oxidase (XOD) can be used, and examples thereof include known formazan reagents such as tetrazolium blue (TB), nitrotetrazolium blue (nitro-TB), tetrazolium violet (TV), nitroblue tetrazolium (NBT), 3-(4,5-dimethyl-2-thiazolyl)-2,5-diphenyl-2H-tetrazolium (MTT), 2-(4-iodophenyl)-3-(4-nitrophenyl)-5-(2,4-disulphenyl)-2H-t etrazolium salt (WST-1), 2-(4-iodophenyl)-3-(2,4-dinitrophenyl)-5-(2,4-disulphenyl)-2H-tetrazolium salt (WST-3), 2-(2-methoxy-4-nitrophenyl)-3-(4-nitrophenyl)-5-(2,4-disulphenyl)-2H-tetrazolium salt (WST-8), 2,3,5-triphenyltetrazolium, and 3-(4,5-dimethylthiazol-2-phenyl)-5-(3-carboxymethoxyphenyl)-2-(4-sulfophenyl)-2H-tetrazolium salt (MTS).
[0022] The concentration of the color former is preferably in the range of 0.1 to 0.6 mM when the color former is WST-8. A color former concentration in this range can give stable color development. In a color former concentration higher than 0.6 mM, the intensity of color development reaches the peak level, which is economically wasteful. Accordingly, the concentration of 0.6 mM has been determined to be the upper limit, but the concentration may be higher than 0.6 mM.
[0023] In each of the first reagent solution and the second reagent solution, the concentration of the xanthine oxidase (XOD) is preferably in the range of 0.1 to 10 U/mL, and the concentration of the nucleoside phosphorylase (NP) is, preferably in the range of 0.05 to 20 U/mL. In the second reagent solution, the concentration of the alkaline phosphatase (AP) is preferably in the range of 5 to 200 U/mL.
[0024] The lower limit concentrations of the xanthine oxidase (XOD), the nucleoside phosphorylase (NP), and the alkaline phosphatase (AP) have been determined to be 0.1 U/mL, 0.05 U/mL, and 5 U/ml, respectively, because the stabilities of these enzymes are decreased at concentrations lower than these levels. The upper limit concentrations of the xanthine oxidase (XOD), the nucleoside phosphorylase (NP), and the alkaline phosphatase (AP) have been determined to be 10 U/mL, 20 U/mL, and 200 U/mL, respectively, because the storage stabilities of the reagents are decreased at concentrations higher than these levels.
[0025] The first reagent solution and the second reagent solution may or may not contain serum albumin (BSA).
[0026] The first reagent solution and the second reagent solution preferably each have a pH of 6.8 to 8.5, in which the above-mentioned enzymes can function. The pH levels of the first reagent solution and the second reagent solution are preferably adjusted in the range of 6.8 to 8.5 with a buffer such as potassium phosphate.
[0027] The first reagent solution and the second reagent solution may be each impregnated in paper and then lyophilized to give two types of test papers that can be used for measuring freshness of fish meat, etc.
Advantageous Effects of Invention
[0028] In the present invention, each reagent is prepared by freezing a reagent solution dissolving the above-described two or three types of enzymes and an enzyme protecting agent, and drying the resulting frozen product under reduced pressure in a temperature range of not higher than the glass transition temperature (Tg). This provides advantages that the storage stability (remaining activity) of each reagent has been increased and that each reagent can be stored at relatively high temperature for a long time.
[0029] In addition, since each reagent can be stored at relatively high temperature (for example, 55° C.) over a long period of time, the kit can be used, for example, for raw material quality inspection in seafood processing factories and food factories using seafood products. This provides an advantage that freshness of individual fish can be objectively determined on site.
[0030] Furthermore, each reagent can be stored at relatively high temperature (for example, 55° C.) over a long period of time. This provides an advantage that the kit can be simply used for determining freshness of fish in areas not having refrigeration facilities, such as developing countries.
BRIEF DESCRIPTION OF EMBODIMENTS
[0031] FIG. 1 is a graph showing a relationship between [HxR+Hx] concentration (W) and absorbance (454 nm).
[0032] FIG. 2 is a graph showing a relationship between [IMP+HxR+Hx] concentration (W) and absorbance (454 nm).
[0033] FIG. 3 is a graph showing a correlation between Ki value determined by a reagent kit of the present invention and Ki value determined by HPLC.
[0034] FIG. 4 is a graph showing a relationship between storage period of a reagent kit of the present invention and Ki value.
[0035] FIG. 5 is an explanatory diagram showing a method image of a reagent kit of the present invention.
[0036] FIG. 6 is a graph showing a relationship between storage period (day) and remaining activity of the first reagent stored at 25° C.
[0037] FIG. 7 is a graph showing a relationship between storage period (day) and remaining activity of the second reagent stored at 25° C.
[0038] FIG. 8 is a graph showing a relationship between storage period (day) and remaining activity of the first reagent stored at 40° C.
[0039] FIG. 9 is a graph showing a relationship between storage period (day) and remaining activity of the second reagent stored at 40° C.
[0040] FIG. 10 is a graph showing a relationship between storage period (day) and remaining activity of the second reagent stored at 55° C.
[0041] FIG. 11 is a graph showing a relationship between storage period (day) and remaining activity of the second reagent stored at 55° C.
[0042] FIG. 12 is a graph showing a relationship between storage period (day) and remaining activity of the first reagent at each humidity.
[0043] FIG. 13 is a graph showing a relationship between storage period (day) and remaining activity of the second reagent at each humidity.
[0044] FIG. 14 is a graph showing a relationship between storage period (day) of an enzyme composite (reagent kit) not containing an enzyme protecting agent and Ki value of fish meat measured by the reagent kit using the same fish meat on each day of the storage period.
[0045] FIG. 15 is a graph showing a relationship between storage period (day) of an enzyme composite (reagent kit) containing sucrose and Ki value of fish meat measured by the reagent kit using the same fish meat on each day of the storage period.
[0046] FIG. 16 is a graph showing a relationship between storage period (day) of an enzyme composite (reagent kit) containing sucrose and gelatin and Ki value of fish meat measured by the reagent kit using the same fish meat on each day of the storage period.
DESCRIPTION OF EMBODIMENTS
[0047] The object of providing a reagent kit for measuring freshness, the storage stability of the kit is high, has been realized by a simple method without reducing basic activities of the enzymes.
Example 1
[0048] Nucleoside phosphorylase (NP) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a NP solution. Xanthine oxidase (XOD) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a XOD solution. Then, stabilizers contained in the NP solution and the XOD solution were removed by dialysis. Sucrose was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a sucrose solution. WST-8 (color former) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a WST-8 (color former) solution.
[0049] Then, all of these NP solution, XOD solution, sucrose solution, and WST-8 (color former) solution were mixed to prepare a first reagent solution. This first reagent solution was put in a 2-mL polypropylene tube and immersed in liquid nitrogen for one minute to rapidly freeze the solution. Then, this polypropylene tube was put in a lyophilizer, in a state that the upper lid was opened, for drying. The drying was performed under a reduced pressure of 3.0×10 −2 Torr. On this occasion, the temperature was increased from −40° C. to 5° C. by 5° C. for each 3 hours, subsequently, from 5° C. to 25° C. by 10° C. for each 3 hours. Then, the dried product was taken out from the lyophilizer and was transferred to a desiccator containing P 2 O 5 and stored therein for 7 days for complete dehydration to obtain a first reagent.
[0050] Nucleoside phosphorylase (NP) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a NP solution. Xanthine oxidase (XOD) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a XOD solution. An alkaline phosphatase (AP) solution was prepared. Then, stabilizers contained in the NP solution, the XOD solution, and the AP solution were removed by dialysis. Sucrose was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a sucrose solution. WST-8 (color former) was dissolved in 20 mM potassium phosphate buffer (pH=7.8) to prepare a WST-8 (color former) solution.
[0051] Then, all of these NP solution, XOD solution, AP solution, sucrose solution, and WST-8 (color former) solution were mixed to prepare a second reagent solution. This second reagent solution was put in a 2-mL polypropylene tube and immersed in liquid nitrogen for one minute to rapidly freeze the solution. Then, this polypropylene tube was put in a lyophilizer, in a state that the upper lid was opened, for drying. The drying was performed under a reduced pressure of 3.0×10 −2 Torr. On this occasion, the temperature was increased from −40° C. to 5° C. by 5° C. for each 3 hours, subsequently, from 5° C. to 25° C. by 10° C. for each 3 hours. Then, the dried product was taken out from the lyophilizer and was transferred to a desiccator containing P 2 O 5 and stored therein for 7 days for complete dehydration to obtain a second reagent.
[0052] Then, 60 mg of the first reagent was dissolved in 1 mL of distilled water, and a fraction of 150 μL of the resulting solution was mixed with 150 μL of squeezed juice of fish meat. The absorbance A of the solution mixture was measured at 454 nm with a spectrophotometer. Then, as shown in FIG. 1 , the [HxR+Hx] concentration A (μM) in the squeezed juice of fish meat was determined from the relationship between absorbance (Abs. at 454 nm) and [HxR+Hx] concentration (μM) prepared in advance.
[0053] Separately, 60 mg of the second reagent was dissolved in 1 mL of distilled water, and a fraction of 150 μL of the resulting solution was mixed with 150 μL of squeezed juice of fish meat. The absorbance A of the solution mixture was measured at 454 nm with a spectrophotometer. Then, as shown in FIG. 2 , the [IMP+HxR+Hx] concentration B (μM) in the squeezed juice of fish meat was determined from the relationship between absorbance (Abs. at 454 nm) and [IMP+HxR+Hx] concentration (μM) prepared in advance.
[0054] Then, Ki value (=A/8) was determined based on (HxR+Hx)×100/(IMP+HxR+Hx)=Ki(%), wherein (HxR+Hx) is the concentration A, and (IMP+HxR+Hx) is the concentration B.
[0055] Separately, the Ki value of the same fish meat was determined by high-performance liquid chromatography (HPLC). A correlation between the Ki value determined by the reagent kit of the present invention and the Ki value determined by HPLC was obtained. The results were as shown by the graph in FIG. 3 . It can be confirmed from the results shown by the graph in FIG. 3 that there is a high correlation, R2=0.996, between the Ki value determined by the measuring method of the present invention and the Ki value determined by HPLC.
Example 2
[0056] The reagent kits of the present invention were stored at 5° C., 25° C., or 40° C. for 50 days, and the Ki value of fish meat (Japanese horse mackerel) was measured by each of the kits. The results are shown in FIG. 4 . It can be confirmed from the results that the reagent kit of the present invention can be stored at 40° C. for 50 days in a state maintaining the enzyme activities considerably high.
Example 3
[0057] In an experiment as in Example 1, when the concentration of alkaline phosphatase (AP) was less than 5 U/mL, the resulting Ki values were unstable, which may be caused by that decomposition of IMP by alkaline phosphatase (AP) was incomplete, and when the concentration of alkaline phosphatase (AP) was higher than 200 U/mL, the storage stability of the reagent was decreased. However, when the concentration of alkaline phosphatase (AP) was from 5 to 200 U/mL, such disadvantages did not occur to give stable Ki values. Accordingly, the optimum concentration range of alkaline phosphatase (AP) is judged to be from 5 to 200 U/mL.
Example 4
[0058] In an experiment as in Example 1, when the concentration of nucleoside phosphorylase (NP) was less than 0.05 U/mL, the resulting Ki values were unstable, which may be caused by that decomposition of HxR by nucleoside phosphorylase (NP) was incomplete, and when the concentration of nucleoside phosphorylase (NP) was higher than 20 U/mL, the storage stability of the reagent was decreased. However, when the concentration of nucleoside phosphorylase (NP) was from 0.05 to 20 U/mL, such disadvantages did not occur to give stable Ki values. Accordingly, the optimum concentration range of nucleoside phosphorylase (NP) is judged to be from 0.05 to 20 U/mL.
Example 5
[0059] In an experiment as in Example 1, when the concentration of xanthine oxidase (XOD) was less than 0.1 U/mL, the resulting Ki values were unstable, which may be caused by that decomposition of Hx by xanthine oxidase (XOD) was incomplete, and when the concentration of xanthine oxidase (XOD) was higher than 10 U/mL, the storage stability of the reagent was decreased. However, when the concentration of xanthine oxidase (XOD) was from 0.1 to 10 U/mL, such disadvantages did not occur to give stable Ki values. Accordingly, the optimum concentration range of xanthine oxidase (XOD) is judged to be from 0.1 to 10 U/mL.
Example 6
[0060] In an experiment as in Example 1, when the concentration of sucrose was less than 50 mM, the resulting Ki values were unstable, and when the concentration of sucrose was higher than 400 mM, the enzyme solution was crystallized. However, when the concentration of sucrose was from 50 to 400 mM, such disadvantages did not occur to give stable Ki values. Accordingly, the optimum concentration range of sucrose is judged to be from 50 to 400 mM.
Example 7
[0061] In an experiment as in Example 1, when the concentration of WST-8 (color former) was less than 0.1 mM, the color development was unstable, and when the concentration of WST-8 (color former) was higher than 0.6 mM, the degree of color development reached the peak level regardless of an increase in concentration. However, when the concentration of WST-8 (color former) was from 0.1 to 0.6 mM, such disadvantages did not occur to give stable Ki values. Accordingly, the optimum concentration range of WST-8 (color former) is judged to be from 0.1 to 0.6 mM.
Example 8
[0062] In an experiment as in Example 1, when the pH was lower than 6.8 or higher than 8.5, the enzymes did not function, but when the pH was from 6.8 to 8.5, such disadvantage did not occur to give stable Ki values. Accordingly, the optimum pH range is judged to be from 6.8 to 8.5.
Example 9
[0063] In the above-described examples, the color intensity of a reagent was determined using an absorptiometer, but, as shown in FIG. 5 , the [IMP+HxR+Hx] concentration or the [HxR+Hx] concentration may be determined by lyophilizing each reagent, dispensing the resulting powder to each well of a plate reader, adding an appropriate amount of fish meat extraction to the wells to develop a color, and comparing the color intensity with color samples. Alternatively, an enzyme solution lyophilized in a state being dispensed to each well of a plate reader may be used as a reagent kit.
Example 10
[0064] A first reagent solution containing 0.3 U/mL of nucleoside phosphorylase (NP) and 0.6 U/mL of xanthine oxidase (XOD) was prepared by dissolving 0.02 mg of NP and 2 mg of XOD in 1 mL of a solution containing 200 mM sucrose or in 1 mL of a solution containing 200 mM sucrose and 0.5% gelatin.
[0065] A second reagent solution containing 45 U/mL of alkaline phosphatase (AP), 0.3 U/mL of nucleoside phosphorylase (NP), and 0.6 U/mL of xanthine oxidase (XOD) was prepared by dissolving 1.5 μL of AP, 0.02 mg of NP, and 2 mg of XOD in 1 mL of a solution containing 200 mM sucrose or in 1 mL of a solution containing 200 mM sucrose and 0.5% gelatin.
[0066] One milliliter of the first reagent solution was put in a 2-mL polypropylene tube, and 1 mL of the second reagent solution was put in another 2-mL polypropylene tube. These polypropylene tubes were immersed in liquid nitrogen for at least one minute to rapidly freeze the solutions. The resulting frozen products were stored at −90° C.
[0067] Then, each frozen product was transferred to a lyophilizer cooled in advance to −40° C., and the temperature was increased from −40° C. to 5° C. by 5° C. for each step, subsequently, from 5° C. to 25° C. by 10° C. for each step, while maintaining the temperature in each step for 3 hours, to dry the frozen product. In this procedure, the pressure in the lyophilizer was maintained at 3.0×10 −2 Torr over the drying process. The frozen product lost its water by the lyophilization to form a dried solid.
[0068] The remaining water in the dried solid was further removed in a vacuum desiccator over P 2 O 5 at room temperature for 7 days. The dried solid obtained from the frozen product of the first reagent solution and the dried solid obtained from the frozen product of the second reagent solution were placed in a glove box replaced with dried nitrogen as a first reagent and a second reagent, respectively, and were stored at 25° C., 40° C., or 55° C. for 45 days.
[0069] Then, 60 mg of the first reagent was dissolved in 1 mL of distilled water. To a fraction of 75 μL of the resulting solution, 75 μL of 4 mM HxR and then 150 μL of 20 mM potassium phosphate buffer were added to prepare a first reagent solution. The absorbance at 292 nm of the first reagent solution was measured at 20° C. using a UV-VIS spectrophotometer. The enzyme activity was evaluated by comparing it with the initial activity.
[0070] Similarly, 60 mg of the second reagent was dissolved in 1 mL of distilled water. To a fraction of 75 μL of the resulting solution, 75 μL of 4 mM HxR and 1 mM MgCl 2 and then 150 μL of 20 mM potassium phosphate buffer were added to prepare a second reagent solution. The absorbance at 292 nm of the second reagent solution was measured at 20° C. using a UV-VIS spectrophotometer. The enzyme activity was evaluated by comparing it with the initial activity. The remaining activity was expressed by percentage with respect to the activity before the lyophilization.
[0071] The remaining activities of the enzymes in the first reagent stored at a storage temperature of 25° C. for from 0 to 45 days were as shown in FIG. 6 ; the remaining activities of the enzymes in the second reagent stored at a storage temperature of 25° C. for from 0 to 45 days were as shown in FIG. 7 ; the remaining activities of the enzymes in the first reagent stored at a storage temperature of 40° C. for from 0 to 45 days were as shown in FIG. 8 ; the remaining activities of the enzymes in the second reagent stored at a storage temperature of 40° C. for from 0 to 45 days were as shown in FIG. 9 ; the remaining activities of the enzymes in the first reagent stored at a storage temperature of 55° C. for from 0 to 45 days were as shown in FIG. 10 ; and the remaining activities of the enzymes in the second reagent stored at a storage temperature of 55° C. for from 0 to 45 days were as shown in FIG. 11 .
[0072] It can be confirmed from the results shown in FIGS. 6 to 11 that the remaining activities of the first reagent and the second reagent containing sucrose were increased in every cases compared with those not containing sucrose and that the remaining activities of the reagents containing both sucrose and gelatin were further increased in every cases compared with those containing only sucrose. Note that the water contents of the first reagent and the second reagent were measured with a Karl Fischer moisture titrator (737 KF, Herisau, Switzerland) and that the heat characteristics of the first reagent and the second reagent were investigated with a differential scanning calorimeter (DSC-50, Shimadzu, Japan).
Example 11
[0073] A first reagent containing sucrose and gelatin and a second regent containing sucrose and gelatin were prepared and were stored at 55° C. for from 0 to 45 days in a relative humidity environment of 0%, 33%, or 53%. The remaining activity of each reagent in each humidity environment was investigated on each day of the storage period. Herein, each reagent was produced by the same method as in Example 10, and the remaining activity of each reagent was measured by the same method as in Example 10.
[0074] The remaining activity of the first reagent in each humidity environment was as shown in FIG. 12 , and the remaining activity of the second reagent in each humidity environment was as shown in FIG. 13 . It can be confirmed from the results shown in FIGS. 12 and 13 that the remaining activity in a relative humidity of 0% is significantly high compared with that in relative humidity of 33% or 53%. It can be confirmed that in order to prevent a decrease in remaining activity of a reagent, it is necessary to store the reagent in an atmosphere in which the relative humidity has been reduced as much as possible so as to be near 0%.
Example 12
[0075] A first reagent not containing sucrose and gelatin, a first reagent (Tg: 65° C., MT: 0.81%) containing sucrose but not containing gelatin, and a first reagent (Tg: 77° C., MT: 0.5%) containing both sucrose and gelatin were prepared and stored at 5° C., 25° C., or 40° C. for from 0 to 112 days.
[0076] A second reagent not containing sucrose and gelatin, a second reagent (Tg: 65° C., MT: 0.78%) containing sucrose but not containing gelatin, and a second reagent (Tg: 76° C., MT: 0.99%) containing both sucrose and gelatin were prepared and stored at 5° C., 25° C., or 40° C. for from 0 to 112 days. Herein, the fundamental compositions and conditions for preparing the first reagents and the second reagents were the same as those in Example 10, and a color former, WST-8, was added to each reagent.
[0077] Inosine (HxR) standard solutions were prepared by adding 0, 5, 10, 20, 30, or 50 μM HxR to 20 mM potassium phosphate buffer. Inosinic acid (IMP) standard solutions were prepared by adding 0, 5, 10, 20, 30, or 50 μM IMP and 1 mM MgCl 2 to 20 mM potassium phosphate buffer. The actual HxR concentrations in the HxR standard solutions and the actual IMP concentrations in the IMP standard solutions were determined by high-performance liquid chromatography (HPLC).
[0078] The first reagent solution (150 μL) was added to 150 μL of each of the HxR (0, 5, 10, 20, 30, and 50 μM) standard solutions, and the absorbance at 454 nm of each solution was measured with a UV-VIS spectrophotometer at 25° C. to determine a relationship between the HxR concentration and the absorbance, and a standard curve was prepared based on the relationship. The second reagent solution (150 μL) was added to 150 μL of each of the IMP (0, 5, 10, 20, 30, and 50 μM) standard solutions, and the absorbance at 454 nm of each solution was measured with a UV-VIS spectrophotometer at 25° C. to determine a relationship between the IMP concentration and the absorbance, and a standard curve was prepared based on the relationship.
[0079] Fish meat (1 g) was mixed with 10% perchloric acid (4 mL) while mincing, and 5% perchloric acid (4 mL) was further added thereto and mixed. The resulting mixture was centrifuged at a speed of 2000 rpm at 5° C. for 10 minutes. The supernatant was collected and was adjusted its pH to 6.8 to 7.0 with 8 M or 1 M KOH. The supernatant was centrifuged again at a speed of 2000 rpm at 5° C. for 10 minutes. The sample solution was filtered through Watman No. 1 filter paper and diluted with distilled water graded by high-performance liquid chromatography (HPLC) to obtain 20 mL of a fish extract. The diluted sample solution was filtered again through millipore paper with a pore size of 0.65 μm and stored at −90° C. until measurement of freshness.
[0080] Then, the Ki values of the same fish meat sample on each day of the storage period and at each storage temperature were investigated using the first reagent and the second reagent. Herein, the Ki value of the fish meat sample was determined as follows: First, the first reagent and the second reagent (60 mg each) were each dissolved in 1 mL of distilled water, and to 150 μL of each of the resulting solutions, the fish extract (20 μL) and 20 mM potassium phosphate buffer (130 μL) were added to prepare a first reagent solution and a second reagent solution.
[0081] The absorbance at 454 nm of each of the first reagent solution and the second reagent solution was measured with a UV-VIS spectrophotometer at 25° C., and the concentration of HxR+Hx and the concentration of IMP+HxR+Hx were respectively determined using the results obtained by the first reagent solution and the second reagent solution based on the standard curves. Then, the Ki value was determined by fitting the concentration of HxR+Hx and the concentration of IMP+HxR+Hx to the equation shown by the following Expression 1:
[0000] Ki (%)=( HxR+Hx )×100/( IMP+HxR+Hx ) [Expression 1]
[0082] The Ki values determined using the enzyme composite (first reagent and second reagent) not containing sucrose and gelatin were as shown in FIG. 14 ; the Ki values determined using the enzyme composite (first reagent and second reagent) containing only sucrose were as shown in FIG. 15 ; and the Ki values determined using the enzyme composite (first reagent and second reagent) containing sucrose and gelatin were as shown in FIG. 16 .
[0083] It can be confirmed from the results shown in FIGS. 14 to 16 that the variation in the Ki values determined using the enzyme composite (first reagent and second reagent) containing sucrose was small compared to that in the Ki values determined using the enzyme composite (first reagent and second reagent) not containing sucrose and gelatin and that the variation in the Ki values determined using the enzyme composite (first reagent and second reagent) containing sucrose and gelatin was further small. | A reagent kit for measuring freshness, which can be stored at a relatively high temperature with high storage stability, is obtained by lyophilizing reagent solutions each containing a plurality of enzymes and an enzyme protecting agent. The reagent kit includes a first reagent and a second reagent. The first reagent is obtained by drying a frozen product of a first reagent solution containing XOD, NP, an enzyme protecting agent, and a color former under reduced pressure at a temperature not higher than the glass transition temperature (Tg). The second reagent is obtained by drying a frozen product of a second reagent solution containing XOD, NP, AP, an enzyme protecting agent, and a color former under reduced pressure at a temperature not higher than the glass transition temperature (Tg). The enzyme protecting agent is sucrose and/or gelatin, and the color former develops a color by conjugation with a reaction of decomposing Hx into xanthine and uric acid by XOD. | 2 |
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to a high vacuum pump and, more particularly, to a high-vacuum pump having a centrifugally filtered intake.
According to the invention, a high vacuum pump is provided in which an operating inlet enters the top of a sump tank. The pump has a coaxial intake at its rotor hub terminating in a mesh filter screen projecting downwardly from the central intake port into an input sump tank. The input sump tank is filled with water up to the bottom of the filter screen so when the level from an intake liquid raises above the screen, water and air is pulled through the rotating screen upwardly into the pump and outwardly radially from the pump. Another novel feature, which appears to give the pump over double the normally expected vacuum, lies in the liquid pressure seal on the top and bottom of the impeller assembly.
During a period when the pump is not in use, such as in the evening in the case of an installation in a dentist's office, for example, a timer opens the solenoid actuated valve which supplies flushing water to the sump tank, raising the level to a drain level which then drains out the top layer of water where floating debris has a tendency to collect. Periodically, the sump tank is removed, emptied, flushed, and replaced. One of the main purposes of the assembly is the elimination of mercury in sewage which is becoming of increasing concern.
An object of the present invention is the provision of a highly efficient high vacuum pump.
Another object of the invention is the provision of a high vacuum pump having a centrifugally filtered intake.
A further object of the invention is the provision of a high vacuum pump with a radial outlet.
Yet another object of the invention is the provision of a high vacuum pump for utilization with an aspirator.
Other objects and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which like reference numerals designate like parts throughout the Figures thereon and wherein:
FIG. 1 is an exploded view in perspective of the preferred embodiment of the present invention;
FIG. 2 illustrates the electrical system of the embodiment of FIG. 1;
FIG. 3 is a vertical exploded view partially sectioned of the embodiment of FIG. 1;
FIG. 4 is an assembled sectional view of the central portion of FIG. 3;
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 3;
FIG. 6 is a sectional view taken along lines 6--6 of FIG. 3; and
FIG. 7 is a phantom sectional view through the pump housing along lines 7--7 of FIG. 3 with cross hatching deleted for clarity.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the pump assembly of the present invention is shown generally at 11 having a motor 12 with a shaft 12A (not shown) projecting into pump housing 14. Motor 12 is carried by pump housing 14 via motor flange 16. Pump housing 14 is carried by main mounting plate 17 and has a shaft (not shown) carrying a cylindrical filter screen 18 (not shown) projecting downwardly therefrom and surrounded by a cone 19. Sump tank 21 is removably coupled to main mounting plate 17 via clamps 22. Sump tank 21 also has handles 23 and terminates in its upper portion at a sealing flange 24. An operating inlet 26 empties into sump tank 21 at 27. Electrical leads 28 are coupled to solenoid valve 29 and motor 12. Cooling and sealing inlet 31 is coupled through solenoid valve 29 into pump housing 14. A flushing inlet 32 is coupled through solenoid valve 33 and into sump tank 21 at 34. Main drain outlet 36 is coupled from pump housing 14. Sump tank 21 has a flush drain 40.
Referring to FIG. 2, input electrical leads 35 are coupled through switch 37 to timer 38. Timer 38 couples power through leads 39 to solenoid-actuated valves 41 and 33. Solenoid actuated valve 41 is in exhaust line 42 of sump tank 21. Sump tank 21 is shown filled with water to operating level 43. Flushing level 44 is shown in dotted lines and debris zone 46 is indicated between operating level 43 and dotted line 47. Operating inlet line 26 is shown having air bubbles 48 moving toward cylindrical filter drum 20 with heavy debris 49 collecting in the bottom of sump tank 21 at 51.
Referring to FIG. 3, motor 12 is carried by motor flange 16 which is coupled via threaded bolts 15 to pump housing 14. Shims 15A assure proper spacing. Motor shaft 12A is threadably coupled to the pump hub (not shown) and passes through elastomeric seal washer 51, static ceramic thrust washer 52, rotating graphic washer 53, compression spring 54, washer 55, and sleeve 56, which abuts the pump hub 58A. Impeller assembly 58 is carried by hub 58A which in turn carries filter screen cylinder 20 via threaded shaft 59 which mounts end plate 61 to the bottom of filter cylinder 20. Deflector cone 19 is mounted via threaded bolts 63 to main mounting plate 17. Pump housing 14 is mounted to main mounting plate 17 via threaded bolts 64 which pass through shims 66 for proper spacing thereof. Cooling vent 68 is in communication with rotating graphite washer 52 and static ceramic thrust washer 51 on one end via chamber 60 (FIG. 4) and with the sealing water input 69 at another end. Sealing gap 71, formed by recess 71A in pump housing 14 and top impeller plate 71B, is also in communication with sealing water input port 69. Recess 74 forms an annular water sealing groove in communication with inlet 69. A lower water seal gap 93 is formed between bottom impeller plate 93A and recess 93B in main mounting plate 17.
Referring to FIG. 4, motor flange 16 is shown carried by pump housing 14 with motor shaft 17A projecting downwardly and in threadable engagement with hub 58A. Hub 58A is in threadable engagement with filter shaft 59 which passes through first intake chamber 81 disposed above cylindrical filter screen 20. Cylindrical filter screen 20 is held in screen mounting groove 82 in impeller core 83. Impeller vanes 84 are carried by impeller core 83. First input chamber 81 is in communication with inlet ports 86 and 87, which in turn, are in communication with second intake chamber 88. Second intake chamber 88 is in communication with inlet/outlet port 89. Inlet/outlet port 91 is in communication with impeller vane 84 and outlet chamber 92. Motor shaft 12A carries sleeve 56, washer 55, rotating graphite washer 53, static ceramic thrust washer 52 and elastomeric seal washer 51. Compression spring 54 is compressed between rotating graphite washer 53 and washer 55. Water channel 68 is in communication with static ceramic thrust washer 52 and elastomeric seal washer 51 and rotating graphite washer 53. Water seal gap 71 is in communication with water channel 68 (FIG. 3). Water seal gap 93 receives water from centrifically thrown water from impeller blades 84.
Referring to FIG. 5, a lower and sectional view as taken and indicated on FIG. 3 is shown with the housing 14 cross hatched and a new feature being first visible, this feature being the transfer chamber 14A into which the gas liquid pumped medium can be transferred from the input section and from which it is taken by the output action of the impeller 58. The impeller 58 lies within a declivity 71A (FIG. 3) outlined by recess shoulder 73 (also see FIG. 3) and the flat surface of that declivity forms the upper boundary 71A of water seal gap 71 previously indicated. A further declivity 74 constitutes an annular water groove existing within that surface, this water groove 74 is supplied with sealing water via channel 68. Centrally located within FIG. 5 is a shaft bore 101 surrounded by the sealing component cavity 60 and contiguous in its near extremity with the second intake chamber 88. On the opposite side of cavity 60 is the mouth of the outlet chamber 92A deeper in the casting 14, the casting being the pump housing 14, communicates through an outlet chamber 92 indicated by dash lines and communicates with the main drain outlet 36.
Referring now to FIG. 6, wherein the impeller 58 is depicted in cross section along lines 6--6 shown on FIG. 3. A central clearance bore for the filter bolt is designated at 12C. This is surrounded by threads for the filter bolt designated at 12B and are an integral portion of the motor shaft 12A which is surrounded by threads to receive the hub 58A which also contains inlet/outlet ports 86/87, the number depending on the area in which the flow from these ports impinges. Flow from inlet ports impinges on the deflector ridge 72 visible in FIGS. 4 and 5, and flow inlet from ports 87, impinges on the open second intake chamber 88. The core of the impeller is indicated 83 and is surrounded by inlet/outlet ports 89/91. The function of these ports and the number ascribed to them depends upon their location within the operating unit at any given time. Between the multiplicity of input/output ports 89/91 lie a multiplicity of curved vanes 84.
FIG. 7 represents a phantom section of the pump housing 14 looking down along the section lines 7--7 indicated in FIG. 3. Cross hatching of the pump housing 14 has been omitted so that the interrelation between that housing 14 and the impeller 58 may be viewed. In a center location is the motor shaft 12A surrounded by sleeve 56. These are immediately surrounded by inlet ports 86 on the top, bottom, and left side where the upward flow through the intake ports 86 impinges on the deflector ridge 72, and they are surrounded on the right side by inlet ports 87 where the upward flow freely enters into inlet chamber 88. Flow from all of the inlet ports 86 and 87 either comes around the sleeve 56 or flows directly into inlet/outlet ports 89 at the top of the impeller and viewable through the inlet chamber opening 88. The rising pump media is therefore transferred radially to the ports between vanes 84 throughout almost the entire right half of FIG. 7. Solid arrows of flow indicate that this pumped media now flows from between the vanes 84 and enters a transfer chamber 14A which becomes increasingly larger in the direction of impeller rotation which is in this view counterclockwise. On the left side of the figure, arrows indicate the pump media entering inbetween vanes 84 and traveling inward toward the impeller core 83 (see FIG. 6). From whence that pumped media flows upward through inlet/output ports 91 and into the mount of outlet chamber 92A from which it passes into the outlet chamber 92 (see FIG. 4) and out the main drain outlet 36 (see FIG. 3). | A high vacuum pump having a centrifugally filtered intake with a particular utility as an aspirator in a dentist's office, for example, having a coaxial intake/output at the pump's rotor hub with a radial outlet therefrom, a liquid pressure seal on the top and bottom of the pump impeller assembly and an automatically flushed sump tank surrounding the intake filter. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. Ser. No. 11/319,112, filed Dec. 27. 2005. which claims the benefit of U.S. Provisional Application No. 60/649,286, filed Feb. 2, 2005.
TECHNICAL FIELD
[0002] The present invention relates to a process for the evaluation and geocoding of geographic information systems (GIS) data elements and, more particularly, to a process that uses multiple “locate” tests and a weighting scheme to express the search results as a multidimensional vector.
BACKGROUND OF THE INVENTION
[0003] Geocoding is generally thought of as the act, method, or process of programmatically assigning x and y coordinates (usually, but not limited to, latitude and longitude) to records, lists and files containing location information (full addresses, partial addresses, zip codes, census FIPS codes, etc.) for cartographic or any other form of spatial analysis or reference. Currently, geocoding is used to convert a street address or other textually-specific geographic location information into a physical location. Geocoding is currently performed by running ungeocoded information (“raw data”) through proprietary software that performs table lookup, fuzzy logic and address matching against an entire “library” of all known or available addresses (referred to hereinafter as “georeferenced library”) with associated x,y locating coordinates. The raw data that match the records from the georeferenced library are then assigned the same x,y coordinates associated with the matched record in the georeferenced library. A “centroid” is defined as a geographic center of an entire area, region, boundary, etc. for which the specific geographic area covers. Street vectors are defined as address ranges that are assigned to segments of individual streets. Street vectors are used in displays of digitized computer-based street maps, and usually appear as left-side and right-side address ranges. They are also used for geocoding a particular address to a particular street segment based on its point along the line segment. FIG. 1 contains a table showing the address range on both sides of the street for one particular street segment of Elm St.
[0004] Geographic information systems (GIS) store, retrieve and display topological information. The topological information is obtained from a topology that is a topographic study of a geographic region. The topographic study may be a map having features of the geographic region including rivers, lakes, etc, as well as bridges and roads.
[0005] A geo-referenced library can be compiled from a number of various sources, including US Census address information and US Postal address information, as well as ZIP Code boundaries and other various sources of data containing geographic information and/or location geometry. In the prior art, if a raw data address could be matched exactly to a specific library street address, then an attempt was made to match the raw data address to an ever-decreasing precision geographic hierarchy of point, line or region geography until a predetermined tolerance for an acceptable match was met. Current geocoding technology generally provides for two main types of precision: street level and postal ZIP centroid. Street level precision is the placement of geocoded records at the street address (as shown in record 10 of FIG. 2 ). Street level precision attempts to geocode all records to the actual street address. In all likelihood, some matches may end up at a less precise location, such as a ZIP centroid (e.g., ZIP+4, ZIP+2, or ZIP). One of the disadvantages of ZIP code matching alone is that current geocoding technology only examines the ZIP code field when matching. If the ZIP codes in the raw data records do not already have ZIP+4 values, then current geocoding technology will only match to the larger area 5-digit ZIP code centroids. Conversely, if only the street level precision is used, current geocoding technology will attempt to return street-level coordinates and will optionally fall back to the slightly less precise ZIP+4 coordinates.
[0006] The typical output from a geocoding process (a “match”) is a longitude/latitude coordinate pair specifying a point on the earth's surface. Current geocoding technology is considered to be imprecise, and only works well when the input is a well-forned and existing street address and the desired output is a physical point location. Sub-optimal performance has been the result when one or more of the following elements is involved in the geocoding process: (1) the input element is an incomplete street address; (2) the input postal address is valid, but has a large interpolation error, or is located via a zip code centroid or other imprecise method; (3) the address is ambiguous (i.e., multiple “hits” are returned for the input address); (4) the input element is not a point location, but a set of locations or polygon; (5) the geocoding system has multiple data sets for a single locator type; or (6) the desired result is not a point longitude/latitude location, but a bounding geometry (minimal bounding rectangle—MBR) in which the input element must definitely lie.
[0007] Thus, a need remains in the geocoding art for a method that is able to return a more precise result from any of a variety of incomplete input data.
SUMMARY OF THE INVENTION
[0008] The need remaining in the prior art is addressed by the present invention, which relates to a process for evaluation and geocoding of GIS data elements and, more particularly, to a process that uses a plurality of “locate” tests and a weighting scheme to express the match results as a multidimensional vector.
[0009] In accordance with the present invention, multiple inputs and data sources, as well as ambiguous and partial input data, is used to generate an output with improved precision by applying a weighting function to each input element and generating a set of test vectors (i.e., the input data element weighted by the known accuracy of the element/source). A sum of a plurality of tests is then generated as the “characteristic vector” of the test set. By using two (or more) different sets of tests, two (or more) characteristic vectors are formed. Various well-known algebraic techniques can then be used to evaluate the results of each set of tests and select the “best match” result.
[0010] For example, the length of a characteristic vector can be calculated and used to determine the likelihood of a “match” between the test results and the input data. A comparison of the lengths of multiple characteristic vectors is used to determine the “best match” between the input address information and the output longitude/latitude result. A correlation between the tests used in each test set can be determined by analyzing the angle between two characteristic vectors (e.g., an angle of 90°—orthogonal vectors—defining each test set as completely independent, and an angle of 0°—parallel vectors—defining each test set as containing the same individual tests). To establish how closely two match results agree with each other, a vector subtraction is performed between the two characteristic vectors. The value of each component gives the difference for each test, and the norm of the result yields the overall difference in confidence level.
[0011] Other and further aspects of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Referring now to the drawings,
[0013] FIG. 1 is a diagram of a street level data along an address range for an exemplary street segment;
[0014] FIG. 2 contains a table showing examples of prior art geocoded records with data fields including centroids of different precision;
[0015] FIG. 3 illustrates the application of an address block range to a particular address;
[0016] FIG. 4 illustrates the utilization of longitude and latitude information to form a minimum boundary rectangle; and
[0017] FIG. 5 is a flowchart illustrating an exemplary process of utilizing multiple tests to form characteristic vectors in accordance with the present invention.
DETAILED DESCRIPTION
[0018] A vector is defined as a geometric element possessing both length and direction. A “characteristic vector”, for the purposes of the present invention, is defined as a “locate” match result that is a measure of both the reliability of the match and the tests used to find the match. The characteristic vector, by itself, does not indicate anything about the actual physical location of a match.
[0019] Simple geocoding involves a single test (or set of dependent tests) that is used to generate a single result (the most likely match). In accordance with the teachings of the present invention, multiple tests and multiple data inputs are used to generate a plurality of characteristic vectors, where vector mathematical properties are then exploited to convert imprecise point location results into precise bounding geometries.
[0020] Consider a set of tests t 0 , t 1 , . . . , t n and their associated results for a specific point, expressed as “uncertainty” factors u 0 , u 1 , . . . , u n . Various tests for geocoding include, but are not limited to: (1) street address; (2) cross-street location; and (3) gridname. If a weight w i is assigned to each test, the overall certainty of a selected group of tests can be expressed as a characteristic vector in the following form:
[0000] w 0 (1− u 0 )+ w 1 (1− u 1 )+ . . . + w n (1− u n ).
[0000] As will be discussed below, a “weighting constant” w is used to adjust the percentage of each test result used in calculating the characteristic vector. A second set of tests can be used to perform the same “locate” process, generating a second characteristic vector. As stated above, this process can be considered as a sum of vectors in an n-dimensional vector space, which allows for the use of tools and theorems from vector algebra in generating the solution set for geocoding. The sum is the characteristic vector for the specific test manifold, where its resultant geometry (either a point object or a bounding polygon) is denoted as Γ, or Γ(r) for a single result candidate r. With proper manipulation of the weighting constants, a single test with multiple data sources can also be expressed as multiple tests, appended to the characteristic vector.
[0021] The likelihood of a single match being the actual location of an object is, in geometric terms, the length of the characteristic vector x. Mathematically, it can be expressed as the norm of x:
[0000] | x |=( x 1 2 +x 2 2 +x 3 2 + . . . ) 1/2 .
[0000] For example, consider a match agreed upon by a street address test with a certainty of 0.8, a cross street test with a certainty of 0.3, and a grid test with a certainty of 0.6. The overall certainty of this match is then the square root of (0.8) 2 +(0.3) 2 +(0.6) 2 , or 0.94. This is a generalized value appropriate for all calculations and comparisons. To display this result as percentage, by dividing the length of the unit vector (in this case, the length is equal to 3), for a result of 54%. The most probable match among a match result set is simply the longest characteristic vector, or mathematically the maximum of the norm of the vector set, expressed as:
[0000] max|x j |, j=1, 2, . . . , n.
[0022] The result of geocoding an object will often include more than one potential location. For example, a locate on “123 Elm Street, Anytown, USA, inswide grid 3722A7730C” could result in a match on South Elm Street, a second match on North Elm Street, and a third match based on the grid name. Any of these three may be the actual location, or all three could be incorrect. The certainty of the result set (e.g., the probability that one of the three is correct), is the norm of the vector sum of the set. Defined geometrically, the certainty is defined as the length of the line made by connecting each of the vectors end-to-end. Mathematically, this can be expressed as:
[0000] |(x 1 +x 2 +x 3 + . . . )|.
[0000] To establish how closely two match results agree with each other, a vector subtraction is performed. The value of each component gives the difference for each corresponding test, and the norm of the result gives the overall difference in confidence level. A vector operation can also be used to determine how closely two different result sets agree, by first summing the characteristic vectors of each set, then performing a vector subtraction of one sum from the other.
[0023] Often, in comparing two match results, the actual confidence of the match is irrelevant, since the requester simply wants to know if the matches used any or all of the same tests. The angle between the two vectors yields this information, with an angle of 90° associated with the use of completely independent tests (i.e., no tests used for match 1 were used in match 2 ), and an angle of 0° associated with identical tests being used for both match 1 and match 2 . Any angle between these two values gives a measure of the variance in the composition of the tests used to develop the two matches.
[0024] If a series of locate tests is performed on an object, it is usually assumed that those tests are independent, that is, their results and degrees of certainty are arrived at by different means and do not depend on each other. In mathematical terms, the assumption is that the characteristic vector is an “orthonormal” basis, implying that the individual elements in the characteristic vector are orthogonal (perpendicular) to each other. If two tests are not independent, the result may be skewed. This skewed dependency can be corrected by first converting the vectors to an orthonormal basis, or by summing and normalizing the dependent tests, then adding the resultant single vector to the characteristic vector.
[0025] For example, a “locate” based on both a street address test and a grid test (match 1 ), versus a “locate” based on two slightly different grid tests (match 2 ) may yield different results. Logic would imply that the latter “locate” process would be more reliable than one performed simply upon a single grid test (i.e., a one-dimensional search), but less reliable than the first “locate” based on two independent tests. To compensate for this dependence, the test results for the dependent vectors may first be added together, then normalized. Generalizing for a set of n dependent tests, the process is:
[0000] (d 1 +d 2 + . . . +d n )/n.
[0000] This is the preferred method, in accordance with the present invention, for handling a set of mutually dependent tests.
[0026] Any single test will typically return an exact point location or a small region, indicating the approximate location of an object. Bounding objects are test results expressed as the smallest region in which the object must lie; such objects therefore convey both the location of the object as well as the degree of uncertainty in the location of the object. Error weights are often used with the bounding process, where in particular error weights are used in two ways. First, the error weights are used to adjust the uncertainty of a particular test, such as to decrease (or eliminate altogether) its contribution to the overall certainty and selection of a match. Second, the error weights can be used to modify the size of a bounding object for a given test.
[0027] In the first case, consider street address data that is reported from three different vendors. The first vendor is known to always accurately report street address data,. The second vendor is known to often give incorrect values, and the third vendor fails to report data altogether. The street address test might the use an error weight array of (1.0, 0.5, 0.0) for this example, giving data from the first vendor 100% confidence weight, only 50% for the second vendor (making the results from the first vendor more dominant), and ignore the data reported by the third vendor. An example of the second defined use of error weights would be an array of values for each state in the United States. A state with 100% accurate grid data would receive a weight of 0.0, meaning the bounding object for a grid cell would be drawn exactly the same size as the grid, where a state with known positioning error in grids might have a weight of 0.25, to force the bounding object to be drawn 25% larger than the grid it encloses.
[0028] A weighting function is used instead of a weighting matrix when the uncertainty is expressible as a function of test types, test parameters, position and other factors. One exemplary function relates to returning the maximum interpolation error for a given street address block. For an address of, for example, “123 Elm”, a street address database does not store the actual latitude and longitude values. Instead, it stores the endpoints of an address block range (ABR) from 100-199 Elm, as shown in FIG. 3 , and the uses the actual address as an offset:
[0000] Location (“123 Elm”)−Location (“”100 Elm”)+123/199
[0000] [Location(“199 Elm”)]
[0000] Interpolation relies on the assumption that all addresses are distributed evenly along a street. To create a bounding area for a street address “locate” request, the point returned from this interpolation must be expanded by the maximum error possible for that address block.
[0029] In most situations, it is not necessary to require the exact address of an object as much as to determine if the object lies within a given area. Examples of this include queries such as “all homes more than 5 miles from a police station”, or “does this location lie within a cable right-of-way”. In these cases, treating multiple match locations separately is not appropriate. Instead, it is preferable to combine all matches into one larger entity that must contain the search object, where this is defined as the “apposite bounding surface”. An apposite bounding surface is calculated in one of three ways: minimum bounding rectangle (MBR), convex hull, or poly-polygon. The MBR is defined as the smallest rectangle which fully encloses all of the bounding objects, the comers of which are quickly calculated by taking the “min” and “max” of the latitude and longitude values of each bounding object in the result set:
[0000] MBR ( x 1 , y 1 , x 2 , y 2 )=(min| x |, min| y |, max| x |, max| y |).
[0000] The convex hull is calculable by any well-known algorithm, and the bounding poly-polygon is formed simply by concatenating each of the individual bounding polygons into single multipart object. An MBR is generally less accurate and is typically used to increase performance for smaller geometries. It may also be used for orthogonally aligned data (such as grids or street blocks) in which case its accuracy may actually be superior.
[0030] The size of a bounding geometry test is both test-specific and application-specific. For a street address test, it is generally computed based on the interpolation interval of the underlying street address block, that is, the mean (or max) error in calculating a specific address from the location of an address block endpoint. For addresses located via a zip code centroid, the geometry is sized to the defining polygon of the zip code, or an MBR for the zip code. For tests such as nearest street/intersection, the geometry is sized as a linear function of the local object density.
[0031] For example, a geocoding search results in two possible locations for an object, as shown in FIG. 4 . The latitude-longitude values for the first location's bounding rectangle (denoted as rectangle A in FIG. 4 ) are 34.2 North, 115.50 West, to 34.75 North, 115.90 West. The second bounding rectangle (rectangle B) is from 34.05 North, 115.80 West to 34.59 North, 116.00 West. Calculating the MBR results in: 34.05 North, 115.50 West to 34.75 North, 116.00 West, where this is then defined as the apposite bound for the object, and is indicated as the shaded region in FIG. 4 . Once the apposite bound for the object is created, a query such as “is this object located within 100 feet of a cable that runs from 115.00 West, 33.5 North to 116.5 West, 33.60 North” (shown as query Q on FIG. 4 ) can be answered. Since the MBR in this example is at all points more than 100 feet from the cable, the query can be answered in the negative without needing to know the true location of the object.
[0032] In summary, the flowchart of FIG. 5 illustrates the basic processes of the present invention used to convert input data (which may be incomplete, ambiguous, etc.) into a relatively precise “locate” match result. As shown, the process begins at step 100 by selecting a subset of tests to be used to retrieve “locate” information for the input data, where the particular subset chosen may depend upon the type of input data (e.g., street address vs. ZIP code vs. gridname), as well as the desired result (e.g., point location vs. boundary). Once, a first set of tests has been selected, the input data is applied to the tests to generate the output, where for each test a “certainty factor” (1−u) and weighting function (w) is determined (step 110 ). A characteristic vector is then generated (step 120 ) by summing each test element component's certainty factor multiplied by its weighting constant. Once a characteristics vector is formed, algebraic techniques are used to assess the likelihood that the vector matches the input data. If steps 100 - 120 are repeated with a different test set (where one or more of the individual tests are different) another characteristic vector is generated, and vector concepts can then be used to assess the differences between the two characteristic vectors and define the vector that is the best match to the input data.
[0033] While the present invention has been described with reference to one or more particular embodiments, it is to be understood that those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. The following claims set forth the scope of the present invention. | A process for evaluating and geocoding of GIS data elements utilizes a plurality of “locate” tests and a weighting scheme to express the match results as a multidimensional vector. Multiple inputs and data sources, as well as ambiguous and partial input data, are used to generate an output with improved precision by applying a weighting function to each input element and generating a set of test vectors (i.e., in the input data element weighted by the known accuracy of the element/source). A sum of a plurality of tests is then generated as the “characteristic vector” of the test set. By using two (or more) different sets of tests, two (or more) characteristic vectors are formed. Various well-known algebraic techniques can then be used to evaluate the results of each set of tests and select the “best match” result. | 6 |
THE FIELD OF THE INVENTION
The present invention generally relates to computer networks, and more particularly to a network device for receiving input data items in a plurality of formats and automatically transferring the input data items to a computer network.
BACKGROUND OF THE INVENTION
Currently, there are limited options for transferring information to a network such as the Internet. One option is to couple a personal computer (PC) to the network. Numerous internal or external devices may be connected to the PC, such as disk drives, CD-ROM drives and scanners, allowing data with different data formats from different media to be input into the PC. Typically, numerous software applications are associated with each device connected to the PC, making the process of entering data from each device into the PC complex, with numerous steps required to enter the data and have it transmitted to the network. For example, to send a document via e-mail using a PC, the document typically has to be scanned using a first software application, and then stored in a file on the PC. An e-mail application then has to be opened up, and the stored file has to be attached to a new e-mail message. The PC must then connect to an exchange server before the e-mail message with the attached file is finally transmitted.
In addition to using a PC for transferring data to a network, another option for transferring information to a network is a “digital sender”. Hewlett-Packard Company makes a couple of different models of digital senders. Information regarding Hewlett-Packard digital senders is publicly available via Hewlett-Packard's website at www.hp.com. Information regarding Hewlett-Packard's digital senders is also provided in “HP 9100C Digital Sender User Guide,” 1 st ed., 1998, Pub. No. C1311-90910, and “HP 9100C Digital Sender Administrator Guide,” 1 st ed., 1998, Pub. No. C1311-90915, which are hereby incorporated by reference.
A digital sender is a network device that converts paper-based documents into electronic data. A digital sender includes a scanner for scanning in paper documents. The digital sender can send the electronic data by several methods, including via Internet e-mail, via facsimile (Fax) either through a network fax server or an Internet fax service provider, and via “JetSend” to other JetSend enabled network devices. JetSend is a Hewlett-Packard communications technology built into some printer and scanner firmware and computer software. JetSend enabled devices can connect, “talk” to each other, and exchange information directly through the network. The JetSend capability is independent of servers and programs, and uses simple addressing such as TCP/IP addresses and host names.
A digital sender allows data to be transferred to the Internet with fewer steps than that required by a PC. The digital sender includes a keypad that allows a user to enter an e-mail address. A user can scan in a document, enter one or more e-mail addresses for the desired destinations, press a send button, and the digital sender automatically e-mails the information to the various destinations. The digital sender automatically logs onto an exchange server, and transmits an e-mail message with the scanned document attached, without any further user input required. Thus, a digital sender provides a more efficient means for transferring paper-based source information to the Internet.
It would be desirable for a single network device to provide an “on-ramp” onto a network for all types of data and content, regardless of the scope or format of the data, or the type of input media, and without requiring numerous manual steps as in prior art methods.
SUMMARY OF THE INVENTION
The present invention provides a device and method for automatically transferring data received in a plurality of input formats from a plurality of input sources to a computer network in a plurality of output formats without requiring a user to input the data into a personal computer. A network device configured to be coupled to a network having an e-mail server receives a plurality of input data items from a plurality of input sources in a plurality of input formats. The network device outputs a plurality of output data items in a plurality of output formats to the network. The network device includes a plurality of input/output ports configured to be coupled to the plurality of input sources. The plurality of input data items are received by the network device through the plurality of input/output ports. The network device includes an input device for entering destination information and output format information for each of the plurality of input data items. An interface bridge is coupled to the plurality of input/output ports. The interface bridge receives the plurality of input data items from the plurality of input/output ports and outputs the plurality of input data items using a single output protocol. A controller is coupled to the interface bridge. The controller receives the plurality of input data items from the interface bridge. The controller automatically converts each of the input data items to an output data item based on the entered destination and output format information, and automatically outputs the output data items to the network.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a first perspective view of a network on-ramp device according to the present invention.
FIG. 2 illustrates a second perspective view of a network on-ramp device according to the present invention.
FIG. 3 illustrates a diagram of a network, including a network on-ramp device according to the present invention.
FIG. 4 illustrates an electrical block diagram of a network on-ramp device according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
FIGS. 1 and 2 illustrate perspective views of a network on-ramp device according to the present invention. Network on-ramp device 10 includes display 18 , keyboard 24 , input/output (I/O) ports 14 A- 14 C (collectively referred to as I/O ports 14 ), SCSI docking port 16 , network ports 22 A- 22 D (collectively referred to as network ports 22 ), and power cord 26 . On-ramp device 10 does not require a PC to connect to a network, but rather hooks directly into a network via one of network ports 22 .
In one embodiment, I/O ports 14 and network ports 22 are plug-in modules that may be inserted in or removed from on-ramp device 10 . By using plug-in modules for I/O ports 14 , all types of input devices, whether currently existing or to be developed, may be easily coupled to on-ramp device 10 , regardless of the input/output port type used by the input device. By using plug-in or removable modules for network ports 22 , many different types of network connections can be made. In one embodiment, SCSI docking port 16 is also a plug-in module.
FIG. 1 also shows input device 50 , which is a flatbed scanner in the embodiment shown. Input device 50 is preferably any type of device that can transmit and/or receive electronic data to and from network on-ramp device 10 , including a floppy disk drive, digital camera, personal digital assistant (PDA) device, smart card reader, memory card reader, scanner, microphone, printer, or other input device. In one embodiment, input device 50 is coupled to on-ramp device 10 via SCSI docking port 16 . In other embodiments, input device 50 is coupled to on-ramp device 10 via one of I/O ports 14 . Multiple input devices 50 may be connected to network on-ramp device 10 at the same time. On-ramp device 10 accepts full media, including voice data, image data, personal digital assistant (PDA) data, or any other type of data from virtually any type of input source device 50 .
I/O ports 14 preferably include one or more of the following types of ports: IR port, IEEE 1394 port, USB port, serial port, Centronics port, ATA port, and an IDE port. Other I/O ports 14 may also be used. I/O ports 14 are capable of communicating in multiple protocols, including IEEE 1394 (firewire), IEEE 802.11, and JetSend. Other protocols may also be used. IEEE 802.11 and Jetsend are both protocols for infrared communications. Network ports 22 include one or more of the following types of ports: Phone port, coaxial cable port, IR port, and an RF port. Network ports 22 are capable of communicating in multiple protocols, including TCP/IP, Ethernet, and token ring. Other protocols may be used.
Data is entered into on-ramp device 10 by a user via keyboard 24 . Data is displayed by on-ramp device 10 via screen 18 . Alternative methods of data entry and display may be used, including a touch screen display. Power is supplied to on-ramp device 10 via power cord 26 .
FIG. 3 illustrates a diagram of a network including a network on-ramp device according to the present invention. Network 100 includes communication line 102 , on-ramp software 104 , third-party application software 105 , computer 106 , on-ramp device 10 , light-weight directory access protocol (LDAP) server 108 , e-mail server 110 , Internet 112 , Internet fax service provider 114 , network printer 116 , JetSend device 118 , fax server software 120 , computer 122 , phone line 124 , computer 126 and link software 128 . Computers 106 and 122 are preferably servers running on-ramp software 104 . Computer 126 is preferably a PC running on-ramp software 104 and link software 128 . E-mail server 110 preferably supports simple mail transport protocol (SMTP). In one embodiment, a permanent TCP/IP network connection exists between network on-ramp device 10 and e-mail server 110 . Software for performing the functions provided by on-ramp software 104 , fax server software 120 and link software 120 are commercially available, or are within the skill of one of ordinary skill in the art to develop. These functions are discussed below.
In one embodiment, network on-ramp device 10 is not server-based, which allows easier installation and configuration. Network on-ramp device 10 operates as a standalone unit on network 100 and does not require network privileges to administer. Network on-ramp device 10 is network operating system (NOS) independent. Network on-ramp device 10 runs on any TCP-IP network, including Ethernet (10Base-T, 100Base-T or 10Base-2) or token ring. Network on-ramp device 10 is coupled to network 100 via one of network ports 22 . An appropriate network port module 22 is inserted into network on-ramp device 10 based on the type of network configuration (e.g., Ethernet or token ring). Network 100 is discussed in further detail below.
FIG. 4 illustrates an electrical block diagram of network on-ramp device 10 . Network on-ramp device 10 includes I/O ports 14 and 16 , interface bridge 200 , keyboard 24 , file processor 202 , CPU 204 , memory 206 , network ports 22 , network bridge 210 , and display 18 .
The operation of I/O ports 14 and 16 was discussed above with reference to FIGS. 1 and 2 . Interface bridge 200 is a standard network device that communicates with I/O ports 14 and 16 , and CPU 204 . I/O ports 14 and 16 use a variety of communication protocols. Interface bridge 200 converts the communications from I/O ports 14 and 16 to a single protocol for use by CPU 204 . Interface bridge 200 also converts communications received from CPU 204 to an appropriate protocol for the desired one of I/O ports 14 and 16 .
An input data item to be transferred to network 100 is provided to on-ramp device 10 from an input device 50 coupled to one of I/O ports 14 or 16 . The input data item is received by interface bridge 200 and passed on to CPU 204 , which stores the input data item in memory 206 . Memory 206 also stores on-ramp software 104 for operation of on-ramp device 10 . CPU 204 may also include its own on-board memory. Memory 206 preferably includes both nonvolatile memory, such as ROM, PROM, EEPROM or other non-volatile memory, and temporary or volatile memory such as RAM.
Destination information and output format information for input data items are entered by a user via keyboard 24 . The user may also enter sender information identifying the sender, such as a name or e-mail address, and subject information identifying a subject of input data items. Based on the destination information and output format information entered by a user, file processor 202 performs appropriate conversions on an input data item and generates an output data item.
File processor 202 performs various processing tasks on input data items. File processor 202 processes many different file types, including HTML, MOV, AVI, MPEG, PDF, MP3, JPEG, MTIFF, WAV, ZIP, e-mail, as well as other file types, and includes the capability to convert file types to other file types. The functions performed by file processor 202 are controlled by CPU 204 based on destination information and output format information provided by a user via keyboard 24 . Functions performed by file processor 202 include file compression/decompression, formatting a file for the web, passing a file through unchanged, generating an e-mail with an input data item added as an attachment, converting an input text communication to a fax communication, converting an input speech communication to a text document, formatting text for printing, as well as other processing functions. Software and hardware for performing the functions provided by file processor 202 are commercially available, or are within the skill of one of ordinary skill in the art to develop.
Network bridge 210 is a standard network device that converts data received from CPU 204 to an appropriate protocol for a selected one of the network ports 22 . In one embodiment, network bridge 210 uses TCP/IP in addition to either an Ethernet or token ring protocol. Network bridge 210 also converts data received from network ports 22 to an appropriate protocol for CPU 204 .
CPU 204 outputs output data items generated by file processor 202 to network bridge 210 . Network bridge 210 outputs the output data items to one of network ports 22 , for transfer of the output data items to one or more destinations on network 100 . In one embodiment, the destinations for an output data item include an Internet e-mail address, a fax phone number, a computer on the network, a printer on the network, a JetSend device, a software program installed on a computer on the network, and a device coupled to network on-ramp device 10 via one of I/O ports 14 and 16 . Each of these types of destinations are discussed below. The destination information entered by a user may specify multiple destinations for input data items.
In one embodiment, an output data item generated by file processor 202 takes the form of an e-mail message. An e-mail message generated by file processor 202 preferably includes two parts. The first part is a header, which contains sender and destination information. The second part is a digitized document attachment. File processor 202 generates the digitized document by converting an input data item into a document format, such as PDF or TIFF format. The type of document format is specified in the output format information entered by a user. The types of conversions that are performed by file processor 202 depend upon the format of the input data item and the output format information entered by a user. For example, if the input data item is a voice communication and the output format information indicates that the input data item is to be transmitted over the network as a PDF attachment to an e-mail message, the voice communication is converted into a text document. The text document is then converted into a PDF file. The PDF file is attached to an e-mail message by file processor 202 . File processor 202 preferably uses multipart Internet message encoding (MIME) to encode e-mail messages.
Keyboard 24 of network on-ramp device 10 allows any e-mail address to be typed in, or selected and retrieved from an internal address book stored in memory 206 of network on-ramp device 10 . In addition, network on-ramp device 10 also supports LDAP queries, which provides the ability of real-time address queries. The LDAP capabilities are provided by LDAP server 108 (shown in FIG. 3 ).
Network on-ramp device 10 includes the capability to send faxes. In order to provide fax capabilities, computer 122 (shown in FIG. 3 ) includes fax server software 120 . Computer 122 also includes phone line 124 to transmit faxes received from network on-ramp device 10 . Network on-ramp device 10 sends digitized documents via communication line 102 to computer 122 , which handles outbound dialing to transmit the documents over phone line 124 . Again, the digitized documents are generated by file processor 202 by converting an input data item, regardless of the format, into a document format. Fax numbers may be entered through keyboard 24 on network on-ramp device 10 , or they can be retrieved from an internal fax address book stored memory 206 .
Network on-ramp device 10 is also capable of sending faxes via the Internet. To provide Internet fax capabilities, the user must subscribe to an Internet fax service provider service. As shown in FIG. 3 , e-mail server 110 provides Internet fax capabilities using Internet fax service provider 114 . In order to transmit a document via Internet fax, file processor 202 first converts an input data item into a document format. Network on-ramp device 10 transmits the document via communication line 102 to e-mail server 110 , which handles the Internet fax transmission.
Network on-ramp device 10 communicates with any “JetSend” enabled device reachable through a known IP address on network 100 . File processor 202 converts an input data item to an output data item based on destination information and output file format information entered by a user. The output data item is then transmitted from on-ramp device 10 to JetSend device 118 via communication line 102 of network 100 .
Network on-ramp device 10 includes the capability to send documents back to a user's PC 126 (shown in FIG. 3 ) or other PC, for further manipulation or archiving of the documents. Such documents are sent directly from network on-ramp device 10 , with point-to-point TCP/IP communication between the network on-ramp device 10 and the destination PC 126 . This process is accomplished through peer-to-peer transmission. In one embodiment, addresses of destination computers are predefined in registered user profiles stored in memory 206 . Users enter such profiles in on-ramp device 10 through keyboard 24 . In order to provide the capability to transmit documents to a PC 126 , the PC 126 runs link software 128 . In one embodiment, link software 128 is a software driver that shows a tray icon on the windows task bar, and which enables PC 126 to receive data from network on-ramp device 10 . The documents sent to PC 126 are received in the tray as PDF or TIFF files, although other formats may be used.
If a desktop application is installed on PC 126 , such as Adobe Circulate, the application is executed automatically by link software 128 each time a new document arrives in the tray, and the document is automatically routed to the opened application. Adobe Circulate may be used to receive, store, view, organize, distribute and manipulate documents. Link software 128 preferably includes a control panel applet that allows a user to provide settings for the program, such as where to store scanned documents until they are opened in a program on the computer. The storage location is known as the default inbox location, and the program in which the documents are opened is known as the target program. From the control panel applet, a user can set which program is the target program. In one embodiment, the target program can be either the Adobe Circulate program or another program capable of accepting PDF or multipage TIFF files.
Network on-ramp device 10 includes a “copy” feature, which allows direct point-to-point communication with network printer 116 (shown in FIG. 3 ), to print out copies of an input data item. File processor 202 converts an input data item into printing data in an appropriate printing control language for network printer 116 . The printing data is then output by on-ramp device 10 to network printer 116 via communication line 102 of network 100 . A user selects a printer to “copy” to from keyboard 24 on network on-ramp device 10 .
Network on-ramp device 10 also includes the capability to transfer documents to a specific “network share”. A network share is defined as the network address of a computer 106 (shown in FIG. 3 ) running on-ramp software 104 , plus a path to a directory on that computer 106 . A document transferred to a network share can easily be imported into a third-party application 105 . On-ramp software 104 handles the receipt of documents transmitted from on-ramp device 10 , and provides the ability to automatically import the documents into a specified third-party application 105 . Using this capability, input data items may be transmitted directly to a specified web page. File processor 202 converts an input data item to an output data item appropriate for a specified network share based on destination information and output format information entered by a user. The destination information specifies one or more particular network shares. A document transmitted from network on-ramp device 10 to computer 106 is preferably delivered as a PDF or TIFF file, although other formats may be used.
In addition to specifying destinations on network 100 , destination information entered by a user may also specify a device 50 coupled to on-ramp device 10 via one of I/O ports 14 and 16 . For such destinations, file processor 202 converts an input data item to an output data item based on entered destination and output format information, and then outputs the output data item to interface bridge 200 . Interface bridge 200 outputs the output data item to the I/O port 14 or 16 coupled to the specified device 50 using an appropriate communication protocol.
It will be understood by a person of ordinary skill in the art that functions performed by on-ramp device 10 may be implement in hardware, software, firmware, or any combination thereof. It will also be understood that on-ramp device 10 may easily be modified to work with communication protocols, file types, and data formats, other than the specific examples provided, whether currently existing or to be developed. In one embodiment, on-ramp device 10 is always on, and always ready to transfer data to a network, and provides a means for simply and efficiently transferring input data items in a variety of input formats to a variety of destinations in a variety of output formats.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the chemical, mechanical, electromechanical, electrical, and computer arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | A network device configured to be coupled to a network includes a plurality of input/output ports configured to be coupled to a plurality of input sources and receive a plurality of input data items. The network device includes an input device for entering destination information and output format information for each of the plurality of input data items. An interface bridge coupled to the plurality of input/output ports receives the plurality of input data items from the plurality of input/output ports and outputs the plurality of input data items using a single output protocol. A controller coupled to the interface bridges receives the plurality of input data items. The controller automatically converts each of the input data items to an output data item based on the entered destination and output format information, and automatically outputs the output data items to the network. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for compensating a failing nozzle in a printhead comprising a series of print elements for operation in an inkjet printing process in which a colorant is applied to a receiving medium for locally changing an optical density, thereby printing an image. The invention further relates to an inkjet printing system comprising control means configured to apply the invented method.
2. Description of the Related Art
Inkjet printing systems are getting increasingly sophisticated. Additional features relating to speed and print quality are continuously introduced for enhancing the range of applicability of inkjet printing systems. Furthermore, the printheads, that form the heart of the inkjet print process, are perpetually improved. Still, it occurs that a print element in a printhead does not discharge an ink drop according to predetermined specifications. Either no ink is applied on positions where an ink dot is supposed to be applied, or an ink dot is applied on a different position from where it is supposed to be applied. The cause of this malfunctioning is often found in the clogging of a nozzle, comprised in the print element, from which the ink is discharged, in residual ink on a nozzle plate of the printhead, or in the introduction of air in the ink channel. Whatever the cause, a non- or malfunctioning print element is known as a failing nozzle. There exist techniques that remediate a failing nozzle, depending on the cause of failing, but these are not the subject of the present invention.
Obviously, a failing nozzle implicates an inferior print quality, since an ink dot can not be provided as required by a control unit of a printer. This ink dot is referred to as a missing dot. The print quality consequence may be debilitated in various ways, depending on the way a printhead is applied in the inkjet printing system. In some systems, a printhead is reciprocated in a scanning direction to print swaths, each swath contributing to a printed image on a receiving sheet-like material. This material is stepwise transported, relative to the beam along which the printhead reciprocates, in a subscanning or transport direction, that is substantially perpendicular to the scanning direction. Alternatively, the printhead beam is moved stepwise across a receiving substrate. In either system, the array of print elements extends in the subscanning direction and a print mode, or print strategy, may be devised wherein a print position on the receiving material is served more than once, each time by a different print element. These print modes are known as multipass print modes. The print data for a specific print position that is served by a failing nozzle of one print element may then be transferred to another print element that is also serving that specific print position. Such a substitution method is the subject of U.S. Pat. No. 5,124,720. Of course, also single pass print modes are known. For these, no similar substitution method is available.
In other print systems, a configuration of one or more printheads, each comprising an array of print elements, extends in a direction substantially perpendicular to a transport direction, which is the direction in which the receiving substrate and the printhead are movable relative to each other. This is also known as a line-type ink jet configuration. The configuration is made as wide as the receiving material on which an image is printed, hence the name page wide printhead array, and the position of the printheads is fixed in the direction perpendicular to the transport direction. Each print position on the substrate is served by a single print element only and the print strategy is essentially a one-pass strategy. Substitution methods as described above, are not applicable for these systems. A method for diminishing the effects of failing nozzles is provided in U.S. Pat. No. 5,587,730. In this patented invention, a second printhead is placed behind a first printhead for each applied colorant, thereby providing a spare nozzle for each print position. However, in most cases, this is not a very economical solution.
In order to compensate a failing nozzle in any of the systems mentioned above, different methods exist that provide additional ink in the neighbourhood of a missing dot, i.e. a dot that would and should be printed by the print element associated with the failing nozzle, if it would function normally. In European patent 1060896 B, a method is described to provide an addressable correction point in the vicinity of a missing dot. This correction point receives the image forming material from a different print element than the print element with the malfunctioning nozzle. In this way, the optical density that the printed material is supposed to achieve, is not affected by the failing nozzle. Another method to retain an optical density is the provision of marking material of another color on the same print position as a missing dot, as elucidated in U.S. Pat. No. 5,581,284. This compensates at least some of the lightness deviation that is caused by a missing dot, although other color properties, such as chroma and hue, still deviate. In all these methods, print data associated with the print element having a failing nozzle is transferred to another print element, applying marking material either or not on the same position as the missing dot. If a print element is capable of applying more than one dot size, a transfer of print data may imply a change of dot size at a neighbouring print position.
However, despite all these possibilities for compensating a failing nozzle, linear imperfections in inkjet printed images still occur. These are especially apparent if the images are printed in a one-pass print system. In spite of an applied compensation, an optical density in a uniform area shows lines of lower optical density, i.e. light lines, but also lines of higher optical density, i.e. dark lines on positions in the printed image associated with failing nozzles. These lines are also referred to as undercompensated failing nozzles and overcompensated failing nozzles, respectively. The present invention addresses this non-uniformity associated with failing nozzles, which is considered to be a problem for some applications of inkjet printing. An object of the present invention is to reduce this non-uniformity.
SUMMARY OF THE INVENTION
According to the present invention, a method is provided for compensating a failing nozzle in a printhead comprising a series of print elements with nozzles for operation in an inkjet printing process in which a colorant is applied to a receiving medium for locally changing an optical density, thereby printing an image, a nozzle being recorded in a list as a failing nozzle if an associated print element is unable to eject an ink drop within predetermined specifications, the method comprising at least two compensation mechanisms, each providing additional optical density in the environment of a missing dot in the printed image associated with a failing nozzle and comprising the steps of a) selecting a failing nozzle from the list of failing nozzles, b) determining an environment density and a density deficit in an environment of a missing dot associated with said failing nozzle, c) comparing the environment density with a predetermined threshold, and d) selecting a compensation mechanism from the at least two compensation mechanisms, based on the result of the comparison, each compensation mechanism adding an amount of colorant to compensate the density deficit. A failing nozzle leads locally to a density deficit due to a shortage of colorant, since the failing nozzle does not apply an ink drop or is controlled not to apply an ink drop. However, if this density deficit is filled up with colorant according to a fixed mechanism for compensating the failing nozzle, in some cases the compensation will be too large, leading to an overcompensated linear defect or a dark line in the printed image, and in other cases the compensation will be too small, leading to an undercompensated linear defect or a light line in the printed image. Of course, there are also situations in which the compensation according to a fixed method is sufficiently redressing the deficit, but this is accidental and not structural. The determination of an environment density around a position in the printed image where the failing nozzle is supposed to supply colorant, enables the selection of an appropriate compensation mechanism. Up to a predetermined threshold, a density deficit may be compensated by a mechanism that is suitable for providing an amount of additional optical density in an environment wherein sufficient positions are available that may accommodate additional colorant. Above this threshold, little or no extra colorant can be provided, since the environment already is filled with a maximum amount of the present colorant and a different mechanism is to be invoked to provide additional optical density. It may also be the case, that above said threshold, the probability of additional colorant overlapping other applied colorant is so high that little or no additional optical density will result. Thus, the additional colorant is not effective in providing additional optical density. In both situations, a different mechanism for compensating a failing nozzle is appropriate. Using the presently invented method, a compensation of a failing nozzle is achieved that better approximates the required optical density in an image and both undercompensation and overcompensation are reduced.
In a further embodiment, the predetermined threshold is dependent on a failing nozzle identifier. The compensation for a failing nozzle is provided by print elements around the failing nozzle. Depending on the accuracy of the dot positioning associated with the print elements around the failing nozzle, a compensation by the neighbouring print elements may have different effect on the optical density around the missing dot associated with the failing nozzle. Therefore, the threshold for selecting a compensation mechanism may be lowered for failing nozzles for which the neighbouring print elements are less effectively compensating the density deficit, whereas the threshold may be raised for failing nozzles for which the neighbouring print elements are very effectively compensating the density deficit.
In a further embodiment, the at least two compensation mechanisms comprise a first mechanism for transferring a signal for ejecting an ink drop to a neighbouring print element of a failing nozzle and a second mechanism for adding ink dots of another colorant in an environment of a missing dot associated with a failing nozzle. The first mechanism involving a neighbouring nozzle starts from an assumption that a neighbouring nozzle, usually applying the same colorant, is able to compensate for the density deficit, either because this neighbouring nozzle would not be enabled if the failing nozzle would be working, or because it is not applying a maximum drop size. This mechanism has a small probability of overlapping dots and therefore the additional optical density may be sufficient. If a resulting extra dot overlaps other dots, more colorant is needed to have sufficient additional optical density. The second mechanism, involving ink dots of another colorant, may give a very large additional density, since there are hardly restrictions on the number of print elements that may be activated for supplying ink in the vicinity of the missing dot. However, it is prudent to apply this latter compensation mechanism only when the environment density is very large, since for low environment density, it may easily produce overcompensation.
In a further embodiment, the compensation method comprises a step of passing a density deficit to a next position in the image associated with said failing nozzle. A density deficit for a specific failing nozzle, in the case the environment density is smaller than the threshold, may be compensated by a first mechanism. If the additional optical density provided by this first mechanism is smaller than the deficit, a part of the deficit remains. In a uniform area in the image, a next position will be compensated in a similar way, leading to an undercompensated line in the image. By passing the remaining deficit to a next position, the total deficit of the next position may exceed the threshold, activating a second compensation mechanism that provides more additional density. Thus, the compensation method incorporates the deficit that is accumulated in a line in a uniform image and undercompensation and overcompensation may alternate to better approximate the needed compensation.
In a further embodiment, a density deficit is determined by optically capturing an output of the inkjet printing process. Monitoring the output enables a determination of the print quality, both in test prints and in regular prints. A density deficit may be determined from the output according to known algorithms, thereby providing information about the effect of the applied compensation mechanisms for failing nozzles. This information is used to further control the compensation method for reducing the occurrence of over- and under compensation.
Further details of the invention are given in the dependent claims. The present invention may also be embodied in an inkjet printing system, comprising control means that are configured to apply a method for compensating a failing nozzle incorporating features as given above and in the claims.
The scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIGS. 1A, 1B, 1C show dot positions for a low density area and a failing nozzle;
FIGS. 2A, 2B, 2C show dot positions for a moderate density area and a failing nozzle;
FIGS. 3A, 3B, 3C show dot positions for a high density area and a failing nozzle;
FIGS. 4A, 4B show dot positions for a high density area and two neighbouring failing nozzles;
FIG. 5 is an inkjet printing system applying the invented method, and
FIG. 6 is a flowchart of an embodiment of the invented method.
DETAILED DESCRIPTION OF EMBODIMENTS
The present invention will now be described with reference to the accompanying drawings, wherein the same or similar elements are identified with the same reference numeral.
FIG. 1A shows an arrangement of dots that is intended to be produced by an inkjet printer. In this example, two different dot sizes are applied, but this is not essential in the present invention. A larger number of dot sizes is possible, but also a single dot size may be applied. The positions on a receiving medium where a dot may be applied, are often referenced as print pixels. The lines between the print pixels are a guidance for the eye only and are not part of the image as printed. In FIG. 1A , print pixel 1 does not receive a dot, print pixel 2 receives a small dot and print pixel 3 a large dot. The size of the dots is not necessarily limited to the print pixel area, as shown in FIG. 1A , but may just as well extend across the print pixel boundaries. The print pixels are arranged in rows, labeled i, and columns, labeled j. Each column is printed by one and the same print element, comprising a nozzle. The print element is controlled at an appropriate timing to apply an appropriate dot size. However, a print element may not deliver a dot according to predetermined specifications. This print element is designated as having a failing nozzle and most often controlled not to apply ink drops at all. FIG. 1B shows the same dot pattern as in FIG. 1A for the situation wherein the print element corresponding to column 4 comprises a failing nozzle. Locally, ink density is missing, leading to a conspicuous light line. Because the ink density in the dot pattern is not very high, there are print pixels neighbouring the print pixels in column 4 , which do not receive an ink dot. Therefore, the missing ink dots in column 4 may be transferred to an open position in a neighbouring column as is done for print pixel 5 in the column on the left side and for print pixel 6 in the column on the right side. This mechanism of transferring an ink dot to a neighbouring print pixel is known in the prior art.
FIG. 2A shows a more dense arrangement of ink dots for an area having a darker appearance than FIG. 1A . Similarly, FIG. 2B shows the effect of a failing nozzle corresponding to column 4 . In this case, there are no open positions in neighbouring columns. However, a missing ink density may still be complemented in neighbouring print pixels by increasing the size of the ink dots in these print pixels. In FIG. 2C , print pixel 7 shows an example of this increment. Print pixel 8 represents an extra large ink dot that is only applied to complete a missing neighbouring ink dot and is not applied in a regular pattern. This mechanism is also known in the prior art and is an obvious continuation of the mechanism shown in FIG. 10 . Both mechanisms can be viewed as a transfer of a print signal referring to ink density to a neighbouring print pixel.
FIG. 3A shows an even more dense arrangement of ink dots. In this case, a failing nozzle corresponding to column 4 may lead again to a light line, as shown in FIG. 3B . If a signal transfer to neighbouring print pixels, as shown in FIG. 3C for print pixel 8 , is not sufficiently compensating the missing ink density, a further mechanism may be used for providing extra optical density. In FIG. 3C , this further mechanism involves the addition of ink dots 9 of another colorant around the print pixels corresponding to the failing nozzle of column 4 . In order to make sure that the ink dots of the second colorant cover the open print pixel, a number of dots in the row direction is supplied.
A further extension of the shown mechanisms may be used in the special case that two neighbouring nozzles are failing, as shown in FIG. 4A and FIG. 4B , wherein the failing nozzles correspond to columns 10 . In this special case, an even broader pattern of ink dots 9 of another colorant may be used to compensate the missing optical density.
In the mechanisms as described above, a missing optical density, or density deficit, is determined by estimating the effect of the application of an ink drop on the resulting optical density. If a drop is applied in accordance with the calculated pattern, no missing optical density occurs. However, if a failing nozzle is present, an estimation of a missing density is made for an environment of a missing dot and an appropriate compensation mechanism is selected. In a further embodiment, the effect of the compensated pattern on the optical density may be estimated in order to determine whether the compensation is sufficient. If an optical density deficit persists, it may be transferred to a next print pixel in order to have it compensated in this next position. An alternative way to implement a determination of a density deficit is shown in FIG. 5 .
FIG. 5 shows some functional elements in a print system wherein the present invention is implemented. An image data source 22 transfers raster image data to an image processing module 11 , wherein the raster image data are converted to print signals. A special section, nozzle failure compensation (NFC) section 12 , is dedicated to the processing actions for handling the print signals in the environment of a failing nozzle. In this section the presently invented methods are implemented. The printheads 13 for the colorants cyan, magenta, yellow and black apply the print signals as processed in the image processing module 11 to generate ink drops accordingly. These ink drops are jetted along the direction 14 towards a receiving medium 15 that is transported in the transport direction 16 by a conveyance mechanism that is not shown in this figure. At the arrival on the receiving medium 15 , the ink drops take the shape of ink dots corresponding to a pattern as defined by the image processing module 11 . The ink dots are monitored by a scanner 17 using an illumination spot 18 . The signals from scanner 17 , or any other optical capturing device, are sent to a scan processing module 20 . This module interprets these scanner signals, among others to update a list of failing nozzles that is shared with the nozzle failure compensation (NFC) section 12 , that applies a method according to the present invention. Engine control and maintenance may also use the results of the scan processing module 20 . Furthermore, scan processing may comprise a part that estimates an environment density and a density deficit around a nozzle position to provide information on the correctness of the applied compensation.
FIG. 6 shows a flowchart of the method that has been applied. The pixels of a raster image are arranged in rows numbered i and columns numbered j. A row of pixels is printed in a transverse direction to a transport direction, whereas a column of pixels is oriented in the transport direction. For each colorant, a column of pixels is associated with a single print element. A defect print element, or a failing nozzle, is known by its column number j. In processing a raster image, each color plane is processed separately. The flowchart shows the processing of a single color plane wherein each pixel has an intended colorant density. Step S 0 starts the processing loop for a pixel in row i, column j. In step S 1 , it is checked whether nozzle N[j] is in the list of failing nozzles that is available. If it is not failing (N), the loop jumps to step S 8 for a next pixel. If the nozzle N[j] is failing (Y), an environment density ED[j] is calculated from the density of pixels around the current pixel [i,j] in step S 1 . Furthermore, in step S 3 , a density deficit DD[j] is determined, wherein a remaining deficit RD[j] from a previous pixel row is included. This density deficit relates to the missing density resulting from the failing nozzle j. In step S 4 , the environment density ED[j] is compared to a threshold T[j]. Each column j may have a different threshold. If the environment density ED[j] is larger than the threshold T[j] (Y), an additional density AD[j] is provided with another colorant in step S 6 . In the case of cyan and magenta colorant, an black colorant is added, in the case of black colorant, a combination of cyan and magenta colorant is added. The additional colorant in a different color channel is added to the already present density in that color channel. It may be necessary to limit the total colorant density in dependence of the material of the receiving medium. However, since the failing nozzle does not provide colorant, this limit will not often be traversed. A yellow colorant plane is not subjected to this method, because the optical density of this colorant is not very high. If ED[j] is not larger (N), a compensation density CD[j] of the same colorant is determined and added to neighbouring pixels of the same colorant plane in step S 5 . After determining these supplementary colorant amounts, a remaining deficit RD[j] is determined in step S 7 , which is kept to be used in the next row, i+1, in step S 3 . The use of the remaining deficit RD[j] enables the transfer of an optical density that is not yet compensated for the row i to be compensated in row i+1. The loop started in S 0 is repeated, indicated by step S 8 , until all pixels [i,j] have been addressed.
As an example of the calculations involved in determining the various densities the following tables for three columns of an image are presented for a printer applying 3 sizes of ink drops. Therefore, 4 levels are discerned in the image colorant planes, 0 for no ink drop and 1 to 3 for ink increasing drop volumes. The first three columns indicate the pixel level in a part of the image. Each size of an ink drop is associated with a colorant density in a range of 0 to 255. In this embodiment, level 0, no ink drop, is associated with a density of 0, level 1, the smallest ink drop, is associated with a density of 80, level 2 is associated with a density of 120, and level 3, the largest ink drop, is associated with a density of 150. Columns 4 to 6 indicate an associated optical density D[j] and columns 7 to 9 indicate the optical density DE that results because nozzle j is not jetting ink. Column 10 indicates the environment density ED[j] for the failing nozzle, which is the sum of the optical densities of the nine immediately surrounding pixel densities D[j]. The density deficit DD[j] in column 11 is the difference between the intended environment density ED[j] and its equivalent value in the case of failure of nozzle j. Note that the first and last row are used twice in the calculation of ED[j] to prevent edge effects, which is a usual procedure in image processing. The environment density in this embodiment is calculated for 3 times 3 pixels around a specific pixel corresponding to a failing nozzle. For 600×600 ppi (pixels per inch) images this is a common size, but for higher resolutions, such as 1200×1200 ppi an environment may also comprise 5 times 5 pixels and also anisotropic environments, such as 5 times 3 pixels are possible. However, the essential steps will be the same.
TABLE 1
Image pixel level for a number of columns in an image around
a failing nozzle j for six consecutive lines in an image.
j − 1
j
j + 1
D[j − 1]
D[j]
D[j + 1]
D′[j − 1]
D′[j]
D′[j + 1]
ED[j]
DD[j]
i
1
1
1
80
80
80
80
0
80
640
240
i + 1
1
1
0
80
80
0
80
0
0
720
280
i + 2
2
2
1
120
120
80
120
0
80
870
320
i + 3
3
2
2
150
120
120
150
0
120
980
390
i + 4
3
3
2
150
150
120
150
0
120
1260
420
i + 5
3
3
3
150
150
150
150
0
150
1320
450
Using a threshold T[j]=1050, the density deficit is accommodated by different mechanisms. Up to the threshold, pixel levels in the nine pixel environment are raised by an appropriate amount, whereas above the threshold, a further colorant will be used. In this printer, no additional level is available for applying an extra large dot. In Tables 2a to 2f, it is indicated how the density deficit DD[j] is compensated. The rows are updated one by one and the updated value is represented in the table. The density deficit DD′[j] includes the remaining deficit RD[j] from the previous row. The remaining density RD[j] is the difference between the intended environment density ED[j] and the environment density ED′[j] after processing an image line. The optical density D″[j] is updated to compensate the deficit DD′[j] by raising the density levels in the row under consideration and adding a level 1 drop if in the environment an empty position, which is level 0, occurs. If the environment density ED[j] is above the threshold, which is indicated by underlining the deficit values, an additional density AD[j] is applied by using a different colorant, as described before. The numerical values used are just for illustrative purposes and may be adapted to a specific process or print conditions. The pixel levels in the last three columns are derived from the density levels D″[j]. When processing a specific line, the densities D″[j] of previous lines have already been processed and these processed values are used in determining ED′[j].
TABLE 2a
Compensated pixel values for the image part of Table 1 after processing line i.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i + 1
280
0
80
0
0
0
720
0
1
0
0
TABLE 2b
Compensated pixel values for the image part of Table 1 after processing line i + 1.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i+1
280
360
150
0
120
0
710
10
3
0
2
i+2
320
0
120
0
80
0
870
0
2
0
1
TABLE 2c
Compensated pixel values for the image part of Table 1 after processing line i + 2.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i + 1
280
360
120
0
120
0
680
10
2
0
2
i + 2
320
330
150
0
150
0
840
30
3
0
3
i + 3
390
0
150
0
120
0
980
0
3
0
2
TABLE 2d
Compensated pixel values for the image part of Table 1 after processing line i + 3.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i + 1
280
360
120
0
120
0
680
10
2
0
2
i + 2
320
330
150
0
150
0
840
30
3
0
3
i + 3
390
420
150
0
150
0
870
110
3
0
3
i + 4
420
0
150
0
120
0
1260
0
3
0
2
TABLE 2e
Compensated pixel values for the image part of Table 1 after processing line i + 4.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i + 1
280
360
120
0
120
0
680
10
2
0
2
i + 2
320
330
150
0
150
0
840
30
3
0
3
i + 3
390
420
150
0
150
0
870
110
3
0
3
i + 4
420
530
150
0
150
200
1100
160
3
0
3
i + 5
450
0
150
0
150
0
1320
0
3
0
3
TABLE 2f
Compensated pixel values for the image part of Table 1 after processing line i + 5.
DD[j]
DD′[j]
D″[j − 1]
D″[j]
D″[j + 1]
AD[j]
ED′[j]
RD[j]
j − 1
j
j + 1
i
240
240
120
0
120
0
560
80
2
0
2
i + 1
280
360
120
0
120
0
680
10
2
0
2
i + 2
320
330
150
0
150
0
840
30
3
0
3
i + 3
390
420
150
0
150
0
870
110
3
0
3
i + 4
420
530
150
0
150
200
1100
160
3
0
3
i + 5
450
510
150
0
150
200
1500
−180
3
0
3
In this embodiment, the environment density and density deficit are estimated from a predetermined correspondence between ink drop levels and density. Alternatively, these densities are established optically by an arrangement of an optical capturing device, such as scanner 17 in FIG. 5 . In either way, the nozzle failure compensation is tuned to an amount of colorant density that is being short as a consequence.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A method is provided for compensating a failing nozzle in a printhead comprising a series of print elements with nozzles for operation in an inkjet printing process in which a colorant is applied for locally changing an optical density, thereby printing an image. The method comprises at least two compensation mechanisms, each providing a different amount of additional optical density in the environment of a missing dot in the printed image. A nozzle is recorded as a failing nozzle if the associated print element does not apply an ink dot within predetermined specifications. An environment density is determined in an environment of a missing dot associated with said failing nozzle. The environment density is compared with a predetermined threshold, and an appropriate compensation mechanism is selected from the at least two compensation mechanisms. The method is applied in an inkjet printing system for balancing under- and overcompensated optical density. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Reference is made to commonly-assigned copending U.S. patent application Ser. No. 11/263,371, filed concurrently herewith, entitled DEVELOPER HOUSING DESIGN WITH IMPROVED SUMP MASS VARIATION LATITUDE, by Steven C. Hart and Ajay Kamar; copending U.S. patent application Ser. No. 11/263,369, filed concurrently herewith, entitled XEROGRAPHIC DEVELOPER UNIT HAVING VARIABLE PITCH AUGER, by Steven C. Hart and Ajay Kamar; copending U.S. patent application No. 11/262,577, filed concurrently herewith, entitled XEROGRAPHIC DEVELOPER UNIT HAVING MULTIPLE MAGNETIC BRUSH ROLLS WITH A GROOVED SURFACE, by Ajay kumar, Keith A. Nau, David A. Reed, Jonathan D. Sadik, and Cory J. Winters; copending U.S. patent application Ser. No. 11/262,575, filed concurrently herewith, entitled XEROGRAPHIC DEVELOPER UNIT HAVING MULTIPLE MAGNETIC BRUSH ROLLS ROTATING AGAINST THE PHOTORECEPTOR, by Michael D. Thompson, James M. Chappell, Steven C. Hart, Patrick J. Howe, Ajay Kumar, Steven R. Leroy, Paul W. Morehouse, Jr., Palghat S. Ramesh, and Fei Xiao; and copending U.S. patent application Ser. No. 11/262,576, filed concurrently herewith, entitled XEROGRAPHIC DEVELOPER UNIT HAVING MULTIPLE MAGNETIC BRUSH ROLLS ROTATING WITH THE PHOTORECEPTOR, by James M. Chappell, Patrick J. Howe, Michael D. Thompson, and Fei Xiao, the disclosures of which are incorporated herein.
BACKGROUND
This invention relates generally to the development of electrostatic images, and more particularly concerns a two component development apparatus having a variable pitch auger to improve pickup latitude in developer housing.
Generally, the process of electrophotographic printing includes sensitizing a photoconductive surface by charging it to a substantially uniform potential. The charge is selectively dissipated in accordance with a pattern of activating radiation corresponding to a desired image. The selective dissipation of the charge leaves a latent charge pattern that is developed by bringing a developer material into contact therewith. This process forms a toner powder image on the photoconductive surface which is subsequently transferred to a copy sheet. Finally, the powder image is heated to permanently affix it to the copy sheet in image configuration.
Two component and single component developer materials are commonly used. A typical two component developer material comprises magnetic carrier granules having toner particles adhering triboelectrically thereto. A single component developer material typically comprises toner particles having an electrostatic charge. so that they will be attracted to, and adhere to, the latent image on the photoconductive surface.
There are various known development systems for bringing toner particles to a latent image on a photoconductive surface. These are: single component, two component, and hybrid systems. Additionally the single component and hybrid systems may be either scavenging or scavengeless; two component development systems are almost always scavenging. The term scavenging or scavengeless denotes whether the development method would disturb any previously developed image already on the photoconductive surface if any previously developed image is left undisturbed, the system is scavengeless.
Single Component Development Systems: A (scavenging) single component development system uses a donor roll for transporting charged toner to the development nip defined by the donor roll and the photoconductive surface. The toner is loaded onto the donor roll by direct contact with a toner reservoir and sometimes with the assistance of a toner loading brush or foam roll. The donor roll rotates to bring the charged toner into the development nip. Using a combination of AC and/or DC electrical biases, the toner is moved from the donor roll to the photoconductive surface. Thus, the toner is developed on the latent image recorded on the photoconductive surface.
A scavengeless single component development system is physically similar to a scavenging single component system except that it uses a donor roll with a plurality of electrode wires closely spaced therefrom in the development zone. An AC voltage is applied to the wires detaching the toner from the donor roll and forming a toner powder cloud in the development zone. The electrostatic fields generated by the latent image attract toner from the toner cloud to develop the latent image.
Two Component Development Systems: in a two component development system, a magnetic developer roll (with rotating external shell and an interior magnetic assembly which can be either stationary or rotating) attracts developer from a reservoir. The developer includes carrier and toner. As the external shell rotates and transports the developer material, the developer material is subsequently trimmed or metered to a desired uniform thickness. This layer of material is commonly referred to as a magnetic brush. Further rotation of the external shell advances the developer material into the development nip. In the development nip, the magnetic brush is brought into contact with the photoreceptor. Here, the toner is attracted from the carrier beads to the photoreceptor to develop the latent image. Further rotation of the developer roll returns the carrier beads and unused toner to the developer housing reservoir or sump.
Hybrid Development Systems: A hybrid development system is a cross between a single component development system and a two component system. A Hybrid system uses two component developer materials in conjunction with a magnetic developer roll to form a magnetic brush. However instead of developing the image directly with the magnetic brush, the magnetic brush is used to apply a uniform layer of toner onto a donor roll. Then as the donor roll rotates, the toner layer is advanced into the development nip and the latent image is developed in a manner similar to single component systems. A Hybrid System may be either scavenging or scavengeless.
Two component systems, either strictly two component or hybrid, require a uniform layer of developer material on the developer roll to function optimally. This layer of material must be provided independent of many factors. In some developer housing designs, developer material is picked up from one auger, trimmed to the desired thickness, used to develop an image or to load a donor roll, and then released into different auger. This results in a gradient in the developer material mass (or volume fill) down the length of the pick up auger region; one end of the auger is nearly full and the other end would be almost empty. One solution known in the prior art to deal with this variation, is to vary the “pick up” magnetic pole strength along the developer roll with a weaker pick up pole strength being used to acquire material in the almost full end of the auger and a very strong magnetic pole strength being used to acquire material from the almost empty end of the auger. An undesirable feature of this approach is that it is difficult to manufacture a magnetic structure with the appropriately varying magnetic strength.
A second solution known in the prior art is to simply use a uniform and very strong pickup magnet. An undesirable outcome of this solution is that much more material than necessary would be picked up from the nearly full end of the donor roll. This causes a small non-uniformity in the layer thickness, increases mechanical power requirements needed to rotate the donor roll, increases developer material abuse, and leads to a higher unit manufacturing cost (UMC).
SUMMARY
There is provided an “upper transport auger” or “pick up auger” with a variable pitch. The optimum pitch variation is linear down the length of the auger. A variable pitch auger can maintain a constant volumetric filling when used in a developer housing where developer material is picked up from one auger, used to develop an image, and then released into different auger. The significance of this is that the distance between the developer material available for “pick up” and the developer roll is kept constant down the length of the roll and auger. Maintaining the “pick up” material supply at a constant (and close) distance from the pickup region of the developer roll. This eliminates the need to overachieve the “pick up” function at one end, or alternatively to manufacture a magnet assembly with a uniformly varying magnetic pick up field strength. This enables the use of lower strength “pick up” magnetic fields and at the same time presents a uniform amount of material to the trim region independent of position down the length of the roll. The lower strength pick up magnetics reduces the mechanical power required to drive the housing, enhances developer roll shell life, and reduces developer material abuse. The uniform amount of material presented to the trim region also improves the MOR uniformity.
There is also provided a developer system, comprising: a developer housing having a sump containing developer material including toner particles; a developer member rotatably mounted in said housing for transferring toner particles to a latent image on said photoreceptive member in a development zone; a pickup auger, positioned in an auger channel, for transporting and delivering developer material to said developer member, along a path adjacent to said developer member, said pickup auger having a first end portion and a second end portion, and said pickup auger includes a plurality of blades extending along the length of thereof, said plurality of blades being adapted and arranged in said auger channel to maintain a constant developer material distance from said developer member along the length said auger channel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of an illustrative electrophotographic printing machine incorporating developer unit having the features of the present invention therein.
FIG. 2 is a schematic elevational view showing one embodiment of the developer unit used in the FIG. 1 printing machine.
FIG. 3 is an illustration of the portion of the developer unit of the present disclosure
FIGS. 4 and 5 illustrate developer material flow patterns in developer unit used in FIG. 2 .
FIG. 6 is a side view illustrating the developer material flowing in an auger of the present disclosure.
FIG. 7 is experimental data.
FIG. 8 is a side view illustrating the developer material flowing in another embodiment of an auger of the present disclosure.
DETAILED DESCRIPTION
While the present invention will be described in connection with a preferred embodiment thereof, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Inasmuch as the art of electrophotographic printing is well known, the various processing stations employed in the FIG. 1 printing machine will be shown hereinafter schematically and their operation described briefly with reference thereto.
Referring initially to FIG. 1 , there is shown an illustrative electrophotographic printing machine incorporating the development apparatus of the present invention therein. The electrophotographic printing machine employs a belt 10 having a photoconductive surface 12 deposited on a conductive substrate. Belt 10 moves in the direction of arrow 16 to advance successive portions of photoconductive surface 12 sequentially through the various processing stations disposed of throughout the path of movement thereof. Motor 24 rotates belt 10 in the direction of arrow 16 . Roller 22 is coupled to motor 24 by suitable means, such as a drive belt.
Initially, a portion of belt 10 passes through charging station A. At charging station A, a corona generating device, indicated generally by the reference numeral 26 charges photoconductive surface 12 to a relatively high, substantially uniform potential. High voltage power supply 28 is coupled to corona generating device 26 to charge photoconductive surface 12 of belt 10 . After photoconductive surface 12 of belt 10 is charged, the charged portion thereof is advanced through exposure station B.
At exposure station B, a controller receives the image signals from Print Controller representing the desired output image and processes these signals to convert them to signals transmitted to a laser based output scanning device, which causes the charge retentive surface to be discharged in accordance with the output from the scanning device. Preferably the scanning device is a laser Raster Output Scanner (ROS) 36 . Alternatively, the ROS 36 could be replaced by other xerographic exposure devices such as LED arrays.
After the electrostatic latent image has been recorded on photoconductive surface 12 , belt 10 advances the latent image to development station C. At development station C, a developer unit, indicated generally by the reference numeral 38 , develops the latent image recorded on the photoconductive surface. Developer rolls 40 and 41 are mounted, at least partially, in the chamber of the developer housing. The chamber in the developer housing stores a supply of developer material. In one embodiment the developer material is a single component development material of toner particles, whereas in another, the developer material includes at least toner and carrier.
With continued reference to FIG. 1 , after the electrostatic latent image is developed, belt 10 advances the toner powder image to transfer station D. A copy sheet 70 is advanced to transfer station D by sheet feeding apparatus 72 . Preferably, sheet feeding apparatus 72 includes a feed roll 74 contacting the uppermost sheet of stack 76 into chute 78 . Chute 78 directs the advancing sheet of support material into contact with photoconductive surface 12 of belt 10 in a timed sequence so that the toner powder image developed thereon contacts the advancing sheet at transfer station D. Transfer station D includes a corona generating device 80 which sprays ions onto the back side of sheet 70 . This attracts the toner powder image from photoconductive surface 12 to sheet 70 . After transfer, sheet 70 continues to move in the direction of arrow 82 onto a conveyor (not shown) that advances sheet 70 to fusing station E.
Fusing station E includes a fuser assembly, indicated generally by the reference numeral 84 , which permanently affixes the transferred powder image to sheet 70 . Fuser assembly 84 includes a heated fuser roller 86 and a back-up roller 88 . Sheet 70 passes between fuser roller 86 and back-up roller 88 with the toner powder image contacting fuser roller 86 . In this manner, the toner powder image is permanently affixed to sheet 70 . After fusing, sheet 70 advances through chute 92 to catch tray 94 for subsequent removal from the printing machine by the operator.
After the copy sheet is separated from photoconductive surface 12 of belt 10 , the residual toner particles adhering to photoconductive surface 12 are removed therefrom at cleaning station F. Cleaning station F includes a rotatably mounted fibrous brush 96 in contact with photoconductive surface 12 . The particles are cleaned from photoconductive surface 12 by the rotation of brush 96 in contact therewith. Subsequent to cleaning, a discharge lamp (not shown) floods photoconductive surface 12 with light to dissipate any residual electrostatic charge remaining thereon prior to the charging thereof for the next successive imaging cycle.
It is believed that the foregoing description is sufficient for purposes of the present application to illustrate the general operation of an electrophotographic printing machine incorporating the development apparatus of the present disclosure therein.
Referring now to FIG. 2 , there is shown an embodiment of the present disclosure in greater detail. The overall function of developer unit 100 is to apply marking material, such as toner, onto suitably-charged areas forming a latent image on an image receptor such as belt 10 (a portion of which is shown), in a manner generally known in the art. In various types of printers, there may be multiple such developer units, such as one for each primary color or other purpose.
Among the elements of a the developer unit shown in FIGS. 2 and 3 , which are typical of developer units of various types, are a housing 112 , which functions generally to hold a supply of developer material, as well as augers such as 130 , 132 , 134 , which variously mix and convey the developer material, and magnetic development rolls 136 , 138 , which in this embodiment form magnetic brushes to apply developer material to the belt 10 .
For the illustrated embodiment wherein the magnetic development rolls 136 , 138 , are a relatively rigid cylinder, disposed within each magnetic development rolls 136 , 138 there is a stationary “magnetic structure” 110 , 111 . The magnetic structure 110 , 111 is designed to remain in one position while the magnetic development roll rotates around it. The magnetic structure 110 , 111 includes any number of magnetic members as necessary, and these magnetic members may be in the form of discrete metal magnets, or areas of specific magnetic polarity within a continuous structure, such as in a “plastic magnet.” Conceivably, the magnetic structure 110 , 111 may comprise electromagnets as well. The purpose of the magnetic structures 110 , 111 within magnetic development rolls 136 , 138 is to attract the magnetic carrier from the developer supply and cause the magnetic carrier to magnetically adhere to the surface of the magnetic development roll as a given portion of the surface of magnetic development roll is advanced, with motion of magnetic development roll, towards the development zone. As is well-known in the art of xerography, two-component developer generally functions as follows: the carrier particles, or beads, attracted by the magnets within magnetic structure 110 , 111 , form filaments of a “magnetic brush”, particularly around the poles defined in the magnetic structure, much in the manner of iron filings. Adhering triboelectrically to the carrier beads is any number of toner particles. The magnetic brush of carrier beads thus serves to convey the toner particles to the development zone. In a typical two-component contact developing system, the magnetic brush with toner particles thereon is brought into direct contact with the surface 12 of the belt 10 , to develop the latent image thereon.
Other types of features for development of latent images, such as developer rolls, paddles, scavengeless-development electrodes, commutators, etc., are known in the art and could be used in conjunction with various embodiments pursuant to the claims. In the illustrated embodiment, there is further provided air manifolds 140 , 142 , attached to vacuum sources (not shown) for removing dirt and excess particles from near belt 10 .
FIGS. 4-6 are diagrams for the developer material flow pattern in the housing. The diagrams are topologically correct. The inboard to outboard placement of the features is relationally correct. The location of the “pick up”, trim, handoff, and development functions are logically correct. For the actual placement of the various components/features, please refer to FIG. 2 .
Auger 134 is an upper transport auger located in auger channel 220 . Mixing/pump auger 130 and transport auger 132 are located below auger 134 and are disposed in auger channel 224 and auger channel 226 . Auger 134 receives developer material from the pump section 200 of the mixing/pump auger 130 and developer material moves along portion 202 of the developer material flow pattern. The auger 134 then transports this material from outboard to inboard along the full length of the housing along portion 204 of the developer material flow pattern. The upper developer roll 40 “picks up” material from auger 134 for use in the development process. Any material that is not “picked up” and used to develop the image is ultimately dropped back down into the mixing/pump auger 130 (as illustrated by the downward arrows) at the inboard end of the developer housing along portion 206 of the developer material flow pattern.
Now focusing on the developer material, the developer material flows in the lower portion of the housing, spillway 145 is located at an opening near the top of the wall 146 separating the mixing/pump auger 130 from the lower front auger 132 . It is located just before the junction between the mixing section 203 and pump section 200 of the mixing/pump auger 130 . Spillway 145 is an opening defined in wall 146 and acts as a pressure relief vent; if more material is delivered to the pump section 200 of the mixing/pump auger 130 than the pump can utilize, the excess material spills over the wall 146 and into the lower front auger 132 .
The mixing/pump auger 130 has several functions. It a) transports material from inboard to outboard along the developer material flow pattern 208 , as shown in FIG. 4 , b) mixes in the replenisher (replacement toner and carrier) supply delivered at the inboard end, c) pumps developer material up to the upper transport auger 134 , and d) acts as part of the material mass (volume) buffer to accommodate changes in developer sump charge mass (volume). Auger 130 has been designed with a larger pitch to diameter ratio (P/D) preferably by a factor of 2 in the mixing transport section 203 than in the pump section 200 . This results in a larger transport rate in section 203 than in section 200 . Transport rate is the physical displacement of material per unit time. It is expressed in units of mm/sec or units of mm/rev of the auger. Given equal cross sectional filling factors, section 203 will have a larger volumetric flow rate than section 200 . Volumetric flow is the volume of developer material crossing AN imaginary plane per unit time. In an auger, this is equal to the “Transport rate” times the cross sectional area of the filled portion of the auger (channel).
Now focusing on the present disclosure, referring to FIG. 6 , an “Upper Transport Auger” or “Pick Up Auger” with a variable pitch, it has been found that the optimum pitch variation is linear down the length of the auger 134 . A variable pitch auger maintains a constant volumetric filling in auger channel 220 . The significance of this is that the distance between the developer material in the auger channel 220 available for “pick up” and the developer roll is kept constant down the length of the roll and auger channel. This maintains the “pick up” material supply at a constant (and close) distance from the pickup region of the developer roll thereby eliminating the need to over achieve the “pick up” function at one end. This enables the use of lower strength “pick up” magnetic fields and at the same time presents a uniform amount of material to the trim region independent of position down the length of the roll. The lower strength pick up magnetics reduces the mechanical power required to drive the housing, enhances developer roll shell life, and reduces developer material abuse. The uniform amount of material presented to the trim region improves the MOR uniformity.
In operation, material (for use in development) is removed uniformly down the length of the upper transport auger by the upper developer roll 40 at the pickup region. This material is trimmed/metered to a desired layer thickness and utilized to develop an image. After development, the material is delivered to the lower auger, not back into the upper transport auger. Since, the developer material is not returned to the pickup upper transport auger, the auger's material transport requirement (to supply the developer material to the upper developer roll) decreases linearly down the length of the auger. Material transport for an auger is proportional to the pitch, filled cross sectional area, and rotational speed. Hence, the material transport rate may be decreased linearly and the filled cross sectional area may be held constant if the pitch of the auger is linearly decreased (at the appropriate rate).
Applicants have found that a Pitch to Diameter ratio of 0.7 on the outboard (up feed) end and about 0.4 on the inboard (down feed) end of the auger provides an approximately constant cross sectional filling area for nominal conditions. It should be noted that the pitch can be varied stepwise or varied continuously.
As illustrated in FIG. 7 , nominal conditions are: developer mass on roll (MOR) of about 37 mg/cm 2 , roll surface velocity of about 700 mm/sec, auger rotational speed of 800 RPM.
There are several benefits. Since, the upper transport auger's filled cross sectional area in the channel is approximately constant, there is less observed variation in MOR between the inboard and outboard (trimming is a slight function of the amount of material presented to the trim blade). Because the gap between the developer material surface and the developer roll surface is small and uniform, applicants have been able to reduce the strength of the pick up pole magnet. As a result, less material is in general picked up and delivered to the trim region. This reduces the amount of power required to drive the developer roll, reduces wear on both the developer roll surface and developer material itself, and significantly increases the nominal trim blade gap required to meter the desired 37 mg/cm 2 MOR.
Now referring to FIG. 8 which illustrates an alternative embodiment of the present disclosure for maintaining a uniform constant cross sectional filling factor within the pick up auger channel. As illustrated in FIG. 8 , core 300 has a plurality of blades 302 positioned about core 300 . The core size of the auger is varied to maintain a uniform constant cross sectional filling factor within the pick up auger channel. Preferably the core is round and the root diameter is varied in a fashion so as to compensate for the volume of developer material which has been picked up and used for development. In the case where the volume of developer material used for development is constant down the length of the developer roll, the root diameter. D R , would need to increase and can be determined by the following equation:
D R ( L )=(( D 0 ) 2 +K×L ) 1/2 .
where, L is the distance down the length of the magnetic brush, D 0 is the root diameter of the auger at the edge of the magnetic brush, and K is a function of auger pitch (P), auger rotational period ( T ), developer roll surface velocity (V), developer material density ( ρ), and developer roll mass per unit area on the roll (MOR).
K is given by: K= 4× P×V×MOR×T /(π×ρ).
It should be noted that the two concepts of varying core size and varying Pitch to Diameter ratio can be combined to also produce an useful auger for maintaining a uniform constant cross sectional filling factor within the pick up auger channel.
It is, therefore, apparent that there has been provided in accordance with the present invention, an Auger that fully satisfies the aims and advantages hereinbefore set forth. While this invention has been described in conjunction with a specific embodiment thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. | A developer system, including: a developer housing having a sump containing developer material including toner particles; a developer member rotatably mounted in the housing for transferring toner particles to a latent image on the photoreceptive member in a development zone; a pickup auger, positioned in an auger channel, for transporting and delivering developer material to the developer member, along a path adjacent to the developer member, the pickup auger having a first end portion and a second end portion, and the pickup auger includes a plurality of blades extending along the length of thereof, the plurality of blades being adapted and arranged in the auger channel to maintain a constant developer material distance from the developer member along the length the auger channel. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for transposing particulate material of the type comprising a tube through which one belt run of an endless belt passes so that particulate material is carried through the tube by the moving belt. Such transportation apparatus are well known and many examples have been manufactured and are described in the literature.
However one particular problem arises in relation to apparatus of this type in regard to providing a folding action so that the tube can be folded back with one potion lying alongside a second portion generally for transportation. This problem particularly but not exclusively arises in relation to discharge tubes for discharging materials from a transportation container in that the discharge tube must extend to a particular height or location for effecting the discharge action but during transportation of the container it is necessary to fold back the tube so that its length is reduced.
In many discharge devices of this type, an auger is used within the tube for transposing material and the folding action of this type of transposing apparatus can be relatively easy by breaking the drive shaft of the auger flight at the fold position.
However some materials require more delicate handling and hence cannot accommodate the vigorous action provided by the auger flight. Such materials therefore require the belt transportation system.
Up till now it is believed that no arrangement has been provided for folding a belt type transportation apparatus.
SUMMARY OF THE INVENTION
It is one object of the present invention, therefore to provide an improved belt type transportation apparatus for particulate material which allows a folding action.
According to one aspect of the invention there is provided a folding apparatus for transporting particulate material comprising: a tube having a feed end and a discharge end; an endless belt having a first belt run and a second belt run with the first belt run passing through the tube and the second belt run passing along the tube outside the tube such that the first run can carry materials through the tube from the feed end to the discharge end; guide means at the feed end and discharge end around which the belt is wrapped; and hinge means for folding the tube from an initial operating position about an axis transverse to the tube and generally parallel to the first and second belt runs such that one portion of the tube on one side of the hinge means can fold back to a folded position in which said one portion lies generally alongside a second portion of the tube on an opposed side of the hinge means.
Preferably the hinge means is arranged such that one of the first and second belt runs is extended relative to the initial operating position by folding around the axis to form an extension portion which is released when the tube is returned to the initial operating position and wherein there is provided take up means for taking up the extension portion.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of apparatus according to the present invention showing the tube in the initial operating position and showing only a centre part of the tube adjacent a hinge for a folding action.
FIG. 2 is a top plan view of the portion of the apparatus of FIG. 1.
FIG. 3 is a side elevational view of the portion of the apparatus of FIG. 1 showing the apparatus in the folded position.
FIG. 4 is a longitudinal vertical cross section through the apparatus of FIG. 1 showing only the hinge area.
FIG. 5 is a cross sectional view along the lines 5--5 of FIG. 4.
FIG. 6 is a cross sectional view along the lines 6--6 of FIG. 4.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
The apparatus for transporting particulate material is shown in one embodiment in the drawings FIGS. 1 through 6 and comprises a cylindrical tube 10 having a feed end 11 and a discharge end 12 for transporting particulate material from the feed end to the discharge end. In general, the tube will likely be inclined from a lower feed end to a raised discharged end but this is not necessarily the situation in all embodiments.
The apparatus further comprises a flexible belt 14 having an upper belt run 14A and a lower belt run 14B. At each of the feed end and discharge end, the belt wraps around a roller 15, 16 respectively so as to form the belt into a continuous or endless belt which moves in the upper belt run 14A through the inside of the tube and through the lower or return belt run 14B downwardly along the outside of the tube. The width of the belt is greater than the diameter of the tube so that the belt lies across a bottom part of the tube as best shown in FIG. 5 and follows approximately the curvature of the tube. Outside the tube, the belt run 14B lies generally flat since it is not constrained by the curvature of the tube itself.
In conventional operation of a transportation apparatus of this type, particulate material is discharged onto the belt at a portion of the belt exposed at the feed end of the tube, is transported through the tube while supported by the upper surface of the belt and is discharged at the upper end of the tube as the belt wraps around the roller 16. As best shown in FIG. 5, in this embodiment the second run 14B of the belt is housed within a container 17 which is attached to the tube 10 and extends along the full length of the tube 10 so that the belt is protected and so that the belt is prevented from interfering with persons or equipment in the area of the apparatus. The container 10 includes two downwardly and outwardly inclined sidewalls 18 which are welded to the outside surface of the tube at a position above the mid height of the tube. At the outside edge of the walls 18 is defined a pair of depending walls 19 which extend vertically downwardly to a horizontal base wall 20. The width of the base wall 20 and thus the space in between the side walls 19 is greater than the width of the belt 14. The height of the side wall 19 is arranged so that it is sufficient to provide a reasonable space within which the belt runs. If preferred, the belt can be supported on rollers mounted in the container 17 so as to support the belt away from the base wall 20. In the arrangement as shown, the belt 20 runs against the base wall in some areas and is supported on rollers in some areas as described hereinafter.
The tube 10 and the container 17 together with the belt mounted therein is a conventional arrangement and is well known for transporting materials.
The improvement of the present invention relates to the folding device by which the tube can be broken at a point along its length defining an upper portion 21 and a lower portion 22 which can be pivoted about a hinge line so that the upper portion 21 can be folded back to lie generally alongside the lower portion as best shown in FIG. 3.
Thus the tube 10 is divided at a line 23 which is directly at right angles to the axis of the tube so as to form two butting ends of the tube when in the position shown in FIG. 4. The tube can be stiffened by a pair of stiffening rings 24 and 25 welded around the tube at the butting ends.
The container 17 is also divided into two sections but instead of the dividing line being arranged at right angles to the axis of the tube, the dividing line extends at an angle from an upper end 26 to a lower end 27 spaced to one side of the line 23. The upper end 26 lies on the line and is located at the junction between the upper edge 18A of the portion 18 of the container.
The hinging action of the upper portion 21 relative to the lower portion 22 is effected about a pin 29 defining an axis of rotation of the upper portion. The pin is offset to one side of the tube with that side being opposite to the container 17. The pin lies in the plane containing the line 23 and is at right angles to the axis of the tube. The pin 29 is mounted for rotation on a pair of upstanding lugs 30 welded to the lower portion 22 adjacent the line 23. The lugs are at right angles to the pin and are parallel and are welded at a bottom edge 31 to the outside surface of the tube 10. The pin 29 is attached to a similar pair of lugs 32 which extend from the pin downwardly and away from the line 23 and are welded similarly to the surface of a tube 10 at a weld line 33. The lugs 32 are spaced outwardly of the lugs 30. Thus rotation of the pin 29 about its axis within the bearings defined by the lugs 30 causes rotation of the lugs 32 and the upper portion 21 of the tube 10 carried thereby to effect the movement from the position shown in FIG. 1 to the position shown in FIG. 3.
The rotation of the pin 29 is effected by a chain wheel 35 which has a hub 36 welded to the pin and to one of the lugs 32. The chain wheel lies in a radial plane of the axis of the pin 29 and is located at one end of the pin 29. The chain wheel 35 is driven by a chain 37 from a sprocket 38. The sprocket 38 is mounted on a shaft 39 which is in turn driven by a worm and wheel system including a wheel 40 and a worm 41. The worm 41 is attached to a manual crank 42 such that rotation of the worm 41 about a vertical axis within a container 43 causes rotation of the wheel 40 thus driving rotation of the chain wheel 35 and causing movement of the upper portion between the extended and folded positions. The container 43 is mounted on the tube in a support bracket 44 with an adjustment turnbuckle 45 effecting sliding movement of the container 43 for tensioning the chain 37.
As it will be seen by comparing the position shown in FIGS. 1 and 3, the movement to the folded position shown in FIG. 3 causes a significant extension in the lower belt run 14B since the lower belt run must extend around the outside of the tube around the bands 24 and 25 of the tube. As the belt is not extensible, this extension portion 14C must be taken up as the tube is returned to the operating position shown in FIGS. 1 and 4.
For this purpose is provided a pair of guide rollers 40 and 41. The roller 40 is carried on the lower portion 22 of the tube and is carried by that portion so as to be located at a position beyond the line 23 and just outside the wall of the tube 10. The roller 41 is carried by the portion 21 and is again located beyond the line 23 relative to that portion. Thus each of the rollers 40 and 41 is spaced from the line 23 by approximately the same distance and they range on opposite sides of the line. The roller 41 is however mounted so that it spaced further from the wall of the tube. This arrangement of the rollers as shown best in FIG. 4 provides a serpentine section of the belt run 14B which wraps around roller 40 forming a return section 14D of the belt and then wraps around 41 to form a further return section 14E of the belt. The section of the belt defined by the portion 14D and the portion 14E up to a point approximately indicated at 14F defines the extension portion 14C of the belt.
As the roller 41 is mounted outwardly from the tube by a further distance than the roller 40, as the tube is moved into the folded position shown in FIG. 3, the roller 41 moves outwardly around the roller 40 so as to gradually release the extension portion 14C as the roller 41 moves gradually past the roller 40 to take up the position shown in FIG. 3.
The roller 40 is mounted on a pair of arms 43 and 44 which are welded to the outside surface of the tube 10 approximately at its mid height and extends from the tube in an inclined direction downwardly and forwardly to the position beyond the line 23. The arms carry suitable mounting shaft 45 for the roller so that the roller is rotatable on the shaft by suitable bearings (not shown).
In the embodiment shown, the roller 41 is carried on a shaft 47 which is mounted on a pair of brackets 48 and 49 mounted on the side wall of the container 17. As the roller is mounted at a position below the base wall 20 of the container, an extension portion of the container is provided at the area of the fold and defined by two inclined base wall portions 20A and 20B which incline downwardly to an apex 20C at the roller 41. The side walls 19 are similarly extended so as to join with the edges of the base portions 20A and 20B. Thus the roller 41 is carried with the portion 21 of the tube but is attached to the container 17 of that portion rather than to the tube itself.
The arms 43 and 44 are bent outwardly as they extend from the tube wall toward the roller so as to allow the belt to pass between the arms in the operating position shown in FIG. 4 and to slide up inside the arms to engage the rib 24 on the end of the tube in the folded position shown in FIG. 3. As also shown in FIG. 3, the belt remains engaged around the roller 41 in the folded position so that it is held out away from the rib 25 of the tube. The upper or inner run 14A of the belt remains inside the tube and simply slides up to engage the ribs 24 and 25 at their positions adjacent the hinge pin 29.
In this way actuation of the crank 42 moves the upper or outer part 21 of the tube between the operating and folded positions and automatically maintains the belt in properly controlled position in view of the fact that the extension portion necessary for the folding action is controlled in its movement by the rollers 40 and 41.
An additional roller 50 is mounted on the base 20 at the connection between the base 20 and the base portion 20A so as to support the run 14B of the belt at that area and to prevent its rubbing vigorously against the junction between the base portion 20A and the base wall 20.
In an alternative arrangement (not shown), the container 17 can be omitted so that the belt run 14B is exposed on the outside of the tube. In this arrangement, the roller 41 can be mounted on arms similar to the arms 43 and 44 with those arms being bent further outwardly to engage 25 around the arms 43 and 44 when in the overlap position shown in FIGS. 1 and 4.
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A conveyor for particulate material of the type including a tube with a belt running through the tube and defining a return run of the belt outside the tube provides a folding action by which the length of the tube can be reduced by folding an upper portion back against a lower portion. The folding action is actuated by a hand crank which drives a chain wheel connected to a pivot pin carrying the upper portion. The pivot pin is mounted to one side of the tube which is opposite to the return run of the belt. In order to provide an extension portion of the return run which can be released to provide the length necessary for the folding action, the return run passes over a pair of rollers to form a serpentine section of the return run at the fold line of the tube. Each of the rollers is carried on a respective one of the upper and lower portions on opposite sides of the fold line to release the serpentine portion as the folding action is effected. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates generally to combustion and, more specifically, to a catalyst delivery system for delivering a controlled amount of catalyst in a molecular form to a combustion chamber.
BACKGROUND OF THE INVENTION
[0002] The concept of adding a catalyst to a combustion process is not new. However, there is no proven process that gives greater catalytic effect on combustion than for the catalyst to be proportionally and correctly mixed with the incoming air stream.
[0003] Some have attempted to coat the combustion chamber with nanoparticles. But, this has not been very successful because the combustion chamber will not stay coated under the extreme conditions of temperature and pressure. To try to recoat the combustion chamber by adding varying nanosubstances (solids) or dissolved rare earth compounds to the incoming air stream are not reliable, controllable or efficient. Simply coating the surfaces of a combustion chamber will have an effect at the outer edges of the combustion, but not at the core or ignition point and throughout the combustion.
[0004] Others have tried to add catalytic solutions directly to the fuel. However, the catalyst is weakened by the sheer nature of the catalyst molecules having to release themselves from the fuel molecules before having a catalytic effect on the overall combustion reaction in the millisecond that the combustion lasts.
[0005] Others have also simply placed Platinum balls into the fuel line or fuel tank, expecting the Platinum molecules to release into the fuel and cause a catalytic effect. Each of the aforementioned methods may have some level of success, but none of them seems to have a way to control the amount or the quality of catalyst delivered. Also, none of them appear to address a controlled repeatability and correct ratio of catalyst to fuel or the longevity of the catalyst delivery process.
[0006] Therefore, a need exists for a delivery system that improves the amount of actual catalytic material that reaches the combustion chamber. A need also exists for a delivery system that allows a user to control the delivery rate of the catalyst to the combustion chamber. One of the primary purposes of the invention is to reduce the overall fuel consumption of combustion devices and at the same time reduce the gaseous pollution and particulate matter created by the inefficient combustion of today's engines. It is a well known fact that catalyst(s) have a positive effect on combustion. What has always been a challenge is a way to control the amount and size of the catalyst to achieve the greatest effect on the combustion and this invention does that.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a delivery system that improves the amount of catalyst that reaches a combustion chamber.
[0008] It is another object of the present invention is to provide a catalyst delivery system that reduces the overall fuel consumption of combustion devices.
[0009] Another object of the present invention is to provide a catalyst delivery system that reduces particulate matter created by inefficient combustion in present day engines.
[0010] Another object of the present invention is to provide a catalyst delivery system that reduces the overall pollution, e.g. NOx, Co2, etc., created by inefficient combustion in present day engines.
[0011] Still another object of the present invention is to provide a catalyst delivery system that reduces the engine and exhaust temperatures created by inefficient combustion in present day engines.
[0012] Still another object of the present invention to provide a delivery system that allows a user to control the delivery rate of catalyst to a combustion chamber based on the amount of fuel being consumed.
[0013] Yet another object of the present invention is to provide a delivery system that allows a user to control the size of the catalytic molecules to achieve the greatest effect on combustion.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] In accordance with one embodiment of the present invention, a dry micro fog device for a combustion engine is disclosed. The device comprises a hollow chamber having a collection area for base materials, a piezoelectric disc for transforming base materials into a micro aerosol, wherein the piezoelectric disc is coupled to the hollow chamber, below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening for delivering the micro aerosol from the hollow chamber to an air intake of the combustion engine, and a bottom cover sealing a bottom portion of the hollow chamber.
[0015] In accordance with another embodiment of the present invention, a catalyst delivery system for a combustion engine is disclosed. The delivery system comprises an amount of liquid containing at least one catalyst, a hollow chamber having a collection area for the liquid, a piezoelectric disc for transforming the liquid into a micro aerosol, wherein the piezoelectric disc is coupled to the hollow chamber, below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening for delivering the micro aerosol from the hollow chamber to an air intake of the combustion engine, a bottom cover sealing a bottom portion of the hollow chamber, and a control mechanism for maintaining a constant level of liquid in the collection area.
[0016] In accordance with another embodiment of the present invention, a method for delivering catalyst to a combustion engine is disclosed. The method comprises the step of providing a dry micro fog device comprising a hollow chamber having a collection area, a piezoelectric disc coupled to the hollow chamber and coupled below the collection area, a top cover sealing a top portion of the hollow chamber, wherein the cover has an opening, and a bottom cover sealing a bottom portion of the hollow chamber. The method comprises the further steps of providing a liquid catalyst solution in the collection area, vibrating the piezoelectric disc, reducing the liquid catalyst solution to a micro aerosol comprising catalytic molecules that are between approximately 1.7 microns to 3 microns in size, and creating a venturi effect with the air flowing through the air intake to draw the aerosol from the hollow chamber into the air intake through the opening of the top cover.
[0017] The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a front view of one embodiment of a catalyst delivery system of the present invention.
[0019] FIG. 2 is a side cross-sectional view of the dry fog device of the catalyst delivery system of FIG. 1 .
[0020] FIG. 3 is a cross sectional view of the collection area, bottom cover, and piezoelectric disc of the dry fog device of FIG. 2 .
[0021] FIG. 4 is a side internal view of the dry fog device of FIG. 2 .
[0022] FIG. 5 is an elevated perspective view of the catalyst delivery system of FIG. 1 with the dry fog device shown in phantom lines coupled at the docking station on the air intake.
[0023] FIG. 5A is an elevated perspective internal view of the dry fog device of FIG. 2 .
[0024] FIG. 5B is an elevated perspective internal view of another embodiment of the dry fog device.
[0025] FIG. 5C is an elevated perspective internal view of another embodiment of the dry fog device.
[0026] FIG. 6 is a top perspective view of the delivery tube and splash guard of the dry fog device.
[0027] FIG. 7 is a bottom perspective view of the delivery tube and splash guard of FIG. 6 .
[0028] FIG. 8 is a top perspective view of another embodiment of the delivery tube and splash guard of the dry fog device.
[0029] FIG. 9 is a top view of the delivery tube and splash guard of the dry fog device of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The novel features believed characteristic of the invention are set forth in the appended claims. The invention will best be understood by reference to the following detailed description of illustrated embodiments when read in conjunction with the accompanying drawings, wherein like reference numerals and symbols represent like elements.
[0031] FIGS. 1-9 show a catalyst delivery system for a combustion engine, referred to as system 10 , of the present invention. The system 10 comprises a dry micro fog device 12 and a control mechanism 14 to control the amount of catalyst that reaches the combustion chamber, piezoelectric frequency, and the delivery rate of catalyst to a combustion chamber.
[0032] Referring to FIG. 1 , an embodiment of the catalyst delivery system 10 is shown. The dry fog device 12 is shown coupled to a side portion of an air intake 58 of a combustion engine. It should be clearly understood, however, that substantial benefit may be derived from the dry fog device 12 being coupled to a different portion of the air intake 58 . The dry fog device 12 converts base materials, such as a catalytic solution 16 , into a micro aerosol 17 that is then delivered into the air intake 58 . It should be clearly understood that the base materials may be water, water/glycol, oil, alcohol, esters, etc.
[0033] Maintaining an optimal level of catalytic solution 16 above the piezoelectric disc 26 , maintains the peak of efficiency of the micro aerosol 17 (see FIG. 4 ) output at all times and allows the piezoelectric disc 26 to operate for the longest length of time. The level of catalytic solution 16 will depend upon the type of liquid being nebulized; oil, water, water/glycol, etc. The viscosity of the liquid will determine the level in the collection area 24 that will provide for the best micronic fog effect.
[0034] In this embodiment, the system 10 has a supply of additional catalytic solution 16 that may be added to the collection area 24 through an inlet valve 52 . In FIG. 1 the additional catalytic solution 16 is held in a housing 48 and the flow of the catalytic solution 16 to and from the housing 48 is controlled by the control mechanism 14 . The additional catalytic solution 16 may be stored directly in the housing 48 or, for convenience, may be kept in disposable bags placed within the housing 48 . Furthermore, the housing 48 may be available in several sizes, allowing it to hold various amounts of catalyst solution, depending upon the maintenance cycle of the combustion engine.
[0035] When the amount of catalytic solution 16 in the collection area 24 falls below a desired level, additional catalytic solution 16 will be pumped from the housing 48 and to the collection area 24 via a length of tubing 56 that connects the housing 48 to the inlet valve 52 . In order to maintain an optimal level of catalytic solution 16 in the collection area 24 above the piezoelectric disc 26 (see FIGS. 2-3 ), the dry fog device 12 also has an outlet valve 54 that allows any overflow of catalytic solution 16 to be drained from the collection area 24 and pumped to the housing 48 via another length of tubing 56 that connects the outlet valve 54 to the housing 48 . As shown, the outlet valve 54 is positioned at a level below the inlet valve 52 and is positioned at the desired level.
[0036] In another embodiment, the control mechanism 14 may comprise a sensor placed within the collection area 24 for identifying the level of catalytic solution 16 remaining in the collection area 24 . Once the sensor detects that the level of catalytic solution 16 has fallen below the desired level, the control mechanism 14 will then pump additional catalytic solution 16 to the collection area 24 via tubing 56 connecting the housing 48 to the inlet valve 52 .
[0037] As shown in FIG. 1 , the control mechanism 14 of the system 10 comprises a pump and electronics assembly 64 . The control mechanism 14 also has inputs 46 to receive power from the engine and/or an independent power source. The tubing 56 connected to the inlet valve 52 and outlet valve 54 are also connected to the pump and electronics assembly 64 of the control mechanism 14 . Electrical wiring 62 also connects the piezoelectric disc 26 of the dry fog device 12 to the control mechanism 14 .
[0038] The control mechanism 14 is shown in FIG. 1 as being coupled to the housing 48 and shown separated from the dry fog device 12 . This allows the pump and electronics assembly 64 , the driver circuit, and power connections to be held remote from any sonic vibration or disruptive impact vibration destruction caused by the dry fog device 12 when the piezoelectric disc 26 is being operated. While this is preferred, it should be clearly understood that substantial benefit may still be derived from the control mechanism 14 being coupled directly to the dry fog device 12 . While this is the control mechanism 14 shown in the Figures, it should be clearly understood that any suitable control mechanism 14 may be used to control the flow of catalytic solution 16 between the dry fog device 12 and the housing 48 containing additional catalytic solution 16 .
[0039] Referring now to FIGS. 2-5 , the dry fog device 12 of the system 10 is shown coupled to an air intake 58 . In this embodiment, the dry fog device 12 has a hollow chamber 18 . While the hollow chamber 18 is shown as being L-shaped and attached to the side of the air intake 58 , it should be clearly understood that substantial benefit may be derived from the hollow chamber 18 having an alternative shape and being coupled to a different area of the air intake 58 .
[0040] A docking station 66 is coupled over an opening 82 in the air intake 58 . The docking station 66 is shown as having a curved portion 68 that conforms to the curve of the air intake 58 and has an opening 84 that is aligned with the opening 82 in the air intake 58 . The docking station 66 also has a straight portion 70 that connects to a top portion 20 of the hollow chamber 18 . The straight portion 70 of the docking station 66 and the top portion 20 of the hollow chamber 18 may be threaded and held together by a locking ring (shown in FIG. 5 ). However, it should be clearly understood that the straight portion 70 of the docking station 66 and the top portion 20 of the hollow chamber 18 may be coupled in any other suitable way as long as an air tight connection is created between the air intake 58 and the dry fog device 12 .
[0041] The hollow chamber 18 has a collection area 24 (shown in FIGS. 2-4 ) near a bottom portion 22 of the hollow chamber 18 . Base materials, such as catalyst solution 16 are held in the collection area 24 . While it is shown that the base materials be a liquid catalyst solution 16 , it should be clearly understood that substantial benefit may still be derived from the base materials being in gel or powder form.
[0042] A nebulizer, such as a piezoelectric disc 26 (shown in FIGS. 2-3 ), is located near the bottom portion 22 of the hollow chamber 18 , below the collection area 24 . The piezoelectric disc 26 transforms the catalyst solution 16 into an aerosol 17 (shown in FIG. 4 ) within the hollow chamber 18 . A bottom cover 34 seals the bottom portion 22 of the hollow chamber 18 and is shown as defining a recessed area 36 (shown in FIGS. 2-3 ) for housing the piezoelectric disc 26 . The bottom cover 34 is also shown as housing the electrical wires 62 (shown in FIGS. 2-3 ) that connect the piezoelectric disc 26 to the pump and electronics assembly 64 of the control mechanism 14 . The bottom cover 34 is shown as being threaded to correspond with a threaded bottom portion 22 of the hollow chamber 18 . It should be clearly understood, however, that the bottom cover 34 may be coupled to the bottom portion 22 of the hollow chamber 18 in any suitable way as long as an air-tight connection is formed.
[0043] The dry fog device 12 may also have anti-splashing material, such as open cell foam 74 (shown in FIGS. 2-4 ), placed within the collection area 24 for preventing splashing within the collection area 24 during the vibrations caused by the operating engine and/or the equipment that the engine is housed in. The open cell foam 74 is shown conforming to the shape of the hollow chamber 18 , lining the inner walls of the collection area 24 . The open cell foam 74 will also define a hollow center portion 76 directly above the piezoelectric disc 26 , allowing the piezoelectric disc 26 to be submerged in the catalytic solution 16 . The bottom portion 22 of the hollow chamber 18 is also shown defining a flange 78 (shown in FIGS. 2-4 ), on top of which the open cell foam 74 will sit.
[0044] As shown in FIGS. 2 and 3 , when the bottom cover 34 is coupled to the bottom portion 22 of the hollow chamber 18 , the recessed area 36 of the bottom cover 34 comprises a flange 80 that is aligned with the flange 78 of the bottom portion 22 of the hollow chamber 18 . The piezoelectric disc 26 is situated between two O-rings 44 ; one O-ring 44 placed below the flange 78 of the bottom portion 22 of the hollow chamber 18 and one O-ring 44 placed above the flange 80 of the bottom cover 34 . This O-ring configuration reduces leakage from the collection area 24 and keeps the piezoelectric disc 26 in place within the recessed area 36 of the bottom cover 34 .
[0045] Referring to FIGS. 5A-5C , the dry fog device 12 also has a top cover 28 that seals the top portion 20 of the hollow chamber 18 . The top cover 28 has an opening 30 for delivering aerosol 17 from the hollow chamber 18 to the air intake 58 of the combustion engine. Airflow within the air intake 58 blows across the opening 30 , creating a venturi effect, thereby causing the aerosol 17 to be pulled from the hollow chamber 18 through the opening 30 in the top cover 28 and into the air intake 58 . The top cover 28 may also have a pressure balance hole 32 to relieve any excess negative pressure in the hollow chamber 18 , though one is not required.
[0046] In another embodiment, the dry micro fog device 12 may have a delivery tube 38 (shown in FIGS. 2 , 4 , 5 , 5 A, and 5 B) that passes through the opening 30 of the top cover 28 . The delivery tube 38 has a first end 40 that is located within the hollow chamber 18 and is located above the collection area 24 . The delivery tube 38 also has a second end 42 that is located within the air intake 58 . The second end 42 of the delivery tube 38 is preferably placed at a specific position within the air intake to ensure optimal function. This specific position is determined according to the size of the air intake 58 and the velocity of the air blowing through the air intake 58 . Generally, the second end 42 of the delivery tube 38 will be placed more than one quarter inch away from the inner perimeter of the air intake 58 . This will assure that the delivery tube 38 is not placed in the eddy of the air stream in the intake 58 , whether reverse or turbulent air stream.
[0047] In the embodiment shown in FIG. 5B , airflow within the air intake 58 blows across the open second end 42 of the delivery tube 38 creating a venturi effect, thereby causing the aerosol 17 to be pulled from the hollow chamber 18 through the delivery tube 38 and into the air intake 58 . The second end 42 of the delivery tube 38 may flex due to the violence of the venturi effect.
[0048] As shown in FIGS. 5-5A , the second end 42 of the delivery tube 38 may be T-shaped so that a portion of the second end 42 is in line with the air intake 58 . Airflow within the air intake 58 will blow through the open T-shaped second end 42 creating a venturi effect within the T-shaped second end 42 , thereby causing the aerosol 17 to be pulled from the hollow chamber 18 through the delivery tube 38 and into the air intake 58 . This T-shaped configuration reduces the violence of the venturi effect.
[0049] Referring to FIGS. 6-9 , the dry fog device 12 may also have a splash guard 60 (also shown in FIGS. 2 , 4 , and 5 ) coupled to the first end 40 of the delivery tube 38 for preventing large particles of catalytic solution 16 from entering the delivery tube 38 . The splash guard 60 is shown as being a disc coupled to the first end 40 by a plurality of prongs. The splash guard 60 may be solid (shown in FIGS. 6 , 7 , and 9 ) or the splash guard may be porous (shown in FIG. 8 ). It should be clearly understood that the splash guard 60 may be coupled to the first end 40 in any suitable way as long as the open first end 40 is not obstructed. It should also be clearly understood that substantial benefit may be derived from the splash guard 60 being integral to the first end 40 or from there being no splash guard 60 .
[0050] All component parts, including plastics, wiring, tubes, connectors, metals and catalyst are designed to withstand the atmospheric conditions and the contamination conditions in or around the combustion engine.
Statement of Operation
[0051] The catalyst delivery system 10 may be constructed with a combustion engine, or more preferably, will be adaptable to an existing combustion engine. In the case of an existing combustion engine, an opening 82 in the air intake 58 must be made. A docking station 66 will be coupled to the air intake 58 , making sure to align the opening 84 of the docking station 66 with the opening 82 in the air intake 58 . The top portion 20 of the hollow chamber 18 will then be coupled to the straight portion 70 of the docking station 66 . If a delivery tube 38 is used, the second end 42 of the delivery tube 38 should be positioned at its optimal location within the air intake 58 .
[0052] The collection area 24 of the hollow chamber 18 will be filled with catalytic solution 16 . The piezoelectric disc 26 may then be operated and controlled by the control mechanism 14 . By controlling the voltage, a user may control the piezoelectric disc 26 frequency and therefore control the aerosol output (consumption of catalytic solution 16 ). This will assure reduction in pollution and fuel consumption.
[0053] The piezoelectric disc 26 may be operated at frequencies between approximately 1.6-2.4 megahertz, thus creating an aerosol 17 (or dry fog) of catalytic molecules between approximately 1.7-3 microns in size. These molecules are so small that they quickly evaporate when introduced into the in-coming air stream in the air intake 58 , thereby releasing pure unattached catalyst into the combustion zone. This not only increases the catalytic effect and reliability, but also simultaneously reduces the amount of catalyst needed in the base solution. Furthermore, the greatly reduced size of the catalyst molecules reduces the possibility of the catalyst attaching to any surface before reaching the combustion engine.
[0054] The piezoelectric disc 26 has a finite life cycle which has been greatly increased by the present invention. The control mechanism 14 causes the piezoelectric disc 26 to have an ON/OFF cycle from approximately 10-20 milliseconds to approximately 10-40 milliseconds (and so on). By having the OFF cycle of the piezoelectric disc 26 set at 1-4 times the length of the ON cycle, the life cycle of the piezoelectric disc 26 is increased exponentially. This will also control the amount of aerosol 17 outflow. The ON/OFF cycles may be changed as needed to extend the life of the piezoelectric disc 26 as desired.
[0055] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | A system and method for delivering catalytic molecular structure to a combustion chamber is disclosed. Catalyst base materials are reduced to a micronic fog by a device using the ultrasonic vibration of a piezoelectric disc. The liquid base materials evaporate instantly upon entering the engines air stream therefore releasing pure catalyst molecules into the combustion zone, thus reducing the time taken for catalytic combustion to the lowest denominator possible and allowing for the greatest effect achievable. This further reduces the amount of catalyst needed in the base solution compared to any other type of device or additive. The system also allows a user to control the delivery rate of the catalyst to the combustion chamber. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a thread trimmer provided in a pattern sewing machine for forming various patterns according to pattern data. The thread trimmer automatically cuts the specified portion of a crossover thread connecting a pattern and a next pattern to be formed.
In a known pattern sewing machine various patterns are formed according to various pattern data stored beforehand in a memory. The pattern sewing machine is provided with a thread trimmer comprising a fixed knife and a movable knife. At a desired time after a series of sewing operations, the thread trimmer trims needle thread and bobbin thread.
While the pattern sewing machine forms patterns on the fabric, a pattern is connected via a crossover thread to the next pattern to be formed. As shown in FIGS. 3A and 3B, when characters A and B are formed on the fabric, a stitch connecting the end a of the character A and the beginning b of the character B corresponds to the crossover thread. When the characters A and B are distant from each other, as shown in FIG. 3B, a needle bar is disconnected and no stitches are formed between the characters A and B. The needle thread connecting the end a of the character A and the beginning b of the character B also corresponds to the crossover thread. The crossover thread is formed during the operation of the pattern sewing machine. After the operation is completed, the crossover thread is no longer needed, so an operator cuts the crossover thread with scissors. The cutting of the crossover thread is both troublesome and time consuming.
SUMMARY OF THE INVENTION
An object of this invention is to provide a thread trimmer for a pattern sewing machine, that can automatically cut the specified portion of the crossover thread connecting a pattern and the next pattern to be formed by the pattern sewing machine.
To attain this and other objects, the present invention provides a pattern sewing machine which comprises a needle bar carrying a needle at a lower end and being moved vertically by an arm shaft driven by a sewing machine motor, a memory means storing a pattern data indicative of a pattern, and a phase detection means for detecting a rotary phase of the arm shaft and for sending out a timing signal indicative of lowering of the needle bar. The pattern sewing machine further comprises a thread trimming means for trimming a needle thread and a bobbin thread after stitches are formed on a fabric according to a relative movement of the needle and the fabric, and a trimming designation means for specifying a cut portion of a crossover thread between the respective pattern and a next pattern to be formed according to the pattern data stored in the memory means. The pattern sewing machine also comprises a trimming memory means for storing a trimming signal indicative of the cut portion of the crossover thread specified by the trimming designation means, and a trimmer drive means for driving the thread trimming means in response to both the trimming signal and the timing signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a control circuit for a pattern sewing machine embodying this invention.
FIG. 2 is a schematic view of the pattern sewing machine.
FIGS. 3A and 3B are schematic views of character patterns formed by the pattern sewing machine.
FIG. 4A is an illustration of a series of patterns to be formed and scissors symbols on a liquid crystal display.
FIG. 4B shows the actual formation of the series of patterns displayed on the liquid crystal display shown in FIG. 4A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 2, in an electronically controlled pattern sewing machine 10, a support 18 hangs from a pin 16 in a head 14 at the left end of an arm 12, as the figure is viewed, such that the support 18 can rotate by a predetermined angle. The support 18 supports a needle bar 22 carrying a needle 20 at its lower end, such that the needle bar 22 is vertically movable. In the arm 12, an arm shaft 24 is horizontally provided. A connecting rod 26 is connected from the arm shaft 24 via a needle bar connecting stud 28 to the needle bar 22. In a bed leg 30 a sewing machine motor 32 is provided. The drive power of the sewing machine motor 32 is transmitted through a belt 34, a pulley 36 and the arm shaft 24 to the connecting rod 26, thereby moving the arm shaft 24 rotatably and the needle bar 22 vertically.
In the bed leg 30, a sector gear 38 rotatably meshes with a pinion 42 of a stepping motor 40 for rocking the needle bar 22. As shown in FIG. 2, the sector gear 38 is connected through a connector 44 to the support 18. By rotating the stepping motor 40 forward and backwards, the sector gear 38 rotates by a bounded angle. The rotation of the sector gear 38 is transmitted via the connector 44, thereby rocking the support 18 and the needle bar 22.
An arm bed 46 houses a feeding mechanism 48. The feeding mechanism 48 operates almost synchronously with the needle bar 22. A feed dog 50 is connected to the feeding mechanism 48, for feeding not-shown fabric vertically and back and forth. The feeding mechanism 48 includes a feed bar assembly 52 for supporting the feed dog 50, a feed lifting rock shaft 54 for moving the feed bar assembly 52 vertically, and a feed rock shaft 56 for moving the feed bar assembly 52 back and forth. A fork 52a and a T portion 52b are formed at the front and back end of the feed bar assembly 52, respectively. The feed lifting rock shaft 54 is pivotably supported at the side of the operator in the arm bed 46. A feed lifting crank 58 perpendicularly extends from the feed lifting rock shaft 54 and connects via a stud 60 to the fork 52a. The feed rock shaft 56 is supported in the back of the arm bed 46 such that the feed rock shaft 56 can rock around an axis. Rods 61 and 62 extend perpendicularly from the feed rock shaft 56. The T portion 52b of the feed bar assembly 52 is pivotably attached to the rods 61 and 62.
A rocking shaft 64 is rotatably provided at the back of the feed lifting rock shaft 54. A cam 66 is secured to the rocking shaft 64 and is engaged with a forked rod 68 extending perpendicularly from the feed lifting rock shaft 54. The rocking shaft 64 is connected via a rod 70 to a connecting rod 24a formed onto the arm shaft 24. When the sewing machine motor 32 is driven, the arm shaft 24 rotates, thereby moving the needle bar 22 vertically. The drive power of the sewing machine motor 32 is transmitted via the arm shaft 24 to the rod 70, thereby rotating the rocking shaft 64. The drive power is transmitted from the rocking shaft 64 through the cam 66, the forked rod 68, the feed lifting rock shaft 54 and the feed bar assembly 52, thereby moving the feed dog 50 vertically.
A sector gear 72 is secured to the right end of the feed rock shaft 56 as the figure is viewed. The sector gear 72 meshes with a pinion 76 of a stepping motor 74 in the bed leg 30. When the stepping motor 74 is driven synchronously with the vertical movement of the feed dog 50, the feed dog 50 moves back and forth in the raised or lowered position of the feed dog 50.
In the arm bed 46 a thread trimmer 78 is provided in the area where the needle 20 lowers. The thread trimmer 78 trims needle thread and bobbin thread according to a predetermined command. The thread trimmer 78 is composed of a fixed knife 80 provided in the vicinity of a not-shown rotary hook assembly, a movable knife 82 for slidably engaging the fixed knife 80, and a trimmer stepping motor 84 for driving the movable knife 82. In the specified range of the rotary phase of the arm shaft 24, the movable knife 82 cooperates with the fixed knife 80 and trims the needle thread and the bobbin thread.
As shown in FIG. 2, a phase detector 88 is provided onto the arm shaft 24, for detecting the rotary phase of the arm shaft 24 and the current position of the vertically moving needle bar 22. The phase detector 88 detects whether the needle bar 22 is in an elevated position or in a lowered position. The phase detector 88 is comprised of a disc 90 having a radial slit and a photo interrupter 92 for holding therein the disc 90. When the rotary phase of the disc 90 and the arm shaft 24 is about 360 degrees, the photo interrupter 92 detects that the light beam passes through the slit in the disc 90, and sends a timing signal to a CPU 94 shown in FIG. 1. The timing signal corresponds to the current position of the needle bar 22.
A liquid crystal display 96 is provided at the side of the operator on the arm 12. The liquid crystal display 96 shows the pattern selected by the operator. A pattern input unit 97 composing a key panel is provided onto the bed leg 30. The operator can register the selected pattern with the pattern input unit 97. The drive mechanism for a needle thread take-up 98 and the mechanism for connecting a presser foot assembly 99 are well known for those skilled in the art and are omitted from the drawing and the description for simplicity.
The control system of the pattern sewing machine 10 will now be explained referring to the block diagram in FIG. 1. The pattern input unit 97 and the phase detector 88 are connected directly to an I/O interface 11 in a control circuit C. The phase detector 88 determines the timing of feeding the fabric. The sewing machine motor 32, the stepping motor 74, the stepping motor 40 and the liquid crystal display 96 are connected via drive circuit 15, 19, 17 and 21, respectively, to the I/O interface 11.
The trimmer stepping motor 84 is connected via a drive circuit 23 and an AND circuit 25 to the I/O interface 11. The AND circuit 25 sends a drive signal to the drive circuit 23 when the thread trimming signal sent from a memory 35 (described hereinafter) is logically ANDed with the signal indicative of the lowering of the needle bar 22 sent from the phase detector 88. The memory 35 stores the portion of the crossover thread to be cut. When the drive circuit 23 receives the thread trimming signal and the signal indicative of the lowering of the needle bar 22, the trimmer stepping motor 84 is driven. The needle thread and the bobbin thread are cut between the movable knife 82 and the fixed knife 80 of the thread trimmer 78.
Other elements (not shown) for operating the pattern sewing machine 10 are also connected via the I/O interface 11 for example a start/stop switch for selectively starting or stopping the operation of the pattern sewing machine 10, a speed detector for detecting the rotary speed of the arm shaft 24, a volume adjustment for adjusting the rocking amount of the needle bar 22, a volume adjustment for adjusting the feed amount of fabric, and a clock pulse generator for synchronizing the operation of movable components.
The CPU 94, a ROM 29 and a RAM 31 are connected via a bus 27 to the I/O interface 11. The ROM 29 stores the pattern data involving the needle location data for sewing various characters, symbols and other patterns. The needle location data includes the feed amount data and the needle rock data. The ROM 29 also stores the control program for reading the selected stitch pattern data and controlling the stepping motor 74 based on the feed amount data in response to the feed start signal. The ROM 29 further stores the control program for controlling the sewing machine motor 32 and the control program for determining the feed start timing based on the feed amount data and the speed signal. The RAM 31 includes memory for temporarily storing the results of the computation by the CPU 94.
The I/O interface 11 is connected via the bus 27 to a thread trimming designation unit 33 and the memory 35. The thread trimming designation unit 33 specifies the cut portion of the crossover thread between the previous and next patterns, before the next pattern is formed according to the stitch pattern data stored in the CPU 94. The thread trimming designation unit 33 reads the thread trimming code included in the stitch pattern data from the CPU 94 and determines which stitch corresponds to the end of a specified pattern and to the cut portion. The memory 35 stores the portion to be cut of the crossover thread specified by the thread trimming designation unit 33. The information regarding the portion to be cut of the crossover thread could be temporarily stored in the RAM 31, if memory is available.
The operation of the thread trimmer 78 of the pattern sewing machine 10 will now be explained. The threading of the eye in the needle 20 precedes the operation of the pattern sewing machine 10. The pattern to be formed is input using the pattern input unit 97, and the input and selected pattern is shown on the liquid crystal display 96. Subsequently, a start/stop switch (not shown) is pressed, sending the start signal to the CPU 94. According to the control program stored in the ROM 29 the sewing machine motor 32 is driven via the drive circuit 15, thus rotating the arm shaft 24. According to the feed amount data for each sewing operation stored in the ROM 29, the stepping motor 74 is driven via the drive circuit 19, thus moving the feed dog 50 vertically and back and forth. According to the needle rock data for each sewing operation stored in the ROM 29, the stepping motor 40 is driven via the drive circuit 17, thus oscillating the needle bar 22 in a direction perpendicular to a cloth feeding direction. Such controlled vertical and horizontal movement of the needle bar 22 and the needle 20 as well as the vertical and reciprocating movement of the feed dog 50, forms stitches successively on the fabric (not shown) according to the stitch pattern data. When the stitches are formed into patterns, as shown in FIGS. 3A and 3B, the crossover thread connects the end of the pattern and the beginning of the next pattern. In this embodiment since the thread trimming designation unit 33 specifies the cut portion of the crossover thread and the memory 35 stores the cut portion of the crossover thread, the crossover thread is automatically cut.
Specifically, as shown in FIG. 3A, when the characters A and B are formed, the thread trimming designation unit 33 specifies that the portion between the end a of the character A and the beginning b of the character B is cut. The portion to be cut is stored in the memory 35. In operation, when the needle 20 lowers into the end a of the character A, as shown in FIG. 1, the memory 35 sends a thread trimming signal to one terminal of the AND circuit 25 connected to the drive circuit 23. The thread trimmer 78 operates when the needle 20 lowers into the fabric and the needle thread as well as the bobbin thread come between the movable knife 82 and the fixed knife 80 of the thread trimmer 78. Therefore, the other terminal of the AND circuit 25 receives the timing signal from the phase detector 88 which indicates that the needle bar 22 is in its lowered position. The AND circuit 25 sends a drive signal to the drive circuit 23 on the condition that the AND circuit 25 receives the thread trimming signal from the memory 35 and the timing signal from the phase detector 88. The drive circuit 23 drives the trimmer stepping motor 84, thereby operating the movable knife 82 of the thread trimmer 78. The needle thread as well as the bobbin thread are thus cut at the end a as shown in FIG. 3A.
Similarly, when the needle lowers into the beginning b of the character B, the memory 35 sends the thread trimming signal to one terminal of the AND circuit 25. The AND circuit 25 sends the drive signal to the drive circuit 23 on the condition that the AND circuit 25 receives the thread trimming signal from the memory 35 and the timing signal from the phase detector 88. The drive circuit 23 drives the trimmer stepping motor 84 to operate the thread trimmer 78. The needle thread as well as the bobbin thread are thus cut at the beginning b.
As shown in FIG. 3B, when the characters A and B are distant from each other and the needle bar 22 is disconnected, the characters A and B are connected by the needle thread and the bobbin thread without any stitch being formed.
When the thread trimming designation unit 33 specifies the portion to be cut of the crossover thread, the symbol of scissors is shown on the liquid crystal display 96 as shown in FIG. 4A. By blinking the symbol, the portion to be cut of the crossover thread could be indicated. The operator can visually confirm the portion to be cut of the crossover thread with the liquid crystal display 96 as shown in FIG. 4A. The series of patterns displayed as shown in FIG. 4A is actually formed as shown in FIG. 4B.
In this embodiment, the operator manually sets the portion to be cut into the thread trimming designation unit 33. The portion to be cut can be automatically determined according to input patterns. By including a trimming flag into the pattern data beforehand as shown in Table 1, any necessary trimming can be carried out automatically.
TABLE 1______________________________________PATTERN TRIMMING FLAG______________________________________UNDERLINED ALPHABETICAL 0 (NO TRIMMING)WORDSSPACING 1 (TRIMMING)JAPANESE HIRAGANA/KATAK- 1 (TRIMMING)ANA CHARACTERS (REQUIRINGNO UNDERLINING)______________________________________
For example, the following pattern comprises the combination of two underlined alphabetical words and the spacing interposed between the words. In this combined pattern, crossover thread is designated by an underline.
B.sub.-- R.sub.-- O.sub.-- T.sub.-- H.sub.-- E.sub.-- RS.sub.-- E.sub.-- W.sub.-- I.sub.-- N.sub.-- G
When the operator registers the pattern data of the above pattern with the pattern input unit 97, the trimming flag is included in the pattern data. Where the trimming flag is one, the crossover thread is automatically trimmed. When the trimming flag is zero, the crossover thread is not trimmed.
The present invention is not limited to the embodiment described above but includes all embodiments and modifications within the scope and spirit of the invention. | A thread trimmer for a pattern sewing machine is disclosed. When the pattern sewing machine forms patterns, a pattern is connected to a next pattern by a crossover thread. The thread trimmer automatically cuts a specified portion of the crossover thread. Therefore, the operator can avoid the troublesome and time-consuming cutting of the crossover thread manually with scissors. Furthermore, the sewing efficiency of the pattern sewing machine is enhanced. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improved apparatus for repairing indentions in a rigid skin, and more particularly, but not by way of limitation, to an improved apparatus for repairing dents in the metal skin of the body of an automobile.
2. Description of the Prior Art
In the construction of vehicles and the like, an outer facade or skin surface often forms a body so as to enclose the operative parts of the vehicle, and to function as the outer skin in the wind stream created while the vehicle is moving. Examples of such vehicles are automobiles, trucks, travel trailers and airplanes. In the use of such vehicles and the like, the outer skin may be exposed to accidental damage brought about by normal usage in traffic, and may incur damage from weather elements, including hail, snow and rain. These are examples of the abuse generally created by external forces brought against the skin surfaces of vehicles and the like. As a result thereof, it often happens that indentations, or dents, are caused in the facade or skin surfaces, and it is often necessary or desirable to restore the skin surfaces to their original shapes.
Repair to outer skin surfaces, such as automobile body surfaces, is performed by a number of techniques. If damage is very extensive, it may be necessary to remove part of the outer skin, such as for example a fender, and to replace the removed part with a new or rebuilt component. If the body skin is dented, the dented area may be built up by adding material to fill in the dent, followed by surfacing finishing techniques to match the appearance of the repaired areas with the appearance of the surrounding surfaces. Yet another way of repairing dents in body skin surfaces is to force the dented area back to its original shape, or at least to approximately its original shape, by applying a force against the dented area in a direction generally opposite to the direction of impression of the dent.
It is a relatively easy matter to repair dented portions of a body skin when it is possible to have relatively free access to the back or dent protrusion side of the body skin. However, it is a different matter when the body skin is constructed in a manner so as to enclose a space wherein it is impracticable to work the rear side of the body skin. In this case, techniques have been worked out to pull the dent from the side of impression by attaching a pulling member to the area of indentation, such as by the use of a welding rod or the like. Several prior art patents that teach apparatus practicing this technique of dent straightening are U.S. Pat. No. 3,545,250, issued to Jones; U.S. Pat. No. 3,187,538, issued to Painter; U.S. Pat. No. 3,091,983, issued to Kliss; U.S. Pat. No. 2,799,190 issued to Awot; U.S. Pat. No. 2,957,376, issued to Parisi; U.S. Pat. No. 2,749,795 issued to Boykin, Jr.; and U.S. Pat. No. 674,133 issued to Cathriner.
While the prior art has generally met with success in repairing indentations in the body skin of automobiles and the like, usually the machinery or apparatus to perform the same has been bulky, or at best, rather awkward to manipulate. This is especially true when a vehicle has a large number of indentations, such as when an automobile has suffered the effects of multiple indentations caused by the striking thereof by falling ice or hail. Not only must a large number of impressions or dents be straightened, it is generally to be expected that the body skin is covered by paint or by a vinyl covering, such as in vinyl-topped automobiles, in which case it is undesirable to mar the surface as is generally required by most prior art devices.
Yet another problem with the straightening of dents is that of overpulling the indented portion wherein there is caused a positive protrusion after pulling the dent back to the surface. In other words, the metal skin forming the dented portion is plastically deformed so that it is not returned to its exact shape. Rather, the dented area will protrude from its original position, necessitating followup surface working to match the surface finish of the undented portion of the body skin.
SUMMARY OF THE INVENTION
The present invention provides an improved apparatus for straightening an indentation in a metal skin or the like wherein a dent-engaging member is placed in contact engagement with the dent, and a frame means, backup means, chuck means and retracting means cooperatively pull the dent-engaging member so as to force the indented portion of the body skin back to its original shape.
Accordingly, an object of the present invention is to provide an improved dent-straightening apparatus that easily and quickly attaches to and removes the dent.
Another object of the present invention is to provide an improved dent-straightening apparatus that is easily and quickly removed from the dented portion after straightening the dent.
Another object of the present invention is to provide an improved dent-straightening apparatus that minimizes the marring of the dented area while straightening.
Another object of the present invention is to provide an improved dent-straightening apparatus that prevents overpull of the dented area.
Another object of the present invention is to provide an improved dent-straightening apparatus that operates efficiently, minimizing the time and effort required to repair a body skin having one or many dents.
Another object of the present invention is to provide an improved dent-straightening apparatus that offers ease of manufacture, having a minimum of parts, thereby minimizing fabrication costs.
Another object of the present invention is to provide an improved dent-straightening apparatus that offers economy of operation.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate various embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the improved dent-straightening apparatus of the present invention.
FIG. 2 is a front elevational view of the dent-straightening apparatus shown in FIG. 1.
FIG. 3 is a cutaway depiction of the dent-straightening apparatus of FIG. 1 showing the operation of the lifting action of the handle member acting upon the peripheral flange of the chuck assembly.
FIG. 4 is a side elevational view of another embodiment of the improved dent-straightening apparatus of the present invention.
FIG. 5 is a front elevational view of the dent-straightening apparatus of FIG. 4.
FIG. 6 is a view of the dent-straightening apparatus of FIG. 4 in contacting engagement with a dent, illustrating the positioning of the dent-straightening apparatus along a curved body skin surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and particularly to FIGS. 1 through 3, the improved dent-straightening apparatus of the present invention is illustrated and generally designated by the numeral 10. The apparatus 10 basically comprises a frame member 12 that has a stationary handle member 14 extending therefrom. As appearing in FIG. 1, the handle 14 has a shaped gripping portion 16 having a finger contoured edge 18 along the underside thereof.
The frame member 12 further comprises, as shown in cut-away in FIG. 3, a box-like structure 20 having a top 22 and a bottom 24 and side walls 26 and 28. The front of the structure 20 is enclosed with the wall 30. The stationary handle 14 is welded to the box-like structure at 32, and an opening 34 is left between the adjoining point 32 and the top 22 of the box 12.
As best viewed in FIG. 3, a pair of apertures 36 are positioned in the top 22 and the bottom 24 in an inline relationship for the passing therethrough of a slide rod, the details of which will be given below. While bearings may be disposed within or about the apertures 36, it has been found sufficient for the purpose of the apparatus 10 to provide a reinforcing guide bead 38 on the top 22 and about the aperture 36 that passes through the top 22.
Connected to and extending from the wall 28 is a support member 40, and in like manner, connected to and extending from the wall 26 is a support member 42. The support members 40 and 42 curve out from the walls 28 and 26 and downward to support a base plate 44 that is connected to the support members 40 and 42 by attaching means such as by the screws 46 that are shown in dashed-line form in FIG. 2. Of course, if the screws 46 are used, appropriately spaced apertures in the base plate 44 and matching, threaded apertures must be disposed in the ends of the support members 40 and 42 for receiving the screws. In practice, it has been found that a variety of shapes for the base plate 44 are useful for straightening dents in contoured body skins, as will be made clear below, and this makes necessary a variety of attaching means be used for connecting variously shaped base plates to the support members 40 and 42. For example, the support members 40 and 42 may be made hollow, and extending stub inserts may be attached to the upper surface 48 of the base plate 44. Such inserts then together with the hollow cores of the support members 40 and 42 form a plug and socket, or male and female arrangement whereby the base plate 44 may be connected to the support members 40 and 42, in which case set screws or the like may be disposed at appropriate locations to firmly retain the inserts in the hollow core of the supports 40 and 42.
It has been found generally desirable to have the underside 50 of the base plate 44 smooth, and any attaching means used to connect the base plate 44 to the support members 40 and 42 should do so in a manner that does not affect the smoothness of the surface 50. For instance, the screws 46 are selected as tapered head screws, and the apertures through which they pass in the base plate 44 are appropriately tapered to receive the screw heads flush with the surface 50.
Slidingly disposed in the apertures 36 is a chuck assembly 52 comprising a vise chuck 54 and a slide rod 56. The vise chuck 54 is of conventional design, and need not be described in detail for purposes of this disclosure. It is sufficient to state that the vise chuck 54 has an outer sleeve 58 and gripping jaws 60 disposed at one end thereof. At the other end of the housing 58 is a threaded aperture with receiving threads that matingly engage a threaded portion 62 at the lower end of the slide rod 56. In known manner, as the housing 58 is tightened onto the threads 62, the jaws 60 are caused to grip uniformly about the shank of a member placed therein, such as that of the threaded engaging member 66, which will be described in more detail below. Chucks such as the vise chuck 54 may be found in such usages as electric drills, cabinetry drills, etc.
At the upper end 68 of the slide rod 56, a knob 70 is connected to the slide rod. The knob 70 is sized and shaped to generally fit the hand of an individual for manual rotating of the slide rod 56 in the apertures 36. Also attached to the slide rod 56, and intermediate to the knob end 68 and the threaded end of rod 56 is a peripheral flange 72 that is shaped to have a smooth under surface 74.
Extending through the opening 34 and the box structure 20 is the handle member 76 that is pivotally supported on the frame 12 by means of a pivot pin 78 that passes through an appropriately placed aperture in the handle member 76 and oppositely placed, aligning apertures in the side walls 26 and 28 of the frame 12. The pin 78 serves as an arbor for rotation of the handle 76 thereabout, and the pin is retained by staking means or the like in its position through the appropriate apertures.
The handle member 76 serves as part of a retracting means, as will become clear below, and comprises an extending portion 80 extending in one direction from the pivot point 78, and a forked portion 82 extending in the opposite direction therefrom. The extending portion 80 has a gripping portion 84 that is used in cooperation with the gripping portion 16 of the stationary handle 14, forming manually operated retracting means for the embodiment of the apparatus 10 shown in FIGS. 1 through 3.
The forked end 82 of the handle 76 comprises a pair of tines 86 that are spaced apart sufficiently to clear the slide rod 56 while liftingly contacting the undersurface 74 of the peripheral flange 72.
The engaging member 66 as will be made clear below, may comprise a variety of sizes and shapes, one of which is shown in FIGS. 1 through 3 wherein is shown an engaging member 66 having a threaded dent-contacting portion 88, and although not viewable in the figures, a shank portion opposite to the threaded end 88 that is gripped by the jaws 60 as described above. The engaging member 66 is a disposable portion of the apparatus 10, and in practice, it has been found that varying shapes and sizes of engaging members are desirable for various surfaces to be repaired. For example, it has been found that in some applications it is desirable to use an engaging member that has a shank portion for gripping, and a hook member instead of the threaded portion 88 shown for the engaging member 66 illustrated in the FIGS. 1 through 3. In any event, the engaging member 66 is gripped by the chuck assembly 52 for selective reciprocating movement relative to the base plate 44 that has a relief aperture 90 appropriately placed for the clearing passage therethrough of the engaging member 66.
OPERATION OF THE PREFERRED EMBODIMENT
The operation of the improved dent-straightening apparatus 10 as illustrated and described in FIGS. 1 through 3 will now be discussed. In brief summary, the improved dent-straightening apparatus 10 comprises frame means 12, backup means or base plate 44, chuck means or assembly 52 and retracting means 76 and 16, which elements cooperate to position and reciprocatingly move an engaging means 66. As described for the illustration of the embodiment 10 in FIGS. 1 through 3, the gripping portions 16 and 84 of the stationary handle 14 and the pivotable handle 76 are manually manipulated to raise the chuck assembly 52. This description will have further clarity by the use of the dashed outlines of the moving components of the apparatus 10 in the figures, and these dashed outlines will be given primed numeral designations to aid in clearly understanding the operation of apparatus 10.
When the handle 76 is in the position designated 76', the forked portion 82 is cuased to pivot to the position designated 82', and the tines 86, designated as 86' in the corresponding position, are caused to act against the underside 74 of the peripheral flange 72, and to raise the peripheral flange to a position designated 72'. Of course, this results in the raising of all of the components of chuck assembly 52 to the position designated 52', resulting in the raising of the engaging member 66 to a position designated as 66'.
Now to describe the operation of the apparatus 10 in its utility purpose, it will be necessary to discuss the operation relative to a body skin 92 shown in cross section in FIG. 3, and having a dent 94 impressed therein. It will be understood that the dent 94 was formed by a force applied in an impressing direction 96 against the body skin 92, resulting in the indentation 94.
The operator of the apparatus 10 is instructed to place the handle member 76 in the up position as shown in the FIG. 1, and to place the base plate 44 onto the body skin 92 so that the aperture 90 in the base plate 44 generally is over the center 98 of the dent 94. It is noted that the base plate 44 is sized so as to span a larger area than the dent 94, such that a portion 100 of the base plate 44 is supported on the body skin area 92 that is in close proximity and generally about the dent 94. While the size of the plate 44 is conveniently shown relative to a small dent 94, it will be understood that the plate 44 may be sized as necessary in order that a portion of the plate is supported on an unmarred portion of the body skin 92.
The next step for the operator of apparatus 10, having placed the apparatus as instructed above, is to manually push the chuck assembly 52 downwardly in the direction 96 by pushing on the knob 70. This action causes the engaging member 66, which has been placed into the vise chuck 54 as described in the description of the construction above, into contact with the center 98 of the dent 94. The threaded portion 88 has a self-tapping thread for threaded engagement with the dent 94. In some applications, such as when working to straighten dents in automobile bodies, it has been found desirable to place a small hole through the dent 94 at its center 98 to assist in starting the threaded portion 88 therethrough. While desirable, this has not been found to be essential to the use of apparatus 10. Once the threaded portion 88 is placed in contact with the center 98 of dent 94, the knob 70 is manually turned while applying a downward and rotating movement to the knob 70. This engages the threaded portion 88 of engaging member 66 through the center 98 of dent 94. This downward screw force is continued until the engaging member 66 is in secure engagement with dented portion 90 of body skin 92; the object here being to have the engaging member capable of pulling firmly on the dent 90.
To straighten the dent 94, the operator now merely squeezes the gripping portions 16 and 84 together, causing the downward movement of the handle 76 to the position 76'. This in turn causes the raising of the peripheral flange 72 by the action of the forked portion 82 of handle 76, which in turn pulls the engaging member 66 toward the base plate 44. The threaded engagement of the engaging member 66 with the dent 94 causes the upward movement of the chuck assembly 52 to apply a force to the dent 94 in a direction generally opposite to the impressing direction 96, and raises the dented portion up to and forced against the base plate 44. The length of each of the handles 14 and 76 is determined so as to provide a large mechanical advantage in forcing the chuck assembly 52 to move upward against the restraining force offered by the material forces of the dent.
It will be clear that detaching the apparatus 10 from the dent 94 is effected by reverse turning of the knob 70 so that the threaded portion 88 is released from the area that previously formed the dent, this area being at this time in the position designated 94'. Once released, the dent-straightening apparatus 10 is free to be used in the same manner as described to straighten another dent.
The result of raising the dent 94 to its previous position, (34') is that the dent 94 has been repaired, and the only remaining disturbance to the body skin 92 is the hole which was placed into the center 98 of the dent 94. In some applications, this hole is sufficiently small that it simply does not show. In other applications, it will be necessary to fill in this small hole by known surface repair techniques and procedures. In any event, further damage to the body skin 92 has been minimized to effectuate the repair, which has been made quickly and without a resulting overpull of the dented portion 94. That is, the base plate 44 has served as backup means against which the dented portion 94 is forced to provide a level repair surface, the base plate serving both to mold the dented portion and to prevent the chuck assembly 52 from overpulling the dent.
Description of the Embodiment of FIGS. 4 through 6
Referring to FIGS. 4 through 6, shown therein is another embodiment of the improved dent-straightening apparatus of the present invention, generally designated by the numeral 110. The apparatus 110 comprises the elements described above for the embodiment 10, but in somewhat varying arrangement.
The apparatus 10 comprises as its frame means the handle frame 112 which includes a yoke 114 and a first handle member 116 connected to the base 118 of the yoke 114. The yoke 114 is connected to a pair of plates 120 that are welded to extend normal from a base plate 122. Each of the tines 124 of yoke 114 is made of one-half round stock having a flat inner surface 126 that is positioned adjacent to the respective plate 120, and extending stub rod 128 extends from each of the surfaces 126. Appropriately placed apertures toward the top of the plates 120 receive the rods 128 such that the rods are pivotable therein. This arrangement provides a pivotal connection between the yoke 114 of the handle frame means 112 with the base plate 122. For base plate removal purposes, the plates 120 may be made resilient to the degree that the plates 120 may be removed from the stub rods 128, and different shaped base plates placed thereon, as will become clear below.
The apparatus 110 also comprises chuck assembly 130 which includes a vise chuck 130 which is of the same general construction as the vise chuck 54 described above. That is, the vise chuck 130 comprises a housing 132 and the chuck jaws 134. The end of the housing 132 opposite to the chuck jaws 134 contains a threaded bore that engages the threaded end 136 of the slide rod 138. At the other end of the slide rod 138, that is at its end opposite to the threaded end 136, a knob 140 is pressed thereover and staked in stationary relationship thereto by means of the set pin 142.
A barrel member 144 has a longitudinal bore therethrough (not shown) that rotatingly and slidingly supports the portion of the slide rod 138 between its threaded end 136 and the knob 140. Projecting from opposite sides of the barrel 144 and attached thereto are the protruding rods 146, the purpose of which will become clear below.
A second handle member 150 is also provided, as viewed in FIG. 4. The second handle member 150 has a gripping portion 152 and an angled portion 154. In close proximity to the joint 156 where the angle portion 154 is connected to the grip portion 152, a pair of links 158 are disposed on either side of the first and second handle members 116 and 152. Protruding from each side of the handle members is a pair of link pins 160 that are disposed through appropriately placed apertures in the links 158, the link pins being head staked so that the links are pivotally held onto the pins 160. This arrangement allows the pivoting of the second handle member 150 relative to the first handle member 116, as well as permitting the second handle member to move in the directions 162 and 164 relative to the first handle member 116. Of course, this movement is limited by the length of the links 158, which is determined to permit angular movement of the chuck assembly 130 relative to the base plate 122 as will be made clear below.
Attached to the second handle member 150 at the distal end of 154 opposite to the joint 156 is a second yoke member 166 disposed so as to be generally parallel to the gripping portion 152, although this is not essential to the operation of apparatus 110. The tines 168 are appropriately apertured to fit over the protruding rods 146 with sufficient clearance to be rotatable thereabout. The exterior ends of the protruding rods 146 are staked in a conventional manner to hold the tines 146 thereupon.
Shown in the FIGS. 4 through 6 is the engaging member 66, described above, held grippingly by the chuck jaws 134 of the vise chuck 131 in the same manner as above described for apparatus 10. The base plate 122 has a relief aperture through which the engaging member 66 clearingly passes.
Operation of the Embodiment of FIGS. 4 through 6
The operation of the improved dent-straightening apparatus 110 as illustrated and described in FIGS. 4 through 6 will now be discussed. In brief summary, the improved dent-straightening apparatus 110 comprises handle frame means 112, backup means or base plate 122, chuck means or assembly 130 and retracting means 150 and 116, which elements cooperate to position and reciprocatingly move an engaging means 66. As was described above for the embodiment 10 of FIGS. 1 through 3, the operation of the embodiment of FIGS. 4 through 6 is essentially the same. The first handle member 116 and the second handle member 150 are manually manipulated to raise the chuck assembly 130. The description for the previously discussed embodiment was aided by the use of dashed outlines of the moving components of apparatus 10, and since the operation of apparatus 110 will not be understood without the use of such dashed lines, these have been omitted from FIGS. 4 through 6. However, it will be understood that the moving components of apparatus 110 assume similar positions as described for the apparatus 10.
When the second handle member 150 is squeezed toward the first handle member 116, the second yoke member is caused to pivot away from the first yoke 114, being pivotable about the link means of the links 158 connected to the handle members. Of course, this movement forces the chuck assembly 130 in a movement away from the base plate 122.
The operation of the apparatus 110 in its utility purpose is the same as that of apparatus 10, discussed above. In order to avoid redundance, the operation of apparatus 110 will be described in its use to straighten a dent 170 in a contoured body skin 172, the object being to raise the dent portion 170 to assume a profile position of 170' which represents its position prior to the indentation.
For the purpose of discussing the operation of apparatus 110, the base plate 122 which was described in the discussion of the structure of apparatus 110 above has been replaced with a base plate 174. In order that the base plate 174 serve as backup means for the contour of body skin 172, it is usually desirable to use a contoured base plate 174 which is curved to have its under surface 176 matingly align with and rest upon the curved surface 178 of body skin 172. It is within the contemplation of the invention herein that a number of shaped base plates may be necessary for the utilization of the dent-straightening apparatus 10 or 110 for various curvatures of body skins that are to be repaired with the apparatus. To this end, the base plate has been designed to be readily removed and exchanged with a properly shaped base plate for any particular curvature of the body skin under repair. It should also be noted that the base plate was made stationary relative to the frame means of apparatus 10, while the base plate of apparatus 110 has been made to pivot relative to the frame means of apparatus 110. Depending upon the use of the dent-straightening embodiments taught herein, it may or may not be a desirable feature to have the base plate pivotable relative to the frame means. It will be understood that the base plate 44 of apparatus 10 may be made pivotable by an appropriately designed attachment fixture holding the base plate relative to the frame means, and that the base plates 122, 174 described for apparatus 110 may be made stationary relative to the frame means.
As was described for the operation of apparatus 10 above, the engaging member 66, having a threaded portion 88, is engaged with the dent 170 in the same manner as described above for apparatus 10. It will be understood that the dent removal results from squeezing the handle members 116 and 150 together to force the dent 170 against the curved base plate 174. However, there is some difference to the operation of 110 in that the engaging member 66 can be placed in a non-centered position relative to the dent 170, as is shown for illustration purposes in FIG. 6. That is, by moving the second handle member 150 in the directions 162, 164 relative to the first handle member 116, the chuck assembly 130 is tilted relative to the base plate 174. This permits the relative profile as shown for purposes of disclosure in FIG. 6. In some applications, it has been found that this is a desirable feature in that it permits irregularly shaped dents to be straightened by the apparatus 110. For example, the dent 170 may not raise in a uniform manner, but may have a wrinkled portion even after the bulk of the dent has been raised from its depressed profile. With the apparatus 110, this presents no particular difficulty as the engaging member 16 may be removed from the dent proper and reinserted into the recalcitrant non-raised portion of dent 170 for completion of the straightening thereof.
Thus, the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments of the invention have been described for purposes of this disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed within the spirit of the invention disclosed and as defined in the appended claims. | An improved apparatus for repairing indentions in a rigid skin, the apparatus comprising frame means supportingly holding backup means positioned to rest on a portion of the skin in close proximity to the indention, chuck means slidingly supported by the frame means to grippingly hold and movably position a dent engaging member contacting the indented portion of the skin. Retract means move the chuck means in a direction to pull the dented skin towards the backup means. In the preferred embodiment, the backup means comprise an apertured base plate contoured to matingly match the contour of the rigid skin in close proximity to the indention, a portion of the dentengaging member clearingly extending through the aperture. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of, and claims priority under 35 U.S.C. §120 to, application Ser. No. 11/132,280, filed on May 19, 2005, now issued as U.S. Pat. No. 8,395,426. The subject matter of this earlier filed application is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a power-on reset used in restoring a storage device, register, or memory to a predetermined state when power is applied. The present invention further relates to digital power-on reset ‘simplifying operation of the device.
2. Description of the Related Art
A power-on reset is used in restoring a storage device, register, or memory to a predetermined state when power is applied. A power-on reset circuit is a necessary circuit for most systems to have. A system generates power-on reset signals to. reset all subsystems and to make sure all things are initialized properly. All subsystems, including chips, rely on an external reset signal to reset the chips. In the prior art systems, a dedicated analog circuit is used to generate the reset signal.
The power-on reset circuit detects the power-on condition, and outputs reset signals to reset other circuits. The reset circuit is responsible for generating enough reset time. The output reset signal may last for a sufficient period to make sure all components are properly reset.
FIG. 1 illustrates the behavior of the chip after power-on. When power-on occurs, step 101 , the chip detects the reset signal, step 102 . If the reset signal is keeping on, the chip will always be in a reset state, step 103 . After the reset signal is off, the chip will start chip initialization, step 104 , and get into service when initialization is done, in step 105 . The power-on reset event should occur only once after power-on.
FIG. 2 illustrates a traditional wire connection between a reset circuit 201 and chips 202 . For the reset circuit 201 , after the power is on, the reset circuit 201 will detect the condition, and generate a reset cycle to all chips 202 . The quality of a reset signal is very important. The reset signal has to be most nearly a square wave. Any instability may cause the system to become locked up. Such instabilities, such as a glitch, will improperly reset the chip.
FIG. 3 illustrates a simple power-on reset circuit. It is an analog circuit and relies on a capacitor C to detect the power-on condition. After the power is on, the capacitor C is not charged, and its voltage is zero. The power VCC will charge the capacitor C through resistor R. Before the capacitor C is fully charged, the circuit has enough time to reset other components 301 . A length of the reset time is based on a value of resistor R and capacitor C, i.e. the RC pair. And after capacitor C is fully charged, the reset cycle is also finish. This makes sure the power-on reset event only occur once. The circuit or similar ones are widely used to perform the power-on function, and such a circuit is not costly. Since the output of RC pair is not a perfect square wave, a filter, like a Schmitt trigger, is also integrated into the circuit.
The general flow of a power-on process is illustrated in FIG. 4 . In step 401 , the power-on event occurs and a reset signal is generated, in step 402 . Thereafter, the reset is complete, in step 403 , and the process ends.
However, there are drawbacks in the approach. The power-on reset circuit is an analog type circuit, and is not able to be built in digital chip. It can only be installed outside the chips that need to be reset. The chips that need to be reset require a dedicated input pin to get the reset status. The quality of the reset signal is also of concern, since a glitch or any unstable voltage is not permitted. However, the usage of filter can improve the quality of this voltage in the prior art. Thus, there is a need for an improved power-on reset circuit that does not have at least some of the drawbacks discussed above.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention that together with the description serve to explain the principles of the invention, wherein:
FIG. 1 illustrates a process of resetting and initializing a chip;
FIG. 2 illustrates a connection between a reset circuit and chips that receive a reset signal;
FIG. 3 illustrates a schematic of a power-on reset circuit;
FIG. 4 illustrates a process of powering on and generating the reset signal;
FIGS. 5A and 5B illustrate a reset circuit within a chip, according to one embodiment of the present invention.
FIG. 6 illustrates a process of performing a power-on reset, according to one embodiment of the present invention; and
FIG. 7 illustrates a process of performing a power-on reset, according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
The present invention proposes an alternative solution to the prior art external power-on reset circuits. By using a digital circuit, namely a digital power on reset controller 501 , it can perform the same functions. As illustrated in FIG. 5 , the reset circuit 501 can be built in a digital chip 502 easily. It can detect if the chip has been reset or not after power-on. If the chip 502 has not been reset after power on, the reset circuit 501 then generates the reset signal internally to reset the chip 502 . Only digital components are used to construct the reset circuit 501 . Since only digital components are required, the reset circuit 501 can be integrated into digital chips, and, thus, no external reset pin is need in this embodiment.
Since, according to this embodiment, no external pin is required, there is no problem with the reset signal quality, as with the analog circuits discussed above. Since the circuit is pure digital, a near perfect reset signal can be generated.
The approach uses a set of registers called reset registers. The reset registers do not have any reset input. After power is on, the value of reset registers is supposed to be unknown. The value of the reset registers may be 0, 1, 2, or any random number. If the value of reset registers is compared to a magic number, like 0x55, 0xAA, or any unique number, the result should be not equal.
Since the comparison of the reset register with the magic number is not equal right after power on, the reset circuit 501 will begin to initialize the reset registers with the unique magic number, thereby avoiding the reset circuit 501 from detecting the power-on event again. Then, the circuit generates the reset signal. Using a counter 506 , the length of reset time is easily controlled. Since logic gates and registers can implement the approach, the generated reset signal is pure digital. It is easy to guarantee the quality of the signal.
The process is also illustrated in FIG. 6 . In step 601 , the power-on event commences. In step 602 , the values of the reset registers are compared with a magic number. If the magic number and the register values are the same, then the process ends, since there is no need for the reset signal to be generated. When the register values do not match the magic number, the reset registers are initialized, step 603 , and the reset signal is generated, in step 604 . Thereafter, the reset process is finished, in step 605 .
After the whole reset cycle is done, the value of the reset registers is equal to the magic number now. Thus, the reset signal generation event need not happen again. Only one reset event happens after power-on.
The present invention, according to certain embodiments, has a set of reset registers and a magic number. If the reset registers are composed of n registers, then after power-on, the probability of the reset registers value come out to be the magic number is 1/(2n). The greater the number of reset registers, the lower the probability that a false match could occur and result in an increased correctness of the approach.
The choice of magic number is also important. If all zeros or all ones were chosen as the magic number, then the reset registers with same physical characteristic may come out the value of all zeros or all ones. If the value with zeros and ones mixed is selected, the likelihood of false positive is reduced. The safest number is half of the bits are all zeros, and the other is all ones, like 0x55 or 0xAA. It is rare for the reset registers to come out to such values after power-on.
According to most embodiments, only a series of registers and simple circuit are needed. The effort for implementation is simple when compared to many other application circuits. And since the circuit is digital, it may be easily integrated into digital chips.
One problem can arise if there is also a need for a manual reset from the system. In that case, an external pin to indicate the situation may be necessary. As illustrated in FIG. 7 , and alternate process is implemented to comport with the use of an external pin. The steps from the process of FIG. 6 remain the same, i.e., steps 601 - 605 are implemented as steps 700 , 701 , 704 , 705 and 706 , respectively. A step 703 is added to reset the filter and a synchronization to perform the desired function. The process flow is the same and the power-on reset task is processed as usual. However, in step 703 , it is determined whether a signal from an external reset input, 702 , to decide whether to manual reset the system or not.
During power-on, no matter whether the input from the external reset input 702 is zero or one, the power-on reset circuit will perform its function. After reset, once the external reset input is asserted, the reset circuit will be activated again.
The reset filter and synchronization step 703 also performs a reset filtering function to filter the glitch input from external reset input 702 , and synchronize the phase to system clock domain. This is important to avoid the issues associated with the analog systems discussed above.
In summary, the digital power-on reset controller of the present invention provides a low cost way of generating the power-on reset signal. It is easy to implement and can be an embedded circuit for most chips that need the function. In addition, the input reset pin can be removed when there is no need for an external reset. Moreover, the signal quality of the rest signal is fully digital and less prone to glitches.
The above-discussed configuration of the invention is, in a preferred embodiment, embodied on a semiconductor substrate, such as silicon, with appropriate semiconductor manufacturing techniques and based upon a circuit layout which would, based upon the embodiments discussed above, be apparent to those skilled in the art. A person of skill in the art with respect to semiconductor design and manufacturing would be able to implement the various modules, interfaces, and tables, buffers, etc. of the present invention onto a single semiconductor substrate, based upon the architectural description discussed above. It would also be within the scope of the invention to implement the disclosed elements of the invention in discrete electronic components, thereby taking advantage of the functional aspects of the invention without maximizing the advantages through the use of a single semiconductor substrate.
With respect to the present invention, the devices discussed herein may be any electronic device that utilizes a power-on reset. These devices may also include network devices and can include switches, routers, bridges, gateways or servers.
The foregoing description has been directed to specific embodiments of this invention. It will be apparent, however, that other variations and modifications may be made to the described embodiments, with the attainment of some or all of their advantages. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention. | A digital power-on reset circuit for an electronic device includes at least one reset register and a comparator circuit. The power-on reset circuit is incorporated into the electronic device and the comparator circuit is configured to compare values in the at least one reset register with at least one predetermined value when a power-on reset state is determined and generate a reset signal when the values do not match the at least one predetermined value. | 7 |
The present invention relates to foam-forming composition of urea, which can be used to treat psoriasis, and thickened areas of the soles, elbows, knees and the like.
Urea, especially in high concentrations, can be used to treat dry scaly skin, or skin that has thickened to a non-cosmetic or uncomfortable degree. This activity has been attributed to the ability of urea to solubilize and denture protein. Urea can be used to treat xerosis, ichthyosis (e.g., ichthyosis vulgaris), psoriasis, atopic dermatitis, and the like. Such treatment can include itch relief, at least temporary itch relief.
Dermatological compositions of concentrated urea have been formulated in oily bases. Such a oil-based formulations provide a protective layer and localize the urea on the skin. Despite the bias in the industry to formulate in oil-based ointments, Applicant sought to make a water-based, foam-forming composition.
In seeking to formulate a water-based, foam-forming composition, it was discovered that high urea concentrations destabilize formulations that are otherwise stable, water-based dermatological formulations, yielding compositions that form sediments to a degree that makes proper dispensing difficult. Described herein are parameters within which one can formulate stable, water-based compositions of urea at high concentration.
SUMMARY OF THE INVENTION
Provided, among other things, is a delivery module for a non-greasy, water-based urea composition comprising: an aerosol delivery device; within the aerosol delivery device, the urea composition comprising 20% or more urea by weight, non-greasy lipophilic component(s), and a frothing agent, the urea composition having a viscosity low enough to support aerosol delivery, and the urea composition effective to form a foam upon propellant-driven aerosol delivery; and within the aerosol delivery device, a propellant.
Further provided, among other things, is a urea composition comprising: urea 20-50%; fatty acid(s) and/or analogous alkyl amine(s) 1-5%; hydrophilic polymer(s) 0.5-1.5%; titrant, as needed in amount effective to substantially neutralize the fatty acid(s) or alkyl amine(s); frothing agent 0.3-4%; and humectant 0.5-7%.
Also provided, among other things, is a method of treating dermatitis, psoriasis, xerosis, ichthyosis, eczema, keratosis, keratoderma, dry and rough skin, corns, calluses, damaged, or ingrown and devitalized nails comprising applying to affected skin a foamed, non-greasy, water-based urea composition comprising: 20% or more urea by weight, non-greasy lipophilic component(s), and a frothing agent, the urea composition having a viscosity low enough to support aerosol delivery, and the urea composition effective to form a foam upon propellant-driven aerosol delivery.
DETAILED DESCRIPTION OF THE INVENTION
Urea can be present, for example, in amounts from about 20% by weight to to about 50% by weight, or to about saturation (in the composition). Unless otherwise detailed, all amount percentages presented in this specification are weight percentages. In certain embodiments, urea is 20% or more, 25% or more, 30% or more, 31% or more, or 32% or more, or 33% or more, or 34% or more, or 35% or more, or 36% or more, or 37% or more, or 38% or more, or 39% or more of the urea composition. In certain embodiments, urea is 49% or less, or 48% or less, or 47% or less, or 46% or less, or 45% or less, or 44% or less, or 43% or less, or 42% or less, or 41% or less of the urea composition.
It is believed that urea formulated in an aqueous solution can facilitate urea absorption on skin. A non-greasy skin-feel, which can be achieved with the present formulation, allows for more frequent applications than would be cosmetically acceptable with oil based formulations.
The composition can contain lipophilic components that are believed to help distribute urea on and into the skin. A major portion of such lipophilic components can be amphiphates in amounts effective to stabilize the lipophilic components in solution and/or emulsified. Example amphiphates are fatty acids, which can be substantially or essentially ionized, wherein the salt is soluble in the aqueous solution of the urea composition. Further examples are alkyl amines with one alkyl per amine having a size distribution analogous to that of an appropriate fatty acid composition. Further examples are nonionic detergents.
The fatty acid can, for example, be of any composition found in a natural source, including hydrolysis of esterified fatty acids. Or, the fatty acid component can be hydrogenated to remove substantially all or a portion of any unsaturation. In certain embodiments, the fatty acid component or the alkyl moiety of the alkyl amine component is selected such that 50 mole % or more is C12 or higher, or C14, or C16 or higher. In certain embodiments, the fatty acid component or the alkyl moiety of the alkyl amine component is selected such that 50 mole % or more is C22 or lower, or C20 or lower, or C18 or lower. In certain embodiments, 75 mole % or more of the fatty acid component is from C12 or C14 or C16 to C22 or C20 or C18. In certain embodiments, 80 mole % or more, 85 mole % or more, 90 mole % or more, 95 mole % or more, 97 mole % or more, 98 mole % or more, or 99 mole % or more, meets one of the size parameters of this paragraph.
For carboxylic acid containing lipophilic components, useful salts include the alkali metal salts such as sodium or potassium salts; ammonium salts; salts formed with suitable organic bases, such as amine salts (such as triethyl amine, triethanol amine, or the like) and quaternary ammonium salts; or the like. Bivalent or trivalent salts can be used where they do not adversely affect solubility. For amine-containing lipophilic components, useful salts include maleates, fumarates, lactates, oxalates, methanesulfonates, ethanesulfonates, benzenesulfonates, tartrates, citrates, halides (e.g., hydrochlorides, hydrobromides), sulfates, phosphates, nitrates, and the like. As needed, the lipophilic components are provided such that a sufficient amount of constituent ionizable molecules are in ionized (salt) form to provide solubility. Such ionized forms can be prepared by adding a titrant, though recitations of compositions described by such titration include the equivalent compositions formed by pre-formed salts or otherwise.
The lipophilic component may include 50% or less of a more hydrophobic component, such as one that can be termed an emollient. This more hydrophobic component can be, for example, 45% or less, or 40% or less, or 35% or less, or 30% or less, or 25% or less, or 20% or less, of the lipophilic component.
In certain embodiments, the lipophilic component is 1% or more, or 1.5% or more, or 2% or more, or 2.5% or more, or 3% or more of the urea composition. In certain embodiments, the lipophilic component is 8% or less, 7.5% or less, 7% or less, 7.5% or less, 6% or less, 5.5% or less, 5% or less, or 4.5% or less, or 4% or less, or 3.5% or less of the urea composition. Where the lipophilic component comprises, as predominant component(s), fatty acids or analogous alkyl amines, these predominate components can be 1% or more, or 1.5% or more, or 2% or more, or 2.5% or more, or 3% or more of the urea composition; and 5% or less, or 4.5% or less, or 4% or less, or 3.5% or less of the urea composition.
An emollient, if present, can be a silicone oil such as polydimethylsiloxane (i.e., dimethicone), petrolatum, or the like. In certain embodiments, the emollient(s) are 0.5% or more, or 0.6% or more, or 0.7% or more, or 0.8% or more, or 0.9% or more, or 1% or more of the urea composition. In certain embodiments, the emollient(s) are 2% or less, or 1.9% or less, or 1.8% or less, or 1.7% or less, or 1.6% or less, or 1.5% or less, or 1.4% or less, or 1.3% or less, or 1.2% or less, or 1.1% or less, or 1% or less of the urea composition.
A non-greasy feel is measured in reference to oil-based ointments and by comparison of the feel of the Example composition (described in the Example below), applied to skin at 1 mg/cm 2 , compared to the oil-based product described in the Table at Column 3 of U.S. Pat. No. 5,919,470 (Bradley Pharmaceuticals, Inc.), applied in the same amount. While the feel of compositions of the invention may vary, in making the comparison between the non-greasy standard, the greasy standard, and the prospective non-greasy composition, it will be apparent which category the prospective composition falls within. The non-greasy skin feel may be moist and smooth feeling, but the difference in greasy feel relative to the greasy comparative shall be clear.
The hydrophilic polymer(s) can be any non-toxic water soluble polymer(s) that (in the aggregate) stabilize foam and contribute to film formation on the skin. Examples include polyvinyl pyrrolidone, polyethylene glycol, starch, water-soluble derivatives of starch, cellulose, methyl cellulose, hydroxymethylcellulose, other water-soluble derivatives of cellulose, carbomers, or the like. For polyvinyl pyrrolidone, for example, useful average molecular weights include from 8,000 to 63,000, such as about 38,000. For all polymers used in the composition, the size should be sufficient to limit penetration of the horny layer of the skin, if skin penetration is an issue for the given polymer.
In certain embodiments, hydrophilic polymer(s) are 0.2% or more, 0.3% or more, 0.4% or more, 0.5% or more, or 0.6% or more, or 0.7% or more, or 0.8% or more, or 0.9% or more, or 1% or more, or 1.5% or more of the urea composition. In certain embodiments, the hydrophilic polymer(s) are 3% or less, 2.5% or less, 2% or less, 1.5% or less, or 1.4% or less, or 1.3% or less, or 1.2% or less, or 1.1% or less, or 1% or less of the urea composition.
The composition can also contain a humectant, such as glycerol, propylene glycol, other polyols, polydextrose, lactic acid, or the like. In certain embodiments, humectant(s) are 0.5% or more, or 0.6% or more, or 0.7% or more, or 0.8% or more, or 0.9% or more, or 1% or more, or 1.2% or more, or 1.4% or more, or 1.6% or more, or 1.8% or more, or 2% or more, or 2.5% or more, or 3% or more, or 3.5% or more, or 4% or more of the urea composition. In certain embodiments, the humectant(s) are 7% or less, or 6.5% or less, or 6.0% or less, or 5.8% or less, or 5.6% or less, or 5.4% or less, or 5.2% or less, or 5% or less of the urea composition.
The frothing agent can be, for example, a non-ionic detergent such as Polysorbate 20, polyoxyethylene sorbitan fatty acid esters, sorbitol fatty acid esters, or the like. In certain embodiments, the frothing agent(s) are 0.3% or more, or 0.4% or more, or 0.5% or more, or 0.6% or more, or 0.7% or more, or 0.8% or more, or 0.9% or more, or 1% or more, or 1.1% or more, or 1.2% or more, or 1.3% or more, or 1.4% or more, or 1.5% or more, or 1.6% or more, or 1.7% or more, or 1.8% or more, or 1.9% or more, or 2.0% or more, or 2.1% or more, or 2.2% or more, or 2.3% or more of the urea composition. In certain embodiments, the frothing agent(s) are 4% or less, 3.5% or less, 3% or less, 2.9% or less, 2.8% or less, 2.7% or less, 2.6% or less, 2.5% or less, 2.4% or less, 2.3% or less, 2.2% or less, 2.1% or less, 2% or less, 1.9% or less, 1.8% or less, 1.7% or less, 1.6% or less, 1.5% or less, or 1.4% or less, or 1.3% or less, or 1.2% or less, or 1.1% or less, or 1% or less, or 0.9% or less, or 1.8% or less of the urea composition.
In certain embodiments, the urea composition can contain soothing agent(s) such as homogenized oatmeal. In certain embodiments, the soothing agent(s) are 0.02% or more, 0.03% or more, 0.04% or more, 0.05% or more, or 0.06% or more, or 0.07% or more, or 0.08% or more, or 0.09% or more, or 0.01% or more of the urea composition. In certain embodiments, the soothing agent(s) are 0.2% or less, or 0.15% or less, or 0.14% or less, or 0.13% or less, or 0.12% or less, or 0.11% or less, or 1% or less of the urea composition.
Additional optional ingredients include sunscreens, antimicrobial agents or preservatives, fragrances, and the like.
Suitable propellants include, for example, propane, butane, isobutene, other hydrocarbons, hydrofluorocarbons, chlorofluorocarbons (Cl/F/(H)/C), and the like.
The amount of urea composition applied to an affected area of skin can vary with a number of variables including the condition of the skin, the sensitivity of the patient or the area of skin, and the like. In any single administration, the delivery device can deliver to the affected area an appropriate layer of foam that provides an appropriate amount of urea composition. The aerosol-driven foam can be applied to the affected area and rubbed into the skin until absorbed. Typically, the composition is applied twice a day.
Topically applied urea is believed to dissolve the intercellular matrix of the skin which results in enhanced shedding of scaly, dry skin and thus a softening of the hyperkeratotic areas of the skin. Urea topically applied to the nail plate has a similar effect on the intercellular matrix of the nail plate. Topically applied urea can be used for enzymatic debridement and promotion of normal healing of surface lesions, particularly where healing is retarded by local infection, necrotic tissue, fibrinous or purulent debris, or eschar. Topically applied urea is useful for the treatment of hyperkeratotic conditions such as dermatitis (e.g., atopic dermatitis), psoriasis, xerosis, ichthyosis, eczema, keratosis, keratoderma, dry, rough skin, corns and calluses, damaged, ingrown and devitalized nails, and the like.
EXAMPLE 1
The following composition is formulated:
Component
Wt. %
Water
46.47
PVP
0.95
Oatmeal
0.1
Stearic acid
3.13
Propylene Glycol
2.9
Glycerin
2.0
Dimethicone
1.0
Phenonipe ™ (a mixture of
0.5
preservatives from )
Triethanol amine
0.65
Polysorbate 20
2.30
Urea
40.0
Total
100.00
The oatmeal is homogenized in a portion of the water. The remaining water is heated to 70° C. With stirring, the following were added in order: PVP, oatmeal slurry, and stearic acid. Then, the remainder is added less the urea. The temperature controller is set to 60° C., allowing the temperature to decline. When the temperature is down to 60° C., the urea is added in portions as follows: 8 parts of 100, 8 parts, 8 parts, 16 parts, 16 parts, 16 parts, remainder. Care is taken that the temperature is 60° C. or higher on each addition. The regulator is then set to 25° C., and the composition is agitated for 30 minutes. Aerosol dispensers can be filled with the composition at 25° C.
Or, The water is heated to 70° C. With stirring, the following were added in order: oatmeal, PVP, and stearic acid. Then, the remainder is added less the urea. The temperature controller is set to 60° C., allowing the temperature to decline. When the temperature is down to 60° C., the urea is added in portions as follows: 8 parts of 100, 8 parts, 8 parts, 16 parts, 16 parts, 16 parts, remainder. Care is taken that the temperature is 60° C. or higher on each addition. After the last urea addition, and after the temperature has again reached 60° C., the regulator is then set to 25° C., and the composition is agitated for 30 minutes. Aerosol dispensers can be filled with the composition at 25° C., and with stirring during filling.
EXAMPLE 2
The following composition is formulated:
Component
Wt. %
Water
48.07
PVP
0.95
Oatmeal
0.1
Stearic acid
3.13
Propylene Glycol
2.9
Glycerin
2.0
Dimethicone
1.0
Phenonipe ™ (a mixture of
0.5
preservatives from )
Triethanol amine
0.65
Polysorbate 20
0.70
Urea
40.0
Total
100.00
The oatmeal is homogenized in a portion of the water. The remaining water is heated to 70° C. With stirring, the following were added in order: PVP, oatmeal slurry, and stearic acid. Then, the remainder is added less the urea. The temperature controller is set to 40° C., allowing the temperature to decline. When the temperature is down to 50° C., the urea is added in portions as follows: 8 parts of 100, 8 parts, 8 parts, 16 parts, 16 parts, 16 parts, remainder. Care is taken that the temperature is 40° C. or higher on each addition. The regulator is then set to 25° C., and the composition is agitated for 30 minutes. Aerosol dispensers can be filled with the composition at 25° C.
Or, The water is heated to 70° C. With stirring, the following were added in order: oatmeal, PVP, and stearic acid. Then, the remainder is added less the urea. The temperature controller is set to 40° C., allowing the temperature to decline. When the temperature is down to 50° C., the urea is added in portions as follows: 8 parts of 100, 8 parts, 8 parts, 16 parts, 16 parts, 16 parts, remainder. Care is taken that the temperature is 40° C. or higher on each addition. After the last urea addition, and after the temperature has again reached 40° C., the regulator is then set to 25° C., and the composition is agitated for 30 minutes. Aerosol dispensers can be filled with the composition at 25° C., and with stirring during filling.
DEFINITIONS
The following terms shall have, for the purposes of this application, the respective meanings set forth below.
Effective Amount
To treat the indications of the invention, an effective amount of a urea will be recognized by clinicians but includes an amount effective to treat, reduce, alleviate, ameliorate, eliminate or prevent one or more symptoms of the disease sought to be treated or the condition sought to be avoided or treated, or to otherwise produce a clinically recognizable favorable change in the pathology of the disease or condition. In effective amount can be a dermatological treatment effective concentration of urea.
Publications and references, including but not limited to patents and patent applications, cited in this specification are herein incorporated by reference in their entirety in the entire portion cited as if each individual publication or reference were specifically and individually indicated to be incorporated by reference herein as being fully set forth. Any patent application to which this application claims priority is also incorporated by reference herein in the manner described above for publications and references.
While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred devices and methods may be used and that it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow. | Provided, among other things, is a delivery module for a non-greasy, water-based urea composition comprising: an aerosol delivery device; within the aerosol delivery device, the urea composition comprising 20% or more urea by weight, non-greasy lipophilic component(s), and a frothing agent, the urea composition having a viscosity low enough to support aerosol delivery, and the urea composition effective to form a foam upon propellant-driven aerosol delivery; and within the aerosol delivery device, a propellant. | 8 |
[0001] This application claims priority of Chinese patent application No. 201210181661.X, entitled “PAPER MONEY DETECTION AND COUNTING DEVICE AND DETECTION AND COUNTING METHOD” and filed with the State Intellectual Property Office on Jun. 4, 2012, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to the field of financial technology, and in particular to a device and method for detecting and counting banknote-like objects, which is applicable to an Automated Teller Machine (ATM) for anti-interference detection on partly broken banknotes or banknotes with holes.
BACKGROUND OF THE INVENTION
[0003] Light sensors are usually used in ATMs for detecting transmission states of banknotes in a passage. When multiple banknotes pass through the light sensor sequentially, multiple transmission states each representing presence or non-presence of each of the banknotes will be generated.
[0004] In a typical method for detecting banknotes, when the sensor outputs a transmission state representing a transition from non-presence of a banknote to presence of a banknote, it is determined that the front end of the current banknote is detected, and the detection of the current banknote is started; or when the sensor outputs a transmission state representing a transition from presence of a banknote to non-presence of a banknote, it is determined that the back end of the current banknote is detected, and the detection of the next banknote is started; or the above two ways may be used together. By using the method of detecting the transmission states, banknotes can be distinguished and counted in accordance with the detection sequence.
[0005] However, in a case that the signal representing the presence or non-presence of the banknote is interfered, especially in a case that a banknote with a hole is detected, following problems as shown in FIG. 1 will occur.
[0006] 1. Due to installation locations, not all of the light sensors can detect the hole 101 of the banknote 100 . Therefore, intervals (which may be time intervals or distance intervals) from non-presence to presence states or from presence to non-presence states outputted from different light sensors (for example, the first sensor 201 and the second sensor 202 ) are different.
[0007] 2. Due to the hole 101 , the sensor (for example, the first sensor 201 ) may count the banknotes inaccurately.
[0008] In a case that the banknote processing device in the ATM detects the above to abnormal transmission, one of the following processes may be performed:
[0009] a, return the banknote causing the abnormal transmission to a cash input/output port;
[0010] b, store the banknote causing the abnormal transmission into a recycling box; and
[0011] c, stop the current operation, resume the ATM and restart a new service.
[0012] No matter which of the above processes is used, the efficiency of the ATM is decreased, and thereby the service performance of the ATM for the user is decreased.
[0013] During the circulation, the banknote becomes worse and is unavoidably to be broken. In addition, banknotes of certain countries have holes on themselves as features. For example, some countries of Southeast Asia use plastic banknotes with features of transparent holes. If banknotes having the holes or broken banknotes are transmitted in the passage, wrong determinations may be made by using the existing banknote processing device for detecting and counting, thereby the efficiency of the ATM is decreased. Therefore, it is desired a more reliable method and device for detecting and counting banknotes being transmitted.
SUMMARY OF THE INVENTION
[0014] A device and a method for detecting and counting banknote-like objects are provided by embodiments of the present invention, which can eliminate interferences produced by broken banknotes and especially by banknotes with transparent holes, increase accuracy of banknote counting, and reduce wrong determination probability.
[0015] A device for detecting and counting banknote-like objects is provided by an embodiment of the present invention, including:
[0016] a sensor unit, adapted to convert output signals of a plurality of sensors distributed on a banknote transmission passage into transmission states each representing presence or non-presence of a banknote, where each of the plurality of sensors corresponds to a banknote counter;
[0017] a calculating unit, adapted to calculate, for any of the plurality of sensors, a banknote distance between a current detecting position and a front position of a current detected banknote according to the transmission states outputted from the sensor unit;
[0018] a control unit, adapted to, once the banknote distance calculated by the calculating unit exceeds a banknote interval reference, search the transmission states previously outputted with respect to the sensor, and
[0019] if at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found, add 1 to a count value of a banknote counter corresponding to the sensor;
[0020] if at least one transmission state representing a transition from non-presence of a banknote to presence of a banknote is found, determine that detection of the current banknote is finished and send a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, as a front position of a next detected banknote, to the calculating unit, so that the calculating unit uses the front position of the next detected banknote as an initial position for calculating a next banknote distance.
[0021] In addition, a method for detecting and counting banknote-like objects is correspondingly provided by an embodiment of the present invention, including steps of:
[0022] A1, converting output signals of a plurality of sensors distributed on a banknote transmission passage into transmission states each representing presence or non-presence of a banknote;
[0023] A2, calculating, for any of the plurality of sensor, a banknote distance between a current detecting position and a front position of a current detected banknote according to the transmission states outputted from a sensor unit;
[0024] A3, once the calculated banknote distance exceeds a banknote interval reference, searching the transmission states previously outputted, and if at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found, adding 1 to a count value of a banknote counter corresponding to the sensor;
[0025] A4, once the calculated banknote distance exceeds the banknote interval reference, searching the transmission states previously outputted, and if at least one transmission state to representing a transition from non-presence of a banknote to presence of a banknote is found, determining that detection of the current banknote is finished and using a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, as a front position of a next detected banknote for calculating a next banknote distance.
[0026] According to the embodiments of the present invention, there have following advantages. The device and method for detecting and counting banknote-like objects provided by the embodiments of the present invention are especially applicable to an Automated Teller Machine (ATM) for anti-interference detection on partly broken banknotes or banknotes with holes. Specifically, the counting of the banknotes with respect to each of the various sensors is performed according to a comparison result between a calculated banknote distance and a reference, but not performed by simply detecting the transmission state representing a transition from non-presence to presence or from presence to non-presence. Therefore, there will be no miscounting when interference (for example, a banknote with a hole) appears. Meanwhile, an abnormal transmission of banknotes is determined by determining whether banknote intervals of adjacent sensors are consistent, so the probability of wrong determination is reduced when interference appears. Therefore, according to the device and method for detecting and counting banknotes provided by the embodiments of the present invention, the accuracy of banknote counting is increased and the probability of wrong determinations is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic diagram illustrating that a detecting process of a method for detecting and counting banknote-like objects in the prior art is affected by a banknote with a hole.
[0028] FIG. 2 is a structure diagram illustrating a device for detecting and counting banknote-like objects according to the present invention.
[0029] FIGS. 3 a - 3 c are schematic diagrams of locating a front position of a banknote by to using the device for detecting and counting banknote-like objects shown in FIG. 2 .
[0030] FIG. 4 is a schematic structure diagram of a banknote-pickup mechanism in the prior art.
[0031] FIG. 5 is a flowchart of processes of the device for detecting and counting banknote-like objects shown in FIG. 2 .
[0032] FIG. 6 is a flowchart of processes of a calculating unit of the device for detecting and counting banknote-like objects in FIG. 5 .
[0033] FIG. 7 is a flowchart of processes of a control unit of the device for detecting and counting banknote-like objects in FIG. 5 .
[0034] FIG. 8 is a flowchart of processes of a record and storage unit of the device for detecting and counting banknote-like objects in FIG. 5 .
[0035] FIG. 9 is a flowchart of processing a banknote with a hole by using a method for detecting and counting banknote-like objects provided by an embodiment of the present invention.
[0036] FIG. 10 is a flowchart of a method for detecting and counting banknote-like objects according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Technical solutions of embodiments of the present invention will be described clearly and completely in conjunction with drawings of embodiments of the present invention. Obviously, the embodiments to be described are merely part but not all of embodiments of the present invention. Based on the embodiments described in the present invention, all of other embodiments obtained by those skilled in the art without any creative work fall within the protection scope of the present invention.
[0038] Referring to FIG. 2 , a device for detecting and counting banknote-like objects of the present invention includes a sensor unit 10 , a calculating unit 20 , a control unit 30 and a record and storage unit 40 .
[0039] The sensor unit 10 is adapted to convert, in accordance with a fixed clock cycle, output signals of a plurality of sensors distributed on a banknote transmission passage into to transmission states each representing presence or non-presence of a banknote, where each of the plurality of sensors corresponds to a banknote counter.
[0040] The calculating unit 20 is adapted to calculate, for any of the plurality of sensors, a banknote distance between a current detecting position and a front position of a current detected banknote; calculate an interval (which is refer to as a banknote interval) between the front position of the current banknote and a front position of a next banknote when the control unit 30 determines that detection of the current banknote is finished; and use the front position of the next banknote found by the control unit as an initial position for calculating a next banknote distance.
[0041] The control unit 30 is adapted to, once the banknote distance calculated by the calculating unit exceeds a banknote interval reference, search the transmission states previously outputted from the sensor unit, and
[0042] if at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found, add 1 to a count value of a banknote counter corresponding to the sensor;
[0043] if at least one transmission state representing a transition from non-presence of a banknote to presence of a banknote is found, determine that detection of the current banknote is finished and send a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, as the front position of the next detected banknote, to the calculating unit, so that the calculating unit uses the front position of the next detected banknote as an initial position for calculating a next banknote distance.
[0044] The record and storage unit 40 is adapted to obtain the banknote interval between the front position of the current detected banknote and the front position of the next detected banknote calculated by the calculating unit, store the banknote interval sequentially, compare the banknote interval with a recorded banknote interval with respect to a previous sensor, and if they are not consistent, send a signal for stopping detection of the banknotes.
[0045] Specific structures and principles of the device for detecting and counting to banknote-like objects of the present invention will be further described below in conjunction with FIGS. 2-5 .
[0046] During ATM's services for inputting and outputting banknotes, a banknote-pickup mechanism 41 as shown in FIG. 4 is generally used to send a banknote 43 in a banknote repository into a transmission passage. Such banknote-pickup mechanism can theoretically ensure that one banknote is sent into the passage each time a banknote-pickup wheel 45 rotates one circle. Accordingly, in theory, the banknote interval between two adjacent banknotes is only related to the diameter D of the banknote-pickup wheel 45 , rather than a banknote length. Therefore, the reference S ref may be determined by S ref =kπD, where k is a fixed value and denotes a transmission coefficient indicating a ratio of a transmission rate to a pick-up rate of a banknote in the passage, and πD denotes the perimeter of the banknote-pickup wheel 45 .
[0047] As mentioned above, the front position of the banknote is needed for calculating the banknote distance (the time interval or the distance interval between the front position of the current detected banknote and the current detecting position of any of the sensors) or the banknote interval (the time interval or the distance interval between front ends of two adjacent banknotes), therefore how to detect and determine the front position of the banknote needs to be considered firstly.
[0048] There are two cases in detecting the front position of the banknote: if a banknote detected currently by any of the sensors is the first banknote passing through the sensor, a position corresponding to the transmission state representing a transition from non-presence of a banknote to presence of a banknote outputted from the sensor for the first time is determined as the front position of the first banknote;
[0049] if the banknote passing through the sensor is not the first banknote passing through the sensor (that is, the next banknote), as shown in FIG. 3 , in a case that the distance between the current detecting position (position 2 shown by a dashed line with arrow in the figure) and the front position of a previous banknote (position 1 shown by a solid line with arrow in the figure) is greater than a comparison value, the control unit searches for a to position meeting the following conditions between the position 2 and the position 1 as the front position of the next banknote:
[0050] condition i: the position indicates a transition from non-presence of a banknote to presence of a banknote; and
[0051] condition ii: the position has an interval from the position 1 that is the closest to the banknote interval reference.
[0052] FIGS. 3 a , 3 b and 3 c show respectively three possible cases when the distance between the position 2 and the position 1 is greater than the comparison value, including:
[0053] as shown in FIG. 3 a , there are multiple positions between the position 1 and the position 2 that meet condition i (position 3 and position 4 shown by a dashed line with arrow in the figure), but only position 3 meets condition ii;
[0054] as shown in FIG. 3 b , there is only one position between the position 1 and the position 2 that meets condition i (position 3 shown by a dashed line with arrow in the figure);
[0055] as shown in FIG. 3 c , there is no position between the position 1 and the position 2 that meets condition i.
[0056] In the case shown in FIG. 3 c , a front position of a banknote cannot be found until a transmission state representing a transition from non-presence of a banknote to presence of a banknote appears. A front position of a banknote can be found according to condition i and condition ii in any of the cases. After the front position of the banknote is located, the front position of the banknote will be sent to the calculating unit as a front position of a detected banknote for calculating the next banknote distance value.
[0057] Referring to FIGS. 2 and 5 , at the beginning of a service, the banknote-pickup mechanism 41 firstly separates gathered banknotes, and sends the banknotes into the banknote transmission passage one by one. When the banknotes sequentially pass through sensors distributed on the transmission passage, each sensor outputs a corresponding signal and sends the corresponding signal to the sensor unit 10 of the device for detecting and counting banknotes of the present invention. The sensor unit 10 converts the signals outputted from each of the sensors into transmission states each representing presence or non-presence of a banknote in accordance with a fixed clock cycle provided by a clock unit, and sends the transmission states to the control unit 30 and the calculating unit 20 for processing.
[0058] The calculating unit 20 and the control unit 30 process the transmission states of each of the sensors sequentially.
[0059] The calculating unit 20 firstly calculates, for any of the sensors, a banknote distance between a front position of a current detected banknote and a current detecting position according to the transmission states outputted from the sensor unit 10 .
[0060] The control unit 30 then compares the result calculated by the calculating unit 20 with a banknote interval reference. If the banknote distance value exceeds the banknote interval reference, the control unit searches the transmission states previously outputted with respect to the sensor for a back position of the current banknote (that is, a transition from presence to non-presence), and adds 1 to the count value of the banknote counter corresponding to the sensor when at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found. Meanwhile, the control unit also searches for the front position of the next banknote (that is a transition from non-presence to presence), determines that detection of the current banknote is finished when at least one transmission state representing a transition from non-presence of a banknote to presence of a banknote is found, and sends a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, as the front position of the next detected banknote, to the calculating unit, so that the calculating unit 20 uses the front position of the next detected banknote as an initial position for calculating the next banknote distance.
[0061] If the control unit 30 determines that detection of the current banknote passing through the sensor is finished, the calculating unit 20 calculates the banknote interval between the front position of the current detected banknote and the front position of the next detected banknote, and sends the banknote interval to the record and storage unit 40 . The record and storage unit 40 obtains the banknote interval calculated by the calculating unit 20 and stores the banknote interval into a corresponding storage position of the storage area sequentially. The record and storage unit 40 also compares the banknote interval with a banknote interval with respect to a previous sensor, and if they are not consistent, determines there is an abnormal transmission, and the detection of banknotes is stopped.
[0062] The banknote detecting process is finished after all of the banknotes leave the banknote transmission passage and enter the banknote repository.
[0063] The device for detecting and counting banknote-like objects of the present invention will be described below by using a specific embodiment in conjunction with FIGS. 5 to 9 .
[0064] For convenience of description, a banknote detection flag Fi corresponding to a i th sensor is used to represent whether detection of a banknote is finished, where Fi is TRUE means that detection of the banknote is finished and Fi is FALSE means that detection of the banknote is not finished; and a banknote counter CNTi corresponding to the i th sensor is used to represent the number of the banknotes passed through the i th sensor. In addition, in the embodiment, a clock is used as a unit for calculating, the clock unit outputs a clock with a fixed cycle, and the sensor unit 10 outputs transmission states of banknotes passing through each of the sensors in accordance with the fixed clock cycle, and converts into binary values each representing presence or non-presence of a banknote, which can facilitate the calculation of the banknote distance and the banknote interval by the calculating unit 20 .
[0065] At the beginning of a service, data are firstly initialized, including setting all of the banknote detection flags Fi to FALSE, and resetting all of the banknote counters CNTi and banknote intervals in the storage area to 0. Then the banknote-pickup mechanism 41 separates gathered banknotes, and sends the banknotes one by one into the banknote transmission passage (the direction pointed by the arrow in FIG. 9 ). A first sensor 301 is located at a position where a banknote is firstly detected. Banknote 401 is the first banknote, banknote 402 is a banknote with a hole, and banknote 403 is the last banknote. When the banknotes sequentially pass through the sensors distributed on the transmission passage, each of the sensors will output corresponding signals and send the corresponding signals to the sensor unit 10 . In accordance with the fixed clock cycle, the sensor unit 10 converts the signals outputted from the sensors into transmission states each representing presence or non-presence of a banknote, and provides the transmission states to the control unit 30 and the calculating unit 20 for processing.
[0066] When the banknote 401 passes through the first sensor 301 , the calculating unit starts to calculate a distance between the first sensor 301 and the position 1 (that is, the front position of the banknote 401 , it can be determined by the above-mentioned method) according to the transmission states outputted with respect to the first sensor 301 (as shown in FIG. 9 ). The control unit 30 compares the result calculated by the calculating unit 20 with a preset banknote interval reference S ref . If the banknote distance is less than the banknote interval reference, the control unit 30 sets the detection flag F 1 to FALSE. If the banknote distance is greater than the banknote interval reference, the control unit 30 searches the transmission states previously outputted with respect to the first sensor 301 for the back position of the banknote 401 (that is, a transition from presence to non-presence) and the front position of the banknote 402 (that is, a transition from non-presence to presence). As shown in FIG. 9 , in the outputs of the first sensor 301 , the position 2 pointed by an arrow meets the condition of the back position of the banknote 401 , and the position 3 meets the condition of the front position of the banknote 402 . When the control unit 30 finds the position 2 , the banknote counter CNT 1 corresponding to the first sensor 301 is added by 1; and when the control unit 30 finds the position 3 (representing that the banknote 402 reaches the first sensor), the detection flag F 1 is set to TRUE. In a case that the banknote distance is greater than the reference but the control unit 30 does not find the front position of the next banknote meeting the conditions, the detection flag F 1 is maintained to be FALSE.
[0067] When the detection flag F 1 is set to TRUE, the calculating unit 20 firstly calculates a banknote interval S 11 between the banknote 401 and the banknote 402 (that is, an interval between the position 3 and the position 1 ), and uses the position 3 found by the control unit 30 as an initial position for calculating the next banknote distance. The record and storage unit 40 stores the banknote interval S 11 into its data storage area sequentially. Since the sensor 301 is the first sensor, the record and storage unit 40 does not judge whether there is an abnormal transmission (that is, does not compare the banknote interval) and returns a successful detection result directly. In a next clock cycle meeting the banknote interval reference, the calculating unit 20 continues to calculate a banknote distance between a current detecting position and the position 3 according to the transmission states outputted from the first sensor 301 . In a similar way, the banknote interval S 12 is calculated and stored sequentially in the data storage area of the record and storage unit, and the banknote counter CNT 1 is added accumulatively.
[0068] When the last banknote 403 passes through the first sensor, the calculating unit calculates a banknote distance between the first sensor 301 and position 5 according to the transmission states outputted with respect to the first sensor 301 . If the banknote distance is less than the reference, the control unit 30 sets the detection flag F 1 to FALSE. If the banknote distance is greater than the reference, only the back position of the banknote 403 can be found by the control unit from the transmission states previously outputted with respect to the first sensor 301 since the banknote 403 is the last banknote, so only the counter CNT 1 is added and the banknote interval is not calculated or stored.
[0069] In a similar way, when the banknote 401 passes through the second sensor 302 , the calculating unit 20 starts to calculate a banknote distance between the second sensor 302 and position 1 (that is, the front position of the banknote 401 , it can be determined by the above-mentioned method) according to the transmission states outputted with respect to the second sensor 302 . If the banknote distance is less than the reference, the control unit sets the detection flag F 2 to FALSE. If the banknote distance is greater than the reference, the control unit 30 searches the transmission states outputted previously with respect to the second sensor 302 for the back position of the banknote 401 (that is, a transition from presence to non-presence) and the front position of the next banknote 402 . As shown in FIG. 9 , in the outputs of the second sensor 302 , the position 2 pointed by an arrow meets the condition of the back position of the banknote 401 , and the position 3 meets the condition of the front position of the banknote 402 . When the control unit 30 finds the position 2 , the banknote counter CNT 2 corresponding to the second sensor 302 is added by 1; and when the control unit finds the position 3 (representing the banknote 402 reaches the second sensor 302 ), the to detection flag F 2 is set to TRUE. In a case that the banknote distance is greater than the reference but the control unit 30 does not find the front position of the next banknote meeting the conditions, the detection flag F 2 is maintained to be FALSE.
[0070] When the detection flag F 2 is set to TRUE, the calculating unit 20 firstly calculates the banknote interval S 21 between the banknote 401 and the banknote 402 (that is, the interval between the position 3 and the position 1 ), and uses the position 3 found by the control unit 30 as an initial position for calculating the next banknote distance. The record and storage unit stores the banknote interval S 21 into its data storage area sequentially. Since the second sensor 302 is not the first sensor, the record and storage unit 40 compares S 11 with S 21 , and returns an error of abnormal transmission if they are not consistent (as shown in FIG. 8 ) or returns a successful detection result otherwise. During the next clock cycle meeting the banknote interval reference, the calculating unit 20 calculates the banknote distance between a current detecting position and the position 3 according to the transmission states outputted with respect to the second sensor 302 . Because the second sensor 302 will detect the hole 4020 of the banknote 402 , two transitions from presence to non-presence (position 4 and position 7 ) and two transitions from non-presence to presence (position 5 and position 8 ) will be found by the control unit from the transmission states previously outputted with respect to the second sensor 302 in a case that the banknote distance is greater than the reference. However, according to the accumulative principle of the banknote counter of the present invention, the number of the transitions from presence to non-presence is not considered, and the counter CNT 2 corresponding to the sensor is only added by 1 as long as at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found. Meanwhile, since only the position 5 meets the locating conditions of the front position of the next banknote 403 according to the method described above for locating the front position of the banknote, the detection flag F 2 is set to TRUE when the control unit 30 finds the position 5 .
[0071] When the detection flag F 2 is set to TRUE again, the calculating unit firstly calculates a banknote interval S 22 between the banknote 402 and the banknote 403 (that is, the interval between the position 5 and the position 3 ), and uses the position 5 found by the to control unit 30 as an initial position for calculating the next banknote distance. The record and storage unit 40 stores the banknote interval S 22 into its data storage area sequentially, and compares S 12 with S 22 . Since S 22 is the interval between the position 5 and position 3 rather than the interval between the position 8 and position 3 , the record and storage unit 40 will not detect an error of abnormal transmission. Therefore, the interference caused by the hole 4020 of the banknote 402 is eliminated by the detection and calculation device of the present invention.
[0072] After the transmissions of all banknotes are finished, the values of both banknote counters CNT 1 and CNT 2 are 3 , and no abnormal transmission error of banknotes occurs.
[0073] The present invention is not limited to the above embodiments, and can be implemented with various variations.
[0074] For example, although a light sensor is adopted to detect banknotes in the embodiments of the present invention, other types of sensors (such as a thickness detecting sensor or an image detecting sensor) may be applied to the device as long as their signals can be transformed to binary values which represent transmission states of a banknote. In addition, the detected objects of the present invention are not limited to banknotes, all of objects having regular shape and thin thickness will be suitable for the device.
[0075] In addition, variations in which only the objects to be compared in the present invention is changed (for example, the comparison of the banknote interval is changed to the comparison of the banknote length which is the distance between a front end and a back end of a banknote, or the banknote interval is defined as the distance between back ends of two adjacent banknotes), with the specific principles having no creative improvement with respect to the present invention, all fall within the scope of the present invention.
[0076] Furthermore, in the embodiment of the present invention, it is mainly described a device for eliminating the interference brought by a banknote with a hole, but the interference of the sensor signal itself or the interference due to problems of the banknote transmission (for example, a back end of a banknote is connected with a front end of a banknote, or the banknote interval is too small) are all suitable for the device.
[0077] FIG. 10 is a flowchart of a method for detecting and counting banknote-like to objects according to the present invention. The method includes steps as following:
[0078] S 101 , converting output signals of a plurality of sensors distributed on a banknote transmission passage into transmission states each representing presence or non-presence of a banknote, in accordance with a fixed clock cycle.
[0079] At the beginning of a service, a banknote-pickup mechanism firstly separates gathered banknotes, and sends the banknotes into a banknote transmission passage one by one. When the banknotes sequentially pass through the sensors distributed on the transmission passage, each of the sensors will output corresponding signals. The corresponding signals outputted from each of the sensors are converted into transmission states each representing presence or non-presence of a banknote in accordance with a fixed clock cycle provided by a clock unit, for subsequent processing.
[0080] S 102 , calculating, for any of the plurality of sensors, according to the transmission states output from a sensor unit, a banknote distance between a current detecting position and a front position of a current detected banknote.
[0081] S 103 , once the calculated banknote distance exceeds a banknote interval reference, searching the transmission states previously outputted with respect to the sensor, and if at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found, adding 1 to a count value of a banknote counter corresponding to the sensor.
[0082] In this step, the calculated banknote distance is compared with a preset banknote interval reference. Once the banknote distance exceeds the banknote interval reference, a control unit will search the transmission states previously outputted with respect to the sensor for a back position of the current banknote (that is, a transition from presence to non-presence), and add 1 to a count value of a banknote counter corresponding to the sensor if at least one transmission state representing a transition from presence of a banknote to non-presence of a banknote is found. The banknote interval reference is determined by S ref =kπD, where S ref denotes the banknote interval reference; k denotes a transmission coefficient indicating a ratio of a transmission rate to a pickup rate of a banknote in the passage; and πD denotes a perimeter of a banknote-pickup wheel.
[0083] S 104 , once the calculated banknote distance exceeds the banknote interval reference, searching the transmission states previously outputted with respect to the sensor, and if at least one transmission state representing a transition from non-presence of a banknote to presence of a banknote is found, determining that detection of the current banknote is finished and using a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, as the front position of the next detected banknote for calculating the next banknote distance.
[0084] In this step, once the calculated banknote distance exceeds the banknote interval reference, the searching for the front position of the next banknote (that is, a transition from non-presence to presence) is performed, and if at least one transmission state representing a transition from non-presence of a banknote to presence of a banknote is found, it is determined that detection of the current banknote is finished, and a detecting position representing the transition from non-presence of a banknote to presence of a banknote and having a distance from the front position of the current detected banknote that is the closest to the banknote interval reference, is used as the front position of the next detected banknote and used as an initial position for calculating the next banknote distance.
[0085] S 105 , calculating a banknote interval between the front position of the current detected banknote and the front position of the next detected banknote, storing the banknote interval sequentially, comparing the banknote interval with a recorded banknote interval with respect to a previous sensor, and if they are not consistent, sending a signal for stopping the detection of banknotes.
[0086] If it is determined that detection of the current banknote passing through the sensor is finished, the banknote interval between the front position of the current detected banknote and the front position of the next detected banknote is calculated and stored sequentially. Meanwhile, the banknote interval is compared with a recorded banknote interval with respect to a previous sensor, and if they are not consistent, it is determined that the transmission is abnormal and the detection of the banknotes is stopped.
[0087] Finally, the banknote detection process is finished after all of the banknotes leave the banknote transmission passage and enter the banknote repository.
[0088] The above are only preferred embodiments of the present invention, and it is to be noted that modifications and variations can be made by those skilled in the art without departing from principles of the invention, and these modifications and variations also fall within the protection scope of the invention. | A paper money detection and counting device comprises: a sensor unit which is used for converting the output signals of a plurality of sensors distributed on a paper money transmission passage into a transmission state which characterizes whether paper money is present or not, each sensor corresponding to a paper money counter; a calculation unit which calculates the paper money distance between the current detection position of any sensor and the front end position of the currently detected paper money according to the transmission state output by the sensor unit; and a control unit, once the paper money distance calculated by the calculation unit goes beyond a paper money spacing standard value, the control unit looking up the transmission states output accumulatively by the sensors currently, when it is found that at least one transmission state characterizes that the paper money state changes from existence to nonexistence, adding 1 to the count value of the paper money counter corresponding to the sensor, and when it is found that at least one transmission state characterizes that the paper money state changes from nonexistence to existence, judging that the current paper money detection is completed, and sending to the calculation unit the position where the paper money distance from the front end of the currently detected paper money is closest to the paper money spacing standard value, as the front end position of the next detected paper money, so as to enable the calculation unit to use the front end position of the next detected paper money as an initial position to calculate the distance of the next paper money. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional application Ser. No. 60/029,056 filed Oct. 25, 1996.
TECHNICAL FIELD
This invention relates to organic compounds having pharmacological activity, to compositions containing the compounds, to medical methods of treatment employing the compounds, and to chemical processes and intermediates for their production. More particularly, the present invention concerns a class of (substituted alkylaminophenyl)- and (substituted alkylthiophenyl)benzo b!thiophene compounds, pharmaceutical formulations containing the compounds, their use in the treatment of conditions associated with post-menopausal syndrome, and estrogen dependent cancers, uterine fibroid disease, endometriosis, and aortal smooth muscle cell proliferation.
BACKGROUND OF THE INVENTION
"Post-menopausal syndrome" is a term used to describe various pathological conditions which frequently affect women who have entered into or completed the physiological metamorphosis known as menopause. Although numerous pathologies are contemplated by the use of this term, three major effects of post-menopausal syndrome are the source of the greatest long-term medical concern: osteoporosis, cardiovascular effects such as hyperlipidemia, and estrogen-dependent cancer, particularly breast and uterine cancer.
Osteoporosis describes a group of diseases which arise from diverse etiologies, but which are characterized by the net loss of bone mass per unit volume. The consequence of this loss of bone mass is the failure of the skeleton to provide adequate structural support for the body resulting in bone fractures.
One of the most common types of osteoporosis is that associated with menopause. Most women lose from about 20% to about 60% of the bone mass in the trabecular compartment of the bone within 3 to 6 years after the cessation of mensus. This rapid loss is generally associated with an increase of bone resorption and formation. However, the resorptive cycle is more dominant and the result is a net loss of bone mass. Osteoporosis is a common and serious disease among post-menopausal women.
There are an estimated 25 million women in the United States, alone, who are afflicted with this disease. The results of osteoporosis are personally harmful and also account for a large economic loss due to its chronicity and the need for extensive and long term support (hospitalization and nursing home care) from the disease sequelae. This is especially true in more elderly patients. Additionally, although osteoporosis is not generally thought of as a life threatening condition, a 20% to 30% mortality rate is related with hip fractures in elderly women. A large percentage of this mortality rate can be directly associated with post-menopausal osteoporosis.
The most vulnerable tissue in the bone to the effects of post-menopausal osteoporosis is the trabecular bone. This tissue is often referred to as spongy or cancellous bone and is particularly concentrated near the ends of the bone (near the joints) and in the vertebrae of the spine. The trabecular tissue is characterized by small osteoid structures which inter-connect with each other, as well as the more solid and dense cortical tissue which makes up the outer surface and central shaft of the bone. This inter-connected network of trabeculae gives lateral support to the outer cortical structure and is critical to the biomechanical strength of the overall structure.
In post-menopausal osteoporosis, it is primarily the net resorption and loss of the trabeculae which leads to the failure and fracture of bone. In light of the loss of the trabeculae in post-menopausal women, it is not surprising that the most common fractures are those associated with bones which are highly dependent on trabecular support, e.g., the vertebrae, the neck of the weight bearing bones such as the femur and the fore-arm. Indeed, hip fracture, collies fractures, and vertebral crush fractures are hallmarks of post-menopausal osteoporosis.
At this time, the only generally accepted method for treatment of post-menopausal syndrome is estrogen replacement therapy. Although therapy is generally successful, patient compliance with the therapy is low primarily because estrogen treatment frequently produces undesirable side effects.
Prior to menopause, most women have less incidence of cardiovascular disease than age-matched men. Following menopause, however, the rate of cardiovascular disease in women increases to match the rate seen in men. This increased risk has been linked to the loss of estrogen and, in particular, to the loss of estrogen's ability to regulate the levels of serum lipids. The nature of estrogen's ability to regulate serum lipids is not well understood, but evidence to date indicates that estrogen can upregulate the low density lipid (LDL) receptors in the liver to remove excess cholesterol. Additionally, estrogen appears to have some effect on the biosynthesis of cholesterol, and other beneficial effects on cardiovascular health.
It has been reported in the literature that post-menopausal women undergoing estrogen replacement therapy experience a return of serum lipid concentrations to those of the pre-menopausal state. Thus, estrogen would appear to be a reasonable treatment for this condition. However, the side-effects of estrogen replacement therapy are not acceptable to many women, thus limiting the use of this therapy. An ideal therapy for this condition would be an agent which would regulate the serum lipid levels as does estrogen, but would be devoid of the side-effects and risks associated with estrogen therapy.
The third major pathology associated with post-menopausal syndrome is estrogen-dependent breast cancer and, to a lesser extent, estrogen-dependent cancers of other organs, particularly the uterus. Although such neoplasms are not solely limited to a post-menopausal women, they are more prevalent in the older, post-menopausal population. Current chemotherapy of these cancers has relied heavily on the use of anti-estrogen compounds such as, for example, Tamoxifen. Although such mixed agonist-antagonists have beneficial effects in the treatment of these cancers, and the estrogenic side-effects are tolerable in acute life-threatening situations, they are not ideal. For example, these agents may have stimulatory effects on certain cancer cell populations in the uterus due to their estrogenic (agonist) properties and they may, therefore, be contraproductive in some cases. A better therapy for the treatment of these cancers would be an agent which is an anti-estrogen compound having negligible or no estrogen agonist properties on reproductive tissues.
In response to the clear need for new pharmaceutical agents which are capable of alleviating the symptoms of, inter alia, post-menopausal syndrome, the present invention provides new compounds, pharmaceutical compositions thereof, and methods of using such compounds for the treatment of post-menopausal syndrome and other estrogen-related pathological conditions such as those mentioned below. The reduction of bone density and mass leading to osteoporosis that more rarely occurs in men is also tied to the loss of hormonal regulation and is, therefore, also a target for therapy according to the compounds and methods of the current invention.
Uterine fibrosis is an old and ever present clinical problem known by a variety of names, including uterine hypertrophy, uterine lieomyomata, myometrial hypertrophy, fibrosis uteri, and fibrotic metritis. Essentially, uterine fibrosis is a condition where there is an inappropriate deposition of fibroid tissue on the wall of the uterus.
This condition is a cause of dysmenorrhea and infertility in women. The exact cause of this condition is poorly understood but evidence suggests that it is an inappropriate response of fibroid tissue to estrogen. Such a condition has been produced in rabbits by daily administrations of estrogen for 3 months. In guinea pigs, the condition has been produced by daily administration of estrogen for four months. Further, in rats, estrogen causes similar hypertrophy.
The most common treatment of uterine fibrosis involves surgical procedures both costly and sometimes a source of complications such as the formation of abdominal adhesions and infections. In some patients, initial surgery is only a temporary treatment and the fibroids regrow. In those cases a hysterectomy is performed which effectively ends the fibroids but also the reproductive life of the patient. Also, gonadotropin releasing hormone antagonists may be administered, yet their use is tempered by the fact they can lead to osteoporosis.
Endometriosis is a condition of severe dysmenorrhea, which is accompanied by severe pain, bleeding into the endometrial masses or peritoneal cavity and often leads to infertility. The cause of the symptoms of this condition appear to be ectopic endometrial growths which respond inappropriately to normal hormonal control and are located in inappropriate tissues. Because of the inappropriate locations for endometrial growth, the tissue seems to initiate local inflammatory-like responses causing macrophage infiltration and a cascade of events leading to initiation of the painful response. The exact etiology of this disease is not well understood and its treatment by hormonal therapy is diverse, poorly defined, and marked by numerous unwanted and perhaps dangerous side effects.
One of the treatments for this disease is the use of low dose estrogen to suppress endometrial growth through a negative feedback effect on central gonadotropin release and subsequent ovarian production of estrogen; however, it is sometimes necessary to use continuous estrogen to control the symptoms. This use of estrogen can often lead to undersirable side effects and even the risk of endometrial cancer.
Another treatment consists of continuous administration of progestins which induces amenorrhea and by suppressing ovarian estrogen production can cause regressions of the endometrial growths. The use of chronic progestin therapy is often accompanied by the unpleasant CNS side effects of progestins and often leads to infertility due to suppression of ovarian function.
A third treatment consists of the administration of weak androgens, which are effective in controlling the endometriosis; however, they induce severe masculinizing effects. Several of these treatments for endometriosis have also been implicated in causing a mild degree of bone loss with continued therapy. Therefore, new methods of treating endometriosis are desirable.
Aortal smooth muscle cell proliferation plays an important role in diseases such as atherosclerosis and restenosis. Vascular restenosis after PTCA has been shown to be a tissue response characterized by an early and late phase. The early phase occuring hours to days after PTCA is due to thrombosis with some vasospasms while the late phase appears to be dominated by excessive proliferation and migration of aortal smooth muscle cells. In this disease, the increased cell motility and colonization by such muscle cells and macrophages contribute significantly to the pathogenesis of the disease. The excessive proliferation and migration of vascular aortal smooth muscle cells may be the primary mechanism to the reocclusion of coronary arteries following PTCA, atherectomy, laser angioplasty and arterial bypass graft surgery. See "Intimal Proliferation of Smooth Muscle Cells as an Explanation for Recurrent Coronary Artery Stenosis after Percutaneous Transluminal Coronary Angioplasty," Austin et al., Journal of the American College of Cardiology 8: 369-375 (Aug. 1985).
Vascular restenosis remains a major long term complication following surgical intervention of blocked arteries by percutaneous transluminal coronary angioplasty (PTCA), atherectomy, laser angioplasty and arterial bypass graft surgery. In about 35% of the patients who undergo PTCA, reocclusion occurs within three to six months after the procedure. The current strategies for treating vascular restenosis include mechanical intervention by devices such as stents or pharmacologic therapies including heparin, low molecular weight heparin, coumarin, aspirin, fish oil, calcium antagonist, steroids, and prostacyclin. These strategies have failed to curb the reocclusion rate and have been ineffective for the treatment and prevention of vascular restenosis. See "Prevention of Restenosis after Percutaneous Transluminal Coronary Angioplasty: The Search for a `Magic Bullet`", Hermans et al., American Heart Journal 122: 171-187 (July 1991).
In the pathogenesis of restenosis, excessive cell proliferation and migration occurs as a result of growth factors produced by cellular constituents in the blood and the damaged arterial vessel wall, which factors mediate the proliferation of smooth muscle cells in vascular restenosis.
Agents that inhibit the proliferation and/or migration of aortal smooth muscle cells are useful in the treatment and prevention of restenosis. The present invention provides for the use of compounds as aortal smooth muscle cell proliferation inhibitors and, thus, inhibitors of restenosis.
SUMMARY OF THE INVENTION
In its principal embodiment, the present invention provides a compound having the formula: ##STR2## or a pharmaceutically acceptable salt thereof wherein R 1 and R 2 are independently selected from the group consisting of hydrogen, halo, hydroxy, --O(C.sub. -C 6 alkyl), --OC(O) (C 1 -C 6 alkyl), --OC(O)O(C 1 -C 6 alkyl), --OC(O)Ar, --OC(O)OAr, and --OSO 2 (C 4 -C 6 alkyl); where Ar is unsubstituted phenyl or is phenyl substituted with one or more substituents selected from the group consisting of alkyl of one to six carbon atoms, alkoxy of one to six carbon atoms, hydroxy, nitro, chloro, fluoro, trichloromethyl, and trifluoromethyl.
The linking group W is CHOH, C(O), or CH 2 ; and Y is --CH 2 --, --NH--, --NMe--, --S--, or --SO 2 --.
The substituents R 3 and R 4 are independently selected from the group consisting of H, alkyl of one to six carbon atoms, --C(O)(C 1 -C 6 alkyl), --C(O)NH(C 1 -C 6 alkyl), --C(O)Ar, where Ar is as defined above, or together with the nitrogen to which they are attached, R 3 and R 4 combine to form a 1-pyrrolidinyl, 1-piperidinyl, or a 5- or 6-membered imide or cyclic amide ring.
In a second embodiment, the present invention provides pharmaceutical compositions containing a therapeutically effective amount of a compound of formula I, optionally further comprising estrogen or progestin, in combination with a pharmaceutically acceptable carrier.
In yet another embodiment, the present invention comprises a method of treating osteoporosis, aortal smooth muscle cell proliferation, particularly restenosis, and estrogen-dependent cancer, particularly breast cancer.
DETAILED DESCRIPTION OF THE INVENTION
As used throughout this specification and the appended claims, the following terms have the indicated definitions.
The term "alkyl" refers to a monovalent radical derived by the removal of a single hydrogen atom from a straight or branched-chain saturated hydrocarbon. Alkyl groups include, for example, methyl, ethyl, propyl, isopropyl, butyl, n-butyl, pentyl, isopentyl, hexyl, isohexyl, and the like.
"Aryl," as used herein, means an unsubstituted phenyl group or a phenyl ring substituted with one or more substituents selected from alkyl of one to six carbon atoms, alkoxy of one to six carbon atoms, hydroxy, nitro, chloro, fluoro, trichloromethyl, and trifluoromethyl.
"Aryloxy" denotes an aryl grouop, as defined above, attached to the parent molecular moiety through an oxygen atom.
"Alkoxy" refers to an alkyl group as defined above, attached to the parent molecular moiety through an oxygen atom and is typified by groups such as methoxy, ethoxy, n-propoxy, isopropoxy, and the like.
"Alkoxycarbonyl" and "aryloxycarbonyl" denote, respectively, an alkoxy group or an aryloxy group, as defined above, attached to the parent molecular moiety through a carbonyl group.
"Alkoxycarbonyloxy" and "aryloxycarbonyloxy" mean, respectively, an alkoxycarbonyl group or an aryloxycarbonyl group, as defined above, attached to the parent molecular moiety through an oxygen atom.
The term "estrogen" includes steroidal compounds having estrogenic activity such as, for example, 17β-estradiol, estrone, conjugated estrogen (e.g., Premarin®), equine estrogen, 17α-ethynyl estradiol, and the like.
"Progestin" denotes compounds having progestational activity such as, for example, progesterone, norethynodrel, norgestrel, megestrol acetate, norethindrone, and the like.
Preferred compounds of this invention include compounds of formula I wherein W is --C(O)-- and Y is --NH-- or --S--.
Certain R 3 and R 4 groups also demonstrate preferable characteristics. For example, those compounds of formula I wherein R 3 and R 4 together with the nitrogen to which they are attached form 1-pyrrolidinyl or 1-piperidinyl are preferred. A further preferred subgroup of the preferred 1-pyrrolidinyl or 1-piperidinyl compounds include those compounds wherein R 1 and R 2 are --OH or --OCH 3 .
Particularly preferred compounds of formula I include those having all of the aforementioned limitations, that is, compounds wherein W is C(O); Y is NH or S; R 1 and R 2 are --OH, --OC(O) (C 1 -C 6 alkyl), --OC(O)O(C 1 -C 6 alkyl), --OC(O)Ar, and --OC(O)OAr, especially --OH or --OCH 3 , particularly wherein R 1 and R 2 are the same as one another; and R 3 and R 4 , together with the nitrogen to which they are attached form 1-pyrrolidinyl or 1-piperidinyl.
Although the free-base or acid forms of formula I compounds can be used in the methods of the present invention, it is preferred to prepare and use a pharmaceutically acceptable salt form. Thus, the compounds used in the methods of this invention form pharmaceutically acceptable acid or base addition salts with a wide variety of organic and inorganic acids and bases, and include the physiologically acceptable salts which are often used in pharmaceutical chemistry. Such salts are also part of this invention. Typical inorganic acids used to form such salts include hydrochloric, hydrobromic, hydroiodic, nitric, sulfuric, phosphoric, hypophosphoric, and the like. Salts derived from organic acids, such as aliphatic mono and dicarboxylic acids, phenyl substituted alkanoic acids, hydroxyalkanoic and hydroxyalkandioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, may also be used. Such pharmaceutically acceptable salts thus include acetate, phenylacetate, trifluoroacetate, acrylate, ascorbate, benzoate, chlorobenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, methylbenzoate, o-acetoxybenzoate, naphthalene-2-benzoate, bromide, isobutyrate, phenylbutyrate, b-hydroxybutyrate, butyne-1,4-dioate, hexyne-1,4-dioate, caprate, caprylate, chloride, cinnamate, citrate, formate, fumarate, glycollate, heptanoate, hippurate, lactate, malate, maleate, hydroxymaleate, malonate, mandelate, mesylate, nicotinate, isonicotinate, nitrate, oxalate, phthalate, terephthalate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, propiolate, propionate, phenylpropionate, salicylate, sebacate, succinate, suberate, sulfate, bisulfate, pyrosulfate, sulfite, bisulfite, sulfonate, benzenesulfonate, p-bromophenylsulfonate, chlorobenzenesulfonate, ethanesulfonate, 2-hydroxyethanesulfonate, methanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, p-toluenesulfonate, xylenesulfonate, tartarate, and the like. Preferred salts are the hydrochloride and oxalate salts.
Typical bases used to form pharmaceutically acceptable addition salts would be inorganic bases, such as, sodium hydroxide, potassium hydroxide, alkali carbonates or bicarbonates, calcium carbonate, magnesium carbonate, and the like. Additionally, organic bases may be utilized to form addition salts, e.g., alkyl amines, such as, triethylamine, dimethylamine, i-propylamine, and the like The pharmaceutically acceptable acid or base addition salts are typically formed by reacting a compound of formula I with an equimolar or excess amount of acid or base. The reactants are generally combined in a mutual solvent such as diethyl ether or ethyl acetate. The salt normally precipitates out of solution within about one hour to 10 days and can be isolated by filtration or the solvent can be stripped off by conventional means.
The pharmaceutically acceptable salts generally have enhanced solubility characteristics compared to the compound from which they are derived, and thus are often more amenable to formulation as liquids or emulsions.
Specific examples of compounds contemplated as falling within the scope of the present invention include, but are not limited to the following compounds and their pharmaceutically acceptable salts:
6-hydroxy-2-(4-hydroxyphenyl)-3- (4-(2-(piperidin-1-yl)ethyl)thio)benzoyl!benzo b!thiophene;
6-hydroxy-2-(4-hydroxyphenyl)-3- (2-(4-piperidin-1-yl)ethyl)sulfonyl)benzoyl!benzo b!thiophene;
6-methoxy-2-(4-methoxyphenyl)-3- (4-(2-(piperidin-1-yl)ethyl)amino)benzoyl!benzo b!thiophene;
6-methoxy-2-(4-methoxyphenyl)-3- (4-(N-methyl-N-2-(piperidin-1-yl)ethyl)amino)benzoyl!benzo b!thiophene;
6-methoxy-2-(4-methoxyphenyl)-3- (4-(2-(piperidin-1-yl)ethyl)thio)benzoyl!benzo b!thiophene; and
6-methoxy-2-(4-methoxyphenyl)-3- (2-(4-piperidin-1-yl)ethyl)sulfonyl)benzoyl!benzo b!thiophene.
The compounds of the present invention are derivatives of benzo b!thiophene which is named and numbered according to the Ring Index, The American Chemical Society, as follows: ##STR3## and are synthesized by methods detailed in Reaction Schemes 1 and 2 below.
In the synthetic sequence for preparing compounds of the present invention depicted in Reaction Scheme 1, compounds of the present invention are synthesized by first reacting a protected 6-hydroxy-2-(4-hydroxyphenyl)benzo b!thiophene, 1, under Friedel-Crafts acylation conditions with an activated benzoyl derivative, 2, which is substituted in the 4-position with a suitable leaving group, L. ##STR4##
In compounds of formula 1, the protecting groups R 5 and R 6 are phenolic protecting groups capable of withstanding the conditions of the Friedel-Crafts acylation reaction and are of the type taught by T. Greene, et al. in Chapter 3 of "Protective Groups in Organic Synthesis," Second Edition, John Wiley & Sons, Inc., New York, 1991, pp.143-170. The preferred protecting groups are alkyl ether groups, with methyl being particularly preferred.
The leaving group, L, in compounds of formula 2 is selected from those groups known in the art to participate in nucleophilic aromatic substitution reactions (see J. March, "Advanced Organic Chemistry," 3rd Edition, John Wiley & Sons, New York, 1985, p. 587. Suitable leaving groups include fluoro, chloro, bromo, nitro, (lower alkyl)phenylsulfonyl, (lower alkyl)sulfonyl, phenylsulfonyl, azido, trialkylammonium, phenoxy, alkoxy, thioalkoxy, and amino.
For purposes of the present invention, the preferred leaving groups include fluoro, chloro, bromo, nitro, (lower alkyl)phenylsulfonyl, and lower alkylsulfonyl, with fluoro, bromo, and nitro being most preferred.
In compounds of formula 2, the activating group, A, is selected from groups well known in the art to activate acids for the purposes of carrying out Friedel-Crafts acylation reactions and include acid halides such as the fluoride, chloride and bromide; mixed acid anhydrides with C 1 -C 6 alkanoic acids, C 1 -C 6 alkylsulfonic acids, arylsulfonic acids, C 1 -C 6 alkylsulfonic acids, perfluorinated C 1 -C 6 alkanoic acids, C 1 -C 6 alkylcarbonates, arylcarbonates, and the like. The preferred compounds of formula 2 are those in which A is halogen, most preferably chlorine.
Typically, the acylation reaction betrween 1 and 2 is carried out in an inert organic solvent in the presence of a Lewis acid catalyst. Suitable solvents include halogentaed hydrocarbons such as dichloromethane, chloroform, 1,2-dichloroethane, carbon tetrachloride, chlorobenzene, dichlorobenzene and the like. The amount of solvent is not critical, but is generally sufficient to enable efficient mixing of the reaction components.
Suitable Lewis acid catalysts for the Friedel-Crafts acylation reaction between 1 and 2 include anhydrous aluminum, boron, or zinc halides with aluminum chloride being preferred.
Temperature and time of reaction will vary, depending upon the choice of reaction solvent, Lewis acid catalyst, and activating group, A. Generally, reactions are carried out at temperatures below or at ambient to below or at the reflux temperature of the solvent. Reaction times vary from several minutes to about forty-eight hours. The progress of the reaction toward completion can be followed by well-known techniques such as thin-layer chromatographic analysis of aliquots of the reaction mixture during the course of the reaction.
Typically, the reaction is conducted using 1.0 to 1.5 equivalents of compound 2 for each equivalent of protected benzo b!thiophene, 1, with more of the activated benzoyl compound added during the course of the reaction as needed to drive the reaction to completion. The amount of Lewis acid catalyst employed ranges from between about 0.1 to 5 equivalents.
The product resulting from the acylation reaction, 3, is reacted next with a compound of formula 4 in which R 3 and R 4 have the meanings ascribed to them above. In the case where Y is --SH in compounds of formula 4a, the reaction between 3 and 4a is carried out by mixing the two reagents in the presence of a strong base in a polar aprotic solvent. Suitable strong bases include alkyllithiums, alkali metal amides, or metal hydrodies such as lithium, potassium or sodium hydride, or lithium aluminum hydride or sodium aluminum hydride.
Suitable polar aprotic solvents include N,N-dimethyl-formamide, N-methyl pyrrolidinone, N,N'-dimethylpropylurea, dimethylsulfoxide, tetrahydrofuran, and the like.
Alternatively, the sulfhydryl compound, 4a, can be separately converted to the corresponding anion by reaction with a strong base in a polar aprotic solvent, and the resulting anion subsequently reacted with compound 3.
In the case where Y is --NH 2 , as in compound 4b, the preferred reaction conditions involve reaction of 3 with 4b in dimethylsulfoxide in the presence of the phase transfer reagent 18-crown-6 and 37% potassium fluoride adsorbed on alumina at a temperature of about 120 -- C.
Following the acylation reaction between compounds 3 and 4, the protecing groups of the resulting product, 5, are removed by methods taught in the art to produce the dihydroxy compounds 6 (for deprotection reagents and reaction conditions,see T. Greene, et al. cited above and the references cited therein). In the case where R 5 and R 6 are the preferred protecting group, methyl, the deprotective removal of the methyl groups can be carried out either by the use of an alkali metal ethanethionate (see G. I. Fetruell, et al., Tetrahedron Letters, 1327 (1970); idem. Aust. J. Chem., 25: 1719 (1972) and A. S. Kende, et al., Tetrahedron Letters, 22: 1779 (1981) or by the use of either boron tribromide in methylene chloride at a temperature of between about -80 -- C. to 20 -- C. for a period of 6-12 hours (J. F. W. McOmie, et al., Org. Syn., Coll. Volume V, 412 (1973)) or BBr 3 ΩS(CH 3 ) 2 in ethylene chloride at a temperature of about 80 -- C. to 85 -- C (P. G. Williard, et al., Tetrahedron Letters, 21: 3731 (1981)).
Compounds of the present invention in which W is CHOH are prepared following deprotection step by dissolution in an appropriate solvent and reaction with reducing agent, such as, for example, lithium aluminum hydride, under an inert gas such as nitrogen.
A compound of the present invention wherein W is CHOH are further reduced to provide compounds in which W is methylene via standard procedures. This is accomplished by suspending the compound in an appropriate solvent and cooling under an inert gas such as nitrogen. To this suspension is added a suitable trialkyl silane reducing agent, preferrably triethyl silyl, and a reasonably strong protic acid such as hydrochloric acid, trifluoroacetic acid, and the like.
When a --OC(O) (C 1 -C 6 alkyl) or --OC(O)Ar group is desired at R 1 and R 2 , a dihydroxy compound of formula I, is reacted with an agent such as acyl chloride, bromide, cyanide, or azide, or with an appropriate anhydride or mixed anhydride. The reactions are conveniently carried out in a basic solvent such as pyridine, lutidine, quinoline or isoquinoline, or in a tertiary amine solvent such as triethylamine, tributylamine, methylpiperidine, and the like. The reaction also may be carried out in an inert solvent such as ethyl acetate, dimethylformamide, dimethylsulfoxide, dioxane, dimethoxyethane, acetonitrile, acetone, methyl ethyl ketone, and the like, to which at least one equivalent of an acid scavenger, such as a tertiary amine, has been added. If desired, acylation catalysts such as 4-dimethylaminopyridine or 4-pyrollidinopyridine may be used. See, e.g., Haslam, et al., Tetrahedron, 36:2409-2433 (1980).
The acylation reactions which provide the aforementioned R 1 and R 2 groups are carried out at moderate temperatures in the range from about -25° C. to about 100° C., frequently under an inert atmosphere such as nitrogen gas. However, ambient temperature is usually adequate for the reaction.
Such acylations of the hydroxy group also may be performed by acid-catalyzed reactions of the appropriate carboxylic acids in inert organic solvents or neat. Acid catalysts such as sulfuric acid, polyphosphoric acid, methanesulfonic acid, and the like are used.
The aforementioned R 1 and R 2 groups also may be provided by forming an active ester of the appropriate acid, such as the esters formed by such known reagents as dicyclohexylcarbodiimide, acylimidazoles, nitrophenols, pentachlorophenol, N-hydroxysuccinimide, and 1-hydroxybenzotriazole. See, e.g., Bull. Chem. Soc. Japan, 38:1979 (1965), and Chem. Ber., 788 and 2024 (1970).
When a compound is desired in which R 1 and R 2 is --OSO 2 (C 4 -C 6 alkyl), the suitable starting dihydroxy compound is reacted with, for example, a derivative of the appropriate sulfonic acid such as a sulfonyl chloride, bromide, or sulfonyl ammonium salt, as taught by King and Monoir, J. Am. Chem. Soc., 97:2566-2567 (1975). The dihydroxy compound also can be reacted with the appropriate sulfonic anhydride. Such reactions are carried out under conditions such as were explained above in the discussion of reaction with acid halides and the like.
Compounds of formula I can be prepared so that R 1 and R 2 are different biological protecting groups or, preferably, the same biological protecting group. Preferred protecting groups include --CH 3 , --C(O)C(CH 3 ) 3 , --C(O)C 6 H 5 , and --SO 2 (CH 2 ) 3 CH 3 .
In an alternative synthetic sequence illustrated in Reaction Scheme 2 below, compounds of the present invention where Y is --S-- or --SO 2 -- are prepared by first synthesizing the desired activated (4-substituted)benzoyl compound, 9, (the acid chloride being illustrated). The intermediate is prepared by converting the 4-substituted benzoic acid compounds, 7 to their corresponding amine substituted derivatives, 8. The substituted benzoic acids, 8 are converted to their corresponding acid chlorides, 9, by conventional methods known in the art.
The acid chlorides, 9, are reacted with a hydroxy-protected compound of formula 1 in a conventional Friedel-Crafts acylation reaction to produce the penultimate intermediates, 10. Deprotection (removal of groups R 5 and R 6 produces the desired compounds of the present invention in which Y is either --S-- or --SO 2 --.
Conversion of the aromatic hydroxy groups of compounds 11 to --OC(O) (C 1 -C 6 alkyl), --OC(O)O(C 1 -C 6 alkyl), --O--C(O)Ar, --OC(O)OAr, and --OSO 2 (C 4 -C 6 alkyl) is carried out in the manner described above.
Compounds of formula I can be prepared so that R 1 and R 2 are different biological protecting groups or, preferably, the same biological protecting group. Preferred protecting groups include OCH 3 , O--C(O)--C(CH 3 ) 3 , O--C(O)--C 6 H 5 , and O--SO 2 --(CH 2 ) 3 -CH 3 .
The term "biological protecting groups" refers to those R 1 and R 2 substituents which delay, resist, or prohibit removal of such groups in a biological system such as, for example, following administration of a compound of the present invention containing the above-described R 1 and R 2 groups to a human. Such compounds also are useful for the methods herein described, especially when W is CH 2 . ##STR5##
All reagents obtained from commercial sources were used without further purification unless otherwise indicated. 1 H and 13 C nuclear magnetic resonance spectra were measured as indicated at 300 and 75 MHz respectively. 1 H-NMR chemical shifts are reported as δ values in ppm relative to the NMR solvent employed. 1 H-NMR coupling constants are reported in Hertz (Hz) and refer to apparent multiplicities, indicated as follows: s (singlet), d (doublet), t (triplet), q (quartet), m (multiplet) and b (broad), in conjuction with "s", "d", "t" etc. Column chromatography was performed according to the method of Still et. al. (Still, W. C.; Kahn, M.; Mitra, A. J. Org. Chem. 1978, 43:2923) unless otherwise indicated with EM Science silica gel (230-400 mesh ASTM). In all cases, concentrations were performed under reduced pressure with a rotary evaporator.
The following preparations and examples are presented as representative embodiments of the present invention and are not to be read as limiting the scope of the invention as it is defined by the appended claims.
PREPARATION OF INTERMEDIATES
Preparation 1
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3-(4-nitrobenzoyl)benzo b!thiophene
To a slurry of 4-methoxy-2-(4-methoxyphenyl)benzo- b!thiophene (1.00 g, 3.70 mmol) in 25 mL of dichloroethane at 5 -- C. was added 0.604 (4.52 mmol) of aluminum chloride. The slurry was observed to turn deep red. To this mixture was added 0.838 g (4.52 mmol) of 4-nitrobenzoyl chloride and the resulting mixture was stirred for one hour at 5 -- C. and then for three hours at room temperature. Additional aluminum chloride (0.2932 g, 2.215 mmol) and 4-nitrobenzoyl chloride (0.4065 g, 2.19 mmol) were added, and the resulting mixture stirred for three hours.
A final charge of aluminum chloride (0.272 g, 2.06 mmol) was added, and the resuting mixture stirred at room temperature for sixteen hours. At the end of this time, the reaction was quenched by addition of cold 1N hydrochloric acid and the reaction mixture was partitioned between ethyl acetate and 1N hydrochloric acid. The organic layer was separated, washed sequentially with water, saturated aqueous sodium bicarbonate, and saturated aqueous sodium chloride. The organic layer was collected, dried over anhydrous magnesium sulfate, filtered and concentrated to an oil which was then adsorbed on silica gel. Chromatography (2:1 hexanes:ethyl acetate) yielded 0.2744 g (18%) of the title compound as a solid, mp 168.9-170 -- C.
IR (KBr): 3140, 2820, 1659, 1603, 1528, 1347, 1251, 1045, 829 cm -1 .
1 H NMR (CDCl 3 ): δ 8.04 (d, 2H, J=8.9 Hz), 7.81 (m, 3H), 7.34 (d, 1H, J=2.3 Hz), 7.21 (d, 1H, J=8.7 Hz), 7.05 (dd, 1H, J=8.7), 6.69 (d, 2H, J=8.9 Hz), 3.91 (s, 3H), 3.71 (3H); 13 C NMR (CDCl 3 ): 6192.0, 160.3, 158.0, 149.7, 147.2, 142.7, 140.2, 133.3, 130.8, 130.6, 129.1, 125.4, 124.3, 123.3, 115.3, 114.1, 104.5, 55.7, 55.3; Elemental Analysis: Calc'd. for C 23 H 17 NO 5 S: C, 65.86; H 4.08: N, 3.34; S, 7.64; Found: C, 65.85; H, 4.11; N, 3.29; S, 7.51.
Preparation 2
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3-(4-fluorobenzoyl)benzo b!thiophene
To a slurry of 4-methoxy-2-(4-methoxyphenyl)benzo- b!thiophene (1.02 g, 3.77 mmol) in 25 mL of dichloroethane at 5 -- C. was added 0.600 (4.5 mmol) of aluminum chloride. The slurry was observed to turn deep red. To this mixture was added 0.535 mL (0.718 g, 4.52 mmol) of 4-fluorobenzoyl chloride and the resulting mixture was stirred for twenty-four hours at 5 -- C. and then quenched by addition of cold 20 mL of cold 1N hydrochloric acid. The reaction mixture was partitioned between dichloromethane and 1N hydrochloric acid. The organic layer was separated, and the aqueous layer was back extracted twice with dichloromethane. The organic layers were collected and washed saturated aqueous sodium chloride. The organic layer was collected, dried over anhydrous magnesium sulfate, filtered, concentrated and chromatographed on silica gel (8:1 hexanes:ethyl acetate) to yield 1.0879 g (74%) of the title compound as a solid, mp 108.1-109 -- C.
IR (KBr): 2980, 2940, 2810, 1640, 1598, 1473, 1251, 1152, 831 cm -1 . 1 H NMR (CDCl 3 ): δ 7.78 (dd, 2H, J=5.6, 8.7 Hz), 7.61 (d, 1H, J=8.9 Hz),7.28 (m, 3H), 6.98 (dd, 1H, J=2.5, 8.9 Hz), 6.94 (m, 3H), 6.72 (d, 2H, J=8.7 Hz), 3.88 (s, 3H), 3.73 (3H); 13 C NMR (CDCl 3 ): 6192.8, 167.4, 164.0, 160.0, 157.9, 144.3, 140.2, 134.0, 133.9, 133.8, 132.7, 132.5, 130.6, 130.0, 125.8, 124.2, 115.7, 115.5, 115.1, 114.1, 104.6, 55.7, 55.3; 19 F NMR (CDCl 3 ): δ 48.31 (t, J=6 Hz); Elemental Analysis: Calc'd. for C 23 H 17 FO 3 S: C, 70.39; H, 4.37; S, 8.17; F, 4.84; Found: C, 70.21; H, 4.38;, S, 8.27; F, 5.14.
Preparation 3
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3-(4-bromobenzoyl)benzo b!thiophene
To a slurry of 4-methoxy-2-(4-methoxyphenyl)benzo- b!thiophene (0.99 g, 3.66 mmol) in 25 mL of dichloroethane at 5 -- C. was added 0.622 g (4.66 mmol) of aluminum chloride. The slurry was observed to turn deep red. To this mixture was added (0.997 g, 4.54 mmol) of 4-bromobenzoyl chloride and the resulting mixture was stirred for three hours at 5 -- C. and then quenched by addition of cold 10 mL of cold 1N hydrochloric acid. The reaction mixture was partitioned between ethyl acetate and 1N hydrochloric acid. The organic layer was separated, and washed sequentially with saturated aqueous sodium bicarbonate and saturated aqueous sodium chloride. The organic layer was collected, dried over anhydrous magnesium sulfate, filtered, concentrated to an oil and chromatographed on silica gel (9:1 hexanes:ethyl acetate) to yield several fractions containing product. These fractions were combined, concentrated, and dried in vacuo at 100 -- C. overnight to yield 1.0715 g (65%) of the title compound as a viscous oil.
IR (CHCl 3 ): 3030,1647, 1608, 1586, 1477, 1253, 831 cm -1 . 1 H NMR (CDCl 3 ): δ 7.61 (m, 3H), 7.33 (m, 5H),6.98 (dd, 1H, J=8.7, 2.1 Hz), 6.71 (d, 2H, J=8.7 Hz), 3.83 (s, 3H), 3.69 (s, 3H), 3.69 (s, 3H); 13 C NMR (CDCl 3 ): δ 193.2, 160.1, 157.9, 144.7, 140.2, 136.4, 133.7, 131.7, 131.4, 130.6, 129.7, 128.3, 125.8, 124.2, 115.1, 114.2, 104.6, 55.7, 55.4;
A portion of the product material was recrystallized from ethyl acetate to obtain a sample for elemental analysis.
Elemental Analysis: Calc'd. for C 23 H 17 BrO 3 S: C, 60.94; H, 3.78; S, 7.07; Br, 17.62; Found: C, 61.14; H, 3.93;, S, 6.94; Br, 17.79.
PREPARATION OF COMPOUNDS OF THE INVENTION
EXAMPLE 1
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- (4-(2-(piperidin-1-yl)ethyl)amino)benzoyl!benzo b!thiophene ##STR6## Step a) Preparation of 6-methoxy-2-(4-methoxyphenyl)-3-(4-fluorobenzoyl)benzo b!thiophene
To a slurry of 6-methoxy-2-(4-methoxyphenyl)-benzo b!thiophene (1.02 g, 3.77 mmol) in dichloromethane (25 mL) at 5 -- C. was added aluminum trichloride (0.600 g, 4.5 mmol). The slurry was observed to turn deep red. To this mixture was added p-fluorobenzoyl chloride (0.535 mL, 0.718 g, 4.52 mmol). The resulting mixture was stirred for 24 h at 5C, then quenched by addition of cold 1N HCl (20 mL) and partitioned between dichloromethane and 1N HCl. The aqueous layer was back extracted twice with dichloromethane, and the organics were washed with saturated aqueous NaCl and dried (MgSO 4 ). Following filtration and concentration, the residue was chromatographed on silica gel (8:1 hexanes:ethyl acetate) to afford 1.09 g (74%) of the title compound as a solid, mp=108.1-109.0 -- C.
Infrared: (KBr) 2980, 2940, 2810, 1640, 1598, 1473, 1251, 1152, 831 cm -1 ; 1 H NMR (CDCl 3 ) δ 7.78 (dd, 2 H, J=5.6, 8.7 Hz), 7.61 (d, 1 H, J=8.9 Hz), 7.28 (m, 3 H), 6.98 (dd, 1 H, J=2.5, 8.9 Hz), 6.94 (m, 3 H), 6.72 (d, 2 H, J=8.7 Hz), 3.88 (s, 3 H), 3.73 (s, 3 H); 13 C NMR (CDCl 3 ) δ 192.8, 167.4, 164.0, 160.0, 157.9, 144.3, 140.2, 134.0, 133.9, 133.8, 132.7, 132.5, 130.6, 130.0, 125.8, 124.2, 115.7, 115.5, 115.1, 114.1, 104.6, 55.7, 55.3; 19 F NMR (CDCl 3 ) 6 48.31 (t, J=6 Hz) Elemental Analysis: Calcd. for C 23 H 17 FO 3 S: C, 70.39; H, 4.37; S, 8.17; F, 4.84. Found: C, 70.21; H, 4.38; S, 8.27; F, 5.14.
Step b) Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylamino)benzoyl!-benzo b!thiophene
6-Methoxy-2-(4-methoxyphenyl)-3-(4-fluorobenzoyl)!benzothiophene (0.2 g, 0.51 mmol, prepared as described in Step a) above) was stirred in DMSO (0.33 g, 4.08 mmol) and 1-(2-aminoethyl)piperidine (0.065 g, 0.51 mmol), 18-crown-6 (0.014 g, 0.051 mmol) and 37% KF/Alumina (0.11 g, 0.68 mmol) was added. The reaction was heated to 125° C. and allowed to stir overnight. The reaction was then cooled to room temperature and quenched with H 2 O. It was extracted with EtOAc and washed with H 2 O (3×) followed by brine (1×). The organic layer was dried with MgSO 4 , filtered and concentrated under reduced pressure. The crude product was purified by column chromatography (5% MeOH/MeCl 2 ) to afford 0.18 g (72%) the title compound.
1 H NMR (300 MHz, MeOD d 4 ) : δ 7.68 (d, 2H, J=8.8 Hz), 7.43 (m, 3H), 7.29 (d, 1H, J=2.2 Hz), 6.91 (dd, 1H, J=8.8,2.2 Hz), 6.77 (d, 2H, J=8.8 Hz), 6.41 (d, 2H, J=8.8 Hz), 5.10(t, 1H, J=4 Hz), 3.87 (s, 3H), 3.74 (s, 3H), 3.13 (m, 2H), 2.51 (m, 2H), 2.36 (br, 4H), 1.55(br, 4H), 1.43 (br, 2H); FD+ MS for C 30 H 32 N 2 O 3 S=500; Elemental Analysis: Calcd. for C 30 H 32 N 2 O 3 S: C, 71.97; H, 6.44; N, 5.50; Found: C, 72.17; H, 6.28; N, 5.39.
EXAMPLE 2
Preparation of 6-hydroxy-2-(4-hydroxyphenyl)-3- (4-(2-(piperidin-1-yl)ethylamino)benzoyl!benzo b!thiophene; ##STR7##
6-Methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethyl)amino)benzoyl!benzo b!thiophene (prepared as described in Step b) above was converted to the hydrochloride salt and the resulting product stirred in EtCl 2 at 5° C. BBr 3 was added and the reaction mixture was stirred for 5 hours at 5° C. It was then poured into cold H 2 O and extracted with EtCl 2 followed by extraction with EtOAc. The organic layers were combined and concentrated under reduced pressure. The crude product was purified by column chromatography (15% MeOH/MeCl 2 ) to afford 0.08 g (74%) of the title compound, isolated as the hydrochloride salt.
1 H NMR (300 MHz, MeOD d4) d 7.59 (d, 2H, J=8.8 Hz), 7.34 (d, 1H, J=8.8 Hz), 7.24 (m, 3H), 6.84 (dd, 1H, J=8.8, 2.6 Hz), 6.66 (d, 2H, J=8.8 Hz), 6.49 (d, 2H,J=8.8 Hz), 3.32 (m, 2H), 2.65 (m, 6H), 1.66 (m, 4H), 1.52 (m, 2H); FD+ MS for C 28 H 28 N 2 O 3 S=472; Elemental Analysis: Calcd. for C 28 H 28 N 2 O 3 SΩ0.5 HCl: C, 68.52; H, 5.85; N, 5.71; Found: C, 68.45; H, 5.96; N, 5.53.
EXAMPLE 3
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylthio)benzoyl!benzo b!thiophene ##STR8## Step a) Preparation of 2-(piperidin-1-yl)ethanethiol
Thiourea (6.0 g, 78.8 mmol) was stirred in anhydrous EtOH (25 ml) and 1-(2-chloroethyl) piperidine hydrochloride (14.2 g, 77.3 mmol) in anhydrous EtOH (50 ml) was added slowly over 20 min. via an addition funnel. The resulting solution was heated under reflux overnight. The ethanol was removed under reduced pressure. Ethanol (60 ml) was added followed by a solution of 77 mL of ethyl acetate and 20 mL of petroleum Ether. The product crystalized and was filtered. Some of this intermediate (4.36 g, 19.4 mmol) was dissolved in H 2 O (10 ml) and NaOH(1.09g, 27.2 mmol) in H 2 O (4.8 ml) was added. The mixture was heated with heat gun until a slight red oily layer could be detected. The organics were extracted with Et 2 O, dried with MgSO 4 , filtered. The ether layer contained the title product which was used without further purification.
Step b) Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylthio)benzoyl!-benzo b!thiophene
2-(Piperidin-1-yl)ethanethiol (2.8 g, 19.2 mmol, prepared as described in Step a) above) was stirred in 50 mL of diethyl ether under nitrogen at 0° C. and NaH (0.676g of 60% dispersion in mineral oil) was added. The resulting solution was allowed to stir for 20 minutes. 6-Methoxy-2-(4-methoxyphenyl)-3-(4-fluorobenzoyl)benzo b!thiophene (0.94 g, 2.40 mmol, prepared as described in Example 1, Step a) above) in 100 mL of DMF was added. The reaction mixture was heated to reflux and stirred for 1 hour. The crude mixture was then poured into H 2 O and extracted three times with EtOAc. The organic layer was washed with brine, dried with MgSO 4 , filtered, and concentrated under reduced pressure. The crude product was purified by column chromatography (10% MeOH/MeCl 2 ) to afford 1.3 g (98%) of the title compound.
1 H NMR (300 MHz, CDCl 3 ) δ 7.72 (d, 2H, J=8.5 Hz), 7.60 (d, 1H, J=8.8 Hz), 7.34-7.24 (complex m, 5H), 6.69 (dd, 1H, J=8.8, 2.2 Hz), 6.76 (d, 2H, J=8.8 Hz), 3.90 (s, 3H), 3.76 (s, 3H), 3.56 (m, 4H), 3.01 (m, 2H), 2.58 (m, 2H), 2.29 (m, 2H), 1.88 (m, 3H), 1.43-1.34 (m, 1H). FD+ MS for C 30 H 32 NO 3 S 2 Cl=517. Elemental Analysis: Calcd. for C 30 H 32 NO 3 S 2 Cl: C, 65.02; H, 5.82; N, 2.S3; Found: C, 65.27; H, 6.01; N, 2.66.
EXAMPLE 4
Preparation of 6-hydroxy-2-(4-hydroxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylthio)benzoyl!-benzo b!thiophene ##STR9##
6-Methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)-ethylthio)benzoyl!benzo b!thiophene (0.50 g, 0.90 mmol, prepared as described in Step b) above) was dissolved in 10 mL of dichloromethane at 0° C. and BBr 3 (3.6 ml of 1M, 3.6 mmol) was added. The resulting reaction mixture was stirred for 2 hours. The reaction mixture was then poured into H 2 O and sufficient NaHCO 3 was added to keep pH between 7-9. It was extracted with ethyl acetate, dried with MgSO 4 , filtered, and concentrated under reduced pressure. The crude product was purified by column chromatography (10% MeOH/MeCl 2 ) to afford 0.13 g (29%) of the title compound. 1 H NMR (300 MHz, CDCl 3 ): δ 7.69 (d, 1H, J=8.8 Hz), 7.59 (d, 2H, J=8.5 Hz), 7.29 (d, 1H, J=2.2), 7.16 (d, 2H, J=8.5 Hz), 7.11 (d, 2H, J=8.8 Hz), 6.95 (dd, 1H, J=8.8, 2.2 Hz), 6.58 (d, 2H, J=8.8 Hz), 2.96 (br, 2H), 2.58 (m, 6H), 1.62 (br, 4H), 1.47 (br, 2H); FD+ MS for C 28 H 27 NO 3 S 2 =489; Elemental Analysis: Calcd. for C 28 H 27 NO 3 S 2 : C, 68.68; H, 5.56; N, 2.86; Found: C, 68.86; H, 5.79; N, 2.88.
EXAMPLE 5
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(N-methyl-N-2-(piperidin-1-yl)ethylamino)benzoyl!-benzo b!thiophene ##STR10## Step a) Preparation of 4- (N-methyl-N-(2-piperidin-1-yl)-ethyl)amino!benzoic acid, methyl ester
Methyl p-N-methylaminobenzoate (0.5 g, 3.31 mmol) was stirred in THF (5 ml) at 0° C. under nitrogen. NaH was added. This was stirred for 15 min. and the ice bath was removed. 1-(2-chloroethyl) piperidine (0.54 g, 3.64 mmol) was added in minimal THF. The reaction was stirred at reflux for 48 hours. It was cooled to room temperature, quenched with water and extracted with EtOAc. The organic layer was dried with MgSO 4 , filtered and concentrated under reduced pressure. The crude product was purified by column chromatography (5% MeOH/MeCl2) to afford 0.42g (46%) of 7.
1 H NMR (300 MHz, CDCl 3 ): δ 7.94 (d, 2H, J=8.8 Hz), 6.91 (d, 2H, J=8.8 Hz), 4.12 (t, 2H, J=7.3 Hz), 3.84 (s, 3H), 3.53 (t, 2H, J=7.3 Hz), 3.02 (s, 3H), 2.80 (br, 4H), 1.75 (br, 4H), 1.60 (br, 2H); FD+ MS for C 16 H 24 N 2 O 2 =276.2.
Step b) Preparation of 4- (N-methyl-N-(2-piperidin-1-yl)-ethyl)amino!benzoic acid
4- (N-Methyl-N-(2-piperidin-1-yl)ethyl)amino!benzoic acid, methyl ester (0.40 g, 1.43 mmol, prepared as described in Step a) above) was heated under reflux for two hours in 20 mL of 5N NaOH. The condenser was removed to allow the methanol to escape and heating under reflux was continued overnight. The reaction was acidified with HCl, H 2 O was removed and the resulting 4- (N-methyl-N-(2-piperidin-1-yl)ethyl)amino!benzoic acid was taken directly on to the next step without further purification.
Step c) Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(N-methyl-N-2-(piperidin-1-yl)ethylamino)benzoyl!-benzo b!thiophene
4- (N-Methyl-N-(2-piperidin-1-yl)ethyl)amino!benzoic acid (0.43 g, 1.43 mmol, prepared as described in Step b) above) was stirred in 1:1 toluene (10 ml)/MeCl 2 (10 ml), thionyl chloride (0.84 g, 7.15 mmol), and cat. DMF (1 drop). The reaction was stirred and heated under reflux overnight. The solvents were removed under reduced pressure. The crude acid chloride was triturated with Et 2 O. 6-Methoxy-2-(4-methoxyphenyl)-benzo b!thiophene (0.35 g, 1.30 mmol) and the acid chloride (1.43 mmol) were suspended in dichloromethane and AlCl 3 (0.87 g, 6.50 mmol) was added. The reaction was stirred at room temperature for 3 hours. It was quenched with cold H 2 O (10 ml) and the solvents were removed under reduced pressure. The crude mixture was taken up in MeOH saturated with HCl and refluxed. The MeOH was then removed and the solid was triturated with H 2 O. The crude product was purified by column chromatography (5% MeOH/MeCl 2 ) to afford 0.23g (35%) of the title compound. 1 H NMR (300 MHz, CDCl 3 ) : δ 7.65 (d, 2H, J=8.8 Hz), 7.31 (d, 1H, J=8.8 Hz), 7.21 (m, 3H), 6.82 (d, 1H, J=8.8 Hz), 6.62 (d, 2H, J=8.6 Hz), 3.93 (s, 3H), 3.87 (t, 2H, J=7.3 Hz), 3.74 (s, 3H), 3.00 (s, 3H), 2.80 (br, 6H), 1.75 (br, 4H), 1.60 (br, 2H); FD+ MS for C 31 H 34 N 2 O 3 S=514; Elemental Analysis: Calcd. for C 31 H 34 N 2 0 3 S: C, 72.34; H, 6.66; N, 5.44; Found: C, 72.09; H, 6.63; N, 5.19.
EXAMPLE 6
Preparation of 6-hydroxy-2-(4-hydroxyphenyl)-3- 4-(N-methyl-N-2-(piperidin-1-yl)ethylamino)benzoyl!-benzo b!thiophene ##STR11##
6-Methoxy-2-(4-methoxyphenyl)-3- 4-(N-methyl-N-2-(piperidin-1-yl)ethylamino)benzoyl!benzo b!thiophene (0.191 g, 0.379 mmol, prepared as described in Example 3 above) was dissolved in 20 mL of dichloroethane and BBr 3 ΩSMe 2 (0.71 g, 2.27 mmol) was added. The reaction was heated to 83° C. for 24 hours. The reaction was quenched with H 2 O (10 ml), the organic layer was removed and the aqueous layer extracted with ethyl acetate. The crude product was purified by column chromatography (15% MeOH/MeCl 2 ) to afford 0.118 g (66%) of the free base of the title compound. The hydrochloride salt was formed with methanolic hydrogen chloride, isolated by filtration and vacuum dried.
1 H NMR (300 MHz, CDCl 3 ) δ 7.65 (d, 2H, J=8.8 Hz), 7.31 (d, 1H, J=8.8 Hz), 7.20 (m, 3H), 6.82 (d, 1H, J=8.8 Hz), 6.63 (d, 2H, J=8.6 Hz), 3.87 (t, 2H, J=7.3 Hz), 3.02 (s, 3H), 2.80 (br, 6H), 1.75 (br, 4H), 1.60 (br, 2H); FD+ MS for C 29 H 30 N 2 O 3 S=486; Elemental Analysis: Calcd. for C 29 H 30 N 2 O 3 SΩ0.8 HCl: C, 63.17; H, 5.63; N, 5.08; Found: C, 62.95; H, 5.77; N, 4.91.
EXAMPLE 7
Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylsulfonyl)benzoyl!benzo b!thiophene ##STR12## Step a) Preparation of 4-(2-(piperidin-1-yl)ethyl)sulfonylbenzoic acid
A solution of 5g (20 mmol) p-carboxyphenyl 2-chloroethyl sulfone (prepared by the method of Shiniriki and Nambara; Chem. Pharm. Bull. (Tokyo), 11, 178-183, 1963) in 30 ml piperidine plus 10 ml dimethylformamide was heated to 120 -- C. for one hour. The mixture was cooled to room temperature and triturated with 100 mL of ether and the solids were removed by filtration. The solids were dissolved in 200 mL 1N sodium hydroxide and washed with ether (2×200 mL). The aqueous layer was acidified with 60 ml 1N HCl and ether extracted (2×200 mL). The aqueous layer was stripped under reduced pressure and the resulting sticky white solid was recrystalized from water affording 3.9 g (58% yield) of the title compound as white plates.
1 H NMR (300 MHz, D 6 -DMSO): δ 13.5 (bs, 1H), 11.4 (bs, 1H), 8.23 (d, 2H, J=8.5Hz), 8.08 (d, 2H, J=8.5 Hz), 4.12 (m, 2H), 3.40 (bs, 2H), 3.30 (m, 2H), 2.89 (bs, 2H), 1.76 (m, 5H), 1.36 (br, 1H); 13 C-NMR (300 MHz, D 6 -DMSO): δ 166.0, 141.6, 135.9, 130.4, 128.2, 52.0, 49.0, 48.6, 22.3, 21.2; FAB-MS for C 13 H 20 NO 4 S (M*+1)=298.1 (free base); Elemental Analysis: Calcd. for C 14 H 20 NO 4 SCl: C, 50.37; H, 6.04; N, 4.20; O, 19.17; S, 9.60; Cl, 10.62; Found: C, 50.79; H, 6.16; N, 4.06; 0, 20.47; S, 8.81; Cl, 10.11.
Step b) Preparation of 6-methoxy-2-(4-methoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylsulfonyl)benzoyl!benzo b!thiophene
To a solution of 1.6 g (4.8mmol) of 4-(2-(piperidin-1-yl)ethyl)sulfonylbenzoic acid (prepared as described in Step a) above) in 150 mL MeCl 2 was added 1 drop of dimethylformamide and 2.1 ml thionyl chloride. The resulting solution was stirred overnight at room temperature under a dry atmosphere. An additional 1 drop of dimethylformamide and 1 ml thionyl chloride was added and the mixture was heated under reflux for six hours. After cooling, the solvents were removed under reduced pressure and the crude acid chloride was resuspended in 150 mL toluene and stripped again twice. The solid was triturated with ether (2×50 mL) and dried under vacuum. The resulting off-white solid was resuspended in 200 ml methylene chloride and 1.92 g (14.4 mmol, 3 eq.) aluminum chloride and 1.42 g (5.3 mmol, 1.1 eq.) 6-methoxy-2-(4-methoxyphenyl)benzo b!thiophene was added and the solution was stirred overnight at room temperature under a dry nitrogen atmosphere. The reaction was quenched with 2 ml 5% sodium bicarbonate plus 200 ml water and the organic layer was separated. The aqueous layer was extracted with ethyl acetate (200 ml). The combined organic layers were dried (MgSO 4 ) and stripped. The crude product was chromatographed on silica gel using a zero to 6% methanol in MeCl 2 gradient over 60 minutes. The product was taken up in 120 ml of 1:1 ether/ethyl acetate and hydrogen chloride was bubbled through the solution. The resulting precipitate was isolate by filtration and vacuum dried. The hydrochloride salt was digested in 75 mL methanol plus 50ml ethyl acetate hot then cooled to 5 -- C. and isolated by filtration and vacuum drying affording 1.22 g (43%) the title compound as a bright yellow solid.
1 H NMR (300 MHz, D 6 -DMSO/CDCl 3 ): δ 12.2 (bs, 1H) , 7.88 (d, 2H, J=8.5 Hz), 7.82 (d, 2H, J=8.5 Hz), 7.74 (d, 1H, J =8.8 Hz), 7.36 (d, 1H, J=2.6 Hz), 7.22 (d, 2H, J=8.8 Hz), 7.04 (dd, 1H, J=2.6, 8.8 Hz), 6.73 (d, 2H, J =8.8 Hz), 3.95 (m, 2H), 3.91 (s, 3H), 3.75 (s, 3H), 3.49 (bd, 2H, J=11.4 Hz), 3.31 (m, 2H), 2.94 (bs, 1H), 2.81 (bq, 2H, J=11.8 Hz), 2.13 (bq, 2H, J=13.2 Hz), 1.85 (bd, 3H, J=11.8 Hz), 1.42 (bq, 1H, J=12.9 Hz); FAB-MS for C 30 H 31 NO 5 S 2 (M*+1)=550.0 (free base); Elemental Analysis: Calcd. for C 30 H 32 NO 5 S 2 Cl: C, 61.47; H, 5.50; N, 2.39; Cl, 6.05; 0, 13.65; S, 10.94; Found: C, 61.64; H, 5.57; N, 2.60; Cl, 5.90; 0, 13.56; S, 10.82.
EXAMPLE 8
Preparation of 6-hydroxy-2-(4-hydroxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylsulfonyl)benzoyl!benzo b!thiophene ##STR13##
Aluminum chloride (1.45 g, 10.9 mmol, 8 eq.) was added to a solution of 0.81 mL (10.9 mmol, 8 eq.) of ethanethiol in 25 mL dry EtCl 2 under a dry atmosphere. After stirring for 10 minutes a solution of 800 mg (1.36 mmol, 1 eq.) 6-methoxy-2-(4-ethoxyphenyl)-3- 4-(2-(piperidin-1-yl)ethylsulfonyl)-benzoyl!benzo b!thiophene in 25 mL EtCl 2 was added and the mixture was stirred for 3 hours at room temperature. The reaction was quenched with 10ml 5% sodium bicarbonate, 100 mL water and 200 mL ethyl acetate. The organic layer was removed and the aqueous layer was extracted with ethyl acetate (2×200ml). The combined organic layers were dried (MgSO 4 ) and the solvents were removed under reduced pressure. The crude product was purified by silica gel chromatography using a zero to 10% methanol in MeCl 2 gradient in 30 minutes affording 631mg (89%) of the title compound as a bright yellow solid.
1 H NMR (300 MHz, D 6 -DMSO): δ 9.82 (bs, 2H), 7.84 (s, 4H), 7.46 (d, 1H, J 8.8 Hz), 7.38 (d, 1H, J=2.2 Hz), 7.13(d, 2H, J=8.5 Hz), 6.90 (dd, 1H, J=2.2, 8.8 Hz), 6.62 (d, 2H, J=8.5 Hz), 3.47 (t, 2H, J=6.7 Hz), 2.45 (t, 2H, J=6.7 Hz), 2.14 (bs, 4H), 1.21 (bs, 6H); FAB-MS for C 28 H 27 NO 5 S 2 (M*+1)=522.1; Elemental Analysis: Calcd. for C 28 H 27 NO 5 S 2 : C, 64.47; H, 5.22; N, 2.69; O, 15.34; S, 12.29; Found: C, 64.75; H, 5.36; N, 2.47; O, 15.46; S, 12.04. UV/VIS (methanol) k (extinction) 204 (32,000), 236 (32,000), 295 (17,000), 375 (2860).
The compounds of formula I of the present invention are useful for alleviating the symptoms of hyperlipidemia, estrogen-dependent cancer, particularly estrogen-dependent breast and uterine carcinoma, and the conditions of osteoporosis, and cardiovascular diseases, particularly when the latter two conditions are associated with post-menapousal syndrome.
The terms "alleviating" or "treating" are defined to include prophylactic treatment of a person at risk of incurring one or more symptoms or pathological conditions listed above, holding in check such symptoms or pathological conditions, and treating existing symptoms or pathological conditions, as appropriate.
Compounds of the present invention are also effective for inhibiting uterine fibroid disease and endometriosis in women, and smooth muscle cell proliferation in humans. The following non-limiting biological test examples illustrate the methods of the present invention.
BIOLOGICAL TEST PROCEDURES
I. General Preparation for Post-Menopausal Rat Model
In the examples illustrating the methods, a post-menopausal model was used in which effects of different treatments upon various biological parameters were determined, including serum cholesterol concentration, uterine weight, estrogen receptor binding, uterine eosinophil peroxidase activity, MCF-7 cell proliferation, and bone density.
Seventy-five day old female Sprague Dawley rats (weight range of 200 to 225 g) were obtained from Charles River Laboratories (Portage, Mich.). The animals were either bilaterally ovariectomized (OVX) or exposed to a sham surgical procedure (Intact) at Charles River Laboratories, and then shipped after one week. Upon arrival, they were housed in metal hanging cages in groups of 3 or 4 per cage and had ad libi tum access to food (calcium content approximately 0.5%) and water for one week. Room temperature was maintained at 22.20°±1.70° C. with a minimum relative humidity of 40%. The photoperiod in the room was 12 hours light and 12 hours dark.
II. Four Day Dosing Regimen
After a one week acclimation period (therefore, two weeks post-OVX), daily dosing with test compound was initiated. 17a-Ethynyl estradiol (EE 2 ) (Sigma Chemical Co., St. Louis, Mo.), an orally available form of estrogen, or the test compound were given orally, unless otherwise stated, as a suspension in 1% carboxymethyl cellulose or dissolved in 20% β-cyclodextrin. Animals were dosed daily for 4 days. Following the dosing regimen, animals were weighed and anesthetized with a ketamine:xylazine (2:1, v:v) mixture. A blood sample was collected by cardiac puncture. The animals were then sacrificed by asphyxiation with CO 2 , the uterus was removed through a midline incision, and a wet uterine weight was determined.
A. Cholesterol Analysis
Blood samples were allowed to clot at room temperature for 2 hours, and serum was obtained following centrifugation for 10 minutes at 3000 rpm. Serum cholesterol was determined using a Boehringer Mannheim Diagnostics high performance cholesterol assay. Briefly the cholesterol was oxidized to cholest-4-en-3-one and hydrogen peroxide. The hydrogen peroxide was then reacted with phenol and 4-aminophenazone in the presence of peroxidase to produce a p-quinone imine dye, which was read spectrophotemetrically at 500 nm. Cholesterol concentration was then calculated against a standard curve. The entire assay was automated using a Biomek Automated Workstation.
B. Uterine Eosinophil Peroxidase (EPO) Assay
Uteri were kept at 4° C. until time of enzymatic analysis. The uteri were then homogenized in 50 volumes of 50 mM Tris buffer (pH--8.0) containing 0.005% Triton X-100. Upon addition of 0.01% hydrogen peroxide and 10 mM o-phenylenediamine (final concentrations) in Tris buffer, increase in absorbance was monitored for one minute at 450 nm. The presence of eosinophils in the uterus, as measured by assay of eosinophil peroxidase activity, is an indication of estrogenic activity of a compound. The maximal velocity of a 15 second interval was determined over the initial, linear portion of the reaction curve.
C. Results
Data presented in Table 1 below show comparative results among control ovariectomized rats, rats treated with EE 2 , and rats treated with certain compounds of the present invention. Although EE 2 caused a decrease in serum cholesterol when orally administered at 0.1 mg/Kg/day, it also exerted a marked stimulatory action on the uterus so that the uterine weight of EE 2 treated rats was substantially greater than the uterine weight of ovariectomized test animals. This uterine response to estrogen is well recognized in the art.
In contrast, the compounds of the present invention substantially reduce serum cholesterol compared to the ovariectomized control animals without the general increase of uterine weight that is associated with estrogen compounds known in the art. This benefit of serum cholesterol reduction without adversely affecting uterine weight is quite rare and desirable.
As is expressed in the data below, estrogenicity also was assessed by evaluating the adverse response of eosinophil infiltration into the uterus. The compounds of the present invention did not cause an increase in the number of eosinophils observed in the stromal layer of ovariectomized rats, or in rare instances an increase only at the highest concentrations tested, as measured by assay of eosinophil peroxidase activity, while EE 2 caused a substantial, expected increase in eosinophil infiltration.
The data presented in Table 1 reflect the response of 5 or 6 rats per treatment.
TABLE 1______________________________________ Uterine Serum Dose Weight Uterine Cholesterol (mg/kg (% inc. EPO (% decreaseExample PO) OVX) (Vmax) OVX)______________________________________Ethynyl 0.1 144.1* 123.9* 80.3*estradiol7 0.1 26.4 7.5 -4.4 1 18.6 4.8 12.0 10 48.4* 8.4 28.7*8 0.1 16.2 4.8 -23.3 1 66.9* 13.5 17.2 10 75.0* 23.1 62.3*4 0.1 3.5 3.3 -16.6 1 23.1 1.2 37.5* 10 16.7 1.8 47.5*6 0.1 17.1 4.5 4.7 1 45.4* 3.3 42.0* 10 43.0* 6.0 65.1*2 0.1 -5.0 1.8 -0.5 1 15.8 2.4 13.6 10 35.6* 2.1 42.4*______________________________________ *Indicates value is significantly different than OVX control.
In addition to the demonstrated benefits of the compounds of the present invention, especially when compared to estradiol, the above data clearly demonstrate that these compounds are not estrogen mimetics. Furthermore, no deleterious toxicological effects (survival) were observed with treatment by any of the compounds of the present invention.
III. MCF-7 Proliferation Assay
MCF-7 breast adenocarcinoma cells (ATCC HTB 22) were maintained in MEM (minimal essential medium, phenol red-free, Sigma, St. Louis, Mo.) supplemented with 10% fetal bovine serum (FBS) (V/V), L-glutamine (2 mM), sodium pyruvate (1 mM), HEPES {(N- 2-hydroxyethyl!piperazine-N'- 2-ethanesulfonic acid!10 mM}, non-essential amino acids and bovine insulin (1 μg/ml) (maintenance medium). Ten days prior to assay, MCF-7 cells were switched to maintenance medium supplemented with 10% dextran coated charcoal stripped fetal bovine serum (DCC-FBS) assay medium) in place of 10% FBS to deplete internal stores of steroids. MCF-7 cells were removed from maintenance flasks using cell dissociation medium (Ca++/Mg++ free HBSS (phenol red-free) supplemented with 10 mM HEPES and 2 mM EDTA). Cells were washed twice with assay medium and adjusted to 80,000 cells/ml. Approximately 100 ml (8,000 cells) were added to flat-bottom microculture wells (Costar 3596) and incubated at 37° C. in a 5% CO 2 humidified incubator for 48 hours to allow for cell adherence and equilibration after transfer. Serial dilutions of drugs or DMSO as a diluent control were prepared in assay medium and 50 ml transferred to triplicate microcultures followed by 50 ml assay medium for a final volume of 200 ml. After an additional 48 hours at 37° C. in a 5% CO 2 humidified incubator, microcultures were pulsed with tritiated thymidine (1 uCi/well) for 4 hours. Cultures were terminated by freezing at -70° C. for 24 hours followed by thawing and harvesting of microcultures. Samples were counted by liquid scintillation. Results in Table 2 below show the ED 50 for certain compounds of the present invention.
TABLE 2______________________________________ ED.sub.50Compound Y R.sup.1, R.sup.2 (nM)______________________________________2 NH OH, OH 24 S OH, OH 0.96 NMe OH, OH 107 SO2 OMe, OMe 10008 SO2 OH, OH 30______________________________________
IV. MCF-7 Estrogen Receptor Binding Assay
Representative compounds of the present invention were tested in an estrogen receptor binding assay in which the test compounds were allowed to compete for binding with tritiated 17β-estradiol.
In the assay, serial dilutions of the test compound were mixed with 0.5 nM of 3 H-17β-estradiol, along with 0.5 mg/mL of protein from MCF-7 lysates, to a total volume of 0.14 mL. Binding was allowed to take place for 18 hours at 5 -- C., followed by the addition of 0.07 mL of dextran/charcoal and centrifugation to remove non-bound radioligand. Aliquots of supernate containing bound radioligand were mixed with scintillant and counted. Relative binding affinity (RBA) was calculated as: ##EQU1## The data for representative compounds of the present invention are presented in Table 3.
TABLE 3______________________________________Example Y R.sup.1, R.sup.2 RBA*______________________________________2 NH OH, OH 0.264 S OH, OH 0.156 NMe OH, OH 0.197 SO2 OMe, OMe <0.0028 SO2 OH, OH 0.084______________________________________ *RBA = 1 for 17estradiol
Combination Therapy
The present invention also provides a method of alleviating post-menopausal syndrome in women which comprises the aforementioned method using compounds of the present invention and further comprises administering to a woman an effective amount of estrogen or progestin. These treatments are particularly useful for treating osteoporosis and lowering serum cholesterol because the patient will receive the benefits of each pharmaceutical agent while the compounds of the present invention would inhibit undesirable side-effects of estrogen and progestin. Activity of these combination treatments in any of the post-menopausal tests, vide supra, indicates that the combination treatments are useful for alleviating the symptoms of post-menopausal symptoms in women.
Various forms of estrogen and progestin are commercially available. Estrogen-based agents include, for example, ethenyl estrogen (0.01-0.03 mg/day), mestranol (0.05-0.15 mg/day), and conjugated estrogenic hormones such as Premarin® (Wyeth-Ayerst; 0.3-2.5 mg/day). Progestin-based agents include, for example, medroxyprogesterone such as Provera® (Upjohn; 2.5-10 mg/day), norethylnodrel (1.0-10.0 mg/day), and nonethindrone (0.5-2.0 mg/day). A preferred estrogen-based compound is Premarin, and norethylnodrel and norethindrone are preferred progestin-based agents.
The method of administration of each estrogen- and progestin-based agent is consistent with that which is known in the art. For the majority of the methods of the present invention, compounds of the present invention are administered continuously, from 1 to 3 times daily. However, cyclical therapy may especially be useful in the treatment of endometriosis or may be used acutely during painful attacks of the disease. In the case of restenosis, therapy may be limited to short (1-6 months) intervals following medical procedures such as angioplasty.
As used herein, the term "effective amount" means an amount of compound of the present invention which is capable of alleviating the symptoms of the various pathological conditions herein described. The specific dose of a compound administered according to this invention will, of course, be determined by the particular circumstances surrounding the case including, for example, the compound administered, the route of administration, the state of being of the patient, and the pathological condition being treated. A typical daily dose will contain a nontoxic dosage level of from about 5 mg to about 600 mg/day of a compound of the present invention. Preferred daily doses generally will be from about 15 mg to about 80 mg/day.
The compounds of this invention can be administered by a variety of routes including oral, rectal, transdermal, subucutaneus, intravenous, intramuscular, and intranasal. These compounds preferably are formulated prior to administration, the selection of which will be decided by the attending physician. Thus, another aspect of the present invention is a pharmaceutical composition comprising an effective amount of a compound of the current invention, optionally containing an effective amount of estrogen or progestin, and a pharmaceutically acceptable carrier, diluent, or excipient.
The total active ingredients in such formulations comprises from 0.1% to 99.9% by weight of the formulation. By "pharmaceutically acceptable" it is meant the carrier, diluent, excipients, and salt must be compatible with the other ingredients of the formulation, and not deleterious to the recipient thereof.
Pharmaceutical formulations of the present invention can be prepared by procedures known in the art using well known and readily available ingredients. For example, the compounds of the current invention, with or without an estrogen or progestin compound, can be formulated with common excipients, diluents, or carriers, and formed into tablets, capsules, suspensions, powders, and the like. Examples of excipients, diluents, and carriers that are suitable for such formulations include the following: fillers and extenders such as starch, sugars, mannitol, and silicic derivatives; binding agents such as carboxymethyl cellulose and other cellulose derivatives, alginates, gelatin, and polyvinyl-pyrrolidone; moisturizing agents such as glycerol; disintegrating agents such as calcium carbonate and sodium bicarbonate; agents for retarding dissolution such as paraffin; resorption accelerators such as quaternary ammonium compounds; surface active agents such as cetyl alcohol, glycerol monostearate; adsorptive carriers such as kaolin and bentonite; and lubricants such as talc, calcium and magnesium stearate, and solid polyethyl glycols.
The compounds also can be formulated as elixirs or solutions for convenient oral administration or as solutions appropriate for parenteral administration, for example, by intramuscular, subcutaneous or intravenous routes. Additionally, the compounds are well suited to formulation as sustained release dosage forms and the like. The formulations can be so constituted that they release the active ingredient only or preferably in a particular physiological location, possibly over a period of time. The coatings, envelopes, and protective matrices may be made, for example, from polymeric substances or waxes.
Compounds of the present invention, alone or in combination with a pharmaceutical agent of the present invention, generally will be administered in a convenient formulation. The following formulation examples only are illustrative and are not intended to limit the scope of the present invention.
FORMULATIONS
In the formulations which follow, "active ingredient" means a compound of formula I.
Formulation 1: Gelatin Capsules
Hard gelatin capsules are prepared using the following:
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 0.1-1000Starch, NF 0-650Starch flowable powder 0-650Silicone fluid 350 centistokes 0-15______________________________________
The formulation above may be changed in compliance with the reasonable variations provided.
A tablet formulation is prepared using the ingredients below:
Formulation 2: Tablets
______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 2.5-1000Cellulose, microcrystalline 200-650Silicon dioxide, fumed 10-650Stearate acid 5-15______________________________________
The components are blended and compressed to form tablets.
Alternatively, tablets each containing 2.5-1000 mg of active ingredient are made up as follows:
Formulation 3: Tablets
______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 25-1000Starch 45Cellulose, microcrystalline 35Polyvinylpyrrolidone 4(as 10% solution in water)Sodium carboxymethyl cellulose 4.5Magnesium stearate 0.5Talc 1______________________________________
The active ingredient, starch, and cellulose are passed through a No. 45 mesh U.S. sieve and mixed thoroughly. The solution of polyvinylpyrrolidone is mixed with the resultant powders which are then passed through a No. 14 mesh U.S. sieve. The granules so produced are dried at 50°-60° C. and passed through a No. 18 mesh U.S. sieve. The sodium carboxymethyl starch, magnesium stearate, and talc, previously passed through a No. 60 U.S. sieve, are then added to the granules which, after mixing, are compressed on a tablet machine to yield tablets.
Suspensions each containing 0.1-1000 mg of medicament per 5 ml dose are made as follows:
Formulation 4: Suspensions
______________________________________Ingredient Quantity (mg/5 ml)______________________________________Active ingredient 0.1-1000 mgSodium carboxymethyl cellulose 50 mgSyrup 1.25 mgBenzoic acid solution 0.10 mlFlavor q.v.Color q.v.Purified water to 5 ml______________________________________
The medicament is passed through a No. 45 mesh U.S. sieve and mixed with the sodium carboxymethyl cellulose and syrup to form a smooth paste. The benzoic acid solution, flavor, and color are diluted with some of the water and added, with stirring. Sufficient water is then added to produce the required volume.
An aerosol solution is prepared containing the following ingredients:
Formulation 5: Aerosol
______________________________________ Quantity (% byIngredient weight)______________________________________Active ingredient 0.25Ethanol 25.75Propellant 22 (Chlorodifluoromethane) 70.00______________________________________
The active ingredient is mixed with ethanol and the mixture added to a portion of the propellant 22, cooled to 30° C., and transferred to a filling device. The required amount is then fed to a stainless steel container and diluted with the remaining propellant. The valve units are then fitted to the container.
Suppositories are prepared as follows:
Formulation 6: Suppositories
______________________________________Ingredient Quantity (mg/suppository)______________________________________Active ingredient 250Saturated fatty acid 2,000glycerides______________________________________
The active ingredient is passed through a No. 60 mesh U.S. sieve and suspended in the saturated fatty acid glycerides previously melted using the minimal necessary heat. The mixture is then poured into a suppository mold of nominal 2 g capacity and allowed to cool.
An intravenous formulation is prepared as follows:
Formulation 7: Intravenous Solution
______________________________________Ingredient Quantity______________________________________Active ingredient 50 mgIsotonic saline 1,000 ml______________________________________
The solution of the above ingredients is intravenously administered to a patient at a rate of about 1 ml per minute.
Formulation 8: Combination Capsule I
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Premarin 1Avicel pH 101 50Starch 1500 117.50Silicon Oil 2Tween 80 0.50Cab-O-Sil 0.25______________________________________
Formulation 9: Combination Capsule II
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Norethylnodrel 5Avicel pH 101 82.50Starch 1500 90Silicon Oil 2Tween 80 0.50______________________________________
Formulation 10: Combination Tablet
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Premarin 1Corn Starch NF 50Povidone, K29-32 6Avicel pH 101 41.50Avicel pH 102 136.50Crospovidone XL10 2.50Magnesium Stearate 0.50Cab-O-Sil 0.50______________________________________ | The present invention provides compounds with nitrogen, sulfur or carbon linked basic side chains of formula ##STR1## where R 1 and R 2 are independently hydrogen, halo, hydroxy, alkoxy, alkylcarbonyloxy, alkoxycarbonyl, alkoxycarbonyloxy, arylcarbonyloxy, aryloxycarbonyloxy, or alkylsulfonyloxy; O--SO 2 --(C 4 -C 6 alkyl), chloro, fluoro, or bromo; W is CHOH, C(O), or CH 2 ; Y is --CH 2 --, --NH--, --NMe--, --S--, --SO 2 --; and R 3 and R 4 are independently hydrogen, alkyl, alkylcarbonyl, alkylamino-carbonyl, or arylcarbonyl, or together with the nitrogen to which they are attached form 1-pyrrolidinyl, 1-piperidinyl, or a 5- or 6-membered imide or cyclic amide ring.
The present invention also provides pharmaceutical compositions containing the compounds optionally containing estrogen or progestin, and the use of such compounds, alone, or in combination with estrogen or progestin, for treating osteoporosis, aortal smooth muscle cell proliferation, (particularly restenosis), and estrogen-dependent cancer (particularly breast cancer). | 2 |
RELATED APPLICATIONS
[0001] This application claims priority of U.S. Patent Application Ser. No. 61/090,673 entitled: CONTENT, TRAFFIC AND ADVERTISING ENGINE, SYSTEM AND METHOD; Ser. No. 61/090,680 entitled: SYSTEM AND METHOD FOR AGGREGATING AND PROVIDING AUDIO AND VISUAL PRESENTATIONS VIA A COMPUTER NETWORK; Ser. No. 61/090,678 entitled: CONTENT, TRAFFIC AND ADVERTISING ENGINE, SYSTEM AND METHOD; Ser. No. 61/090,688 entitled: SYSTEM AND METHOD OF VALIDATING CONTENT, TRAFFIC AND ADVERTISING IN A COMPUTING APPLICATION AND ENGINE; Ser. No. 61/090,681 entitled: DYNAMIC READ THROUGH DATA COLLECTION AND AD DELIVERY SYSTEM AND METHOD OF SAME; Ser. No. 61/090684 entitled: SYSTEM AND METHOD FOR TRAFFIC IN A CONTENT AND ADVERTISING ENGINE; and Ser. No. 61/090,672 entitled: System and Method for Providing and Tracking the Provision of Audio and Visual Presentations via a Computer Network, all having common inventor Tod C. Turner; and each of which is incorporated herein by reference as if set forth in its respective entirety herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the provision of information, and more particularly to the provision of informational, entertainment, educational, business and other audio and/or audio/visual presentations via a computer network.
BACKGROUND OF THE INVENTION
[0003] The Internet is a global network connecting millions of computers and linking users in more than 100 countries into exchanges of data, news and opinions. Unlike online services, which are centrally controlled, the Internet is decentralized. Each Internet enabled computer is independent, such that its user can choose which Internet services to use and which local services to make available to the global Internet community.
[0004] There are many types of content available via the Internet, including textual content, graphical content, audio content and video content. The amount of content available via the Internet is virtually unlimited. Accordingly, it can prove difficult for a user of an Internet enabled computer to identify and locate content of a particular type and relating to a particular subject.
[0005] A popular solution to finding desired content is to use a publicly available search engine. A search engine searches documents for specified keywords and returns a list of documents where the keywords were found. Typically, a search engine utilizes a webcrawler to provide documents. An indexer then typically reads the webcrawler provided documents and creates an index based on the words contained in each document. Each search engine typically uses its own methodology to create indices such that, ideally, only meaningful results are returned for each query. This is not always true though due to the complex nature and nuances of human language and efforts by document authors or providers to fool or trick the indexer into ranking its documents above those of others. Examples of conventional search engines include those made available via www.yahoo.com, www.google.com and www.search.com, all by way of non-limiting example only.
[0006] Accordingly, there is a need for a system and method of using the Internet as a global network to unite people with common interests. Such a system and method may be used as productivity tools for business, and to educate and entertain consumers.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0007] A method for tracking digital media presentations delivered from a first computer system to a user's computer via a network including: providing a corresponding web page to the user's computer for each digital media presentation to be delivered using the first computer system; providing a identifier data to the user's computer using the first computer system; providing an applet to the user's computer for each digital media presentation to be delivered using the first computer system, wherein the applet is operative by the user's computer as a timer; receiving at least a portion of the identifier data from the user's computer responsively to the timer applet each time a predetermined temporal period elapses using the first computer system; and, storing data indicative of the received at least portion of the identifier data using the first computer system; wherein each provided webpage causes corresponding digital media presentation data to be streamed from a second computer system distinct from the first computer system directly to the users computer independent of the first computer system; and wherein the stored data is indicative of an amount of time the digital media presentation data is streamed from the second computer system to the user's computer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Understanding of the present invention will be facilitated by consideration of the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings, in which like numerals refer to like parts:
[0009] FIG. 1 illustrates a block diagram of a system of networked computers;
[0010] FIG. 2 illustrates an electronic document according to an embodiment of the present invention;
[0011] FIG. 3 illustrates an electronic document according to an embodiment of the present invention;
[0012] FIG. 4 illustrates a flow diagram of a process according to an embodiment of the present invention;
[0013] FIG. 5 illustrates a flow diagram of a process according to an embodiment of the present invention;
[0014] FIG. 6 illustrates a flow diagram of a process according to an embodiment of the present invention;
[0015] FIG. 7 illustrates a block diagram of a system of networked computers in conjunction with telecommunications devices according to an embodiment of the present invention;
[0016] FIG. 8 illustrates a flow diagram of a process according to an embodiment of the present invention;
[0017] FIG. 9 illustrates an electronic document according to an embodiment of the present invention; and
[0018] FIG. 10 illustrates a flow diagram of a process according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] It is to be understood that the figures and descriptions of embodiments of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purpose of clarity, many other elements found in typical website and audio/visual content delivery systems and methods. Those of ordinary skill in the art may recognize that other elements and/or steps are desirable and/or required in implementing the present invention. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein.
[0020] For non-limiting purposes of explanation only, “computer,” as referred to herein, refers to a general purpose computing device that includes a processor. “Processor,” as used herein, refers generally to a device including a Central Processing Unit (CPU), such as a microprocessor. A CPU generally includes an arithmetic logic unit (ALU), which performs arithmetic and logical operations, and a control unit, which extracts instructions (e.g., code) from memory and decodes and executes them, calling on the ALU when necessary. “Memory,” as used herein, refers to one or more devices capable of storing data, such as in the form of chips, or other medium like magnetic or optical discs. Memory may take the form of one or more random-access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), or electrically erasable programmable read-only memory (EEPROM) chips, by way of further non-limiting example only. Memory may be internal or external to an integrated unit including the processor. Memory may be internal or external to the computer Such memory may store a computer program, e.g., code or a sequence of instructions being operable by the processor. Such a computer may include one or more data inputs. Such a computer may include one or more data outputs. The code stored in memory may cause the processor, when executed by the processor, to set an output to a value responsively to a sensed input.
[0021] One type of computer executable code typically stored in memory so as to be executable by an Internet enabled computer is a browser application. For non-limiting purposes of explanation only, “browser application” or “browser,” as used herein, generally refers to computer executable code used to locate and display web pages. Commercially available browsers are Microsoft Internet Explorer, Netscape Navigator, Apple Safari, Google Chrome and Firefox, which all support text, graphics and multimedia information, including sound and video (sometimes through browser plug-in applications). “Plug-in,” as used herein, generally refers to computer executable code that adds a specific feature or service to a larger system, in the case of a browser plug-in, the browser application.
[0022] The terms “computer,” “computer device and/or “computer system” as used herein may generally take the form of single computing devices or collections of computing devices having a common operator or under common control.
[0023] According to certain embodiments of the present invention, content may be aggregated for presentation to users. According to certain embodiments of the present invention, audio content may be aggregated for presentation to users. According to certain embodiments of the present invention, video content may be aggregated for presentation to users. According to certain embodiments of the present invention, audio and video content may be aggregated for presentation to users.
[0024] Referring now to FIG. 1 , there is shown a block diagram of a system of networked computers 10 . The illustrated system 10 includes a plurality of user computers 20 , a plurality of network server computers 30 and a network 40 interconnecting computers 20 , 30 together.
[0025] Illustrated system 10 includes personal computing devices 22 and a personal digital assistant computer/web-enabled cell phone computer 24 by way of non-limiting example only. Communication links 26 communicatively couple devices 20 with network 40 . Links 26 may take the form of wired and/or wireless communications links, including fiber optic, POTS, DSL, cable and/or multiple access or GSM based wireless telephony or data communications systems, for example. Network 40 may include portions of proprietary and service provider networks, as well as the Internet, for example. Illustrated system 10 includes a database server 32 , a content or web server 34 and a file server 36 , all by way of non-limiting example only. Communication links 26 communicatively couple devices 30 with network 40 as well. “Server”, as used herein, generally refers to a computing device communicatively coupled to a network and that manages network resources. A server may refer to a discrete computing device, or may refer to an application that is managing resources rather than the entire computing device.
[0026] Referring now also to FIG. 2 , there is illustrated a web page 200 according to an embodiment of the present invention. Web page 200 may be provided to computers 20 by computers 30 via network 40 . Illustrated web page 200 aggregates audio and/or video content for presentation to users of computers 20 .
[0027] Referring still to FIG. 2 , the particularly illustrated web page 200 includes a category selector 205 , a ranking selector 210 , a new content indicator 215 , a content type indicator 220 , a page selector 225 , particular content graphics 230 , particular content type indicators 235 and particular content information 240 organized under a browser tab 245 . Web page 200 may take other forms and/or present different content as is conventionally achieved in the pertinent arts.
[0028] Particular content graphics 230 , particular content type indicators 235 and particular content information 240 are organized to indicate individual presentations. In the illustrated embodiment, presentations 265 , 270 , 275 , are respectively shown. A user may select such a presentation for display by selecting an individual presentation for streaming or downloading, such as by clicking on an indicator 235 , 240 or 245 . For non-limiting purposes of explanation, “streaming,” as used herein, generally refers to a technique for transferring data such that it can be processed as a substantially steady or continuous stream and a user's browser or plug-in can start presenting the data before the entire file has been transmitted. For non-limiting purposes of explanation, “downloading,” as used herein, generally refers to a technique for transmitting data (e.g., an entire data file) between computers, such as between file server 36 ( FIG. 1 ) and a computing device 22 ( FIG. 1 ). In certain embodiments of the present invention, a commercially available content (e.g., audio and/or video podcast) delivery application, such as the Flash product available from Adobe Systems Inc., may be used to provide selected presentations to users' computers 20 ( FIG. 1 ).
[0029] Referring still to FIGS. 1 and 2 , a user of a device 20 may request page 200 from content server 34 using a browser application in a conventional manner. Server 34 may provide page 200 to the requesting computer 20 in a conventional manner, optionally using database server 32 to populate page 200 , for example.
[0030] In certain embodiments of the present invention, when a user selects a category in selector 205 , content server 34 may request database server 32 identify which presentations should be used to populate page 200 according to the selected category. Server 34 may then provide such a populated page 200 to the requesting user computer 20 . Examples of categories that may be included and selected using selector 205 include art, autos and vehicles, bloggers and people, celebrity gossip, comedy, education, gadgets, health, how to and DIY, legal, music, news, and pets and animals, for example. By selecting one of these categories, a user may receive pages 200 populated with content according to the selected category.
[0031] In certain embodiments of the present invention, when a user selects a ranking in indicator 210 , content server 34 may request database server 32 identify which presentations should be used to populate page 200 according to the selected ranking. Server 34 may then provide such a populated page 200 to the requesting user computer 20 . Examples of rankings that may be included and selected using indicator 210 include most recent presentations and most popular presentations, for example. By selecting one of these rankings, a user may receive pages 200 populated with content according to the selected ranking.
[0032] In certain embodiments of the present invention, a user may select a populated presentation (e.g., 265 , 270 or 275 , FIG. 2 ). In response thereto, server 34 may request file server 36 either stream or download the selected presentation to the requesting user's computer 20 , such as via a web page 200 in a conventional manner.
[0033] Referring now to FIG. 3 , there is shown a view of web page 200 when tab 250 is selected. In the illustrated embodiment of FIG. 3 , web page 200 includes a text box 255 and search button 260 under tab 250 . In certain embodiments of the present invention, when tab 250 is selected, text box 255 and search button 260 may be presented on the user's computer 20 by server 34 . A user may enter a search term into window 255 in a conventional manner. A user may then activate search button 260 in a conventional manner. Responsively thereto, content server 34 may request database server 32 identify which presentations should be used to populate page 200 according to the entered search term(s). Server 34 may then provide such a populated page 200 to the requesting user computer 20 .
[0034] As will be appreciated by those possessing an ordinary skill in the pertinent arts, there are a number of ways to aggregate and provide content using web page 200 .
[0035] In certain embodiments of the present invention, users may be permitted to directly upload and enter information regarding content, e.g., to file server 36 ( FIG. 1 ). In certain embodiments of the present invention, users may be permitted to link presentations housed elsewhere in memory so as to be accessible to a computer 20 ( FIG. 1 ) via network 40 (FIG. 1 )—essentially registering them with database server 32 ( FIG. 1 ). In certain embodiments of the present invention, presentations may be created using computers 20 , 30 . And, in certain embodiments of the present invention, presentations housed elsewhere in memory so as to be accessible to a computer 20 ( FIG. 1 ) via network 40 ( FIG. 1 ) may be automatically linked to—essentially registering them with database server 32 ( FIG. 1 ).
[0036] Referring now also to FIG. 4 , there is shown a flow diagram of a process 400 according to an embodiment of the present invention. Process 400 is suitable for permitting users to directly upload and enter information regarding content. Process 400 commences with a user providing log on information using a computer 20 at block 405 , which is provided to computers 30 via network 40 , in certain embodiments to server 34 . Computers 30 log the user on at block 410 , and communicates this status to the user via network 40 , in certain embodiments by serving a page 200 ( FIGS. 2 , 3 ) to the logged on user's computer 20 .
[0037] At block 415 , the logged on user requests to upload content, e.g., by interacting in a conventional manner with web page 200 . This request is provided to computers 30 via network 40 . At block 420 , computers 30 request information regarding the content to be uploaded. In certain embodiments, the requested information may include a content title, date, series information and description, akin to that to be displayed in a corresponding indicator 240 ( FIGS. 2 , 3 ). The request may further include a file identifier and location of the content indicative file to ultimately be uploaded. This request may be communicated to the user's computer 20 via network 40 .
[0038] At block 425 , the user provides at least a portion of the requested information, which is communicated to computers 30 via network 40 . Some or all of the information provided may be screened or filtered or verified in conventional manners at block 430 . In certain embodiments of the present invention, information provided at block 425 may be received and screened or filtered or verified at block 430 using web server 34 . All or a portion of that information may then be stored using database server 32 , for later use in populating web pages 200 , for example.
[0039] At block 430 , computers 30 indicate the received information is suitable for use and confirms the content may be uploaded. This indication is provided to the user's computer 20 via network 40 . At block 435 , the user's computer transmits the content to computers 30 via network 40 , e.g., performs a file upload in a conventional manner. The content is received by computers 30 at block 440 . In certain embodiments of the present invention, content transmitted and received at blocks 435 , 440 may take the form of media file suitable for use as a podcast, for example. Such a file may be received by server 34 for example, and provided to server 36 for storage 450 and later retrieval for downloading and/or streaming pursuant to a user's interaction with webpage 200 ( FIGS. 2 , 3 ), for example. In such a case, server 32 may associate the stored content indicative information provided at block 425 with the file stored at block 450 .
[0040] Referring now also to FIG. 5 , there is shown a flow diagram of a process 500 according to an embodiment of the present invention, Process 500 is suitable for permitting users to link presentations housed elsewhere in memory so as to be accessible to a computer 20 via network 40 .
[0041] Process 500 commences with a user providing log on information using a computer 20 at block 505 , which is provided to computers 30 via network 40 , in certain embodiments to server 34 . Computers 30 log the user on at block 510 , and communicate this status to the user via network 40 , in certain embodiments by serving a page 200 ( FIGS. 2 , 3 ) to the logged on user's computer 20 .
[0042] At block 515 , the logged on user requests to link or register content, e.g., by interacting in a conventional manner with web page 200 . This request is provided to computers 30 via network 40 . At block 520 , computers 30 request information regarding the content to be linked. In certain embodiments, the requested information may include a content title, date, series information and description, akin to that displayed in a corresponding indicator 240 ( FIGS. 2 , 3 ). The request may further include a file identifier and location of the content indicative file to be linked. This request may be communicated to the user's computer 20 via network 40 .
[0043] At block 525 , the user provides at least a portion of the requested information, which is communicated to computers 30 via network 40 . Some or all of the information provided may be screened or filtered or verified in conventional manners at block 530 . In certain embodiments of the present invention, information provided at block 525 may be received and screened or filtered or verified at block 530 using web server 34 . In certain embodiments of the present invention, the file location data (e.g., an Internet address at which the file is available) may be checked to see if a valid media file is located thereat. All or a portion of that information may then be stored using database server 32 , for later use in populating web pages 200 , for example.
[0044] At block 530 , computers 30 indicate the received information is suitable for use and confirms the content may be linked. At block 550 the received information may be stored using server 32 for later retrieval and use. Server 32 may also associate the linked content indicative information provided at block 525 with the file address stored at block 550 .
[0045] Certain embodiments of the present invention may provide the ability to track the number of visitors to the platform of the present invention, and additionally the number of visitors per content via the platform of the present invention. Further, the number of pages viewed by each visitor may additionally be tracked, such as in a tabular format, and such information may be continuously updated for as long as a user remains on a given page, that is, for as long as a user continues to watch a particular show. For example, it may be determined when a user begins and ends listening to and/or watching a presentation, e.g., a podcast, for example. Where a selected presentation is streamed from computers 30 , such an inquiry may be relatively simple, by confirming the content streaming is progressing as expected, for example. Where content is housed elsewhere and linked to by computers 30 , such a direct inquiry may not be readily available though. Tracking may be performed, for example, via entry into one or more tables of database server 32 of timed data. At each expiration of a timer, such as every 15 seconds, a table entry may be made corresponding to the user, the page the user is on, and, to the extent the user is on the same page as was the user upon the last expiration of the timer, the user's total time, to the current time, spent on that same page. The user may be identified by, for example, any of a number of known methodologies, such as the information the user used to login, the user's IP address, the user's response to an identifying query, or the like.
[0046] Thus, certain embodiments of the present invention provide a capability to know that a viewer began viewing a particular show at a certain time, and when a user began viewing a different page, or show, thereby providing knowledge of how long a particular viewer spent on a particular page. Such knowledge is not conventionally available, and the provision of such knowledge by certain embodiments of the present invention allows for an increasing scale of payments for advertising displayed on a given page correspondent to how long a viewer or viewers remain, or typically remain, on that particular page or like pages. Thus, a tabular tracking of the present invention allows for the knowledge of how long a viewer spends on a page, what the viewer was viewing or listening to on the given page, the ads shown while the viewer was viewing or listening, how long the ads were shown, and what ads were shown to the view correspondent to that viewer's identification and/or login.
[0047] Referring now also to FIG. 6 , there is shown a flow diagram of a process 600 according to an embodiment of the present invention. Process 600 is suitable for permitting users to create presentations, such as by hosting an audio show that may be recorded to create a podcast, using computers 20 , 30 .
[0048] Process 600 commences with a user providing log on information using a computer 20 at block 605 , which is provided to computers 30 via network 40 , in certain embodiments to server 34 . Computers 30 log the user on at block 610 , and communicate this status to the user via network 40 , in certain embodiments by serving a page 200 ( FIGS. 2 , 3 ) to the logged on user's computer 20 .
[0049] At block 615 , the logged on user requests to create content or host a show, e.g., by interacting in a conventional manner with web page 200 . This request is provided to computers 30 via network 40 . At block 620 , computers 30 request information regarding the content to be created. In certain embodiments, the requested information may include a content title, date, series information and description, akin to that displayed in a corresponding indicator 240 ( FIGS. 2 , 3 ). The request may further include a phone number at which the user may be reached. This request may be communicated to the user's computer 20 via network 40 .
[0050] At block 625 , the user provides at least a portion of the requested information, which is communicated to computers 30 via network 40 . Some or all of the information provided may be screened or filtered or verified in conventional manners at block 630 . In certain embodiments of the present invention, information provided at block 625 may be received and screened or filtered or verified at block 630 using web server 34 . In certain embodiments of the present invention, the user's phone number may be checked to see if it is valid. All or a portion of that information may ten be stored at block 635 using database server 32 , for later use in populating web pages 200 , for example.
[0051] At block 640 , the requesting user indicates he would like to begin creating the presentation, e.g., by interacting in a conventional manner with web page 200 . This indication is communicated to computers 30 via network 40 . At block 645 computers 30 initiate a new presentation creation session. At block 650 , a voice communications session between computers 30 and the user is commenced. In certain embodiments of the present invention, a telephone call may be automatically placed by computers 30 at block 650 to the phone number indicated at block 625 .
[0052] Referring now to FIG. 7 , there is shown a block diagram of a system of networked computers and telephones 700 . Like system 10 , illustrated system 700 includes personal computing devices 22 and a personal digital assistant/web-enabled cellular phone computer 24 by way of non-limiting example only. Communication links 26 communicatively couple devices 20 with network 40 . Links 26 may take the form of wired and/or wireless communications links, including fiber optic, POTS, OSL, cable and/or multiple access or GSM based wireless telephony or data communications systems, for example. Network 40 may include portions of proprietary and service provider networks, as well as the Internet, for example. Illustrated system 10 includes a database server 32 , a content or web server 34 and a file server 36 , all by way of non-limiting example only. Communication links 26 communicatively couple devices 30 with network 40 as well.
[0053] System 700 additionally includes conventional telephone 705 associated with (as indicated by label 720 ) a particular computing device 22 , e.g., by both corresponding to a given requesting user, for example. In the illustrated embodiment, phone 705 may be communicatively coupled to computers 30 independent of network 40 (e.g., via 725 ). In the illustrated embodiment, phone 705 may be communicatively coupled to computers 30 via network 40 (e.g., link 710 ). In certain embodiments of the present invention phone 705 may take the form of a POTS phones. In certain embodiments of the present invention phone 705 may take the form of a VoIP phone. In certain embodiments of the present invention, phone 705 may take the form of a cellular phone. In certain embodiments of the present invention, phone 705 is independent of the associated computer 22 . In certain embodiments of the present invention, phone 705 may be communicatively coupled to computers 30 independent of any connection between the associated computer 22 and computers 30 .
[0054] Referring still to FIGS. 6 and 7 , a requesting user may be called at block 650 by computers 30 placing a conventional telephone call to the phone number provided at block 625 . Upon the call being answered using phone 705 , a pre-recorded audio message indicating the content will be created may be played. Thereafter, the requesting user, or his designee for example, may speak into phone 705 , thereby hosting a show, for example. Responsively thereto, computers 30 may digitize the spoken show and store a media file indicative of it (e.g., using file server 36 ), as indicated at block 655 .
[0055] Information provided at block 625 and stored at block 635 may include identifications of intended audience members for the presentation, e.g., an audience for the show to be hosted. This additional information may be used at block 660 to initiate analogous telephone calls to those numbers as well. In this way, a phone audience may hear the show live at a plurality of locations. For non-limiting purposes of explanation, this is shown in FIG. 7 as phone 730 , which is associated with computer 24 as designated by label 740 .
[0056] Such a “dial out” functionality allows for an understanding of where the user/viewer/listener can be reached, located, and/or may allow for a myriad additional features in the present invention. For example, a pinpoint geographic location of broadcast listeners may be placed on a map, such as via website 200 to thereby illustrate where other listeners of the broadcast are specifically located. Such a mapping functionality may be realized using a commercially available mapping application, such as Google Maps, for example.
[0057] In certain embodiments of the present invention, shows may be streamed analogously as described above as they are being recorded, for example.
[0058] It should further be understood such a content generation functionality provides additional advantages. For example, enhanced telephone conferences may be readily achieved according to certain embodiments of the present invention. Such enhanced conferences may exhibit an automatic dial out to conference attendees, including the host and audience. Such enhanced conferences may exhibit automatic recording and archival for later playback as a podcast, for example. Such enhanced functionalities may advantageously be achieved without the host having access to any particular resources other than a general purpose Internet enabled computer and a conventional telephone. Such enhanced functionalities may advantageously be achieved without the any audience member having access to any particular resources other than a conventional telephone. Accordingly, enhanced telephone conferencing may be readily achieved.
[0059] In certain embodiments of the present invention, certain portions of aggregated content may have access thereto restricted to authorized members. For example, information provided at blocks 425 , 525 and/or 625 may include an authorized group identifier or content password. Such an identifier and/or password may be stored using database server 32 . When a user seeks to playback such protected content, e g., by interacting with web page 200 as set forth above, the user may need to log in (e.g., analogously to log in at blocks 405 , 410 , 505 , 510 , 605 , 610 ) or provide the corresponding password. Where a group identifier is used, database server 32 may indicate what groups a logged in user is authorized for, so as to selectively permit access to protected content to authorized users. Such groups may, by way of non-limiting example only, include businesses and other private organizations.
[0060] Referring now also to FIG. 8 , there is shown a flow diagram of a process 800 according to an embodiment of the present invention. Process 800 is suitable for automatically aggregating and linking to presentations housed elsewhere in memory so as to be accessible to a computer 20 ( FIG. 1 ) via network 40 (FIG. 1 )—essentially registering them with database server 32 ( FIG. 1 ).
[0061] Syndication of Internet content is becoming more commonplace. Really Simple Syndication (“RSS”) is a family of Internet feed formats used to publish content that may be frequently updated, such as podcasts (RSS 2.0). RSS utilizes a standardized format. An RSS document (sometimes referred to as a “feed,” “web feed” or “channel”) typically contains either a summary of content from an associated web site or the full text.
[0062] An RSS may itself be used to aggregate content from multiple web sources in one place. RSS content is typically accessed using an RSS reader application. Such an application may be a thin, web-page based application or a downloaded application executed on a user's computer (e.g., 20 , FIG. 1 ). RSS feeds may typically be subscribed to by entering or selecting the feed's link using the reader. The RSS reader typically checks the user's subscribed feeds for new content at predetermined intervals, downloads updates, and provides a user interface to monitor and view the feeds.
[0063] Embodiments of the present invention will be discussed with regard to RSS 2.0 feeds for non-limiting purposes of explanation only. It should be recognized that embodiments of the present invention may be suitable for use with other types of content (e.g., audio/video) feeds.
[0064] Referring again to FIG. 8 , process 800 commences with a user providing log on information using a computer 20 at block 805 , which is provided to computers 30 via network 40 , in certain embodiments to server 34 . Computers 30 log the user on at block 810 , and communicate this status to the user via network 40 , in certain embodiments by serving a page 200 ( FIGS. 2 , 3 ) to the logged on user's computer 20 .
[0065] At block 815 , the logged on user requests to link an RSS feed, e.g., by interacting in a conventional manner with web page 200 . This request is provided to computers 30 via network 40 . At block 820 , computers 30 request information regarding the content to be created. In certain embodiments, the requested information may include a content title, series information and description, akin to that displayed in a corresponding indicator 240 ( FIGS. 2 , 3 ). The request may further include RSS feed identification and/or access information through which the feed may be accessed. This request may be communicated to the user's computer 20 via network 40 .
[0066] At block 825 , the user provides at least a portion of the requested information, which is communicated to computers 30 via network 40 . Some or all of the information provided may be screened or filtered or verified in conventional manners at block 830 . In certain embodiments of the present invention, information provided at block 825 may be received and screened or filtered or verified at block 830 using web server 34 . In certain embodiments of the present invention, the feed identifier and/or access information may be checked to see if it is valid. All or a portion of that information may then be stored at block 850 using database server 32 , for later use in populating web pages 200 , for example. At block 850 , the feed may further be accessed to acquire information regarding and/or either links to or the feed content itself then present. All of this information may be automatically aggregated using computers 30 in accordance with the methods described herein-above with regard to FIGS. 4 and/or 5 , where the feed information (e.g., RSS associated XML data) is used in lieu of user provided information. The date and time when content is automatically acquired via such a registered RSS feed may also be stored at block 850 using computers 30 , e.g., database server 32 .
[0067] At block 855 , computers 30 may determine if new content exists for one or more feeds stored at block 850 . This may be accomplished in any of a number of conventional manner, including periodically checking when the feed was last updated and/or the content available there-through to data stored at block 850 . When new of changed content is found, the data stored at block 855 may be appended or amended to reflect the new content.
[0068] It should further be understood such a content acquisition provides additional advantages. For example, each user wishing to identify and view content available via an RSS feed may conventionally need to obtain and operate an RSS reader application. Further, each such RSS reader application would need to access each identified RSS feed. This leads to substantial bandwidth usage, for example. In contrast, certain embodiments of the present invention permit a user to access RSS content without the need for his own RSS reader. Further, embodiments of the present invention only require that system 30 access each RSS feed, as opposed to each system 30 user computer 20 wishing to access the RSS feeds, leading to substantial savings in network resources. Further, certain embodiments of the present invention allow user to access and compare content available via RSS feeds they are not even aware of, e.g., by their interaction with webpage 200 as discussed above, where webpage 200 includes content added using the methodology of process 800 , for example. Accordingly, certain embodiments of the present invention provide for enhanced content syndication and aggregation, as compared to even RSS feeds themselves, for example. And, certain embodiments of the present invention provide for automatic aggregation of RSS fed content in combination with non-RSS fed content in a single application independent of any user RSS reader application.
[0069] In certain embodiments of the present invention, web page views and/or web site visits (e.g., sessions) may be tracked. A page view, as used herein, generally refers to a request made to a web server for a web page, as opposed to just a page component, such as a graphic, for example. A visit, as used herein, generally refers to a sequence of web page and/or component requests from a particular user's computer, within some predetermined period of time. Commercially available server log file analysis applications may be used to gather such information, for example.
[0070] In certain embodiments of the present invention, more detailed tracking information may be desired. For example, it may be desirable to know not only that a certain number of users requested and accessed certain presentations, but also how long a user actually watched, and/or listened, to a presented program, after selection via webpage 200 ( FIGS. 2 , 3 ), for example. Certain embodiments of the present invention may provide the ability to track the number of visitors to the platform of the present invention, and additionally the number of visitors per content via the platform of the present invention, and additionally information regarding how long presentations were watched and/or listened.
[0071] For example, and referring now to FIG. 9 , there is shown a view of a web page 900 according to an embodiment of the present invention. Web page 900 generally includes portions 910 , 920 , 930 and 940 . Web page 900 may be provided to a user's computer 30 responsively to user selection of a presentation shown on a populated web page 200 ( FIG. 2 ). By way of non-limiting explanation, should a user viewing web page 200 ( FIG. 2 ) select a presentation 265 for viewing and/or listening, a suitably populated web page 900 may be served by computers 20 . In such a served web page 900 , portion 930 may be utilized to playback the selected presentation in a conventional manner, e.g., by downloading the content into or streaming the content to a media player application or plug-in. Portions 910 , 940 may be used to display related information, such as advertisements for example. In such a case, it may be desirable to be able to reliable identify how long the media was actually, or may typically be played, in order to appropriately value portions 910 , 920 as available advertising billboard space. By way of further, non-limiting, example, while a per-click or per-display pricing schedule for portions 910 , 940 may be used, where portion 920 is used to play-back content a typical user watches and/or listens to for ten minutes, portions 910 , 940 may be worth more than where content play-back is typically for less than thirty-seconds.
[0072] Where content is directly stored using an operator's system (e.g., computers or computer system 20 , FIG. 2 ), such as by using the methodology of process 400 ( FIG. 4 ) or process 600 ( FIG. 6 ), such a tracking may be achieved by tracking requests from and pages viewed by each visitor, such as in a tabular format. As a system operator maintains control over the operation of system 30 in such a case, system 30 may be monitored to determine how long data is streamed therefrom, for example. Data indicative of this period, such as a presentation identifier and a value indicative of the time the presentation was actually streamed for, may be logged by system 30 (e.g., using database server 32 , for example). For example, it may be determined when a user begins and ends listening to and/or watching a presentation, e.g., a podcast, by tracking when a web page was loaded and for example by determining when streaming of data to such a loaded web page ceases. Where a selected presentation is streamed from computers 20 , such a methodology may be directly implemented by system 20 , by confirming the content streaming is progressing as expected, for example.
[0073] Where content is not uploaded to an operator's system (e.g., computers or computer system 20 , FIG. 2 ) and is instead remotely stored from yet aggregated by system 30 , e.g., using the methodology of process 500 ( FIG. 5 ) or process 800 ( FIG. 8 ), for example, tracking may not be so straight forward. As an operator of system 30 does not necessarily exercise control over the content data storage resource, the operator may not be able to directly operate the storage resource in a manner to directly track how long content is streamed therefrom to a particular user.
[0074] In certain embodiments of the present invention, aggregated content playback may advantageously be tracked in a substantially same manner, regardless of whether it is streamed from system 30 or otherwise unrelated computer systems operated by third parties. In certain embodiments of the present invention, tracking information may be continuously or substantially continuously updated for as long as a user continues to watch or listen to a particular show, regardless of whether the content data is streamed from an operator's computer system 30 or a third party's computer system.
[0075] Referring now to FIG. 10 , there is shown a block diagram of a process 1000 according to an embodiment of the present invention. Process 1000 commences with a user's computer 20 receiving a web page from system 20 ( FIG. 2 ) at block 1010 . Such a received web page may take the form of page 900 ( FIG. 9 ), for example. As is shown in FIG. 9 , page 900 includes portion 930 , which may be used to play-back user selected content via his computer 20 and a suitable plug-in or media player, for example. As explained herein, data indicative of the content played using portion 920 may be supplied by system 30 or a third party's computer system. Regardless, page 900 may include a timer applet. “Applet,” as used herein, generally refers to a software component that runs in the context of another program, in the case of page 900 of FIG. 9 , a web browser. Such an applet may typically used to perform a specific function or task, usually narrow in scope. In the case of FIGS. 9 and 10 , such a timer applet may be used to indicate when a pre-determined temporal period has elapsed. For example, such an applet may be used to indicate each time some temporal period, such as 10, 15 or 30 seconds, elapses. Such a timer applet may be started at block 1020 .
[0076] At block 1030 , when the applet determines the predetermined temporal period has elapsed, it signals its continued execution to system 20 . In response, system 30 may log receipt of this indication, such as by using database server 32 . In certain embodiments of the present invention, web page 900 ( FIG. 9 ) may be accompanied with identifying data, such as in form of a cookie. A “cookie,” as used herein, generally refers to a message provided to a web browser by a web server. The browser stores the message in a data or text file. In certain embodiments of the present invention, the applet may cause the cookie, or associated data, to be transmitted from the user's computer 20 to system 30 , where upon receipt it, or data associated with it, may be logged, such as by using database server 32 .
[0077] By way of further non-limiting example, at each expiration of temporal period as determined by the timer applet, such as every 15 seconds, a table entry may be made of the user, the page the user is on, and, to the extent the user is on the same page as was the user upon the last expiration of the timer, the user's total time, to the current time, spent on that same page using database server 32 . The user may be identified by, for example, any of a number of known methodologies, such as the information the user used to login, the user's IP address, the user's response to an identifying query, or the like.
[0078] In certain embodiments of the present invention, the timer applet may cause data indicative of the total time spent on the web page presenting the presentation that has elapsed. In certain embodiments of the present invention, the timer applet may cause data indicative of another temporal cycle having passed while the web page presents the presentation. In the latter, a value indicative of the number of cycles that have passed in database 32 may be incremented each time the data is received, for example.
[0079] Thus, certain embodiments of the present invention provide the capability to know that a viewer began viewing a particular show at a certain time, and to know when a user began viewing a different page, or show, thereby providing knowledge of how long a particular viewer spent on a particular page. Such knowledge is not conventionally available, and the provision of such knowledge by certain embodiments of the present invention allows for an increasing scale of payments for advertising displayed on a given page correspondent to how long a viewer or viewers remain, or typically remain, on that particular page or like pages. Thus, the tabular tracking of the present invention allows for the knowledge of how long viewer spends on a page, what the viewer was viewing or listening to on the given page, the ads shown while the viewer was viewing or listening, how long the ads were shown, and what ads were shown to the view correspondent to that viewer's identification and/or login.
[0080] Those of ordinary skill in the art may recognize that many modifications and variations of the present invention may be implemented without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A method for tracking digital media presentations: providing a corresponding web page for each digital media presentation to be delivered; providing identifier data to the user's computer; providing a timer applet to the user's computer; and, storing data indicative of received identifier data; wherein each provided webpage causes corresponding digital media presentation data to be streamed from a second computer system distinct from a first computer system directly to the user's computer independent of the first computer system; and stored data is indicative of an amount of time the digital media presentation data is streamed from the second computer system to the user's computer. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention concerns a transfer element, in particular a sprue bush or a machine nozzle, for an injection molding system, having a flow lumen for a plasticised plastic material.
[0002] The invention further concerns a hot runner system having a sprue bush and an injection molding machine having a machine nozzle.
[0003] A sprue system or runner is the connection from the machine nozzle of an injection molding machine to what is referred to as the ingate. The ingate forms the transition from the sprue runner into the mold portion cavity configuration, referred to as the mold cavity. The state of the art discloses hot runner systems for injection molding machines. Such hot runner systems represent the technologically most developed sprue systems or runners for injection molding molds. Hot runner systems serve to distribute the plastic material which is prepared in the injection molding machine in a molten state from the machine nozzle of the injection molding machine to the individual cavities in the injection molding tool. In that respect the hot runner system is temperature-controlled in such a way that the plastic material is kept in the molten state throughout the entire injection molding cycle in the hot runner system. Therefore hot runner systems are frequently also considered as a prolongation of the machine nozzle.
[0004] A certain amount of gas is produced during the processing process, during melting and plasticization of plastic materials, in particular PET materials. Presumably the gas contains predominantly substances which are due to additives added to the initial PET material to specifically alter the properties thereof. In that case the gas is produced in particular upon aggregate conversion of the molten material during plasticization by a machine screw by virtue of shearing, heat and overheating, the gas condensing at cooler locations in the injection molding system in the form of dust. That dust is aggressive to a high degree and is deposited in particular at colder parts of the hot runner system. In that case deposit of the dust, in particular in the plunger housings of the needle valves which seal off the hot runner system in relation to the injection molding tool, leads to severe wear of the plunger seals. Therefore many needle valve systems for hot runner systems have vent openings by way of which the dust can escape from the hot runner system before it is deposited in the region of moving parts, for example at the plunger housings of the needle valves, and there gives rise to increased wear.
[0005] The amount of dust in the injection molding system increases with the material throughput through the system, that is to say the plasticised amount of plastic material per unit of time. Modern injection molding systems are designed for an increasingly higher level of material throughput which is required in particular by virtue of the increase in the number of mold cavities or molding spaces in the injection molding tools and due to a reduction in the cycle times. Wear in particular in the plunger housings of the valves of the hot runner plate also increases therewith as the increased amount of dust can no longer adequately escape from the system through the vent bores in the plunger housings of the valves.
BRIEF SUMMARY OF THE INVENTION
[0006] Therefore the object of the present invention, in relation to that state of the art, is to provide a transfer element for an injection molding system which makes it possible to further increase the material throughput of the injection molding system without having to tolerate increased wear of seals and other system components.
[0007] According to the invention that object is attained in that there is provided a transfer element for an injection molding system comprising a flow lumen for a plasticised plastic material, wherein it has a device for degassing of the flow lumen.
[0008] In that case the transfer element can be the sprue bush of a hot runner system or the machine nozzle of an injection molding machine. In that respect alternatively the sprue bush and the machine nozzle of the system can also be equipped in accordance with the invention.
[0009] The sprue bush forms the transfer element at the hot runner side for introducing the hot plasticised plastic material from the injection molding machine into the hot runner system. In that case the sprue bush is provided for it to cooperate with the machine nozzle of the injection molding machine, in which case a sealing surface of the sprue bush generally comes into engagement with a sealing surface of the machine nozzle in such a way that no plastic material escapes when the plasticised plastic material is transferred from the machine nozzle into the sprue bush of the hot runner system.
[0010] In particular, the invention preferably is a transfer element for an injection molding system having a flow lumen for a plasticised plastic material, wherein it has a device for degassing of the flow lumen. The transfer element preferably has a substantially hollow-cylindrical main body having an inner peripheral surface and an outer peripheral surface, wherein the degassing device has at least one gas-permeable passage connecting the inner peripheral surface and the outer peripheral surface.
[0011] Further, the main body is preferably of a two-part structure having an upper part and a lower part which are substantially hollow-cylindrical and each have at least one main face, wherein the upper part and the lower part are so arranged that the main faces at least partially butt against each other.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 shows a sprue nozzle of a hot runner system from the state of the art,
[0013] FIG. 2 shows a sectional view of an embodiment according to the invention of a sprue nozzle,
[0014] FIG. 3 shows a plan view of the main face or separation face in relation to the lower part of the sprue bush upper part of FIG. 2 ,
[0015] FIG. 4 shows an isometric exploded view of the main body of the sprue bush of FIGS. 2 and 3 ,
[0016] FIG. 5 shows a plan view of the main face or separation face in relation to the lower part of the sprue bush upper part of an alternative embodiment,
[0017] FIG. 6 shows a further embodiment of the sprue bush according to the invention,
[0018] FIG. 7 shows an enlarged view of the sprue bush of FIG. 6 ,
[0019] FIG. 8 shows a plan view of the main face or separation face in relation to the lower part of the sprue bush upper part of FIGS. 6 and 7 , and
[0020] FIG. 9 diagrammatically shows the structure of a machine nozzle according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The largest proportion by volume of dust-bearing gas is produced in the plasticization operation in the injection molding machine itself so that it is advantageous if that dust-bearing gas from the injection molding machine can already escape from the flow lumen before the plastic material enters the hot runner system. In that way the gas pressure in the flow lumen of the hot runner system is reduced, that is to say decompression takes place.
[0022] In a preferred embodiment of the invention the transfer element has a substantially hollow-cylindrical main body having an inner peripheral surface and an outer peripheral surface, wherein the degassing device has at least one gas-permeable passage connecting the inner peripheral surface and the outer peripheral surface. The gas can escape from the transfer element by way of that passage before the gas passes into the hot runner system so that substantially no dust can be deposited in the hot runner system.
[0023] Preferably the sprue bush is screwed at its hot runner end to the hot runner system while the machine end of the bush is held in centered relationship by a centering ring in an opening in the plate. In that respect it is particularly advantageous if the gas-permeable passage opens in a region of the outer peripheral surface which is arranged displaced towards the injection molding machine outside the centering ring of the sprue bush. In that way the dust can escape without being deposited at functional elements of the hot runner system.
[0024] In a particularly preferred embodiment the main body of the transfer element is at least of a two-part structure comprising an upper part and a lower part which are substantially hollow-cylindrical and each have at least one main face, wherein the upper part and the lower part are so arranged that their main faces preferably concentrically butt against each other. Such a configuration of the main body of the sprue bush is advantageous as it makes it possible for the passage to be arranged in the separation plane between the upper and lower parts of the main body so that the passage or parts thereof can be produced by grinding it free in the main face of the upper and/or lower part of the main body.
[0025] In practice the diameters of the sprue bushes of the hot runners are typically so selected that they match the diameter of the machine nozzle of the injection molding machine for which the hot runner system is provided. If a different hot runner system is to be used on the same machine at a later time, then in the systems known from the state of the art the machine nozzle or the entire sprue bush of the hot runner system which is to be newly employed has to be replaced, which is complicated and expensive, in order to ensure functioning of the combination of the injection molding machine and the hot runner system. In comparison the two-part structure of the main body according to the invention has the advantage that the upper part of the sprue bush can be easily exchanged and can serve as an adaptor to permit connection of the sprue bush of a hot runner of any dimension to a predetermined machine nozzle.
[0026] In that case it is desirable if the main face of the upper part and/or the lower part has a free-ground clearance so that at least one gap is formed between the main faces, which at least as a portion of a gas-permeable passage connects the inner peripheral surface and the outer peripheral surface of the sprue bush.
[0027] In that respect the term free-ground clearance is used to denote a region of small depth, which is recessed out of the main face of the lower or upper part, being produced for example by grinding or milling.
[0028] It is crucial in terms of the mode of operation of the degassing device that in the radial direction it has at least one portion which is permeable for the gas while the plasticised plastic material cannot issue through that portion. For that purpose the lumen of that portion which in the present application is referred to as the free-ground clearance must be of a very small gap width at least in one direction. Such a gap is of a small dimension at least in a direction parallel to the axis of the transfer element, that is to say parallel to the through-flow direction, or it is of a small dimension in the peripheral direction. In that respect the reference to a small dimension is used to mean preferably a gap width of less than 0.04 mm, particularly preferably 0.03 mm.
[0029] Such a free-ground clearance can be produced in particular of very small depths in the axial direction. The gap formed by a clearance of small depth permits gas to escape without the plastic material being able to escape through such a gap of the sprue bush or the machine nozzle. In that respect a depth for the clearance of less than 0.04 mm and particularly preferably a depth of about 0.03 mm has proven to be advantageous. Such a design configuration permits the escape of a sufficiently large amount of gas while nonetheless no plastic material can issue from the transfer element.
[0030] In that respect it is sufficient if the free-ground clearance of the preferred small depth forms the gas-permeable passage only in the region directly adjoining the inner peripheral surface of the main body while the gas passing through the gap is guided further radially outwardly by a passage of larger cross-section or a groove as the small dimension of the degassing passage is required only in the interior of the main body to prevent the plasticised plastic material from also issuing from the transfer element.
[0031] A preferred length for the free-ground clearance in the radial direction is between 2 and 3 mm, particularly preferably being 1.5 mm.
[0032] In a particularly preferred embodiment the free-ground clearance in the main face of the upper and/or lower part is so arranged that a plurality of gas-permeable passages are formed distributed over the periphery, the passages connecting the inner and outer peripheral surfaces of the main body. In that respect it is particularly advantageous if the individual passages which are at least partially formed by the free-ground clearance are distributed in a star form in the peripheral direction of the transfer element so that gas discharge is possible in all directions.
[0033] In a particularly preferred embodiment the free-ground clearance has a substantially circular region which adjoins the inner peripheral surface and which is continuous in the peripheral direction. In such a circular gap gas can issue from the plastic material in all radial directions and can be discharged from the transfer element.
[0034] In that respect in an embodiment the connection between the gap formed by the free-ground clearance and the outer peripheral surface of the main body can be made by one or more regions with a free-ground clearance.
[0035] Alternatively or additionally there can be provided bores or grooves which extend in the radial direction and which outwardly vent the circular free-ground clearance. The grooves or bores are of a diameter which is larger than the depth of the free-ground clearance. In that way, through bores or grooves involving a lesser consumption of surface area in the peripheral direction, it is possible to discharge the same amount of gas or a larger amount of gas, than through comparable free-ground clearances, in a radial direction. In that way therefore a larger contact surface is afforded between the upper part and the lower part of the sprue bush.
[0036] In a further embodiment the peripherally extending free-ground clearance is concentrically surrounded by a degassing groove which is of a larger flow cross-section than the free-ground clearance and which serves to collect the outflowing gas. The gas which issues from the clearance into the peripherally extending degassing groove is guided in the groove to radially extending passages connecting the groove to the outer peripheral surface of the bush.
[0037] In a particularly preferred embodiment the upper part and/or the lower part has dowel pins which project from the main face and which engage into bores provided for same in the main face of the respective other part. It is possible in that way to provide for exact assembly of the upper and lower parts of the main body.
[0038] Alternatively precise assembly of the upper and lower parts in that way can be achieved by the provision of a mating diameter on the upper and lower parts. With such a mating diameter a portion of the one part which is of an inside diameter that is equal to the mating diameter and a portion of the other part having an outside diameter which is equal to the mating diameter engage into each other and center the parts which are fitted together.
[0039] In a further embodiment the main body of the transfer element has more than two parts which are substantially hollow-cylindrical and each have at least one main face, wherein the main faces of two parts at least portion-wise butt against each other, wherein a respective one of the mutually butting parts forms an upper part and the other forms a lower part in accordance with this invention. In that way as described hereinbefore degassing passages for the transfer element can be provided in the butting or separation regions between the parts in more than one plane.
[0040] The present object is also attained by a hot runner system having a sprue bush having the above-described features and by an injection molding machine having a machine nozzle having the above-described features.
[0041] Further features, advantages and possible uses of the present invention will be apparent from the accompanying Figures and the description relating thereto.
[0042] FIG. 1 shows a sprue bush 1 for a hot runner system from the state of the art. In that case the sprue bush 1 is let into the cover plate 2 of the hot runner system and opens into the hot runner block 3 . The sprue bush 1 has a main body 4 which is of a substantially hollow-cylindrical shape, with an outer peripheral surface 5 and an inner peripheral surface 6 . The hollow-cylindrical main body 4 of the sprue bush 1 is annularly surrounded by heating elements 7 so that the fluid plasticised plastic material does not cool down in the main body 4 of the sprue bush 1 .
[0043] The main body 4 of the sprue bush 1 is screwed at its runner end to the hot runner distributor by means of a flange 27 while the machine end of the main body 4 is held in centered relationship in a suitable opening in the hot runner cover plate by means of a centering ring 8 screwed to the hot runner cover plate 2 .
[0044] FIG. 1 , besides the sprue bush 1 , shows a further transfer element, namely the tip of a machine nozzle 9 . The machine nozzle 9 and the main body 4 of the sprue bush 1 of the hot runner system butt against each other in such a way that a flow of plasticised plastic material 10 can pass without loss from the machine nozzle 9 into the main body 4 of the sprue bush 1 . For that purpose at its upper machine end the main body 4 of the sprue bush 1 has a concentric sealing surface 11 . In this case the sealing surface 11 is curved. The machine nozzle 9 also has at its front tip a concentric sealing surface with a curvature. In this case the curvature of the sealing surface 12 of the machine nozzle 9 is greater than the curvature of the sealing surface 11 of the main body 4 of the sprue bush 1 . Therefore, when the two transfer elements 4 , 9 come into engagement with each other, a line-shaped seal is afforded with a high level of sealing integrity between portions of the sealing surfaces 11 , 12 .
[0045] In following FIGS. 2 through 4 showing a preferred embodiment of the present invention the components identical to the sprue bush 1 and the machine nozzle 9 in FIG. 1 are respectively indicated by the same references.
[0046] In the sprue bush 1 according to the invention as shown in FIG. 2 the main body 4 is made up from an upper part 4 a and a lower part 4 b. In this case provided in the butting junction region 15 between the upper part 4 a and the lower part 4 b of the main body 4 is a passage for degassing of the flow lumen formed by the inner peripheral surface 6 of the main body 4 . That passage in the butting region 15 is of such a configuration that its gap width allows gas or dust to pass therethrough while the plasticised plastic material 10 cannot leave the main body 4 of the sprue bush 1 .
[0047] It can be clearly seen from FIG. 2 that the butting region 15 between the upper part 4 a and the lower part 4 b of the main body 4 is arranged above the centering ring 8 in the main body 4 of the sprue bush 1 . In this arrangement the butting region 15 is displaced with respect to the centering ring 8 in the direction of the machine nozzle 9 . That avoids the dust issuing through the through passage being deposited in outside regions of the sprue bush in which it adversely affects operation of the sprue bush.
[0048] FIG. 3 shows a view from below onto the main face 16 of the upper part 4 a of the main body 4 of the sprue bush 1 . The main face 16 of the upper part 4 a has a free-ground clearance 17 which, in relation to the faces 16 which come into engagement with the main face 18 of the lower part 4 b, involves a difference in height of 0.03 mm. When the upper part 4 a and the lower part 4 b of the main body 4 are screwed together, then the free-ground clearance 17 results in the provision of a system of passages, which permits degassing of dust from the flow lumen 18 of the main body 4 .
[0049] In the illustrated embodiment the clearance 17 has an annular region 19 which directly adjoins the inner peripheral surface 6 of the main body so that the gas can escape from the flow lumen 20 in all directions.
[0050] In the view onto the main face of the upper part 4 a in FIG. 3 it is also possible to see end bores 20 , 21 . In that arrangement the bores 20 of larger diameter serve to receive centering pins 22 while the bores 21 of smaller diameter are provided for passing fixing screws 23 therethrough.
[0051] Screwing and centering of the upper part 4 a and the lower part 4 b of the main body 4 can be clearly seen in the isometric view in FIG. 4 . While centering pins 22 are received in centering bores 24 in the lower part 4 b and centering bores 20 in the upper part 4 a the fixing screws 23 engage through the bores 21 in the upper part 4 a and are screwed into the screwthreaded bores 25 in the lower part 4 b. The screw means and the high pressing force 28 with which the machine nozzle 9 is pressed against the sprue bush 1 provide that the parts 16 of the main face of the upper part 4 a, that project with respect to the clearance 17 , are pressed in force-locking relationship against the main face 18 of the lower part 4 b so that only the passages afforded by the clearance 17 permit degassing of the flow lumen 18 .
[0052] FIG. 5 shows a plan view of the main face of an upper part 4 a ′ of an alternative embodiment of the sprue bush 1 according to the invention. Like the above-described embodiment the main face 16 ′ of the upper part 4 a ′ has a circular free-ground clearance 19 ′ directly adjoining the flow lumen 26 of the upper part 4 a ′. Degassing of the clearance is effected by way of four degassing grooves 29 arranged in a star form around the flow lumen 26 . In this arrangement the degassing grooves 29 are of a diameter greater than the depth of the clearance 19 ′. It is found to be advantageous in this variant that it provides a larger contact face between the upper part ( 4 a ′) and the lower part of the sprue bush.
[0053] FIGS. 6 through 8 show a particularly preferred embodiment of the invention in which the upper part 4 a ″ and lower part 4 b ″ of the main body of the sprue bush have a mating diameter for centering of the upper part 4 a ″ and the lower part 4 b ″. By means of such a mating diameter it is possible to absorb high lateral forces which can occur for example due to lateral displacement between the sprue bush and the machine nozzle. For that purpose the lower part 4 b ″ has an axially projecting portion 34 whose outside surface 30 is of the same or a slightly smaller diameter than the inside surface 31 of the end 35 of the upper part 4 a ″, that is towards the hot runner. After assembly of the upper part 4 a ″ and the lower part 4 b ″ the axially projecting portion 34 of the lower part 4 b ″ engages into the hot runner end of the upper part 4 a″.
[0054] The configuration of the degassing device is shown in detail in FIG. 7 illustrating an enlarged view of part of the assembled elements of FIG. 6 . It is possible to clearly see a circular free-ground clearance 19 ″ in the main face of the upper part 4 a ″, by which a degassing gap is provided in the butting or separation plane 15 ″ between the upper and lower parts after assembly of the upper part 4 a ″ and the lower part 4 b ″. The clearance 19 ″ opens in the radial direction into a peripherally extending annular degassing groove 32 concentrically surrounding the clearance 19 ″. There the gas escaping from the flow lumen of the sprue bush is collected and is discharged from there outwardly by way of degassing bores 33 which extend in the radial direction and which are distributed in a star form around the periphery of the bush.
[0055] FIG. 8 shows by way of explanation a view from below onto the main face of the upper part 4 a ″. It is possible to clearly see the concentric arrangement of the clearance 19 ″ and the peripherally extending degassing groove 32 . This Figure also clearly shows the arrangement of the four radial degassing bores which are arranged at 90° relative to each other and which open into the peripherally extending degassing groove.
[0056] FIG. 9 show a diagrammatic view corresponding to FIG. 2 to illustrate the arrangement and cooperation of a machine nozzle and a sprue bush. In this case, contrary to FIG. 2 , it is not the sprue bush but the machine nozzle that is of a two-part configuration so that the degassing device is provided in the machine nozzle. The main body 9 of the machine nozzle comprises an upper part 9 a and a lower part 9 b, wherein the nozzle upper part in the illustrated embodiment has a free-ground clearance in its main face 36 . A plan view onto the main face of the machine nozzle upper part 9 a shows, apart from suitably adapted radii, the same structure as the main face of the sprue bush upper part in FIG. 3 , with the same functionality as described hereinbefore for the sprue bush. All other configurations of the degassing device for the sprue bush can also be transferred to the machine nozzle.
LIST OF REFERENCES
[0057] 1 sprue bush
[0058] 2 cover plate
[0059] 3 hot runner block
[0060] 4 hollow-cylindrical main body
[0061] 4 a, 4 a ′, 4 a ″ upper part of the main body of the sprue bush
[0062] 4 b, 4 b ′, 4 b ″ lower part of the main body of the sprue bush
[0063] 5 outer peripheral surface
[0064] 6 inner peripheral surface
[0065] 7 heating element
[0066] 8 centering ring
[0067] 9 machine nozzle
[0068] 9 a upper part of the machine nozzle
[0069] 9 b lower part of the machine nozzle
[0070] 10 plastic material
[0071] 11 sealing surface of the sprue bush
[0072] 12 sealing surface of the machine nozzle
[0073] 15 , 15 ″ butting plane
[0074] 16 , 16 ″ main face of the upper part
[0075] 17 free-ground clearance
[0076] 18 main face of the lower part
[0077] 19 , 19 ′, 19 ″ circular region of the free-ground clearance
[0078] 20 bores in the upper part
[0079] 21 bores in the upper part
[0080] 22 dowel pins
[0081] 23 fixing screws
[0082] 24 bores in the lower part
[0083] 25 screwthreaded bores
[0084] 26 flow lumen
[0085] 27 flange
[0086] 28 machine nozzle pressing force
[0087] 29 degassing groove
[0088] 30 outside surface with mating diameter
[0089] 31 inside surface with mating diameter
[0090] 32 peripherally extending degassing groove
[0091] 33 radial degassing bore
[0092] 34 projecting portion
[0093] 35 hot runner end of the upper part 4 a″
[0094] 36 main face of the upper part 9 a of the machine nozzle | The present invention concerns a transfer element ( 1, 9 ) for an injection molding system comprising a flow lumen for a plasticised plastic material. To provide a transfer element for an injection molding system, which makes it possible to further increase the material throughput of the injection molding system without having to tolerate increased wear of seals and other system components, it is proposed in accordance with the invention that it has a device for degassing of the flow lumen. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for the ejection of water from a running felt loop in a paper machine.
2. Description of the Related Art
In traditional devices, water is sucked out of the felt by the application of vacuum to one side of the felt and the purging action of a stream of air entering the other side of the felt. The water is thus conveyed into stationary suction slots or suction holes of a rotating suction roll.
According to another method, the water can be squeezed out by compressing the felt in a press nip. A so-called wringer press serving this purpose is very expensive, consumes a considerable amount of energy, and reduces the service life of the felt. For these reasons, wringer presses are rarely found in today's paper machines.
With the introduction of synthetic needle felts, through-purging with air has become the common method of felt dewatering in all cases where the water cannot be removed directly in the press nip. In this latter case, however, the press rolls must be fitted with special devices for holding the water at the nip exit, making the press rolls expensive and complex.
These rolls supporting the felt can be designed as suction rolls with a perforated rotating shell, or as grooved rolls with grooves of 2.5 to 5 mm depth and 0.5 to 1 mm width on their outer periphery. In the case that the press roll supporting the felt is a shoe press roll, no suction can be applied because the rotating flexible press sleeve must be unperforated in order to form a lubricant film on the pressing shoe.
Because of the special properties of its material, the press sleeve cannot be made very thick or hard. Therefore, only relatively shallow grooves of maximally 1.5 mm depth or blind drilled holes of 2 mm depth can be incorporated into the outer surface. This results in a limited water storage and removal capacity of these press sleeves that cannot be extended to meet the demands of many pressing applications. Therefore, some water must still be removed from the felt by air purging, demanding high permeability felts. Felts of higher permeability, however, include coarse fibers that mark or "emboss" the surface of the paper in a detrimental way and lead to an increased water reabsorption at the press nip exit back into the paper. If, on the other hand, the felt is made sufficiently fine-pored in order to produce an optimally smooth paper surface and to avoid water reabsorption, the concept of air purging will fail.
SUMMARY OF THE INVENTION
The present invention provides a system that allows the dewatering of a felt with an optimized fine surface on its paper side by simple devices to a sufficient degree. This dewatering shall happen in a linear or slightly curved stretch of the felt run, free of rolls that deflect the felt by a substantial angle.
The dewatering of the felt is effected by leading a current of purging gas against the inside surface of the felt loop. The current of purging fluid tears water loose from the inside surface or out of cavities or interstices in the carrier layer of the felt. The water is then conveyed into receptacles located inside the felt loop.
This mode of dewatering is possible in the case wherein the felt possesses good water storage and water release properties at its inside surface. A felt loop can be composed of a carrier layer that contains cavities, interstices and openings at its inner surface. To the outside of the carrier layer is a bat of fine fibers which is needled, with the bat fibers which are drawn into the cavities of the carrier layer being post-treated for reduction of free fiber surface in the cavities. The carrier layer may be a multi-layer plastic fabric.
The purging current is a flow of gas, normally air. For a satisfactory effect, it is important to direct the purging current in such a way that it removes as much water as possible at a given flow rate. This condition is brought about by a purging device that forces the total flow to pass through the base layer of the felt.
This is effected by placing one or more purging nozzles against the inside of the felt in such a way that the felt is gliding over the lips that surround the nozzles. If the purging nozzles are evacuated, ambient air is drawn over the lips through the permeable carrier layer of the felt and into the nozzles. This air tears loose and carries away water stored in the interstices and cavities of the carrier layer of the felts and makes them free for storage of additional water during the next nip passage.
Because acceleration and conveyance of water and air in the carrier layer is causing resistance to flow, it is advantageous to make the lips narrow in order to effect good drainage with a reasonably small pressure differential. Lip width, therefore, is in the range of 10 mm or less, preferably 2 mm to 10 mm and typically 5 mm.
When using purging nozzles oriented in the cross machine direction, the relative velocity of the purging fluid in the felt must be equal to or higher than the felt running speed. This leads to very high vacuum requirements in the nozzle and hence the high vacuum pump drive power. An additional negative effect is abrasion of the nozzle block and of the felts.
For the above reasons, the vacuum slots and purging nozzles are oriented totally or predominantly in the felt running direction. In this embodiment, the felt can be dewatered with a fairly small pressure differential up to the very highest machine speeds. The dewatering is most effective at an angle of inclination from 0 to 10°, preferably 0 to 5°, and more preferably between 0.5° and 2°, between the longitudinal direction of the slots and purging nozzles and the direction of felt travel.
Narrow longitudinal slots can be filled up with dirt much easier than one wide cross machine slot. Therefore, a retraction or swiveling device is advantageous that brings the gliding surface of the nozzle block into a position that facilitates the cleaning of the slots without obstruction by the felt.
According to another embodiment, special cleaning nozzles are directed into the suction slots to enable the continuous or discontinuous cleaning of the slots with pressurized water.
The cleaning of the total purging unit can be continuous, but the individual cleaning nozzle in the suction slot may spray in a sequential pattern. This behavior may be effected by arranging a multitude of cleaning water supply zones across the machine width and activating them in a sequential manner, so that only one zone at a time is active. Alternatively, an oscillating gate bar at the entrance of the nozzles can contain ports that open and close the nozzle entrances when the bar is oscillated in cross machine direction.
An oscillating internal shower pipe with fan nozzles may be useful for moistening and cooling the gliding surface of the nozzle block and for cleaning the cavities within the carrier layer. For this latter purpose, needle shower pipes are exceptionally useful.
In the press nip, the bat layer is compressed and, because of the visco-elastic behavior of the bat fibers, does not recover to its original thickness at once at the nip exit, but rather creeps slowly back during the return run in the felt loop. During this phase of bat expansion, a portion of the water expressed into the carrier layer is sucked back into the bat. It is, therefore, advantageous to place the felt purger as near as possible to the press nip exit, preferably no farther away than one quarter of the total felt length in order to maximize the purging effect.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of one embodiment of a felt purger of the present invention along line I--I in FIG. 2;
FIG. 2 is a top view of a segment of the felt purger of FIG. 1;
FIG. 3 is a cross-sectional view of another simplified embodiment of a felt purger;
FIG. 4 is schematic, side view of one embodiment of a felt return run of a press section including the felt purger of FIGS. 5 to 7;
FIG. 5 is a cross-sectional view of yet another embodiment of a felt purger, with suction slots oriented in the felt running direction;
FIG. 6 is a longitudinal, sectional view of the felt purger of FIG. 5 along line VI--VI;
FIG. 7 is a top view of the gliding surface of the felt purger of FIGS. 5 and 6;
FIG. 8 is another embodiment of the slot pattern of FIG. 7;
FIG. 9 is a schematic, side view of another embodiment of a press section including felt purgers applied to felts;
FIG. 10 is a fragmentary, side, cross-sectional view of a variation of the felt purger of FIG. 5;
FIG. 11 is a top, sectional view of the felt purger of FIG. 10 along line XI--XI;
FIG. 12 is a cross-sectional, side view of a modification of the felt purger of FIG. 10 with sliding bar type cleaning water distribution; and
FIG. 13 is a top, sectional view of the sliding bar of FIG. 12.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and particularly to FIG. 1, there is shown a segment of a running felt loop 1. The running direction may be from left to right or vice versa. The felt 1 is composed of a carrier layer 3, containing larger cavities and a bat layer 2 of fine fibers bonded to it. A nozzle block 5 is fixed with screws 6 and clamps 7 to a tubular suction conduit 4.
Water and purging air is drawn out of the carrier layer 3 and into conduit 4 through suction slot 8, passages 9, groove 10 and passages 11. The water and purging air is passed on through an exhaust pipe (not shown) to the suction side of a pump or blower. On both sides of the suction nozzle 8 there are air supply slots 12 connected by passages 13 to the ambient atmosphere.
Because the lips 14 on both sides of suction slot 8 are too narrow to give the felt 1 sufficient support, the nozzle block 5 is made wide enough to provide additional support for the felt 1 on faces 15 outside the air supply slots 12. In FIG. 2 the components are identified with same reference numbers as in FIG. 1. Felt 1 is not shown for reasons of clarity. Evacuation of conduit 4 is effected in direction of arrow 16 to the end of the conduit 4 (not shown) where it connected into a vacuum line.
FIG. 3 also shows a small horizontal segment 1 of a running felt loop with bat layer 3 and carrier layer 2 sliding over a nozzle block 25 from left to right or vice versa. The nozzle block 25 is keyed to T-bar 26 which is part of a suction or blow box 24. The interior 33 of box 24 is connected to slotted nozzle 30 via passages 27 and grooves 28 inside the T-bar and holes 29 in the nozzle block 25. The slot 30 is separated from the ambient atmosphere by a sharp-edged lip 31 to the right that may or may not touch the felt 1. To the left of the nozzle slot 30, the felt 1 may be supported by the face 32 of nozzle block 25. The nozzle block 25 extends in cross machine direction over the full width of the felt 1.
The flow of purging air, as indicated by arrows for the example of vacuum in conduit 24, is conducted over the edge 31, through the base layer 2, into slots 30, through holes 29, groove 28 and passages 27, and into the chamber 33.
In FIG. 4, a felt 111 is guided in the direction of the arrows over felt rolls 115 to a felt purger 101 and over its supporting surface 109. An internal shower pipe 100 cleans or moistens the inside surface of the felt loop 111 and an external shower pipe 116 cleans and moistens the outside surface of the felt loop 111. A scraping blade 118 is fastened to cross machine beam 117 and removes surface contaminations from the felt 111.
The felt purger 101 is composed of a suction box 107 extending over the width of the machine to which a nozzle block 105 is fastened by clamping bars 106.
For purging water out of the carrier layer 113 of felt 111, the suction box 107 is connected to a vacuum source (blower or pump) via vacuum line 119. Air is drawn from the longitudinal air supply slots 110, through the carrier layer 113 of felt 111, into suction slots 104, through passages 108 and 103, and into suction box 107.
The felt purger 101 is more closely described in FIGS. 5, 6 and 7 using the same reference numbers of identification. FIG. 5 is only an enlarged cross-sectional view of the air purger 101 of FIG. 4. It is visible that the bores 108 extending from bores 103 terminate at a depth at which they intersect with suction slots 104 but do not meet the air supply slots 110. This relation is even more clearly visible in FIG. 6. Each bore 108 connects into several suction slots 104. The felt 111 has a coarse air and water permeable carrier layer 113 through which air is drawn from the air supply slots 110 past the partition bars 112 into the suction slots 104 as indicated by arrows 114.
This flow pattern is also shown in FIG. 7 in top view. For clarity's sake, the felt is not shown. If the felt purger 101 is fitted into the press section with its axis extending in cross machine direction, the air supply slots 110 and the suction slots 104 extends parallel to the felt running direction, indicated by arrow 120. By a rotation of the felt purger 101 about an axis substantially perpendicular to felt 111, the direction of felt run 120' is no longer parallel to the slots 104 and 110. The direction of felt run 120' forms an angle of inclination "X" with each of slots 104 and 110. With such an inclination, the dewatering by air purging through the carrier layer 113 of the felt 111 becomes more effective and more uniform across the width of the felt 111. The same effect can be achieved according to the alternative shown in FIG. 8. In this embodiment, the longitudinal axis of the felt purger 101 runs at right angles to the direction of felt travel 120' and only the longitudinal direction of the slots 104 and 110 is inclined by an angle "X" relative to the direction of felt travel 120'.
FIG. 9 is a simplified view, omitting the machine frames. A top felt run 201 with top felt 204 and a bottom felt run 202 with bottom felt 205 pass through the common press nip 203. The press nip 203 is formed between an upper press roll 206 which is characterized as a shoe press roll by press shoe 207, and a bottom press roll 208, the surface of which may contain grooves or blind drilled holes. The felts 204 and 205 are guided by felt rolls 209, stretch rolls 210 and felt guide rolls 211.
The top felt 204 is carried by a suction pickup roll 212 that transfers a paper web from a belt 213 to the top felt 204 which, in turn, conveys the web into the press nip 203. The paper web is carried away from the nip 203 by the bottom felt 205 and is transferred by suction roll 214 to belt 215. Within the loop of felt 204 there is a felt purger 216 which contacts the felt 204 in operation. Felt purger 216 can be rotated into position 216' for cleaning.
Inside the loop of the felt 205 there is a felt purger 217 contacting felt 205. For cleaning purposes it can be retracted into position 217'. The distances 218 and 219 of the felt purgers 216 and 217 from the press nip 203 are smaller than 25% of the lengths of the respective felts 204 and 205.
In FIG. 10, a felt purger 101 is shown as in FIG. 5, including a nozzle block 105 and a suction box 107, connected by clamps 106. Clamp 106 is fastened to the suction box 107 by screws 121 and 122 and encloses, together with nozzle block 105 and suction box 107, a water chamber 123 that can be supplied with cleaning water through feed pipes 124. The water chamber 123 feeds cleaning water through cleaning nozzles 125 into the crescent-shaped suction slots 104 in order to flush off solid matter that may have accumulated there in the course of time.
In order to avoid an excessive flow of water during the cleaning cycle, it is of advantage to sub-divide the water chamber 123 as shown in FIG. 11 into a number of sections 123' that are sequentially fed with cleaning water through feeding pipes 124'. If there are 10 sections 123' provided across the felt width and only one section 123' is activated at a time, the necessary flow rate of cleaning water is reduced to 1/10 of that necessary with a continuous chamber 123.
FIG. 12 is another modification to FIGS. 5 and 10 with a suction box 107 to which a nozzle block 105 is fastened by use of clamping bars 106 and screws 121 and 122. At least one clamping bar 106 (shown at left) together with nozzle block 105 and suction box 107 encloses a water chamber 123 with water supply lines 124. Cleaning nozzles 125 lead from the water chamber 123 into the suction slots 104. In front of the entrances of the nozzles 125 there is a sliding bar 126 with ports 127 which can be brought into line with the entrances of the nozzles 125 by moving the bar 126 in a horizontal or cross machine direction. The spacing of the ports 127 is arranged in a way that opens and closes the entrances of the nozzles 125 when the bar 126 is oscillated in cross machine direction. Thus, all nozzles 125 are sequentially supplied with cleaning water.
In FIG. 13, one example of the placing of the ports 127 in the bar 126 is shown. By use of this spacing, all suction slots 104 can be cleaned with an equal amount of water. If the spacing of the ports 127 is chosen to be 9/4 of the spacing "T" of the cleaning nozzles 125, only every ninth cleaning nozzle 125 is simultaneously supplied with water. If the stroke "H" of the oscillating bar 126 is twice the distance "T" of neighboring nozzles 125, the maximum water flow is 1/9 of that of the arrangement shown in FIG. 10. This flow is substantially equally distributed to all nozzles 125. Thus, cleaning nozzles 125 are sequentially operable and each cleaning nozzle 125 is discontinuously operable.
The flow of water during a cleaning period can be reduced even further by increasing the distances between the ports 127 in bar 126.
If only every n-th nozzle 125 is fed water, the width of the port 127 is chosen T/4, and the distance from port 127 to port 127 is chosen xT+1/4 T, then the following relations exist: n=4x+1 and stroke H=xT.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | An apparatus for the dewatering of a traveling press felt carries a purging fluid to the inside surface of the felt loop. The purging fluid flushes water from the felt into receptacles inside the felt loop. Purging nozzles oriented in the cross machine direction, or a multitude of suction slots oriented in the running direction, may be used. The nozzles or slots are incorporated into a nozzle block that is fastened to a suction box or a blow box. | 3 |
This is a continuation of application Ser. No. 08/361,380, filed Dec. 22, 1994 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to film material for packaging products wherein the film material comprises a two layer system, an inner layer of oxygen permeable material and an outer layer or "barrier layer" of oxygen impermeable material. The invention is particularly adapted for packaging meat wherein the oxygen impermeable layer can maintain a controlled atmosphere within the package and thereafter be delaminated to allow oxygen to permeate the packaging at the time of display.
Once slaughtered and cut, fresh meat has very limited time to be packaged, displayed, and sold without the introduction of a change in the atmosphere in which it is kept. This atmosphere, if shelf life is to be extended, must retard the growth of bacteria and therefore, deny the meat oxygen in most bacteria grows. By denying the product oxygen, the myoglobin in the meat cannot generate color; the myoglobin chemically requiring oxygen to achieve a fresh, natural appearing color.
In the past, if fresh meat or poultry products are to be in distribution or storage longer than a very few days, they must have been either vacuum packed, or frozen, or packed in a high oxygen modified atmosphere. Vacuum packaging does achieve extended shelf life, but its denial of oxygen from the meat causes the myoglobin in the meat to remain inactive, not able to produce the natural red color of fresh meat, or the natural color of other meats and poultry. In the absence of oxygen, meat turns purple or an unnatural color that is not appealing to consumers. Thus, while extending shelf life, because of the customer's preference for the natural color, this packaging acts as a deterrent to the product's sale and acceptance.
Known modified atmosphere high oxygen packages provide some extension of shelf life with an acceptable color for a time period, but in this atmosphere that allows for the proper color, there are also the natural microbiological processes at work. Bacteria, although initially retarded, accelerate and grow quickly causing mold and decay. Also, the myoglobin in the presence of oxygen becomes oxymyoglobin for good color, and then turns darker in a short time to become metmyoglobin which is an irreversible decay of the product.
In known processes, the product is loaded into an oxygen impermeable tray, flushed with a storage gas to give a good holding atmosphere, then an impermeable lid is applied and the product is sent into distribution. In one application, when the product is ready for display, a septum is placed on the lidding by a special machine, which through the puncture of the lid through the septum, exchanges the existing atmosphere, with one with oxygen that regenerates the color for display. Because of special equipment, additional gas, additional handling and the septum, this process raises the cost of the product significantly.
In another known system, the product is placed in a special tray with an impermeable coating and which has an inner permeable lidding and a dome lid sealed on the tray. The package and the dome are flushed with a storage gas, and at the point of display, the domed lid is removed, leaving the inner lidding and the tray. The product blooms back upon the introduction of oxygen through the inner lidding. In this case, the cost of the special tray, the doomed lid, the process and handling causes the price to be substantially raised to the customer. It is also difficult to pack and store these packages because of the domed lid.
In another system, a package, designed to extend the shelf life of fresh meat and poultry during distribution and storage, is then altered at the time of display, by the removal of a top layer of impermeable film which allows oxygen to penetrate a remaining permeable lidding and cause the meat or poultry to be chemically restored to a fresh color. This type of package has been designed accordingly for fresh meat and poultry to achieve the combination of extended shelf life, fresh red color and desirable retail appearance at a competitive cost. U.S. Pat. Nos. 3,713,849; 4,055,672; 3,574,642; 4,956,212 and 4,886,690 describe these type systems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a combination of impermeable and permeable lidding materials that when sealed to an impermeable tray or pouch can contain and preserve the proper atmosphere to store fresh meat and poultry for extended periods, and that the impermeable layer can be peeled away easily at the time of display, leaving the permeable layer in place; the permeable layer allowing oxygen to change the atmosphere, so as to make the meat color fresh and attractive and sellable at a competitive price. The impermeable layer can be peeled from the permeable layer by grasping the excess film outside the seal that occurs on a preforming tray machine, or a film tab die cut from the seal area on a form, fill and seal machine.
It is another object of this invention that the process described above may be accomplished with a minimum of expense, without additional equipment or supplies other than the standard equipment used for modified atmosphere packages.
Another object of this invention is to be able to apply this lidding material either on preformed trays with the appropriate equipment, and also on gas flush horizontal form, fill and seal machines.
It is an object of the invention to provide a cost effective method of manufacturing using a coextrusion method for forming a laminate lidding then bonding to an impermeable layer and winding into a roll, or combining with a separate permeable layer and either double winding or applying directly to trays.
Another object of the invention is to be able to produce this lidding material from a number of known plastic films and adhesives.
It is also an object of the invention to produce pouches with a peelable film that would allow the product to be loaded into the pouch, or a tray that can be inserted into a pouch, then the pouch filled with the storage gas without oxygen, sealed and stored until display is desired, and a barrier (impermeable) film peeled off to allow the meat to bloom.
The objects of the invention are achieved with an inventive laminate and method of laminating a lidding. The outside oxygen barrier film can be a PVDC (vinylidene chloride copolymer also known as "saran") coated polyester adhesively laminated to a polyethylene coextrusion including a light gauge layer of easy peel polyethylene with anti-fog or like materials. This outside barrier layer can also be an uncoated polyester adhesively laminated to an EVOH (ethylene-vinyl alcohol copolymer) coextrusion with a peel seal layer and anti-fog.
Typically, the inner side of the outside barrier film can be a coextrusion of a support layer of LDPE (low density polyethylene), a tie layer, and an easy peel layer made from LDPE, such as 105.00 Exxon grade of 4% EVA such as 1403.00 Rexene grade or LLDPE (linear low density polyethylene) such as 11-P Novacore grade or varying grades of these, blended with polybutylene such as a number 0110 in a percentage of 15-25%, the amount varying to control peel strength to the inner, permeable film. This polyethylene coextrusion is adhesively laminated to the saran coated polyester or other oxygen barrier material.
The inner film or oxygen permeable film may be a mirror image duplicate of the coextruded polyethylene layer described above, with anti-fog and UV additives included, with the peel seal side wound in contact with the peel seal side of the impermeable layer. Alternately, this permeable layer can be a monoextrusion or a coextrusion using higher permeable resins such as 12% EVA (ethylene/vinyl acetate copolymer) such as #3130 Dupont grade or 18% EVA such as #3165 Dupont grade or Metallocene type such as SLP-9042 Exxon grade with anti-fog and UV additives added.
There are many known films that may be used in the construction of this invention as long as the outside film has high barrier to oxygen and UV light and is able to be easily peeled away from a permeable inside sealant film with anti-fog and UV filters, and the inside film being heat seal compatible to the sealant that is used on the inside of the tray to be used to hold a product.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view through a tray package of the present invention;
FIG. 2 is a sectional view of the tray package of FIG. 1 with a portion of the lidding delaminated;
FIG. 3 is an enlarged sectional view of the lidding shown in FIG. 1;
FIG. 4 is a partial perspective view of an alternate embodiment pouch of the present invention;
FIG. 5 is a schematic flow diagram of a method of manufacturing the lidding shown in FIG. 3;
FIG. 6 is a schematic sectional view of the extruder and die shown in FIG. 5;
FIG. 7 is a schematic view of an alternate coextrusion die
FIG. 8 is a schematic elevational view of an apparatus of coextruding a portion of the materials of FIG. 3;
FIG. 9 is a schematic diagram of the method of manufacturing the lidding of FIG. 3;
FIG. 10 is a schematic view of an alternate method according to the invention;
FIG. 11 is a schematic view of a further assembling step according to the method of FIG. 10;
FIG. 12 is a further alternate assembling step of the invention; and
FIG. 13 is an enlarged sectional view of an alternate lidding.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 discloses a controlled atmosphere package 20 such as for containing a food product 22 having a semirigid tray 24 with a perimeter flange 26. The tray has an oxygen impermeable barrier sealant layer 28 attached to the inside of the tray by adhesive lamination, extrusion coating, or heat seal coating. Once the product 22 is placed within the tray 24, a lidding 30 is heat sealed around a perimeter region 32 to the barrier sealant layer 28 to effectively surround the product 22. The lidding 30 comprises an outer barrier film 36 which is oxygen impermeable, and an inner film 38 which is oxygen permeable. Particularly when the food product 22 is meat or poultry, it is advantageous to seal the product 22 within the container 20 in an oxygen depleted or gas treated atmosphere with the lidding, the barrier film 36 and the permeable inner film 38 sealed around the perimeter 32 to the sealant layer 28 secured to the tray 24. The heat sealed perimeter 32 can be common to both the barrier film 36 and the inner film 38, and the heat seal of both films can be undertaken simultaneously.
FIG. 2 shows the package 20 of FIG. 1 with the barrier film 36 partially lifted from the permeable film 38 with the seal 32 being separated between the barrier layer 36 and the permeable film 38. The seal 32 provides a "peel seal", that is, the seal easily pulls apart without rupturing either film 36, 38. The impermeable layer can be peeled from the permeable layer by grasping the excess film outside the seal that occurs on a preforming tray machine, or a film tab die cut from the seal area on a form, fill and seal machine.
FIG. 3 illustrates the preferred layering of the lidding 30. The barrier film 36 comprises a polyester layer 40 coated by a PVDC coating 42. This laminate 40/42 is adhesively secured by an adhesive layer 43 such as a urethane adhesive, or otherwise laminated, to a low density polyethylene support layer 44 which is coextruded with a tie layer or adhesive layer 45 and an "easy peel" polyethylene film 46. It is possible to eliminate the tie layer 45 and still achieve satisfactory results. Although a number of materials can be used for the tie layer 45, a Bynel #4003 HDPE blended adhesive layer is advantageous.
The low density polyethylene support layer 44 can be a resin such as 12% EVA (ethylene/vinyl acetate copolymer) such as #3130 Dupont grade or 18% EVA such as #3165 Dupont grade or Metallocene type such as SLP-9042 Exxon grade with anti-fog and UV additives added. The easy peel polyethylene film 46 can preferably be an LDPE 105.00 Exxon grade or 4% EVA such as 1403.00 Rexene grade or an LLDPE such as 11-P Novacore grade or varying grades of these, blended with polybutylene such as a #0110 in a percentage of 15-25%, the amount varying to control peel strength of the barrier film 36 to the permeable film 38. The permeable film 38 can be a mirror image of the coextrusion 44/46 having an easy peel polyethylene layer 48 coextruded with a tie layer 49 and a low density polyethylene support layer 50 as described above, the easy peel polyethylene layer 48 facing the easy peel polyethylene 46. Preferably the polyethylene layers have anti-fog and UV additives included.
Alternatively, the permeable film 38 can be a monoextrusion or a coextrusion using higher permeable resins such as 12% EVA, such as #3130 Dupont grade or 18% EVA such as 3165 Dupont grade, or Metallocene type such as SLP-9042 Exxon grade with anti-fog and UV additives added. In this case, the permeable film 38 can forgo the peel seal polyethylene film as described above, while maintaining adequate results.
Alternatively, the barrier film 36 can be uncoated polyester adhesively laminated to an EVOH coextrusion with a peel seal layer.
FIG. 4 illustrates the inventive concept in a pouch having a impermeable seal layer 28' on a back side thereof for holding the product 22 and a front oxygen permeable film 38' sealed to the layer 28' around a perimeter 32' to enclose the product. A barrier film 36' is applied to the permeable film 38' and heat sealed along the perimeter 32' to enclose the product 22 in an oxygen impermeable atmosphere until the barrier film 36' is peeled from the package 20'. The materials as described above for the sealant layer 28 and the barrier film 36 are applicable to the layers 28' and 36' respectively. The materials as described above with regard to the oxygen permeable film 38 are also applicable to the film 38'.
FIG. 5 shows an inventive method of forming the multi-layer extrusion structure of the present invention. In this method, a bubble technique is used.
The bubble can be made by any of the known techniques for extrusion of tubular plastic film. For example, as seen in FIGS. 5 and 6, the polymer is fed into an extruder wherein it is heated above the melting point of the polymer to cause the melting thereof. The extruder 60 may be provided with a jacketed chamber 62 through which a heating medium is circulated. The rotation of a screw 64 forces melted polymer through a die 66 which is provided with a central orifice 68 which in turn is connected to an air supply 69. The resultant tubing 70 is inflated by introducing air into the interior thereof. The inflated tubing 70 is drawn upwardly and interiorly through an air ring 72 by a pair of rotating squeeze rolls 74 in a collapsing frame which also serve to collapse the tubing and retain the air in that portion of the tubing between the squeeze rolls 74 and the die 66. Cooling air is supplied to the air ring 72 and passes therefrom through perforations onto the exterior surface of the tubing 70. The stream of cooling air constitutes a cooling zone serving to chill or set the expanding plastic tube to the desired temperature. The collapsed film is then drawn downwardly at an angle to a slitting station 75 where the folded edges are slit to form sheets. The sheets can then be reeled into a coil 76.
FIG. 7 shows a coextrusion die which can be inventively used to form the multi-layer lidding of the present invention. This die 110 provides coaxial annular passages 114, 116, 118 for producing a three layer coextruded tube 70. Three extruders 60, one for each passage 114, 116, 118 are required. The inner most annular die 114 can be, for example, the easy peel layers 46, 48 and the next layer 116 can be the tie layer or adhesive layers 45, 49 and the next layer 118 can be the LDPE support layers 44, 50. Thus, the easy peel layers 46, 48 are in facing relationship and the support layers 44, 50 are outwardly facing, as also arranged in the laminate of FIG. 3. This coextrusion 120 comprising the layers 44, 45, 46, 48, 49, 50 can then be rolled together and applied to a barrier layer or to trays from a single supply.
FIG. 8 illustrates the arrangement of the apparatus of FIG. 5. Three extruders 60 (one shown) are used communicating into the three coaxial chambers 114, 116, 118 of the die 110. The bubble 70 is formed between the die 110 and the collapsing frame rollers 74. The bubble is collapsed into the coextrusion 120 which progresses downwardly, supported on a rack 122 into the slitting station 75 where the lateral edges are slit to form stacked planar sheets. The sheets of the coextrusion 120 are then rolled together into the coil 76 or alternately directly after slitting, can be rolled into two coils 76, 76'.
FIG. 9 illustrates the further step of laminating the remaining outer layers to the laminate 120. The outer layers 40, 42, are laminated together in a prior known method such as a coating process to form an outer laminate 128 and coiled on a roll 130. The outer laminate 128 is coated with the adhesive layer 43 at an adhesive applying station 130a and is passed through an oven 131 to prepare the adhesive 43 (for driving off adhesive solvent). The resultant laminate 128a is drawn through a laminating station 132, having laminating rollers 134, 136, together with the coextrusion 120. The films 120, 128a are subjected to heat and pressure and bonded together and the completed lidding 30 is coiled on a roll 140. Alternately, the roll 140 can be replaced by a manufacturing line to directly place lidding on trays or to create pouches.
FIGS. 10 and 11 illustrate an alternate process wherein after slitting the coextrusion is separated into two coils 76, 76' representing opposite sides of the collapsed bubble 70. The layers 44, 45, 46 coiled on the roll 76' and laminated in a laminating station 132 to be bonded to the outer laminate 128a. The outer laminate 128a is formed by drawing the laminate 128 through an adhesive applying station 130a to apply the adhesive 43. The coiling on the roll 76' of the coextrusion can be damaged and the layers 44, 45, 46, drawn Immediately through the laminating station. This completes the barrier film 38.
The permeable film 148 is delivered from a roll 150 and can comprise a laminate film 38 as described In FIG. 3 and above, or can be a monoextrusion such as higher permeable resins such as 12% EVA, such a #3130 Dupont grade or 18% EVA such as #3165 Dupont grade, or Metallocene type such as SLP-9042 Exxon grade with anti-fog and UV additives added. The film 148 is double wound with the barrier film 36 in a roll 156. Alternatively, the permeable film 148 and the barrier film 36 can be supplied in separate rolls to be applied simultaneously to trays in a packaging machine.
FIG. 12 illustrates a roll 158 holding the barrier film 36 being a prelaminated PVDC coated polyester with coextruded polyethylene easy peel layer as described above comprising the layers 40, 42, 43, 44, 45, 46, and the roll 150 comprising a permeable film 38 (or 148), either a coextrusion or monoextrusion as described above. The rolls 150, 158 deliver the films 36, 38 to a lidding station 166. A roll 167 holds a tray forming film 168 which is formed by a heated press 169 or similar device into the trays 24 with sealing layer 28. After the product 22 is placed on the tray layer 28, the two films 36, 38 are sealed around the perimeter 32 of the tray layer 28 simultaneously by a heat sealer 170 such as described In U.S. Pat. No. 5,334,405 or U.S. Pat. No. 4,642,234 herein incorporated by reference. The filled trays are separated by a cutter 171 into individual packages. Thus, separate rolls of barrier film 36 and permeable film 38 can be delivered to the packages for lidding trays on a double roll machine.
FIG. 13 illustrates an alternate layering wherein the permeable film 38 is as described in FIG. 3, but an alternate impermeable film 236 Is laminated or rolled with the permeable film. The impermeable film comprises an outer uncoated polyester layer 244 adhesively laminated by an adhesive layer 245 to an EVOH layer 246 coextruded with a tie layer 247 and easy peel layering 44, 45, 46, the layering 44, 45, 46 as previously described. The permeable film 38 can also be a monoextrusion or coextrusion as described above.
Although the present invention has been described with reference to a specific embodiment, those of skill in the art will recognize that changes may be made thereto without departing from the scope and spirit of the invention as set forth in the appended claims. | A package that provides for the control of the atmosphere wherein its hermetically sealed walls, allowing fresh meat and poultry products to be held first in an atmosphere that retards the growth of bacteria until it is placed for sale in a retail display case. The package provides a dual layer lidding film with the inner layer being oxygen permeable and the outer layer being oxygen impermeable. At the time of display, the outer layer is removed so that oxygen can enter the package to activate the myoglobin in the meat to cause the meat to bloom to its usual red color. The lidding in part is formed by facing layers of easy peel polyethylene, LDPE treated with polybutylene. | 1 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/119,396, filed Feb. 10, 1999.
BACKGROUND OF THE INVENTION
[0002] This invention relates to wireless communication and, more particularly, to techniques for effective wireless communication in the presence of fading and other degradations.
[0003] Recently, some interesting approaches for transmitter diversity have been suggested. A delay diversity scheme was proposed by A. Wittneben in “Base Station Modulation Diversity for Digital SIMULCAST,” Proceeding of the 1991 IEEE Vehicular Technology Conference (VTC 41 st ), PP. 848-853, May 1991, and in “A New Bandwidth Efficient Transmit Antenna Modulation Diversity Scheme For Linear Digital Modulation,” in Proceeding of the 1993 IEEE International Conference on Communications (IICC '93), PP. 1630-1634, May 1993. The proposal is for a base station to transmit a sequence of symbols through one antenna, and the same sequence of symbols—but delayed—through another antenna.
[0004] U.S. Pat. No. 5,479,448, issued to Nambirajan Seshadri on Dec. 26, 1995, discloses a similar arrangement where a sequence of codes is transmitted through two antennas. The sequence of codes is routed through a cycling switch that directs each code to the various antennas, in succession. Since copies of the same symbol are transmitted through multiple antennas at different times, both space and time diversity are achieved. A maximum likelihood sequence estimator (MLSE) or a minimum mean squared error (MMSE) equalizer is then used to resolve multipath distortion and provide diversity gain. See also N. Seshadri, J. H. Winters, “Two Signaling Schemes for Improving the Error Performance of FDD Transmission Systems Using Transmitter Antenna Diversity,” Proceeding of the 1993 IEEE Vehicular Technology Conference (VTC 43rd), pp. 508-511, May 1993; and J. H. Winters, “The Diversity Gain of Transmit Diversity in Wireless Systems with Rayleigh Fading,” Proceeding of the 1994 ICC/SUPERCOMM , New Orleans, Vol. 2, PP. 1121-1125, May 1994.
[0005] Still another interesting approach is disclosed by Tarokh, Seshadri, Calderbank and Naguib in U.S. application Ser. No. 08/847,635, filed Apr. 25, 1997 (based on a provisional application filed Nov. 7, 1996), where symbols are encoded according to the antennas through which they are simultaneously transmitted, and are decoded using a maximum likelihood decoder. More specifically, the process at the transmitter handles the information in blocks of M1 bits, where M1 is a multiple of M2, i.e., M1=k*M2. It converts each successive group of M2 bits into information symbols (generating thereby k information symbols), encodes each sequence of k information symbols into n channel codes, and applies each code of a group of codes to a different antenna.
[0006] When knowledge of the channel is available neither at the transmitter nor at the receiver, the above schemes require the transmission of pilot symbols. For one transmit antenna, differential detection schemes exist that neither require the knowledge of the channel nor employ pilot symbol transmission. These differential decoding schemes are used, for instance, in the IEEE IS-54 standard. This motivates the generalization of differential detection schemes for the case of multiple transmit antennas.
[0007] A partial solution to this problem was proposed in U.S. patent application Ser. No. 09/074,224 filed on May 7, 1998, where the detected sequence is used to estimate the channel at the receiver, and those estimates are fed back and used to detect the next transmitted set of symbols. Therefore, the '224 patent application disclosure can be thought of as a joint channel and data estimation.
SUMMARY OF THE INVENTION
[0008] Improvement in the art is realized by utilizing the fact that a space time encoding at the transmitter can be constructed where the symbols transmitted over a plurality of antennas in the time slots of a frame are orthogonal to each other. With this realization, in accordance with the principles of this disclosure, the inputs signals of each frame are mapped onto a coordinate system dictated by the symbols of the previous frame, and symbols from a constellation are selected based on the results of such mapping. Received signals are detected by preprocessing the signals detected at each antenna with signals detected by the antenna at the immediately previous frame, and then applied to a maximum likelihood detector circuit, followed by an inverse mapping circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram of a transmitting unit and a receiving unit in conformance with the principles disclosed herein.
DETAILED DESCRIPTION
[0010] FIG. 1 depicts an arrangement where a transmitting unit 10 has two transmitting antennas, 11 - 1 and 11 - 2 , and a receiving unit 20 has m receiving antenna, 21 - 1 , 21 - 2 , . . . , 21 - m . At each time slot t, signals c 1 i , i=1,2 are transmitted simultaneously from the two transmit antennas. The coefficient α i,j is the path gain from transmit antenna i to receive antenna j. The path gains are modeled as samples of independent complex Gaussian random variables with variance 0.5 per real dimension. The wireless channel is assumed to be quasi-static, so that the path gains are constant over a frame of length l and vary, if at all, from one frame to another.
[0011] At time t the signal r 1 j that is received at antenna j is given by
r t j = ∑ i = 1 2 α i , j c t i + η t j ( 1 )
where the noise samples η 1 j are independent samples of a zero-mean complex Gaussian random variable with variance 1/(2SNR) per complex dimension. The average energy of the symbols transmitted from each antenna is normalized to be ½, so that the average power of the received signal at each receive antenna is 1 and the signal to noise ratio is SNR.
[0012] Assuming coherent detection, the receiver computes the decision metric
∑ t = 1 2 ∑ j = 1 m r t j - ∑ i = 1 2 α i , j c t i 2 ( 2 )
over all codewords
c 1 1 c 1 2 c 2 1 c 2 2 . . . c 1 1 c 1 2 , (3)
and decides in favor of the codeword that minimizes the sum of equation (2).
[0013] In the FIG. 1 arrangement, the encoding matrix of transmitting unit 10 is
G = ( x 1 x 2 - x 2 * x 1 * ) , ( 4 )
which means that as 2b bits arrive at the encoder at each frame, constellation signals s 1 , and s 2 are selected, and setting x i =s i , the first column of the matrix is transmitted in time slot t=1 and the second column of the matrix is transmitted in time slot 2 .
[0014] Maximum likelihood detection amounts to minimizing the decision statistic
∑ j = 1 m ( r 1 j - α 1 , j s 1 - α 2 , j s 2 2 + r 2 j + α 1 , j s 2 * - α 2 , j s 1 * 2 ) ( 5 )
over all possible values of s 1 and s 2 The minimizing values in equation (5) are the receiver estimates of s 1 and s 2 , respectively. Expanding the above metric and deleting the terms that are independent of the codewords, it can be observed that the above minimization is equivalent to minimizing
- ∑ j = 1 m ( Ψ 1 + Ψ 2 ) + ( s 1 2 + s 2 2 ) ∑ j = 1 m ∑ i = 1 2 α i , j 2 , where ( 6 ) Ψ 1 = [ r 1 j α 1 , j * s 1 * + ( r 1 j ) * α 1 , j s 1 + r 2 j α 2 , j * s 1 * + ( r 2 j ) * α 2 , j s 1 ] ( 7 ) and Ψ 2 = [ r 1 j α 2 , j * s 2 * + ( r 1 j ) * α 2 , j s 2 - r 2 j α 1 , j * s 2 * - ( r 2 j ) * α 1 , j s 2 ] . ( 8 )
The above metric decomposes into the two parts
- ∑ j = 1 m Ψ 1 + s 1 2 ∑ j = 1 m ∑ i = 1 2 α i , j 2 and ( 9 ) - ∑ j = 1 m Ψ 2 + s 2 2 ∑ j = 1 m ∑ i = 1 2 α i , j 2 , ( 10 )
where equation (9) is only a function of s 1 , and equation (10) is only a function of s 2 . Thus, the minimization of equation (5), which is derived from equation (2), is achieved by minimizing equations (9) and (10) separately. This, in turn, is equivalent to minimizing the decision statistic
∑ j = 1 m ( r 1 j α 1 , j * + ( r 2 j ) * α 2 , j ) - s 1 2 + ( - 1 + ∑ j = 1 m ∑ i = 1 2 α i , j 2 ) s 1 2 ( 11 )
for detecting s 1 , and the decision statistic
∑ j = 1 m ( r 1 j α 2 , j * - ( r 2 j ) * α 1 , j ) - s 2 2 + ( - 1 + ∑ j = 1 m ∑ i = 1 2 α i , j 2 ) s 2 2 ( 12 )
for decoding s 2 .
[0015] From a careful look at the complex vectors that make up the matrix of equation (4) it can be observed that the pair of constellation symbols (x 1 , x 2 ) and (−x 2 , x 1 *) are orthogonal to each other (i.e., (x 1 , x 2 )(−x 2 *, x 1 *) H =0), where the superscript H denotes transpose conjugate (Hermetian), and, therefore, they can constitute the two orthogonal coordinates of a coordinate system. Viewed in this manner, any pair of complex vectors, such as constellation symbols pair X=(x 3 , x 4 ), can be mapped onto the coordinate system defined by (x 1 , x 2 ) and (−x 2 *, x 1 *), and expressed in this coordinate system as a vector
P X =( A X , B X ). (13)
That is,
( x 3 , x 4 )= A X (x 1 , x 2 )+ B X (−x 2 *, x 1 *), (14)
where A x is the dot product of (x 3 , x 4 ) and (x 1 , x 2 ), and B X is the dot product of (x 3 , x 4 ) and (−x 2 *, x 1 *). This yields
A X =x 3 x 1 *+x 4 x 2 *, (15)
and
B X =−x 3 x 2 +x 4 x 1 . (16)
[0016] Defining V as the set of all vectors P X from signal pairs belonging to constellation A, it can be shown that, if the constellation A is restricted to phase shift keying (where the constellation points lie along the (power) unit circle), V has the following properties:
It has 2 2b elements corresponding to the pairs (x 3 , x 4 ) of constellation symbols. All elements of V have unit length. For any two distinct elements X and Y of V,
∥ P X −P Y ∥X−Y∥. (17)
The minimum distance between any two distinct elements of V is equal to the minimum distance of the 2 b -PSK constellation.
[0021] Now, given a block B of 2b bits, the first b bits are mapped into a constellation to symbol a 3 and the second two bits are mapped into a constellation symbol a 4 . Employing an arbitrary, fixed, starting pair of (a 1 ,a 2 ) that belongs to constellation A (for example
a 1 = a 2 = 1 2 ) ,
the complex vector pair (a 3 ,a 4 ) is mapped to the coordinate system defined by the orthogonal vectors (a 1 , a 2 ) and (−a 2 *, a 1 *), to yield the vector P X =(A X , B X ) for X=(a 3 ,a 4 ), or P(B)=(A(B),B(B)),where
A ( B )= a 3 a 1 *+a 4 a 2 , (18)
and
B ( B )=− a 3 a 2 +a 4 a 1 , (19)
Conversely, given A(B), and B(B), the pair (a 3 ,a 4 ) is recovered in a receiver that knows the pair of (a 1 , a 2 ) by
( a 3 , a 4 )= A ( B )( a 1 , a 2 )+ B ( B )(− a 2 *, a 1 *). (20)
The block B is then constructed by inverse mapping of a 3 and a 4 . Thus, there is a direct mapping from constellation symbol a 3 and a 4 to A(B), and B(B).
[0022] In accordance with the principles disclosed above transmitting unit 10 of FIG. 1 includes element 12 that receives the input signals and maps the input signal blocks with mapping operator M. Operator M corresponds to the mapping from bits of the input signal block directly to the complex vectors A(B), and B(B). The mapped signals are applied to symbol computation element 13 , which with assistance with transmitted symbols from the previous two time intervals, computes symbols from constellation A corresponding to the mapped input signal block, and transmits them over antennas 11 - 1 and 11 - 2 . Those symbols are then fed back to delay element 14 in preparation for the mapping of the next input signal block. Thus, based solely on a 1 and a 2 , the transmitter begins the transmission with the sending of arbitrary symbols s 1 and s 2 at time slot 1 and symbols −s 2 * and s 1 * at time slot 2 . These transmissions do not convey any information, but they are fed back to element 12 , where they are used in the mapping of the next set of inputs, in an inductive manner, as effectively described above.
[0023] To illustrate, suppose that during a frame q (frames having 2 time slots each), symbols s 2q−1 and s 2q are transmitted. More specifically, suppose symbols s 2q−1 and s 2q are respectively transmitted from antenna 11 - 1 and 11 - 2 , and at time slot 1 , and the symbols −s 2q * and s 2q−1 * are respectively transmitted from antenna 11 - 1 and 11 - 2 at time slot 2 of frame q. Suppose further that at frame q+1, a block of 2b bits B q+1 arrives at element 12 . According to the above, element 12 uses the mapping of the form expressed in equations (18) and (19) to obtain A(B q+1 ) and B(B q+1 ), and element 12 computes the constellation points
( s 2(q+1)−1 , s 2(q+1) )=( s 2q+1 , s 2q+2 )= A ( B q+1 )( s 2q−1 , s 2q )+ B ( B q+1 )(− s 2q ,* s q−1 *). (21)
Then, symbols s 2q+1 and s 2q+2 are transmitted from antennas 11 - 1 and 11 - 2 , respectively at time slot 1 , and symbols −s 2q+2 * and s 2q+1 * are transmitted from antennas 11 - 1 and 11 - 2 , respectively, at time slot 2 of frame q+1. These signals are also sent to element 14 in preparation of the encoding of frame q+2. This process is inductively repeated until the end of the frame (or end of transmission).
[0024] The decoding of signals received by unit 20 is performed in detector elements 22 - j , which are coupled to antennas j. Within element 22 - j there is a delay element 221 - j and dot product generators 222 - j and 223 - j . Dot product generator 222 - j develops the dot product of (r 2q+1 , r 2q+2 *)·(r 2q−1 ,r 2q *) for the signals received at antenna j, and dot product generator 223 - j develops the dot product of (r 2q+1 , r 2q−2 *)·(r 2q , −r 2q−1 *) for the signals received at antenna j.
[0025] Considering the outputs of element 21 - 1 , and simplifying the notation by employing r 1 for r 1 1 , η 1 , for η 1 1 , α 1 for α 1,1 , and α 2 for α 2,1 , it can be observed that the signal pairs (r 2q+1 ,r 2q+2 *), (r 2q−1 ,r 2q *), and (r 2q ,−r 2q−1 *) can be expressed by
( r 2q+1 ,r 2q+2 *)=( s 2q+1 ,s 2q+2 )Λ(α 1 ,α 2 )+ N 2q+1 , (22)
( r 2q−1 ,r 2q *)=( s 2q−1 ,s 2q )Λ(α 1 ,α 2 )+ N 2q−1 , (23)
and
( r 2q ,−r 2q−1 *)=(− s 2q *,s q−1 *)Λ(α 1 ,α 2 )+ N 2q , (24)
where r 2q−1 , r 2q , r 2q+1 , and r 2q+2 are the received signals,
Λ ( α 1 , α 2 ) = ( α 1 α 2 * α 2 - α 1 * ) , and ( 25 ) N 2 q - 1 = ( η 2 q - 1 , η 2 q * ) . ( 26 )
Hence, taking the dot product of equations (23) and (22) within element 222 - 1 results in
( r 2 q + 1 , r 2 q + 2 * ) · ( r 2 q - 1 , r 2 q * ) = ( s 2 q + 1 , s 2 q + 2 ) Λ ( α 1 , α 2 ) Λ * ( α 1 , α 2 ) ( s 2 q - 1 * , s 2 q * ) + ( s 2 q + 1 , s 2 q + 2 ) Λ ( α 1 , α 2 ) N 2 q - 1 * + N 2 q + 1 Λ * ( α 1 , α 2 ) ( s 2 q - 1 , s 2 q ) * + N 2 q + 1 N 2 q - 1 * . ( 27 )
Expanding equation (27) results in an output for element 221 - 1 that is
r 2 q + 1 r 2 q - 1 * + r 2 q + 2 * r 2 q = ( α 1 2 + α 2 2 ) ( s 2 q + 1 s 2 q - 1 * + s 2 q + 2 * s 2 q ) + ( s 2 q + 1 , s 2 q + 2 ) Λ ( α 1 , α 2 ) N 2 q - 1 * + N 2 q + 1 Λ * ( α 1 , α 2 ) ( s 2 q - 1 , s 2 q ) * + N 2 q + 1 N 2 q - 1 * , ( 28 )
which reduces to
R 1 =(|α 1 | 2 +|α 2 | 2 ) A ( B q−1 )+ N 1 , (29)
where
N 1 =( s 2q+1 ,s 2q+2 )Λ(α 1 ,α 2 ) N 2q−1 *+N 2q+1 Λ*(α 1 ,α 2 )( s 2q−1 ,s 2q )*+ N 2q+1 N 2q−1 * (30)
Similarly, carrying out the mathematics of equations (27)-(30) for the dot product of (r 2q+1 ,r 2q+2 )·(r 2q ,−r 2q−1 *) within element 223 - 1 reveals that the output of element 223 - 1 corresponds to R 2 , where
R 2 =(|α 1 | 2 +|α 2 | 2 ) B ( B q−1 )+ N 2 . (31)
The vector pair (R 1 , R 2 ) at the output of detector 22 - 1 can then be expressed by
( R 1 , R 2 )=(|α 1 | 2 +|α 2 | 2 )( A ( B q−1 ), B ( B q−1 ))+( N 1 ,N 2 ). (32)
[0026] The procedure disclosed above for antenna 12 - 1 is used for each of the j receive antennas, as depicted in FIG. 1 , yielding a set of vectors R 1 j and R 2 j , j=1,2, . . . , m that is applied to element 25 , wherein the closest vector of V to
( ∑ j = 1 m R 1 j , ∑ j = 1 m R 2 j )
is computed, following the approach disclosed above in connection with equations (5)-(12). Subsequently, the transmitted bits are computed by applying the inverse mapping M −1 in element 26 .
[0027] The above discloses the principles of this invention by way of analysis for a transmitter having two transmit antennas. It should be realized that various modifications are possible to be incorporated without departing from the spirit and scope of this invention and, in particular, it should be understood that extension to arrangements where there are more than two antennas is straight forward using, for example, the codes taught in U.S. patent application Ser. No. 09/186,908, titled “Generalized Orthogonal Designs for Space-Time Codes for Wireless Communication,” which has the effective filing date of Nov. 11, 1997. | Input signals of each frame are encoded by mapping the signals onto a coordinate system dictated by the symbols of the previous frame, and symbols from a constellation are selected based on the results of such mapping. Received signals are detected by preprocessing the signals detected at each antenna with signals detected by the antenna at the immediately previous frame, and then applied to a maximum likelihood detector circuit, followed by an inverse mapping circuit. | 7 |
BACKGROUND
The present invention is directed towards an inflation system and a valve for use in an inflation system. The present invention is particularly suited for inflating inflatable members, such as the emergency exit slides, life rafts, etc. carried on commercial aircraft.
The present invention inflation system utilizes the apparatus for rapid inflation of inflatable objects and related method described in U.S. Pat. No. 5,988,438 by Lewis et. al, and hereby incorporated herein by reference.
The present state of the art in inflation systems for emergency exit slides and rafts in commercial aircraft includes a source of gas which flows into an aspirator, which then flows into the inflatable member. Regardless of which type of gas source is used (stored compressed gas, pyrotechnic gas generator etc.) there is a problem due to the wide ambient temperature range within which the inflation systems are required to operate. The temperature range over which these systems are required to function is from −40° F. to 140° F. The amount of gas available must be enough to pressurize the inflatable element at the coldest temperature. Because of the relationship between pressure and temperature with a fixed volume, as the ambient temperature rises above the minimum, the gas source provides too much pressure. To keep the inflatable member from failing due to stress from this high pressure, relief valves are incorporated into the inflatable member to maintain the desired pressure. Multiple relief valves are usually necessary. These relief valves add a significant amount of weight to the inflation system, take up a significant amount of space, and add cost. An inflation system is desired which can reduce the number and size of relief valves necessary, thereby significantly reducing the weight, cost, and required space of the inflation system.
SUMMARY OF THE INVENTION
A valve comprising a valve body with an inlet port, a charging port, a first chamber, a neutral thrust diffuser, a second chamber, a neutral thrust over pressure relief vent, and an outlet port.
The inlet port, and the charging port are in fluid communication with the first chamber, and the first chamber has a first outlet and a second outlet. The first outlet is blocked by a blocking means, and the second outlet is blocked by a secondary burst disk. The blocking means prevents fluid communication between the first chamber and the second chamber. An actuating means will rupture the blocking means at a predetermined actuation point. The second chamber is in fluid communication with the outlet port, and/or the neutral thrust over pressure relief vent.
A regulating piston comprises a piston and a regulating spring wherein the piston slidably moves within the second chamber such that the regulating piston allows fluid communication between the second chamber and the neutral thrust over pressure relief vent, or between the second chamber and the outlet port, or both.
The secondary burst disk prevents fluid communication between the first chamber and the neutral thrust diffuser.
Cross-sectional flow area one is the cross-sectional area of the outlet port which is in fluid communication with the second chamber, two examples of this are shown in Detail A and Detail B. Cross-sectional flow area two is the cross sectional area of the neutral thrust over pressure relief vent which is in fluid communication with the second chamber.
When the actuating means ruptures the blocking means, the fluid flows from the first chamber through the first outlet and into the second chamber. The fluid exerts pressure on the piston, and slidably moves the piston within the second chamber, such that increased fluid pressure causes the regulating piston to move in a manner which decreases the cross-sectional flow area one. As the fluid pressure continues to increase, the cross-sectional flow area one continues to decrease, and the piston slidably moves to a position which allows fluid communication between the second chamber and the neutral thrust over pressure relief vent. With increasing fluid pressure the cross-sectional flow area one continues to decrease, and the cross-sectional flow area two continues to increase, until the piston can no longer move due to the constraints of the second chamber in combination with the regulating spring.
As the fluid pressure decreases, the piston slidably moves such as to decrease the cross-sectional flow area two, and increase the cross-sectional flow area one.
If the fluid in the first chamber reaches a pressure equal to the burst pressure of the secondary burst disk, the secondary burst disk will burst, allowing the fluid to exit the first chamber through the neutral thrust diffuser.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an aspect of a valve according to the invention.
FIG. 2 is a cross-sectional view of an aspect of a valve according to the invention, in use at a first point in time.
FIG. 3 is a cross-sectional view of an aspect of a valve according to the invention, in use at a second point in time.
FIG. 3A is a detail of cross-sectional flow area one.
FIG. 4 is a cross-sectional view of an aspect of a valve according to the invention, in use at a third point in time.
FIG. 4A is a detail of cross-sectional flow area two.
FIG. 5 is a cross-sectional view of an aspect of a valve according to the invention, in use during an overpressure event.
FIG. 6 is a cross-sectional view of an aspect of an inflation system according to the invention.
DETAILED DESCRIPTION
Various aspects of the invention are presented in FIGS. 1-6 which are not drawn to scale, and wherein like components are numbered alike. Referring now to FIG. 1, according to an aspect of the invention, a valve 1 for use in an inflation system is shown. The valve 1 comprises a valve body 3 with an inlet port 5 , a charging port 6 , a first chamber 7 , a neutral thrust diffuser 9 , a second chamber 11 , a neutral thrust over pressure relief vent 13 , and an outlet port 15 .
Still referring to FIG. 1, the inlet port 5 , and the charging port 6 are in fluid communication with the first chamber 7 , and the first chamber 7 has a first outlet 17 and a second outlet 19 . The first outlet 17 is blocked by a blocking means 21 , and the second outlet 19 is blocked by a secondary burst disk 23 . The blocking means 21 prevents fluid communication between the first chamber 7 and the second chamber 11 . An actuating means will rupture the blocking means 21 at a predetermined actuation point. The second chamber 11 is in fluid communication with the outlet port 15 , and/or the neutral thrust over pressure relief vent 13 .
A regulating piston 25 comprises a piston 24 and a regulating spring 26 wherein the piston 24 slidably moves within the second chamber 11 such that the regulating piston 25 allows fluid communication between the second chamber 11 and the neutral thrust over pressure relief vent 13 , or between the second chamber 11 and the outlet port 15 , or both.
The secondary burst disk 23 prevents fluid communication between the first chamber 7 and the neutral thrust diffuser 9 .
Referring now to FIGS. 3-5, these figures show various ways in which fluid can flow through the valve. Cross-sectional flow area one 48 is the cross-sectional area of the outlet port 15 which is in fluid communication with the second chamber 11 , two examples of this are shown in FIG. 3 A and FIG. 4 A. Cross-sectional flow area two 50 is the cross sectional area of the neutral thrust over pressure relief vent 13 which is in fluid communication with the second chamber 11 . The directional arrows in FIG. 3 A and FIG. 4A show the direction in which the cross-sectional flow area is measured, which is perpendicular to the direction of the flow.
When the actuating means ruptures the blocking means 21 , the fluid flows through to the second chamber 11 this is illustrated in FIG. 3 . The fluid exerts pressure on the regulating piston 25 , and slidably moves the piston 24 within the second chamber 11 , such that increased fluid pressure causes the regulating piston 25 to move in a manner which decreases the cross-sectional flow area one 48 . As the fluid pressure continues to increase, the cross-sectional flow area one 48 continues to decrease, and the piston 24 slidably moves to a position which allows fluid communication between the second chamber 11 and the neutral thrust over pressure relief vent 13 this is illustrated in FIG. 4 . With increasing fluid pressure the cross-sectional flow area one 48 continues to decrease, and the cross-sectional flow area two 50 continues to increase, until the piston 24 can no longer move due to the constraints of the second chamber 11 in combination with the regulating spring 26 .
As the fluid pressure decreases, the piston 24 slidably moves such as to decrease the cross-sectional flow area two 50 , and increase the cross-sectional flow area one 48 .
If the fluid in the first chamber 7 reaches a pressure equal to the burst pressure of the secondary burst disk 23 , the secondary burst disk 23 will burst, allowing the fluid to exit the first chamber 7 through the neutral thrust diffuser 9 this is illustrated in FIG. 5 .
According to a further aspect of the invention, when the piston 24 can no longer move due to the constraints of the second chamber 11 in combination with the regulating spring 26 , the piston 24 blocks all fluid communication between the second chamber 11 and the outlet port 15 , such that all fluid is flowing out of the neutral thrust over pressure relief vent 13 .
In a preferred embodiment of the invention, the piston 24 will slidably move to change the cross-sectional flow area one 48 and the cross-sectional flow area two 50 in a manner which will control the flow rate to meet particular mass flow output rates.
According to an aspect of the invention, a fill valve 33 and a fusible plug 35 are installed in the charging port 6 . In a further aspect of the invention, the valve body 3 has a second port 37 , and a pressure indication device 39 is installed in the second port 37 .
In a preferred embodiment of the invention, the valve body 3 has both a charging port 5 and a second port 37 . A fill valve 33 and a fusible plug 35 are installed in the charging port 5 ; and a pressure indication device 39 is installed in the second port 37 . For convenience, both ports may be standard MS33649 ports.
In a further preferred embodiment of the invention, the regulating piston 25 further comprises a regulating spring adjuster 28 . Use of a regulating spring adjuster 28 can compensate for tolerances in the spring rate of the regulating spring 26 . This is done by moving the regulating spring adjuster 28 either closer to the piston 24 to further compress the regulating spring 26 , or further from the piston 24 to allow the regulating spring 26 to further expand. This enables a designer to more accurately meet specified mass flow output criteria.
In a preferred embodiment of the invention, the blocking means 21 is a primary burst disk, and the actuating means is the fluid pressure, such that when the fluid pressure in the first chamber 7 is above the burst pressure of the primary burst disk, the burst disk will burst, allowing the fluid to flow into the second chamber 11 . When a primary burst disk is used, the burst pressure for the primary burst disk will be less than the burst pressure for the secondary burst disk 23 . There are other blocking means and actuating means which are well known in the art, and which would also be suitable. For example, a burst disk whose burst pressure is above expected fluid pressure could be used for the blocking means. A spring operated knife blade could be used for the actuation means; either with manual actuation, or with a pyrotechnic gas source such as a squib to provide the force necessary to thrust the knife blade through the burst disk. As another example, the blocking means may be a burst disk with a burst pressure which is less than the lowest expected fluid pressure, but which is supported by a removable support means. The actuation means in this case would be removing the burst disk support, so that the fluid pressure is able to burst the disk, and flow through to the second chamber.
FIG. 6 depicts the invention inflation system 40 for inflation of an inflatable member, comprising a gas source 42 , and any aspect of the valve 1 as described above.
In a further aspect of the invention, the gas source 42 is a stored pressurized gas source. Alternatively, the gas source 42 is a pyrotechnic gas generator source.
In a preferred embodiment of the invention, the gas source 42 is an inflator device adapted for producing a sufficient quantity of a gaseous product to substantially inflate an inflatable member operatively associated therewith, comprising: a first stage gas source 60 ; a second stage gas source product to substantially inflate an inflatable member operatively associated therewith, comprising: a first stage gas source 60 ; a second stage gas source 62 of liquefied gas in fluid communication at a first location 64 with the first stage gas source 60 and at a second location 66 , with the valve 1 . Wherein the first stage gas source 60 is capable of providing a sufficient quantity of gas at a sufficiently high temperature to vaporize substantially all of the liquefied gas in the second stage gas source 62 .
In a further preferred embodiment, the inflation system 40 further comprises an aspirator which receives the fluid from the valve outlet port 15 , and also pulls in ambient air, and allows the combination to flow through to the inflatable member. Suitable aspirators are well known to those in the art of inflation systems for inflating inflatable members, such as the emergency exit slides, life rafts, etc. carried on commercial aircraft. One example of suitable aspirators are those described in U.S. Pat. No. 4,368,009 by Heimovics and Seabase, which is hereby incorporated by reference.
In a particular preferred embodiment of the present invention, the first stage gas source 60 and the second stage gas source 62 are in fluid communication, such that, gas produced or stored in the first stage is introduced into the liquefied gas in the second stage gas source 62 , thereby vaporizing the liquefied gas and increasing the pressure within the second stage gas source 62 . The second stage gas source 62 is in constant fluid communication with the first chamber 7 of the valve 1 . The increased pressure within the second stage gas source 62 thus translates into increased pressure within the first chamber 7 of the valve 1 . The valve 1 is preferably a high strength aluminum forged body, anodized and sealed following machining. When this increased pressure is high enough, it causes the primary burst disk to burst, allowing the gas to continue on to the second chamber 11 of the valve 1 . The burst disks are preferably stainless steel.
Once in the second chamber 11 of the valve 1 , the gas pressure will act on the regulating piston 25 . The piston 24 is preferably 6061-T6 aluminum alloy, with a hard coat anodized coating after machining, and a minimum 16 RMS surface finish in the contact areas. The inside wall 27 of the second chamber 11 that the piston 24 rides in is preferably the same material, treatment, and finish as the piston 24 . The clearance between the in. The regulating spring 26 is preferably stainless steel. All stainless steel hardware that contacts aluminum hardware is preferably passivated, and then cadmium plated to minimize the potential for electro-galvanic corrosion. | A valve for use in an inflation system wherein the valve has a spring regulated piston which regulates the flow rate through the valve into the inflatable member, such that if the flow rate gets too high, the regulating piston will divert some or all of the flow out a neutral thrust over pressure relief vent, which vents outside the inflatable member. The valve also has a secondary form of overpressure relief in the form of a neutral thrust diffuser which also dumps outside of the inflatable member. Fluid is prevented from flowing out of the neutral thrust diffuser by a burst disk, but if the fluid pressure is high enough, the burst disk will burst, and the fluid will flow out of the neutral thrust diffuser. | 5 |
BACKGROUND OF THE INVENTION
The subject of this invention is an antitheft device to block the passage of a fluid through a supply pipe, to be used especially as an antitheft device for motor-driven vehicles which blocks the passage of fuel between the fuel tank and the motor of the vehicle. The novel features of this invention enable it to contribute the following advantages to what is already known. These advantages are capable of being put to industrial use.
(a) If it is sought to assure the blocking of the fuel of a vehicle as protection against theft or robbery, the device can be installed in a spot which is easily hidden and the device can be operated by means of an unobtrusive maneuver, preferably by using the foot.
(b) If it is applied to a vehicle which still has fuel in the engine valve duct it does not immediately block the operation of the motor, thus allowing the assailants to drive several hundred meters, reducing in this way the risk of personal harm in a robbery.
(c) A key is needed to unblock the device, which means that if the motor stops running and the device is discovered the car cannot be restarted without the key.
(d) If an attempt is made to force the device, then the connection between the device and the motor would be broken, causing the vehicle to become completely inoperable, unless complicated mechanical adjustments are made, which would require a long period of time and which would not facilitate the perpetration of the theft.
(e) The device is easy to install for a mechanical workshop or if one has a few appropriate tools.
(f) Since it is hidden from view, it has no adverse effect upon the esthetics of the vehicle.
(g) It can be applied to any type of fluid supply line the passage through which it is sought to control, either for the purpose of providing exclusive access to a single person authorized to handle certain fluids or if such fluids are in short supply or are very expensive.
SUMMARY OF THE INVENTION
According to the invention, the antitheft device acting to block the passage of fluid is composed basically of a rigid structure formed by two semi-bodies that can be connected to one another, one of which has two sockets or chambers intended for receiving the two extremities of the supply line, both chambers being joined by a distribution chamber through a gap in the bottom of a cylindrical tubular projection which emerges from the bottom of the semi-body and wherein is housed, in an axially displaceable manner, a piston which is provided with toric joints, so that it can open or close the passage between both chambers, the piston being operated by means of an internal latch which can move axially from a closed position, in which a pivot fits into a groove of its guide, to an open position, when said pivot is withdrawn by the action of the key, to which it is driven by a spring. Both the guide and the latch are housed in the other semi-body.
In particular, this device can be used in blocking the gasoline in vehicles, as an antitheft security valve, and to achieve this purpose the device is connected in the supply line which goes from the fuel tank to the carburetor.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating the description of the device, and by way of example and consequently without limiting the description in any way, the accompanying drawings represent a characteristic design of the present invention. In the drawings:
FIG. 1 shows all of the parts of the device in accordance with the invention presented separately in perspective.
FIGS. 2, 3 and 4 show respectively, a side view in axial section, a bottom view of the lower part, and a view from the top of the main upper main semi-body.
FIGS. 5, 6, 7 and 8 show, respectively, a view from the top, a bottom view of the lower part, a side section and a front view of the lower main semi-body.
FIG. 9 shows a side view of the internal cylinder or latch which is operated by the key.
FIGS. 10, 11 and 12 show, respectively, views from the side, from the front and from the bottom of the guide of the latch.
FIG. 13 shows a side view of the closing piston.
FIGS. 14, 15, 16, 17, 18 and 19 show views of the toric joints.
FIGS. 20 and 21 show, respectively, a top and axial section of the nut which is designed to limit the movement of the piston.
FIGS. 22 and 23 show the antitheft device, in a side elevation view, in its open and closed positions, respectively.
FIG. 24 shows a front view of the antitheft device.
FIG. 25 shows an axial section of the antitheft device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With regard to the drawings, it may be noted that the device is composed of a rigid structure formed basically of two main pieces or semi-bodies 2 and 3, inside of which the elements acting as a lock are housed. The structure is attached to the plate of the vehicle (not shown) by means of an appropriate nut 1.
The lower main semi-body 3 is composed of a guard from the center of which there protrudes internally a hollow cylinder 11. Housed in this cylinder is a cylindrical sleeve horn portion or 12 threaded in its upper part which accepts a hexagonal nut which is also threaded 9 with a central hole 10 through which the spring 24 passes. This hexagonal nut is threaded to the horn when the closing piston 6 is situated inside of this hollow horn 12. This piston is cylindrical in shape with two side grooves 13 into which fit two toric joints 7 which impart fluid tightness to the system, preventing the fuel from passing from the distribution chamber 14 of the lower main semi-body 3 to the rest of the mechanism. The bottom 15 of the cylindrical hole 16 is conical in shape and against it rests the toric joint 8 which fits into a groove 17 of a projection 18 located in the lower part of the piston 6.
The toric joint 8, situated in the lower projection 18 of the piston 6, rests against the conical surface 15 of the bottom of the cylinder, preventing, on account of its mechanical position, the fluid from passing from the entry chamber 19 to the exit chamber 20.
The piston 6 moves rectilinearly between a lower position shown in FIG. 1 and an upper position for allowing passage of fuel or liquid through opening 21 between the inlet chamber 20 and the exit chamber 19.
If the piston 6 is allowed to be raised to the fuel passage position, then the fuel will pass from the entry chamber 19 to the distribution chamber 14 and from that chamber it will pass, through an opening 21 in the shape of a half moon, to the exit chamber 20, thus allowing fuel to be fed to the motor.
The piston 6 has a projection 22 on its upper side with a central rugosity 23 to make it possible to firmly secure a spring 24 which, when it is pushed downward by the internal latch, presses the toric joint 8 onto the conical surface 15 of the bottom of the distribution chamber 14, thus preventing the fuel from passing to the exit chamber 20 through the hole in the shape of a half moon 21.
The threaded nut 9, which fits over an upper portion of the cylindrical member 12 has an aperture 10 therein which is smaller than the threaded portion, thereby providing a radially projecting portion or shoulder 10'. The shoulder 10' is adapted to engage an upper one of the toric joints 7 to seal the chamber against leakage when the piston 16 is withdrawn away from the opening 21 between the inlet chamber 20 and the exit chamber 19.
The lower part of the internal latch 4 which is fitted inside of the guide of the latch 5 has a cylindrical projection 25 which serves the purpose of fitting into a hole 26 of the base 27 of the guide of the latch 5. The cylindrical projection 25 of the latch 4 extends into another cylindrical projection 28, with an intermediate extension 29 into which the other extremity of the spring 24 fits.
The internal latch 4 has a cylinder 30 which rotates by means of a key 31 which is inserted into the resulting groove 32. It has a side pivot 33 which withdraws when the key is activated 31. This side pivot or bolt 33 fits into an opening 34 situated in the side of the guide of the latch 5.
The guide of the latch 5 is composed primarily of a tubular body 35 the bottom of which is covered by a base plate 27 which fits inside of the upper main semi-body 2. At the bottom of the base 27 and centered there is a hole 26 to establish and secure the centering of the internal latch 4.
The guide of the latch 5 has a hole in its side to fit into the bolt 33 of the internal latch and it has another elongated hole 36 which allows the internal latch to move parallel to the common axis of the guide and of the latch, limiting its movement by means of the screw 37 attached to the latch 4.
The guide of the latch 5 is attached to the upper main semi-body 2 by means of some holes 39, in the edges of the base 27 of the guide of the latch, and are attached by screws 38 into some threaded holes 40 of the upper semi-body 2.
Inside of the guide of the latch 5 there is a spring which is shaped in the form of a truncated cone 50 which makes it possible to recede the latch 4 to its open position when the key 31 is activated.
The upper semi-body has a cylindrical internal surface 41 through which the latch and its guide are fitted and which is threaded externally 42 to allow the nut to be attached to the vehicle which is to be protected.
There are some grooves 43 and 44 in both of the main semi-bodies which fit the two semi-bodies together, thus achieving the necessary fluid tightness, which can be increased by adding some joint or seal. The two semi-bodies are fastened together by means of screws 45 which are threaded into the lower semi-body 3.
Lastly, to achieve fluid tightness with the vehicle (not shown), a joint or seal 46 can be added between the upper semi-body and the nut 1.
The device is connected to the fuel system of the vehicle by cutting the fuel supply line (not shown), connecting both extremities of the piping to the openings 47 and 48 situated on opposite sides of the lower main semi-body, thus making both sides of the fuel supply line be connected to the entry opening 19 and the exit opening 20 of the lower main semi-body. This connection can be achieved by means of a set of nuts and threads 49, as appropriate.
This model can be made in any appropriate sizes and materials and can be subject to all kinds of detail modifications provided that they do not alter its basic function.
The nature of the invention having been sufficiently described as well as the way it can be carried out in actual practice, it must be pointed out that the aforementioned arrangements can be subject to all kinds of detail modifications provided that they do not alter the basic principle. | The invention is directed to an antitheft device for blocking the passage of fluid in a supply line. Inlet and outlet chambers are coupled in line with the supply. A distribution chamber in flow communication with the inlet and outlet chambers through a passage has a piston movable from an open to a closed position for likewise opening and closing the device. An internal latch operated by means of a key actuates the piston for opening and closing the supply line. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional and claims the benefit of U.S. patent application Ser. No. 14/225,730, filed on Mar. 26, 2014, which is a continuation and claims the benefit of U.S. patent application Ser. No. 14/087,980, filed on Nov. 22, 2013 (Now U.S. Pat. No. 8,936,633 issued Jan. 20, 2015), which is a continuation and claims the benefit of U.S. patent application Ser. No. 13/663,272, filed on Oct. 29, 2012 (now U.S. Pat. No. 8,647,377 issued Feb. 11, 2014), which is a continuation and claims the benefit of U.S. patent application Ser. No. 13/533,658, filed on Jun. 26, 2012 (now U.S. Pat. No. 8,535,367 issued Sep. 17, 2013), which is a continuation and claims the benefit of U.S. patent application Ser. No. 11/552,913, filed on Oct. 25, 2006 (now U.S. Pat. No. 8,231,565 issued Jul. 31, 2012), which is a continuation and claims the benefit of U.S. patent application Ser. No. 10/301,061, filed on Nov. 20, 2002, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/333,373, filed on Nov. 26, 2001, which are all incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to devices and methods for the treatment of diseases in the vasculature, and more specifically, devices and methods for treatment of aneurysms found in blood vessels. Aneurysms can occur in various areas of the cardiovascular system, but are commonly found in the abdominal aorta, thoracic aorta, and cerebral vessels. Aneurysms are unusual ballooning of the vessel due to loss of strength and/or elasticity of the vessel wall. With the constant pulsating pressure exerted on the vessel wall, the diseased or weakened wall can expand out and potentially rupture, which frequently leads to fatality. Prior methods of treating aneurysms have consisted of invasive surgical techniques. The technique involves a major cut down to access the vessel, and the diseased portion of the vessel is replaced by a synthetic tubular graft. Accordingly, this invasive surgical procedure has high mortality and morbidity rates.
[0003] Due to the inherent risks and complexities of the surgical procedures, various attempts have been made to develop minimally invasive methods to treat these aneurysms. For treatment of abdominal and thoracic aortic aneurysms, most of the attempts are catheter-based delivery of an endoluminal synthetic graft with some metallic structural member integrated into the graft, commonly called stent-grafts. One of the primary deficiencies of these systems is durability of these implants. Because catheter-based delivery creates limitations on size and structure of the implant that you can deliver to the target site, very thin synthetic grafts are attached to metallic structures, where constant interaction between the two with every heartbeat can cause wear on the graft. Also, the metallic structures often see significant cyclical loads from the pulsating blood, which can lead to fatigue failure of the metallic structure. The combination of a thin fragile graft with a metallic structure without infinite life capabilities can lead to implant failure and can ultimately lead to a fatality.
[0004] While the above methods have shown some promise with regard to treating aortic aneurysms with minimally invasive techniques, there remains a need for a treatment system which doesn't rely on the less than optimal combination of a thin graft and metallic structural member to provide long-term positive results. The present invention describes various embodiments and methods to address the shortcomings of current minimally invasive devices and to meet clinical needs.
SUMMARY OF THE INVENTION
[0005] In a first aspect, the present invention provides a two part prostheses where one part is an expandable sponge structure and the other part is an expandable tubular mesh structure. The expandable sponge structure is intended to fill the aneurysm cavity to prevent further dilatation of the vessel wall by creating a buffer or barrier between the pressurized pulsating blood flow and the thinning vessel wall. The expandable tubular mesh structure, which is placed across the aneurysm contacting the inner wall of healthy vessel proximal and distal to the aneurysm, serves two purposes. One, it defines the newly formed vessel lumen, even though it does not by itself provide a fluid barrier between the blood flow and the aneurysm. Two, it keeps the expandable sponge structure from protruding out of the aneurysm and into the newly formed vessel lumen. The expandable tubular mesh structure is delivered first across the aneurysm. Then, the expandable sponge structure is delivered via a catheter-based delivery system through a “cell” of the tubular mesh structure and into the aneurysm sac. When the sponge structure is deployed into the aneurysm sac and comes in contact with fluid, it will expand to a size larger than the largest opening or cell of the tubular mesh structure as to prevent the sponge structure from getting out of the aneurysm sac. The filled aneurysm sac will most likely clot off and prevent further dilation of the aneurysm and subsequent rupture. The blood flow should maintain a natural lumen where the luminal diameter is approximately defined by the diameter of the tubular mesh structure. The advantage of this system is that the sponge filler material acts like a graft but has unparalleled durability. The metallic structure can be optimized for durability as well because the size constraint is somewhat relieved due to the absence of an integrated graft material, which takes up a significant amount of space in a catheter.
[0006] In addition, the expandable sponge structure can be used to repair existing endoluminal stent-grafts which have developed leaks. There are thousands of endoluminal stent-grafts implanted into humans to treat abdominal aortic aneurysms. That number is growing daily. The endoluminal stent-grafts are intended to exclude the aneurysm from blood flow and blood pressure by placing a minimally porous graft supported fully or partially by metallic structural members, typically called stents. The acute success rate of these devices is very high, but there are a significant number of these which develop leaks, or blood flow/pressure re-entering the aneurysm sac, some time after the procedure. If the source of the leak can be accessed by the delivery system, the expandable sponge structure can be deployed through that access point.
[0007] In another aspect, the present invention provides an inflatable tubular balloon graft. It is a tubular graft, straight or bifurcated, where its wall is not a solid structure but a hollow chamber. The chamber can be filled with a variety of materials which can dictate the mechanical properties of the prostheses. The unfilled tubular balloon graft can be folded and loaded into a catheter-based delivery system, and once in position the tubular balloon graft can be “inflated” with the filler material. The material would be filled in a fluid form and may stay a fluid form or can be solidified by various means such as UV light, heat, and time. The advantage of this system is that a metallic structure is not needed to provide structure to the graft. It is instead replaced by the injectable fluid within the chamber of the tubular balloon graft. Customization of the mechanical properties of the graft is easily accomplished by using balloon fillers of varying properties.
[0008] The tubular balloon graft can be completely non-porous, completely porous with same degree of porosity throughout the graft, completely porous with varying porosity within the graft, or partially non-porous and partially porous. Significant porosity on the very outer layer would allow for delivery of an aneurysm sac filling substance or a drug. Porosity on the ends of the graft will help promote cellular in-growth. Porosity on the ends can also be used to in deliver an adhesive so that the graft can be securely attached to the vessel wall.
[0009] Another embodiment of the tubular balloon graft includes a tubular balloon graft with a bulging outer layer. This will allow the outer surface of the tubular balloon graft to fill some or all of the aneurysm. This will provide a primary or secondary barrier for the aneurysm wall from the pulsating blood flow and will provide a means to prevent migration of the graft due to the enlarged area within the graft. An alternate method of construction would be to attach a bulging outer skin to a standard tubular thin-walled graft and provide a port for injection of the filler substance. Alternatively, instead of a bulging outer skin, a very compliant outer skin can be used so that the volume of material is minimized. The compliant outer skin would be able to expand at very low inflation pressures that would be non-destructive to the aneurysm wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A illustrates the two-part prosthesis.
[0011] FIG. 1B illustrates a bifurcated version of the expandable tubular mesh structure and the expandable sponge structure.
[0012] FIG. 1C illustrates an expandable tubular mesh structure placed across an aneurysm and the expandable sponge structure filling up the aneurysm.
[0013] FIGS. 2A-2C illustrate the various cross-sections of the expandable sponge structure.
[0014] FIG. 3A illustrates a long continuous sponge structure.
[0015] FIG. 3B illustrates multiple short sponge structures.
[0016] FIG. 4 illustrates the catheter-based delivery system.
[0017] FIG. 5 illustrates a curved delivery catheter.
[0018] FIG. 6 illustrates a method of ensuring that the delivery catheter's tip stays inside the aneurysm sac.
[0019] FIG. 7A illustrates an expandable basket-like structure.
[0020] FIG. 7B illustrates an expandable braid-like structure.
[0021] FIGS. 8 and 9 illustrate expandable tubular mesh structures.
[0022] FIG. 10 illustrates a delivery catheter tracked over a guidewire and placed in a stent-graft which developed a leak.
[0023] FIG. 11 illustrates the sponge delivered through the delivery catheter.
[0024] FIGS. 12-15 illustrate tubular balloon grafts.
[0025] FIGS. 16 and 17 illustrate tubular balloon grafts being expanded.
[0026] FIG. 18 illustrates a tubular balloon graft.
[0027] FIGS. 19, 20A and 20 B illustrate a vascular graft with an integrated tubular balloon.
[0028] FIGS. 21A-21E illustrate a method of delivering a graft with an external balloon.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1A shows the two-part prosthesis comprising of an expandable sponge structure 1 and an expandable tubular mesh structure 2 placed in an abdominal aortic aneurysm 3 located in the infra-renal aorta not involving the iliac arteries. FIG. 1B shows a bifurcated version of the expandable tubular mesh structure 2 and the expandable sponge structure 1 in an abdominal aortic aneurysm located in the infra-renal aorta and involving both iliac arteries. FIG. 1C shows an expandable tubular mesh structure 2 placed across an aneurysm commonly found in cerebral arteries and the expandable sponge structure 1 filling up the aneurysm. The expandable sponge structure 1 is placed through the expandable tubular mesh structure 2 into the aneurysm, filling up the aneurysmal sac which provides a barrier between the thin fragile wall of the aneurysm and the pressurized pulsating blood. The tubular mesh structure 2 keeps the expanded sponge 1 within the confines of the aneurysm and away from the flow path.
[0030] The expandable sponge structure 1 is preferably made of common medical grade polymers or natural substances like collagen which can be manufactured into a sponge structure. The sponge structure can be processed in such a way so that it can be compressed to a dry condition size substantially smaller than the wet condition size, exhibiting huge expansion ratio. The expanded sponge structure can take various forms. FIGS. 2A-2C show the various expanded cross-sections that the expandable sponge structure 1 can be FIG. 2A shows a circular cross section. FIG. 2B shows a square cross section, and FIG. 2C show a triangular cross section. Any cross section can be used. The most important requirement is that it cannot escape from the aneurysm sac through a cell of the expandable tubular mesh structure 2 . The length of the expandable sponge structure 1 can vary as well. FIG. 3A shows a long continuous structure 1 . And FIG. 3B shows multiple short structures 1 .
[0031] One method of delivering the sponge filler 1 into the aneurysm sac is shown by the catheter-based delivery system in FIG. 4 . The catheter 4 can hold the compressed sponge 1 within its lumen, and when pushed out with the plunger 5 into the blood filled aneurysm sac, the sponge will expand out to a substantially larger size. The expanded size of the sponge filler is preferably larger than the largest opening of the tubular mesh structure as to prevent the sponge from escaping the aneurysm sac. FIG. 5 shows an example of a curved delivery catheter 4 , where the tip is placed through a cell of the tubular mesh structure 2 and the expandable sponge structure 1 is being deployed into the aneurysm sac. It is important that the tip of the delivery catheter is through a cell of the tubular mesh structure into the aneurysm because the expandable sponge will expand very quickly after being exposed to the blood and being unconstrained by a catheter. FIG. 6 shows a method of ensuring that the delivery catheter's 4 tip stays inside the aneurysm sac by having a balloon 6 on the tip of it, and when inflated after the tip is within the aneurysm sac it will prevent the catheter tip from backing out of the aneurysm sac. FIG. 7A shows an expandable basket-like structure 7 and FIG. 7B shows an expandable braid-like structure 6 which are alternatives to having a balloon 6 on the tip of the catheter 4 .
[0032] The expandable tubular mesh structure 2 can be made of a metal or of a polymer. The versions made of a metal can be self-expanding from a smaller compressed state or balloon expandable from a smaller compressed or as-cut state. The self-expanding version may be made of metals which exhibit large amounts of elasticity (i.e. nickel-titanium, spring steel, MP-35N and elgiloy) such that when they are compressed down from their expanded state to the compressed state to load into a delivery catheter, they will substantially return to their expanded condition when released from the catheter. Alternatively, shape memory metals like nickel-titanium can be used to provide large expansion ratios. The balloon expandable version may be made of metals which exhibit large permanent deformations without significantly compromising the mechanical performance. The following are some common medical grade metals which are well suited for this purpose: stainless steel, titanium, tantulum, and martensitic nickel titanium. In either the self-expanding or the balloon expandable case, the intent is to deliver the expandable tubular mesh 2 to the target site in a smaller or compressed condition via a catheter-based delivery system so that the target site can be accessed through a remote vascular access point which is conducive to a percutaneous or minimally invasive approach.
[0033] The expandable tubular mesh structure 2 shown in FIGS. 1A, 1B, 1C, 5, and 6 represent a generic, mesh structure. FIG. 8 shows an expandable tubular mesh structure where long continuous struts 9 are connected to anchoring end members 10 . This allows the structure to be very low in profile in the compressed state, and the durability of this type of structure can be optimized because no radial element exists in the longitudinal struts 9 . FIG. 9 show an alternate expandable tubular mesh structure preferably made from a polymer such as PTFE, Polyester, Polyurethane, and the like. The structure has relatively large holes 11 to give access to the expandable sponge delivery catheter. The ends incorporate an anchoring member 12 , either self-expanding or balloon expandable.
[0034] FIG. 10 shows a delivery catheter 4 which has been tracked over a guidewire 14 , which has been placed into the aneurysm sac through an opening 15 of an existing endoluminal stent-graft 13 which developed a leak. The balloon 6 on the delivery catheter 4 was inflated after the deliver y catheter 4 was positioned within the aneurysm sac. FIG. 11 shows the guidewire 14 removed, and the expandable sponge structure 1 being delivered through the delivery catheter 4 .
[0035] FIG. 12 shows a section view of a tubular balloon graft 19 positioned across an infra-renal aortic aneurysm blocking off the flow to the aneurysm sac. The tubular balloon graft's 19 wall is made of an inner wall 16 , an outer wall 17 and a chamber 18 between them. The chamber 18 can be filled with various materials to dictate the mechanical properties of the prosthesis. FIG. 13 shows a bifurcated tubular balloon graft 20 positioned across an infra-renal aortic aneurysm with bi-lateral iliac involvement.
[0036] The tubular balloon implant can be made of the various biocompatible materials used to make balloon catheters. Those materials include P.E.T. (Polyester), nylon, urethane, and silicone. It can also be made of other implant grade materials such as ePTFE. One method of making such a device is to start with two thin walled tubes of differing diameters. The difference between the diameters of the tubes will dictate the volume of the balloon chamber. The ends of the tubes can be sealed together with adhesive or by heat to form the balloon chamber. A communication port will be necessary to be able to fill the port with the injected material.
[0037] The injected material can be an epoxy, a UV-curable epoxy, silicone, urethane or other type of biocompatible materials such as albumin, collagen, and gelatin glue which is injected into the balloon, and then cured in situ. Or, the injected material doesn't necessarily have to be cured. The as-delivered state may provide the appropriate mechanical properties for the application. Therefore, substances like sterile saline, biocompatible oils, or biocompatible adhesives can be left in the tubular balloon in the as-delivered state.
[0038] The tubular balloon graft can be non-porous to very porous. FIG. 14 shows a version where the tubular balloon graft has a porous outer wall 24 . The chamber 21 of the tubular balloon graft can be used to deliver an aneurysm sac filling substance such as UV curable adhesive 22 . The holes 23 which dictate the porosity of the tubular balloon graft can be created with laser drilling, etching, and other methods. The porosity can be varied in select areas of the graft. FIG. 15 shows a tubular balloon graft with only the ends of the graft have porosity to either promote cellular in-growth or to inject an adhesive which allows secure attachment of the graft ends to the vessel wall.
[0039] FIG. 16 shows a tubular balloon graft 19 which is being expanded from a folded condition (not shown) by a balloon catheter 25 . Once expanded, the chamber 18 of the tubular balloon graft 19 can be filled with the desired substance through the chamber access port 26 . FIG. 17 shows a tubular balloon graft 19 being expanded by an inflation process or filling the chamber 18 of the tubular balloon graft 19 through the chamber access port 26 .
[0040] FIG. 18 shows a version of the tubular balloon graft with an outer wall 17 which is substantially bulged out so that it fills some or all of the aneurysm sac. FIG. 19 shows a vascular graft 27 which has an integrated balloon 28 attached to the outside surface of the graft. The balloon can be pre-bulged and folded down for delivery, or it can be a very compliant material like silicone, urethane, or latex so that it has no folds whether compressed or expanded. FIG. 20A shows the same type of implant, a graft 27 with an external balloon 28 , used in a cerebral vessel aneurysm 29 . FIG. 20B show the same implant as 20 A, except that the implant balloon does not fully fill the aneurysm, which can be acceptable because the graft 27 excludes the aneurysm from the blood flow, and the primary purpose of the balloon 28 is to prevent migration of the graft 27 .
[0041] The graft 27 can be made of commonly used implant polymers such as PTFE, Polyester, Polyurethane, etc. The balloon 28 surrounding the graft can be made of the same commonly used vascular implant materials as well. The graft and balloon materials can be different, but it is commonly known that using the same material for both would facilitate processing/manufacturing. The theory is that the balloon 28 would preferentially only deploy into the aneurysm sac were the resistance to expansion is minimal as compared to the vessel wall. The graft 27 would provide the primary barrier between the pressurized blood and the thin wall of the aneurysm. Secondarily, the balloon itself provides a buffer from the pressurized blood. The balloon's 28 primary function, however, is to hold the graft 27 in place. Since the expanded section of the implant is “locked” into the aneurysm, the graft 27 should not migrate. Also, the balloon 28 , in the filled state, will provide hoop strength to the graft 27 .
[0042] FIGS. 21A-21E demonstrate one method of delivering a graft with an external balloon to the target site. FIG. 21A shows the implant loaded onto a balloon delivery catheter 30 with an outer sheath 32 and positioned over a guide wire 31 at the aneurysm target site. FIG. 21B shows that once in position, the outer sheath 32 is withdrawn. FIG. 21C shows the balloon delivery catheter 33 being inflated, pushing the implant 34 against the healthy vessel walls on both sides of the aneurysm. FIG. 21D shows that the balloon delivery catheter 30 may also have an implant balloon inflation port 35 which can now be used to fill up the implant balloon 28 with a biocompatible substance. The substance can be sterile saline, contrast agent, hydrogel, and UV cure adhesive to name a few. Most likely, low inflation pressures would be used to fill the implant balloon 28 . FIG. 21E shows that once the implant balloon 28 is filled, the implant balloon inflation port 35 can be detached and the delivery catheter 30 removed. | The present invention relates to devices and methods for the treatment of diseases in the vasculature, and more specifically, devices and methods for treatment of aneurysms found in blood vessels. In one embodiment, a system for treating an aneurysm is disclosed. The system comprises a catheter delivery system, an expandable foam configured to pass through the catheter delivery system, and a stent having a first end and a second end. The stent is configured to extend across the aneurysm. The expandable foam is configured to expand in the aneurysm when exposed to a fluid. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 2007-0084104, filed on Aug. 21, 2007 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates to an image forming apparatus, and more particularly to an image forming apparatus that can substantially prevent heat emission from a fusing device to an outside.
2. Description of the Related Art
An image forming apparatus is an apparatus that prints an image on a printing medium, e.g., paper, according to an inputted image signal. As one type of image forming apparatus, an electrophotographic type image forming apparatus is configured such that light is scanned to a photosensitive body charged with a predetermined electric potential to form an electrostatic latent image on an outer peripheral surface of the photosensitive body. The electrostatic latent image is developed into a toner image by supplying a toner to the electrostatic latent image, and the toner image is transferred onto paper.
The toner image transferred onto the paper is just carried on the paper, but is not fused to the paper. Therefore, an image forming apparatus includes a fusing device to fuse the transferred toner image to the paper. The fusing device generally includes a heating roller having a heat source therein, and a press roller in close contact with the heating roller to form a fusing nip at a contact portion with the heating roller. If the toner image transferred paper passes between the rotating heating roller and the press roller, the toner image is fused to the paper by heat transferred from an interior of the heating roller and pressure generated between the heating roller and the press roller.
The image forming apparatus is provided with a cover above the fusing device to permit a user to obtain access to an interior of a main body of the image forming apparatus when intending to inspect the interior of the main body or remove jammed paper from the fusing device.
The heat generated from the heating roller mounted in the fusing device is transferred to the cover mounted above the fusing device by radiation, conduction and convection phenomena. Because a user frequently touches the cover whenever inspecting the interior of the apparatus, if the cover becomes hot by the heat transferred from the fusing device, it gives the user an unpleasant feeling when touching the cover.
To solve this problem, Korean Patent Registration No. 0463273 discloses an image forming apparatus having a heat shielding member mounted between a fusing device and a cover. The heat shielding member intercepts the heat transferred from the fusing device from reaching the cover by reflecting the heat, thereby preventing a temperature rise of the cover.
The above heat shielding member can temporarily intercept the heat emitted from the fusing device from being transferred to the cover, but there is a limitation in maintaining a temperature of the cover low only by the heat shielding member in a circumstance in which the fusing device continuously emits heat.
SUMMARY
Therefore, it is an aspect of the embodiment to provide an image forming apparatus that can minimize a temperature rise of a cover by substantially preventing heat emission from a fusing device to an outside.
Additional aspects and/or advantages will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
The foregoing and/or other aspects are achieved by providing an image forming apparatus, including: a main body; a fusing device mounted in the main body, the fusing device having an outlet to discharge paper; an opening/closing member opening and closing the outlet of the fusing device; a cam member moving the opening/closing member between a first position in which the opening/closing member closes the outlet to prevent heat in the fusing device from being emitted through the outlet and a second position in which the opening/closing member opens the outlet to permit the paper to pass through the outlet; a driving part rotating the cam member; and a control unit controlling the driving part to determine a rotational position of the cam member.
The image forming apparatus may further include a cover mounted above the fusing device opening and closing a portion of the main body.
The driving part may include a driving source and a power intermittence unit intermitting power transmitted from the driving source to the cam member. The power intermittence unit may be configured as an electronic clutch.
The image forming apparatus may further include a first paper sensor to sense a front end of the paper advancing into the fusing device. When the front end of the paper is sensed by the first paper sensor, the control unit may rotate the cam member to move the opening/closing member from the first position to the second position.
The image forming apparatus may further include a second paper sensor to sense a rear end of the paper having passed through the fusing device. When the rear end of the paper is sensed by the second paper sensor, the control unit may rotate the cam member to move the opening/closing member from the second position to the first position. The opening/closing member may move from the second position to the first position by its own weight.
The foregoing and/or other aspects are achieved by providing an image forming apparatus, including: a main body; a cover opening and closing a portion of the main body; a fusing device mounted below the cover, the fusing device having an outlet to discharge paper; an opening/closing member provided movably between a first position in which the opening/closing member closes the outlet and a second position in which the opening/closing member opens the outlet to permit the paper to pass through the outlet; at least one paper sensor to sense a position of the paper; and a driving device moving the opening/closing member between the first position and the second position.
The driving device may include a cam member moving the opening/closing member from the first position to the second position by pushing up the opening/closing member.
The driving device may further include a driving source and an electronic clutch intermitting power transmitted from the driving source to the cam member.
The at least one paper sensor may include a first paper sensor mounted in an inlet of the fusing device, and a second paper sensor mounted in the outlet of the fusing device.
When the first paper sensor senses a front end of the paper, the driving device may move the opening/closing member to the second position. When the second paper sensor senses a rear end of the paper, the opening/closing member may move from the second position to the first position.
The foregoing and/or other aspects are achieved by providing an image forming apparatus, including: a paper feeding device feeding paper through the image forming apparatus; a developing device developing images onto the paper fed by the paper feeding device; a fusing device fusing the developed images onto the paper and including an outlet; and an opening/closing member opening and closing the outlet of the fusing device.
The image forming apparatus may include at least one paper sensor sensing an end of the paper, wherein the opening/closing member may open or close the outlet of the fusing device based on a result of the sensing the end of the paper.
The at least one paper sensor may include a first sensor sensing a front end of the paper entering the fusing device at an inlet of the fusing device and a second sensor sensing a rear end of the paper leaving the fusing device at the outlet of the fusing device, and wherein the opening/closing member may open the outlet of the fusing device when the first sensor senses that the front end of the paper enters the fusing device and close the outlet of the fusing device when the second sensor senses that the rear end of the paper leaves the fusing device.
The fusing device may include a paper guide adjacent to the outlet of the fusing device, the opening/closing member may have an inclined end portion, and the inclined end portion of the opening/closing member may contact a guide surface of the paper guide to prevent heat from leaking out of the fusing device.
The image forming apparatus may include a cam member proximate to the opening/closing member rotating to cause the opening/closing member to open or close based on the result of the sensing the end of the paper.
The foregoing and/or other aspects are achieved by providing a fusing device of an image forming apparatus, including: a plurality of rollers causing a toner image to fuse to paper fed into the fusing device by applying heat and pressure to the paper; at least one paper sensor sensing an end of paper being fed into or out of the fusing device; and an opening/closing member opening and closing the outlet of the fusing device based on a result of the sensing the end of the paper.
The at least one paper sensor may include a first sensor sensing a front end of the paper entering the fusing device at an inlet of the fusing device and a second sensor sensing a rear end of the paper leaving the fusing device at the outlet of the fusing device, and wherein the opening/closing member may open the outlet of the fusing device when the first sensor senses that the front end of the paper enters the fusing device and close the outlet of the fusing device when the second sensor senses that the rear end of the paper leaves the fusing device.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, of which:
FIG. 1 is a sectional view illustrating a constitution of an image forming apparatus in accordance with the present embodiment;
FIG. 2 is an enlarged view of a portion of the image forming apparatus shown in FIG. 1 ;
FIG. 3 is a view illustrating a state in which an opening/closing member pivots by a cam member to open an outlet of a fusing device in FIG. 2 ;
FIG. 4 is a view illustrating a constitution of a driving device to drive the opening/closing member in the image forming apparatus in accordance with the present embodiment; and
FIG. 5 is a view for explaining an operation of opening and closing the outlet of the fusing device by the opening/closing member in the image forming apparatus in accordance with the present embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made in detail to an embodiment, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The embodiment is described below to explain the present invention by referring to the figures.
FIG. 1 is a sectional view illustrating a constitution of an image forming apparatus in accordance with the present embodiment, and FIG. 2 is an enlarged view of a portion of the image forming apparatus shown in FIG. 1 . FIG. 3 is a view illustrating a state in which an opening/closing member pivots by a cam member to open an outlet of a fusing device in FIG. 2 .
As shown in FIG. 1 , an image forming apparatus according to the present embodiment includes a main body 10 forming an exterior appearance, a paper feeding device 20 to supply a printing medium, i.e., paper S, a developing device 30 to develop an image on the paper, a fusing device 40 to fuse an image to the paper by applying heat and pressure to the paper, and a paper discharge device 50 to discharge the printed paper to an exterior of the main body 10 .
The paper feeding device 20 includes a paper feeding tray 21 to load the paper S thereon, a pickup roller 22 to pick up the paper S on the paper feeding tray 21 sheet by sheet, and a feeding roller 23 to feed the picked-up paper toward the developing device 30 .
The developing device 30 includes a photosensitive body 31 on which an electrostatic latent image is formed by a laser scanning unit 60 , a charge roller 32 to charge the photosensitive body 31 , four developing cartridges 33 Y, 33 M, 33 C and 33 K to develop the electrostatic latent image formed on the photosensitive body 31 into a toner image by using toners of yellow, magenta, cyan and black, an intermediate transfer belt 34 , a first transfer roller 35 , and a second transfer roller 36 .
Each of the developing cartridges 33 Y, 33 M, 33 C and 33 K include a developing roller 37 to develop the electrostatic latent image formed on the photosensitive body 31 by supplying the toner thereto, and a supply roller 38 to supply the toner to the developing roller 37 by rotating while contacting the developing roller 37 .
The intermediate transfer belt 34 is supported by support rollers 34 a and 34 b , and runs at the same velocity as a rotational linear velocity of the photosensitive body 31 . The first transfer roller 35 opposes the photosensitive body 31 , and transfers the toner image developed on the photosensitive body 31 onto the intermediate transfer belt 34 . The second transfer roller 36 opposes the intermediate transfer belt 34 . While the toner image is transferred onto the intermediate transfer belt 34 from the photosensitive body 31 , the second transfer roller 36 is spaced apart from the intermediate transfer belt 34 . When the toner image is completely transferred onto the intermediate transfer belt 34 , the second transfer roller 36 is moved into contact with the intermediate transfer belt 34 with a predetermined pressure.
The fusing device 40 fuses the toner image to the paper by applying heat and pressure to the paper. As shown in FIGS. 1 to 3 , the fusing device 40 includes a frame 41 having an inlet 41 a to introduce the paper into the frame 41 and an outlet 41 b to discharge the paper from the frame 41 . Inside the frame 41 are mounted a heating roller 42 having a heat source 42 a to heat the toner image-transferred paper, and two press rollers 43 and 44 in close contact with the heating roller 42 to maintain a constant fusing pressure with the heating roller 42 .
A first paper guide 45 and a second paper guide 46 are mounted near the outlet 41 b of the fusing device 40 . The first paper guide 45 and the second paper guide 46 guide the paper passing through the fusing device 40 to smoothly move the paper toward a paper discharge port 11 formed at a portion of the main body 10 . One end of the first paper guide 45 is hingedly coupled to the frame 41 of the fusing device 40 by a hinge shaft 45 a , and the other end of the first paper guide 45 extends toward the paper discharge port 11 . The second paper guide 46 is mounted opposite to the first paper guide 45 over the outlet 41 b of the fusing device 40 . The second paper guide 46 has a guide surface 46 a to guide the movement of the paper.
A cover 70 is mounted above the fusing device 40 to open and close a portion of the main body 10 . The cover 70 is hingedly coupled to the main body 10 by a hinge shaft 71 . When intending to remove jammed paper from the main body 10 or inspect internal components, a user pulls the cover 70 to open a portion of the main body 10 and can observe the interior of the main body 10 or take appropriate measures.
The paper discharge device 50 includes a discharge roller 51 to discharge the paper passing through the fusing device 40 to the outside of the main body 10 , and a discharge backup roller 52 mounted while opposing the discharge roller 51 .
The operation of the above-structured image forming apparatus will now be explained briefly with reference to FIGS. 1 to 3 . The laser scanning unit 60 irradiates light, for example, corresponding to yellow image information to the photosensitive body 31 charged with a uniform electric potential by the charge roller 32 , and an electrostatic latent image corresponding to the yellow image is formed on the photosensitive body 31 . A developing bias is applied to the developing roller 37 of the yellow developing cartridge 33 Y, and the yellow toner is attached to the electrostatic latent image to develop the electrostatic latent image into a yellow toner image on the photosensitive body 31 . The toner image is transferred onto the intermediate transfer belt 34 by the first transfer roller 35 .
After the yellow toner image corresponding to one page is completely transferred, the toner images of magenta, cyan and black are sequentially transferred onto the intermediate transfer belt 34 through the same procedures as above. Accordingly, a color toner image is formed on the intermediate transfer belt 34 by the toner images of yellow, magenta, cyan and black being overlapped. The color toner image is transferred onto the paper S passing between the intermediate transfer belt 34 and the second transfer roller 36 . The image transferred onto the paper is fused to the paper while passing through the fusing device 40 , by heat transferred from the heating roller 42 and pressure generated between the heating roller 42 and the press rollers 43 and 44 . The paper having passed through the fusing device 40 is discharged to the outside of the main body 10 by the discharge roller 51 .
In the above process, if heat from the interior of the fusing device 40 is continuously emitted through the outlet 41 b of the frame 41 , a temperature of the first paper guide 45 mounted above the outlet 41 b and a temperature of the cover 70 rise, which gives a user an unpleasant feeling when the user touches the cover 70 and the first paper guide 45 to inspect the interior of the apparatus.
To cope with this problem, the image forming apparatus according to the present embodiment includes an opening/closing member 100 to open and close the outlet 41 b of the fusing device 40 , a driving device 200 (refer to FIG. 4 ) to drive the opening/closing member 100 so that the opening/closing member 100 can move between a first position in which the opening/closing member 100 closes the outlet 41 b (refer to FIG. 2 ) and a second position in which the opening/closing member 100 opens the outlet 41 b (refer to FIG. 3 ), and a control unit 300 (refer to FIG. 4 ) to control the driving device 200 so that the opening/closing member 100 can move at an appropriate point of time.
The opening/closing member 100 opens the outlet 41 b of the fusing device 40 only when the paper S passes through the outlet 41 b during the printing operation, and closes the outlet 41 b anytime else, thereby preventing the heat from the interior of the fusing device 40 from being transferred to the cover 70 through the outlet 41 b.
As shown in FIGS. 2 and 3 , the opening/closing member 100 is hingedly coupled to the frame 41 at one end portion by a hinge shaft 110 . Therefore, the other end portion of the opening/closing member 100 can pivot in an up/down direction on the hinge shaft 110 and can move between the first position and the second position. When the opening/closing member 100 is located at the first position to close the outlet 41 b of the fusing device 40 , the other end portion of the opening/closing member 100 extends across the outlet 41 b and is supported by the second paper guide 46 . The other end portion of the opening/closing member 100 has an inclined portion 120 (shown in FIG. 3 ) which is inclined along the guide surface 46 a of the second paper guide 46 . By the inclined portion 120 being closely contacted with the guide surface 46 a of the second paper guide 46 , the heat in the fusing device 40 does not leak.
It is preferred that the opening/closing member 100 is made of a material having an excellent thermal insulation property. Although not illustrated in FIGS. 2 and 3 , it is possible to install an additional thermal insulation member inside the opening/closing member.
FIG. 4 is a view illustrating the constitution of the driving device to drive the opening/closing member in the image forming apparatus according to the present embodiment. As shown in FIGS. 2 to 4 , the driving device 200 includes a cam member 210 to move the opening/closing member 100 between the first position and the second position, and a driving part 220 to rotation-drive the cam member 210 .
The cam member 210 has a cam shaft 211 and a rotating cam 212 provided at an end portion of the cam shaft 211 . During the rotation, the rotating cam 212 interferes with an end portion 100 a in a side direction of the opening/closing member 100 at a specific region, and pushes up the opening/closing member 100 . Therefore, the opening/closing member 100 pivots from the first position to the second position, and opens the outlet 41 b of the fusing device 40 as shown in FIG. 3 . On the other hand, if the rotating cam 212 rotates more from the state shown in FIG. 3 and is separated from the opening/closing member 100 , the opening/closing member 100 pivots downward by its own weight to the first position, and closes the outlet 41 b of the fusing device 40 as shown in FIG. 2 .
The driving part 220 to drive the cam member 210 includes a driving motor 221 as a driving source, and a power intermittence unit 222 to intermit the power transmitted from the driving motor 221 to the cam member 210 . In this embodiment, the power intermittence unit 222 is configured as an electronic clutch 222 a , however the embodiment is not restricted thereto. Various types of clutch devices can be applied to the power intermittence unit 222 .
The electronic clutch 222 a is connected with a clutch gear 223 and the cam member 210 . The clutch gear 223 is connected to the driving motor 221 through a gear train (only two gears 224 and 225 of the gear train are illustrated in FIG. 4 for convenience of illustration). When the electronic clutch 222 a is turned ON, a rotational force of the clutch gear 223 is transmitted to the cam member 210 . When the electronic clutch 222 a is turned OFF, the rotational force of the clutch gear 223 is not transmitted to the cam member 210 . Although FIG. 4 illustrates that the electronic clutch 222 a is directly connected with the cam member 210 , it is also possible to install a series of power transmission gears between the electronic clutch 222 a and the cam member 210 .
As shown in FIGS. 2 and 3 , the image forming apparatus of the present embodiment includes a first paper sensor 80 mounted in the inlet 41 a of the fusing device 40 , and a second paper sensor 90 mounted in the outlet 41 b of the fusing device 40 .
When the first paper sensor 80 senses a front end of the paper, the control unit 300 determines that the paper is advancing into the fusing device 40 , and accordingly controls the driving device 200 so that the opening/closing member 100 opens the outlet 41 b of the fusing device 40 . Also when the second paper sensor 90 senses a rear end of the paper, the control unit 300 determines that the paper has completely passed through the fusing device 40 , and accordingly controls the driving device 200 so that the opening/closing member 100 closes the outlet 41 b of the fusing device 40 .
Hereinafter, the operation of opening and closing the outlet of the fusing device by the opening/closing member in the image forming apparatus according to the present embodiment will be explained in detail with reference to FIGS. 3 to 5 A-C.
While the paper fed in the main body 10 passes between the intermediate transfer belt 34 and the second transfer roller 36 , an image is printed on the paper. The printed paper S, as shown in FIG. 5A , starts advancing into the fusing device 40 . FIG. 5A shows a state in which the paper is positioned close to the first paper sensor 80 . When the front end of the paper is not sensed by the first paper sensor 80 , the opening/closing member 100 is positioned in the first position and keeps closing the outlet 41 b of the fusing device 40 . Accordingly, the heat in the fusing device 40 is not transferred to the cover 70 .
When the paper S is fed more from the state shown in FIG. 5A and the front end of the paper S operates the first paper sensor 80 as shown in FIG. 5B , the control unit 300 determines that the paper is advancing into the fusing device 40 , and accordingly controls the electronic clutch 222 a of the driving device 200 so that the opening/closing member 100 opens the outlet 41 b of the fusing device 40 . In other words, the control unit 300 turns ON the electronic clutch 222 a for a predetermined time. Only while the electronic clutch 222 a is in the ON state, the power of the driving motor 221 is transmitted to the cam member 210 to rotate the cam member 210 at a predetermined angle, and the rotating cam 212 of the cam member 210 interferes with the opening/closing member 100 to push up the opening/closing member 100 as shown in FIG. 5B . As a result, the outlet 41 b of the fusing device 40 is opened.
When the outlet 41 b of the fusing device 40 is opened as shown in FIG. 5B , the paper S is fed toward the discharge roller 51 via the outlet 41 b . At this time, the front end of the paper fed toward the discharge roller 51 operates the second paper sensor 90 as shown in FIG. 3 .
As shown in FIG. 5C , when the rear end of the fed paper S passes away from the second paper sensor 90 , the second paper sensor 90 is returned to its original position. In response to the movement of the second paper sensor 90 , the control unit 300 turns ON the electronic clutch 222 a for a predetermined time. When the electronic clutch 222 a is turned ON, the power of the driving motor 221 is transmitted to the cam member 210 through the electronic clutch 222 a , and accordingly the cam member 210 is returned to its original position. When the cam member 210 is returned to its original position as shown in FIG. 5C , the opening/closing member 100 pivots downward by its own weight and closes the outlet 41 b of the fusing device 40 .
Since the opening/closing member 100 keeps closing the outlet 41 b of the fusing device 40 until the following sheet of paper is introduced into the fusing device 40 , the heat in the fusing device 40 is intercepted by the opening/closing member 100 , and thus cannot be emitted to the outside through the outlet 41 b . As a result, a rise of a temperature of the first paper guide 45 disposed above the fusing device 40 or a temperature of the cover 70 can be minimized.
As apparent from the above description, the image forming apparatus according to the present embodiment can minimize the heat emission from the fusing device to the outside of the fusing device, because the outlet of the fusing device is opened only when needed. Accordingly, a temperature rise of the components arranged near the fusing device can be minimized.
Further, since heat loss from the interior of the fusing device to the exterior is reduced, a fusing temperature can be efficiently maintained at an appropriate level.
Although an embodiment has been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | An image forming apparatus capable of minimizing a temperature rise of a cover by substantially preventing heat emission from a fusing device to an outside is disclosed. The image forming apparatus includes a main body, a fusing device mounted in the main body, the fusing device having an outlet to discharge paper, an opening/closing member opening and closing the outlet of the fusing device, a cam member moving the opening/closing member between a first position in which the opening/closing member closes the outlet to prevent heat in the fusing device from being emitted through the outlet and a second position in which the opening/closing member opens the outlet to permit the paper to pass through the outlet, a driving part rotating the cam member, and a control unit controlling the driving part to determine a rotational position of the cam member. | 6 |
FIELD OF THE INVENTION
The present invention relates to spread spectrum communication systems generally and to noise reducing units in mobile handsets of such communication systems in particular.
BACKGROUND OF THE INVENTION
A conventional spread spectrum signal can be viewed as the result of mixing a narrowband information-bearing signal i[t] with an informationless wideband "spreading" signal p[t]. If B i and B p denote the bandwidths of i[t] and p[t], respectively, then the "processing gain" available to the receiver is G=B p /B i . The receiver synchronizes the incoming signal to a locally generated version p 0 [t] of p[t] and mixes the received signal with p 0 [t], thereby removing p[t] from the signal and "collapsing" the signal to the "information bandwidth" B i .
The spreading signal p[t] is typically a coding sequence of some kind, such as a pseudo-random code. The United States space program initially utilized a Type 1 Reed-Muller code for deep-space communications. In many code division multiple access (CDMA) systems, the code is an M-sequence which has good "noise like" properties yet is very simple to construct.
For example, in the IS-95 standard for cellular communication, the forward channel (base to mobile units) employs, as a spreading code, the product of a 64 chip Walsh code (aimed at separating up to 64 different users per base) and a periodic PN sequence (aimed at separating the different bases). Thus, the spreading signal p[t] for each user is its Walsh code combined with the current 64 chips of the PN sequence of its base station.
In order to synchronize the local version p 0 [t] of the spreading signal with the original version p[t], the base station additionally transmits the current PN sequence via a pilot signal z[t] (the pilot signal z[t] is simply the current PN sequence multiplied by the all 1 Walsh code). The mobile unit then synchronizes its local code generator to the pilot signal after which the mobile unit can despread the received information bearing signals using its Walsh code and the current PN sequence.
The Walsh codes W i , I=1, . . . 64 are perfectly orthogonal to each other such that, in a non-dispersive transmission channel, there will be complete separation among the users even despite being transmitted at the same time and on the same transmission frequencies.
Practical channels, however, are time dispersive, resulting in multipath effects where the receiver picks up many echoes of the transmitted signal each having different and randomly varying delays and amplitudes. In such a scenario, the code's orthogonality is destroyed and the users are no longer separated. Consequently, a mobile unit, when attempting to detect only a single user, regards all other channel users (including signals from other base stations) as creators of interference. This contributes to a decrease in signal-to-noise ratio (SNR) and thus, reduces the reception quality of the mobile unit.
In the presence of multipath channels, the mobile units additionally process the informationless pilot signal to identify and track the multipath parameters of the channel. For this purpose, the mobile units include a channel estimator which detects and tracks the attenuation, denoted by channel "tap" h i , and the relative delay, denoted by τ i , for each of the main paths. The mobile units then utilize the channel information in their detection operations.
One exemplary multipath detector is a rake receiver which optimally combines the different paths into a single replica of the transmitted signal. Rake receivers are described in detail e.g. in the book Digital Communications by J. G. Proakis, McGraw-Hill, Third Edition, 1995. The book is incorporated herein by reference.
A multiple-user detection scheme, such as is often used in base stations, can be viewed as interpreting the cross-talk between the signals of the users as merely a part of the multiple-input, multiple-output channel distortion. The base station accounts for this distortion during the detection process and, in general, the distortion does not translate into an SNR reduction. Therefore, it is not surprising that, with practical multipath channels, multi-user detection schemes are far superior to single-user ones.
Unfortunately, multi-user detection schemes are also significantly more complex than single-user ones. Not only does multi-user detection require (either explicitly or implicitly) processing the received signal with a bank of PN code generators (with each generator being matched to a distinct user), the outputs of this generator bank must further be processed according to some a priori criterion, such as maximum likelihood criterion, whose complexity is exponential in the number of users, or the decorrelation/minimum mean squared error (MMSE) criterion, whose complexity is quadratic in the number of users.
The article "Minimum Probability of Error for Asynchronous Gaussian Multiple-Access Channels" by S. Verdu, IEEE Transactions on Information Theory, January 1986, pp. 85-96, incorporated herein by reference, describes a multi-user detection scheme using the maximum likelihood criterion. The following articles, also incorporated herein by reference, describe multi-user schemes using the decorrelation/MMSE criterion:
L. Rusch and Poor, "MultiUser Detection Techniques for Narrowband Interference Suppression", IEEE Transactions on Communications, Vol. 43, Nos. 2-3-4, pp. 1725-1737, February-March-April 1995;
R. Lupas and S. Verdu, "Linear Multiuser Detectors for Synchronous Code-Division Multiple-Access Channels", IEEE Transactions on Information Theory, Vol. 35, No. 1, January 1989, pp. 123-136;
Z. Xie, R. Short and C. Rushforth, "A Family of Suboptimum Detectors for Coherent Multiuser Communications, IEEE Journal on Selected Areas In Communications, Vol. 8, No. 4, May 1990, 683-690;
Since the number of simultaneous channel users may be quite large, the computational burden associated with multi-user schemes prohibits their implementation in some applications, such as in mobile CDMA receivers.
U.S. Pat. No. 5,506,861 to Bottomley describes a plurality of methods for demodulating multiple CDMA signals which are similar to those presented in the book Digital Communications by J. G. Proakis, Chapter 15, section 15.3, but extended to the multi-path channel case. A common feature of these approaches is that they require a bank of despreaders each of which corresponds to the spreading code of a different channel user. The outputs of this bank of despreaders are then processed according to the MLSE criterion via the Viterbi algorithm or according to the decorrelation/MMSE criterion. However, a bank of despreaders is expensive in terms of complexity and power consumption. Thus, it cannot be implemented in a mobile handset. Furthermore, the Viterbi algorithm and the decorrelation/MMSE detectors are also quite complicated.
U.S. Pat. No. 5,323,418 to Ayerst describes a base station which includes an interference cancellation operation. The cancellation involves sequentially subtracting the interfering signals from the received signal in accordance with their relative power. In this manner, the effects of each user are separately removed, leaving the signal of the desired user for decoding.
U.S. Pat. No. 5,105,435 to Stilwell describes a method and apparatus for canceling user-code noise in spread-spectrum systems. Like most multi-user detection schemes, the system substantially removes the signals of the other users from the received signal, thereby producing the user signal of interest. Stilwell also indicates that, for the mobile receiver, it is enough to remove just the pilot signal out of the received signal, especially considering that the pilot signal is typically a very strong signal, significantly stronger than the user signals.
The article "Spread Spectrum Multiple Access System with Intrasystem Interference Cancellation" by Tatsuro Masamura, The Transactions of the IEICE, Vol. E71, No. 3, March 1988, pp. 224-231 describes an interference recovery circuit which includes a bank of units. Each unit contains a conventional despreader followed by a band pass filter and a respreader. The circuit filters out the interfering signal components from the desired signal and thus, attempts to reduce the overall distortion of the desired signal.
However, Stilwell, Ayerst and Masamura suggest canceling the user-code noise by despreading and respreading the received signal several times. These operations are computationally expensive and, therefore, the methods cannot be utilized in mobile units.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide a detection method and apparatus which is particularly useful for the mobile handset. Rather than detecting and removing one or more user/pilot signals from the received signal before detecting the desired user's signal, as per the prior art, the present invention detects the signal of the desired user and then corrects the resultant signal by removing from it the interference effect of the pilot signal. It is noted that the present invention does not respread the received signal after the correction operation nor does the present invention require the despreading of the pilot signal, both operations which occur in the prior art.
In an alternative embodiment, the present invention additionally removes the interference effects of the pilot signals of neighboring base stations.
Furthermore, in accordance with a preferred embodiment of the present invention, the interference effect is generated from a priori existing channel and pilot information.
There is therefore provided, in accordance with a preferred embodiment of the present invention, a method for receiving spread-spectrum signals including the steps of a) detecting a noisy user signal from a spread-spectrum signal including at least a first user signal and at least one pilot signal, the first user signal including data therein and b) removing an interference effect of the pilot signal on the first user signal from the noisy user signal thereby to create a noise reduced user signal.
Alternatively, in accordance with an alternative embodiment of the present invention, the step of detecting can detect multiple user signals from the received spread-spectrum signal. The method removes the interference effect of the pilot signal on at least one of the user signals from the corresponding one of the noisy user signals thereby to create noise reduced user signals.
Additionally, in accordance with a preferred embodiment of the present invention, the method also includes the step of decoding the data in the noise reduced user signal.
Moreover, in accordance with a preferred embodiment of the present invention, the step of removing interference includes the steps of determining the interference effect per pilot signal and subtracting the interference effect from the noisy user signal.
Further, in accordance with a preferred embodiment of the present invention, the spread spectrum signal has been transmitted along a multipath channel and the step of determining includes, per selected pilot signal, the steps of a) generating the cross-talk effect of the selected pilot signal on the user signal between different paths of the multipath channel and b) generating the interference effect of the selected pilot signal on the user signal.
Finally, in accordance with a preferred embodiment of the present invention, the first step of generating includes the steps of a) determining a transmission effect of transmitter and receiver shaping filters on a transmitted signal per variable amount of delay, b) generating cross-correlations, for variable amounts of delay, between the spreading code of the selected pilot signal and the spreading code of the user signal and c) determining the cross-talk effect between two channel paths i and j from channel tap estimates defining the gain and relative delay of the ith and jth paths, from a selected portion of the cross-correlations in the vicinity of a difference delay defined by the difference of channel delays associated with these channel paths from a selected portion of the transmission effect in the vicinity of the difference delay.
The present invention incorporates the methods described and claimed herein and various receivers and processors which implement the method.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
FIG. 1 is a block diagram illustration of a data detector for a mobile unit, constructed and operative in accordance with a preferred embodiment of the present invention;
FIG. 2 is a block diagram illustration of an interference processor useful in the detector of FIG. 1.;
FIG. 3A is a block diagram of a standard prior art rake receiver useful in the data decoder of FIG. 1;
FIG. 3B is a block diagram of an pilot interference removing rake receiver, constructed and operative in accordance with an alternative preferred embodiment of the present invention;
FIG. 4 is a block diagram illustration of an alternative data detector for a mobile unit which removes the interference effect of multiple pilot signals, constructed and operative in accordance with a preferred embodiment of the present invention; and
FIG. 5 is a block diagram illustration of a base station multi-user data detector constructed and operative in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is now made to FIGS. 1 and 2 which illustrate a first embodiment of the mobile unit data detector of the present invention. FIG. 1 illustrates the detector in general and FIG. 2 illustrates the elements of an interference processor forming part of the detector of FIG. 1.
Detector 10 forms part of a mobile communication unit which, like prior art detectors, receives a signal r(n) and comprises a rake receiver 12, a pilot processor 11 and an optional decoder 18. As in the prior art, the pilot processor 11 includes a synchronizer 13 and a channel estimator 14. However, in accordance with a preferred embodiment of the present invention, detector 10 also comprises an interference processor 20 which utilizes the output of the existing channel estimator 14 and synchronizer 13.
The signal r(n) is the version of the received signal after the latter has been filtered and down converted to a baseband signal and has been sampled at rate of M samples per chip and N chips per symbol where M and N are typically integers. In the IS-95 CDMA standard, there are 64 chips per symbol n and the chip rate is 1.2288×10 6 chips per second, i.e. T chip is about 0.8 μsec. For simplicity, M is set to 1, i.e. upon receipt, the signal r(n) is sampled once per chip.
Synchronizer 13 synchronizes the detector to the PN sequence of the base station and provides the current PN sequence to the rake receiver 12 and the interference processor 20. Channel estimator 14 estimates the channel tap h i and the delay τ i associated with each finger. Rake receiver 12 despreads the user data signal of the current user using the user's Walsh code (which is known a priori), the current PN sequence, the estimated channel taps h i and the estimated finger delays τ i . Rake receiver 12, shown in detail in FIG. 3A, produces the estimated user data signal x(n), sampled once per symbol.
It is noted that the received signal r(n) consists of the data signals of all of the active users (of the current base station and possibly of other, neighboring base stations) the pilot signals of at least the current base station and other interference terms caused by different noise sources in transmission, reception, etc. For the present discussion, the "pilot signal" will refer to the pilot signal of the current base station which is, by far, the strongest pilot signal received by the mobile unit.
In accordance with a preferred embodiment of the present invention, interference processor 20 determines the cross-talk interference effect c(n) of the pilot signal on the user data signal x(n). Since the power of the pilot signal is typically significantly larger than that of any other channel user (to ensure that every synchronizer 13 can synchronize to it), removing the interference effect c(n) of the pilot signal (via a subtractor 22) should considerably improve the estimated user data signal x(n). Furthermore, as described hereinbelow, the interference effect is relatively simple to calculate and thus, interference processor 20 can generally easily be implemented in a mobile handset where the computational burden must be minimized.
Subtractor 22 removes the interference effect c(n) from the rake receiver output x(n) thereby producing a new version x'(n) of the data signal. The new version x'(n) is decoded, via known methods, by optional decoder 18.
Interference processor 20 determines the cross-talk through the rake receiver 12 due to the pilot signal and from this, generates the interference effect caused by the pilot signal. The cross-talk is of the form Re{h i h j *ρ a (k,n)ρ p (k')},i≠j where * indicates the complex conjugate, the function Re{ } indicates the real portion of a complex number, ρ a (k,n) is the cross-correlation of the user and pilot spreading codes for the nth transmitted symbol, ρ p (k') depends on the baseband filter taps and defines the effect of transmit and receive shaping filters on a transmitted signal, k is a delay defined in integral chips (i.e. k is an integer number) and k' is a delay defined in fractional chips (i.e. k' is a real number). Typically, k' is measured in units of T chip /M.
Since the baseband filter taps are known a priori and do not change over time, ρ p (k') can be determined a priori for all possible values of k' and stored in a lookup table 30. A priori transmitter-receiver shaping filter effect generator 32 determines ρ p (k') as follows: ##EQU1## where k' typically varies from -L T .sbsp.chip /M<k'<+L T .sbsp.chip /M in steps of T chip /M, α(t) is the impulse response of the overall transmit shaping filter and β(t) is the impulse response of the overall receive shaping filter. Since ρ p (k') decays as k' increases, L is chosen to indicate that point where ρ p (k') is very small. In other words, L is chosen such that ρ p (L T .sbsp.chip /M)<<ρ p (0). The transmit filter impulse response α(t) is defined in the IS-95 and IS-98 CDMA standards. For IS-95 it is found in section 6.1.3.1.10 "Baseband Filtering" (pages 6-31-6-33 of IS-95-A+TSB74). The receive filter impulse response β(t) is a design option and is typically chosen to be equal to α(t) in order to maximize the expected signal to noise ratio. The impulse responses α(t) and β(t) are thus known a priori. The output of generator 32 is stored in lookup table 30, per value of k'.
Since all Walsh codes and the entire PN sequence are known a priori (recall that the PN sequence is finite and periodic), and since each symbol is transmitted with N values of the PN sequence, ρ a (k,n) can also be generated a priori, for all possible values of k and n and stored in a lookup table 34. A priori spreading code cross-correlator 36 determines ρ a (k,n) as follows. ##EQU2##
q.sub.x (m,n)=x.sub.-- Walsh(m)*PN(m+nN)
x=pilot or user
0≦m≦L-1 per symbol n
-∞≦n≦∞
PN(m+nN+kQ)=PN(m+nN) ∀ m,n,k
where, as defined in the above equation, the pilot and user Walsh codes q(m,n) are sequences of N chips and PN(n) is a periodic extension of a pseudo-random number sequence of length Q where, for the IS-95 standard, Q is 2 15 .
Interference processor 20 additionally comprises a finger cross-talk determiner 38 which receives the estimated channel taps h i and the estimated finger delays τ i from the channel estimator 14 and utilizes them and the information stored in the two lookup tables 30 and 34 to determine the cross-talk effect of two fingers i,j for the given channel, channel delays and pilot signal.
Specifically, interference processor 20 begins by determining the value of k 0 ', where k 0 '=τ i -τ j , after which interference processor 20 activates cross-talk effect determiner 38 to determine the cross-talk effect a i ,j (n) as follows: ##EQU3## where the sum is performed for all k and k' within the ranges around k 0 ' defined by |k-int(k 0 ')|<J and |k'-k 0 '|<J, respectively. J is a design parameter and is typically in the range of 1 to 10. It is noted that the delay differences k' and k are stepped by steps of one chip, where all delay difference k' includes the fractional portion of k 0 '. Thus, if k 0 ', is, for example, 7.25 chips, then k' might have values of 5.25, 6.25, 7.25, 8.25 and 9.25 and k might have values 5, 6, 7, 8 and 9.
The quantity a i ,j (n) can be shown to be an estimate of the interference of the pilot signal along finger i to the user signal at finger j. Any number of fingers can be assumed though three is common. For three fingers, i and j vary from 0 to 2. In the IS-95 standard the Walsh codes are perfectly orthogonal, the term a i ,j (n) is identically zero. However, with non-orthogonal codes, this term is generally non-zero.
To calculate a i ,j (n), interference processor 20 retrieves the value of ρ p (k,n) for each value of k and for the nth symbol from lookup table 34 and the value of τ p (k') for each value of k' from lookup table 30. Interference processor 20 activates the cross-talk effect determiner 38 for each set (i,j) of fingers where, for each set, the value of k o ' is first determined as are the ranges of k and k'.
Interference processor 20 additionally comprises a finger interference effect determiner 40 and a total interference effect determiner 42. Finger interference effect determiner 40 determines the interference effect B j (n) per finger as: ##EQU4## where the sum is performed over the number of fingers in the channel.
Total interference effect determiner 42 determines the total interference effect C(n) as the sum of the B j (n). The total interference effect C(n) is the output of interference processor 20. As shown in FIG. 3B described in detail hereinbelow, the rake receiver 12 can subtract the individual finger interferences B j (n) from the individual finger contribution, thereby directly producing the corrected, estimated user data signal x'(n).
It will be appreciated that, by removing the interference effect of the pilot signal, a significant portion, though not all, of the noise which affects the user signal x(n) has been removed, thus increasing the performance quality of optional decoder 18. Furthermore, as can be seen from the discussion hereinabove, the computational burden of interference processor 20 is relatively small, in particular since the two cross-correlations ρ a (k,n) and ρ p (k') can be determined a priori and stored in the lookup tables 30 and 34. Alternatively, ρ a (k,n) can be determined "on-the-fly", from equation 2, since its computation only involves summation on PN "chips" which, in the IS-95 standard, accept only the values of ±1.
Reference is now briefly made to FIG. 3A which illustrates the elements of rake receiver 12 for a three finger channel and to FIG. 3B which illustrates an alternative version 12' of rake receiver 12 which performs the interference correction therewithin.
Rake receiver 12 has three fingers, each performing approximately the same operation on its associated finger. Each finger includes a despreader 50, a windowing summer 52, a sampler 54, a finger gain multiplier 56 and a complex-to-real converter 58. In addition, the second and third fingers include delays 60.
The first finger, known as the 0 th finger, serves as the reference finger. The second and third fingers (referred to as the 1 st and 2 nd fingers), respectively, have delays defined by τ 1 and τ 2 , respectively, relative to the 0 th finger. Delays 60 delay the received signal r(n) by their delay relative to the 0 th finger. For completion, we set τ 0 =0.
Despreaders 50 despread the received signal r(n) (the 0 th finger) or the delayed signal (the 1 st and 2 nd fingers) via the spreading signal q user , defined hereinabove. Windowing summer 52 sums the output of despreaders 50 over a window of N samples and divides the result by N, as indicated. Samplers 54 sample every Nth datapoint. Finger gain multipliers 56 multiply the sampled signal by the complex conjugate of the associated channel tap h i . Converters 58 take the real portion of the resultant signal. A summer 62 sums the output of each finger and produces therefrom the data signal x(n).
The rake receiver 12' of FIG. 3B is similar to that of FIG. 3A (and therefore, similar elements carry similar reference numerals) with the addition of three subtractors 64 between their respective multiplier 56 and converter 58. Subtractors 64 subtract the finger interference effect B i (n) of the relevant finger from the output of the relevant multiplier 56.
It will be appreciated that, in this embodiment, the output of rake receiver 12' is the corrected data signal x'(n).
Reference is now briefly made to FIG. 4 which illustrates a data detector 10' capable of reducing multi-pilot interference. The detector of FIG. 4 is particularly useful for mobile units when they are approximately equidistant between two or more base stations. At this position, the mobile units receive the pilot signals of the multiple base stations with approximately equal strength. Both pilot signals interfere with the transmitted data signal.
The data detector 10' is similar to data detector 10 of FIG. 1 in that it includes rake receiver 12, subtractor 22 and optional decoder 18. Data detector 10' also includes a plurality NB of interference processors 20, one per base station that is interfering, and associated pilot processors 11. As described hereinabove, each pilot processor 11 includes a synchronizer, a channel estimator and a delay estimator. However, in data detector 10', each pilot processor 11 synchronizes to the pilot of a different base station and, accordingly, each interference processor 20 generates the interference effect of the pilots of the different base stations. Subtractor 22 removes the multiple interference effect outputs of processors 20 from the data signal x(n) in order to produce the corrected signal x'(n) which optional decoder 18 then decodes.
It will be appreciated that the pilot and interference processors 11 and 20, respectively can also be incorporated in a base station, for synchronizing to the pilot signal of a neighboring base station and for determining the interference effect of the neighboring pilot signal on each of the plurality NU of user signals which the base station receives. Thus, as shown in FIG. 5, the base station includes a detector 80 which produces NU data signals x i (n). In accordance with a preferred embodiment of the present invention, the base station includes at least one pilot processor 11 for the neighboring base station's pilot signal and NU interference processors 20, one per user, for determining the interference effect of the neighboring pilot signal on the data signal of each user. The base station also includes NU subtractors 22, one per user, for removing the interference effect C i (n) of the relevant interference processor 20 from the corresponding data signal x i (n).
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims which follow: | Apparatus and a method for receiving spread-spectrum signals is provided. The method includes the steps of detecting a noisy user signal from a spread-spectrum signal including at least a first user signal (including data therein) and at least one pilot signal, and removing an interference effect of the pilot signal on the first user signal from the noisy user signal thereby to create a noise reduced user signal. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plasma display panel (PDP) having a dielectric layer that covers display electrodes and a partition that divides a discharge space.
It is desired that a PDP has a panel structure suitable for a display with high luminance and high resolution.
2. Description of the Prior Art
A surface discharge type is adopted for an AC type PDP for a color display. According to this surface discharge type, in display discharge for securing luminance, display electrodes to be anodes and cathodes are arranged in parallel on a front or a back substrate, and address electrodes are arranged so as to cross pairs of display electrodes. The surface discharge type PDP needs a partition for localizing discharge in the longitudinal direction of a display electrode (i.e., the row direction). As a simplest partition pattern that has a good productivity, a so-called stripe pattern is known well, in which band-like partitions that are linear in a plan view are arranged at boundaries between columns of a matrix display.
There is an arrangement form of the display electrodes in the surface discharge type, in which the number of rows N plus one of display electrodes are arranged substantially at a constant pitch. In this form, neighboring display electrodes make an electrode pair for surface discharge, and each of the display electrodes except both ends of the arrangement works for an odd row and an even row in a display. This form has an advantage in high definition (reduction of a row pitch) and in effective usage of a display screen.
In the conventional PDP that has display electrodes arranged at a pitch equal to the pitch of the partitions of the stripe pattern, an odd row display and an even row display share one display electrode. Accordingly, a display form is limited to an interlace form. In the interlace form, a half of the total number of rows in a whole screen are not used for a display in each of odd and even fields in such a way that even rows are not lighted in an odd field. Therefore, luminance in the interlace form is lower than that in the progressive form. In addition, since the interlace form causes flickers in a display of a still picture, it is difficult to satisfy the request of a display quality that is necessary for a high quality image device such as a DVD or a full-spec HDTV.
A display of the progressive form can be achieved by adopting a partition having a mesh pattern that divides a discharge space into cells. However, a PDP having a mesh pattern partition has a low productivity of filling a gas in the manufacturing process. Since an inner resistance to ventilation is large, vacuum exhaustion process needs a long time.
In order to reduce the resistance to ventilation, there is a method of cutting off the partition in part. Alternatively, the structure disclosed in Japanese unexamined patent publication No. 2001-216903, in which the dielectric layer is raised in part, has a sufficient ventilation path. However, the method of cutting off the partition or raising the dielectric layer in part causes increase of manufacturing steps and a cost of the product.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a PDP having a structure suitable for a progressive display with high definition and a good productivity.
According to one aspect of the present invention, a dielectric layer that covers display electrodes is made a layer whose surface has projections and depressions along undulations of the surface on which the dielectric layer is formed, and a partition is disposed so as to face the projections of the surface of the dielectric layer. The surface layer of the dielectric layer has a step corresponding to the thickness of the display electrode, and a gap corresponding to the step size is formed as a ventilation path between the partition and the dielectric layer. The ventilation path enables exhausting process in manufacturing a PDP to be efficient. Even if the partition has a mesh pattern, the ventilation path enables the exhausting process to be performed quickly. This means that the cell structure is suitable for stabilizing discharge characteristics by cleaning the inside sufficiently. As a method for forming the dielectric layer, a plasma chemical vapor deposition process is suitable. Since the layer that is formed by this process covers groundwork in an isotropic manner, a special process for forming a ventilation path is not required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a cell structure of a PDP according to a first embodiment.
FIG. 2 is a diagram showing an electrode structure of the PDP according to the first embodiment.
FIG. 3 is a cross section showing an inner structure of the PDP according to the first embodiment.
FIG. 4 is a plan view showing an electrode structure of a PDP according to a second embodiment.
FIG. 5 is a cross section showing an inner structure of the PDP according to the second embodiment.
FIG. 6 is a plan view showing an electrode structure of a PDP according to a third embodiment.
FIG. 7 is a cross section showing an inner structure of the PDP according to the third embodiment.
FIG. 8 is a plan view showing an electrode structure of a PDP according to a fourth embodiment.
FIG. 9 is a cross section showing an inner structure of the PDP according to the fourth embodiment.
FIG. 10 is a plan view showing an electrode structure of a PDP according to a fifth embodiment.
FIG. 11 is a cross section showing an inner structure of the PDP according to the fifth embodiment.
FIG. 12 is a plan view showing a partition pattern and display electrodes of a PDP according to a sixth embodiment.
FIG. 13 is a plan view showing a partition pattern and display electrodes of a PDP according to a seventh embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be explained more in detail with reference to embodiments and drawings.
FIG. 1 shows a cell structure of a PDP according to a first embodiment, and FIG. 2 shows an electrode structure of the PDP according to the first embodiment. The PDP 1 comprises a pair of substrate structural bodies (a structure of a substrate on which cell elements are disposed) 10 and 20 . Display electrodes X and Y are arranged at a pitch equal to a row pitch on the inner surface of a glass substrate 11 that is a base of the front substrate structural body 10 . The row means a set of cells having the same order in the column direction. Each of the display electrodes X and Y is made of a linear band-like transparent conductive film 41 for forming a surface discharge gap and a metal film (a bus conductor) 42 that is overlaid on the transparent conductive film 41 at the middle in the column direction. The metal film 42 is drawn out to the outside of the display screen so as to be connected to a driver circuit. The display electrodes X and Y are covered with a dielectric layer 17 , which is coated with a protection film 18 made of a magnesia (MgO). Address electrodes A are arranged on the inner surface of a glass substrate 21 that is a base of the back substrate structural body 20 so that one address electrode corresponds to one column, and the address electrodes A are covered with a dielectric layer 24 . On the dielectric layer 24 , a mesh pattern partition 29 having the height of approximately 150 microns is arranged. The partition 29 has a grid pattern in a plan view comprising a first portion dividing a discharge space into columns (hereinafter referred to as vertical walls) 291 and a second portion dividing the discharge space into rows (hereinafter referred to as horizontal walls) 292 . In addition, fluorescent material layers 28 R, 28 G and 28 B of red, green and blue colors for a color display are arranged so as to cover the surface of the dielectric layer 24 and side faces of the partition 29 . Italic letters (R, G and B) in FIG. 1 indicate light emission colors of the fluorescent materials. The color arrangement has a repeating pattern of red, green and blue colors in which cells in a column have the same color. The fluorescent material layers 28 R, 28 G and 28 B emit light when being excited by ultraviolet rays emitted by the discharge gas. As shown in FIG. 2 , the metal film 42 is arranged so as to overlap the horizontal wall 292 of the partition 29 , and the transparent conductive film 41 protrudes at both sides of the horizontal wall 292 so as to form a surface discharge gap for each cell in cooperation with the neighboring transparent conductive film 41 . In FIG. 2 , four cells 51 R, 51 G, 52 R and 52 G are shown by dot-dashed lines as representatives. Since the partition pattern is a mesh or grid pattern, which is different from a stripe pattern in which horizontal walls are omitted, discharge interference does not occur in the column direction. Namely, in the PDP 1 , a progressive display can be realized without a complicated driving sequence. In addition, the fluorescent material is provided also at the side faces of the horizontal wall 292 , so that the light emission efficiency is improved. By arranging the metal films 42 of the display electrodes X and Y so as to overlap the horizontal wall 292 , light shielding of display light by the metal film 42 can be eliminated. As a result, 10–20% improvement can be recognized.
FIG. 3 is a cross section showing an inner structure of the PDP according to the first embodiment. In the PDP 1 , the transparent conductive film 41 is made of ITO, whose thickness is 0.1 microns. The metal film 42 is made of three layers including chromium (Cr), copper (Cu) and chromium, and its thickness is set to a value within the range of 2–4 microns. The dielectric layer 17 is made of silicon dioxide (SiO 2 ) and is formed at a constant thickness by the plasma CVD process. The thickness of the dielectric layer 17 is preferably a value within the range of 5–10 microns. As shown in FIG. 3 , the dielectric layer 17 has surface in which the projections and depressions of the forming surface (a part of the substrate surface and the surface of the display electrode) are reproduced faithfully. This is a feature that cannot be obtained by a usual forming process in which a paste is applied before burning. Since the surface of the dielectric layer 17 has projections and depressions, a gap to be a ventilation path 37 is formed between neighboring display electrodes X and Y. The ventilation path 37 crosses over the vertical wall 291 and is continuous over a plurality of cells arranged along the display electrode. The size of the ventilation path 37 in the direction of the thickness of the substrate is 2–4 microns, substantially the same as the thickness of the metal film 42 and is sufficiently larger than the roughness of the surface of the dielectric layer 17 (measured value is approximately one micron). Because of this ventilation path 37 , the time necessary for exhaustion in producing the PDP 1 is similar to the conventional PDP having the stripe pattern partition. Supposing that the display electrodes X and Y are thick film electrodes (such as silver electrodes) having the thickness of 8–10 microns, the time for exhaustion can be shortened so that cost efficiency of the production can be improved.
FIG. 4 is a plan view showing an electrode structure of a PDP according to a second embodiment. FIG. 5 is a cross section showing an inner structure of the PDP according to the second embodiment. Each of display electrodes Xb and Yb of the PDP 1 b is made of an I-shaped transparent conductive film 41 b arranged at each column and a linear band-like metal film 42 . The display electrodes Xb and Yb are covered with a dielectric layer 17 b and a protection film 18 b . Since a gap to be a ventilation path 37 b is formed between neighboring display electrodes Xb and Yb also in the PDP 1 b , rapid exhaustion can be performed in its production. The transparent conductive film 41 b is disposed so that the portion protruding from the metal film 42 is like a t-shape. Thus, discharge current is limited, so that light emission efficiency is improved, and capacitance between electrodes can be reduced.
FIG. 6 is a plan view showing an electrode structure of a PDP according to a third embodiment. FIG. 7 is a cross section showing an inner structure of the PDP according to the third embodiment. Each of display electrodes Xc and Yc of the PDP 1 c is made of a T-shaped transparent conductive film 41 c arranged at each column and a linear band-like metal film 42 c . The display electrodes Xc and Yc are covered with a dielectric layer 17 c and a protection film 18 c . Since a gap to be a ventilation path 37 c is formed between neighboring display electrodes Xc and Yc also in the PDP 1 c , rapid exhaustion can be performed in its production. Since the display electrodes Xc and Yc are independent for each row, a progressive display can be driven easily.
FIG. 8 is a plan view showing an electrode structure of a PDP according to a fourth embodiment. FIG. 9 is a cross section showing an inner structure of the PDP according to the fourth embodiment. Each of display electrodes Xd and Yd of the PDP 2 is made of a band-like metal film that is patterned in a shape having a gap that restricts discharge current. The display electrodes Xd and Yd are covered with a dielectric layer 17 d and a protection film 18 d . Since a gap to be a ventilation path 38 is formed between neighboring display electrodes Xd and Yd also in the PDP 2 , rapid exhaustion can be performed in its production.
FIG. 10 is a plan view showing an electrode structure of a PDP according to a fifth embodiment. FIG. 11 is a cross section showing an inner structure of the PDP according to the fifth embodiment. Each of display electrodes Xe and Ye of the PDP 2 b is made of a linear band-like metal film. The display electrodes Xe and Ye are covered with a dielectric layer 17 e and a protection film 18 e . Since a gap to be a ventilation path 38 b is formed between neighboring display electrodes Xe and Ye also in the PDP 2 b , rapid exhaustion can be performed in its production.
FIG. 12 is a plan view showing a partition pattern and display electrodes of a PDP according to a sixth embodiment. The pattern of a partition 29 f of the PDP 3 is a honeycomb pattern that is a type of the mesh pattern, and the shape of a cell is a hexagon. Each of display electrodes Xf and Yf is made of a linear band-like transparent conductive film 41 f and a band-like metal film 42 f that is meandering along the partition 29 f so as to minimize light shield.
FIG. 13 is a plan view showing a partition pattern and display electrodes of a PDP according to a seventh embodiment. The partition pattern of the PDP 3 b is a stripe pattern made of a meandering band-like partition 29 g . The partition 29 g is arranged so as to form a column space in which wide portions and narrow portions are arranged alternately. Since the partition pattern of the PDP 3 b is a stripe pattern, ventilation is free in the column direction crossing the display electrodes Xf and Yf. The ventilation path, which is formed by forming a dielectric layer similar to the above-mentioned embodiment, causes air flow in the direction along the display electrodes Xf and Yf, so that ventilation is performed rapidly.
While the presently preferred embodiments of the present invention have been shown and described, it will be understood that the present invention is not limited thereto, and that various changes and modifications may be made by those skilled in the art without departing from the scope of the invention as set forth in the appended claims. | A plasma display panel having a structure that enables high definition progressive display and has good productivity is provided. A dielectric layer that covers display electrodes is made a layer whose surface has projections and depressions along undulations of the surface on which the dielectric layer is formed. A partition is arranged so as to face the projections of the surface of the dielectric layer for ensuring a ventilation path for exhausting air. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of previously filed Provisional Patent Application, Ser. No. 61/435,897 filed on Jan. 25, 2011.
FIELD OF THE INVENTION
This invention belongs to the field of manufacture of spectrometers. More specifically it is a new shaped aperture to improve resolution in grating spectrometers.
BACKGROUND OF THE INVENTION
Many grating spectrometers use a folded optical configuration similar to that shown in FIG. 1 . The figure shows several aspects of the device that are pertinent to the following background of the art discussion.
The source (not shown) is placed behind the entrance slit ( 1 ), and has a divergence which would lead to overfilling of the entrance mirror, M 1 ( 3 ). Any light that misses M 1 ( 3 ) will not form a dispersed image at the detector plane ( 6 ), but will instead scatter inside the spectrometer, leading to an increase in background signal.
To avoid this stray light problem, an aperture ( 2 ) is used after the slit ( 1 ) to limit the acceptance cone of the spectrometer to only light that will strike the input minor ( 3 ). The aperture ( 2 ) size is usually expressed as an f-number by comparing the size of the beam at M 1 ( 3 ) to the focal length of M 1 ( 3 ).
M 1 ( 3 ) is used as an off-axis collimating element. This introduces a variety of aberrations into the collimated beam, primarily astigmatism and coma. The result is that the nominally collimated beam actually contains a distribution of angles.
The diffraction angle from the grating ( 5 ) depends non-linearly on the angle of incidence, so the angular distribution present in the incident beam is broadened in the diffracted beam. Furthermore, since the diffraction angle is also a function of wavelength, the output distributions differ for the various wavelength components of the beam.
M 2 ( 4 ) is also used as an off-axis element, and therefore contributes its own aberrations into the image formed at the detector ( 6 ). M 2 ( 4 ) must be larger than M 1 ( 3 ) in order to avoid vignetting the dispersed light diffracted from the grating ( 5 ). Since different portions of M 2 ( 4 ) are used by different wavelength components, the aberration contributions are different as well.
These issues are all well-known, and are traditionally addressed by designing the optical system to minimize both the fold angles and the size of the input aperture ( 2 ). By holding both parameters to the smallest possible values the aberrations are minimized.
BRIEF SUMMARY OF THE INVENTION
This invention is a method for improving image quality in a spectrometer using an aperture shaped to provide a narrow beam in the horizontal plane but a wider beam in the vertical plane without sacrificing as much throughput as typically experienced using a reduced diameter round aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
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, in which:
FIG. 1 shows a layout of a generalized prior art Czerny-Turner spectrometer.
FIGS. 2 a ., 2 b ., and 2 c . show a preferred embodiment of the invention.
FIGS. 3 a . and 3 b . show a simulated output of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A key parameter for any photometer is the input NA or f-number. Larger apertures admit more light and therefore provide better sensitivity: all else being equal throughput is expected to be proportional to the square of the aperture size. However, for any optical system aberrations also increase with aperture size. In the case of a spectrometer increased total throughput is of little use if the slit image is blurred in such a way that the peak intensity of a spectral line does not improve because the light is smeared over a larger area. The balance between these competing factors determines the optimum design.
For an optical train which is folded but constrained to a plane the system is less prone to aberrations perpendicular to that plane. That is because the mirrors are effectively being used on-axis in the perpendicular plane, rather than at the fold angle as in the dispersion plane.
This suggests that the system can sustain a larger aperture in the perpendicular than in the dispersion plane. For a spectrometer such as that shown in FIG. 1 an aperture ( 2 ) shaped to provide a narrow beam in the horizontal plane but a wider beam in the vertical plane will provide improved image quality without sacrificing as much throughput as a reduced diameter round aperture ( 2 ).
While the aperture ( 2 ) shape can be anything that provides an adjustable aspect ratio, a convenient choice is an elliptical aperture ( 2 ) with a fixed height which fills the input minor ( 3 ) and a variable width which is chosen to optimize performance.
For a spectrometer with a fixed slit ( 1 ) width it is convenient to use photo-lithographic techniques to pattern the slit ( 1 ) and aperture ( 2 ) on opposite sides of a transparent input block ( 8 ). This avoids the necessity of aligning the aperture ( 2 ) to the slit ( 1 ) during manufacture, and at the same time provides the aperture ( 2 ) with a convenient mount. Having the slit patterned on a glass block also allows the entire optical path to be environmentally sealed for improved performance and deployment possibilities. The advantages of patterning the slit and aperture on a single transparent input block assembly are not limited to spectrometers using a shaped aperture and are equally effective if using a more traditional circular or other shape of aperture and/or slit.
While these issues are common to any folded path spectrometer the details of the aberrations are peculiar to the specific design under consideration. The aperture ( 2 ) f-number, minor ( 3 & 4 ) focal lengths, fold angles, grating ( 5 ) pitch, and angle of incidence at the grating ( 5 ) will all contribute to the final image quality. For this reason the optimum aperture ( 2 ) aspect ratio is also peculiar to the specific design. It should also be noted that the same basic design can be configured differently for different applications and this, too, can affect the optimum choice of aspect ratio.
A schematic layout of the preferred embodiment for discussion is shown in FIGS. 2 a ., 2 b.c and 2 c . Note the crossed Czerny-Turner design. A typical input fiber ( 7 ) has an NA of 0.22, which would result in a beam too large for M 1 ( 3 ). A limiting aperture ( 2 ) is therefore used to maintain an f/4 input beam. The minor ( 3 & 4 ) locations and fold angles are configured to maintain perpendicular input and output beams. The grating ( 5 ) angle is set to place a 575 nm beam at the center of the output range for a 600 LPM grating. The output beam is folded down through the plane of the figure using a right angle prism ( 9 ).
The preferred embodiment detector ( 6 ) is a linear array of 1024 pixels with a 7.8 μm pitch. The signal from the preferred embodiment comprises the digitized intensity profile of the dispersed slit ( 1 ) image as projected onto the detector array. In order to implement the invention the slit ( 1 ) and aperture ( 2 ) are most conveniently placed on opposite sides of a transparent input block ( 8 ) for ease of manufacture and placement within the spectrometer, but the same remarks apply to a situation where the slit and aperture are separately manufactured and mounted.
The effect of the shaped aperture ( 2 ) is conveniently demonstrated using software capable of simulating the system response when illuminated by an extended source such as a multimode optical fiber ( 7 ). Simulations were carried out for the case of a 12.4 μm input slit ( 1 ) to demonstrate the effect of the shaped aperture ( 2 ). Results from simulations at three wavelengths are shown in FIG. 3 , illustrating the variation in aberrations experienced at different wavelengths.
In the simulated preferred embodiment output the peaks are shifted horizontally to allow display on the same plot. In FIG. 3 a the system uses a round f/4 input aperture ( 2 ). In FIG. 3 b an elliptical aperture ( 2 ) that is f/4 in the vertical but f/8 in the horizontal direction is used. Computer model results show that while overall throughput decreases by a factor of 2 with the shaped aperture ( 2 ), the decrease in peak intensity is much less, between 15-25% depending on wavelength, since it is primarily the light forming the “tails” which is eliminated by the shaped aperture ( 2 ).
Since certain changes may be made in the above described shaped input apertures 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. In particular, while the illustrative example used involved use of a linear pixel array as the detection element in order to record the entire dispersed spectrum simultaneously, a common variation of the design uses a slit at the image plane to pass only a small portion of the spectrum at a time. In this case the light is then detected by a single element detector and the spectrum is obtained by rotating the grating to pass a different portion of the spectrum through the exit slit in sequence. Such a variant is also known as a monochromator. All of the remarks regarding image quality and resolution apply equally to this special case. | An aperture shaped to provide a narrow beam in the horizontal plane but a wider beam in the vertical plane that will provide improved image quality in spectrometers without sacrificing as much throughput as typically experienced using a reduced diameter round aperture along with a method of mounting the entrance slit and the limiting aperture on a transparent block for optical stability and ease of alignment is disclosed. | 6 |
[0001] The disclosed system and method provide a binary image generation technique, and more particularly, a system and method suitable for eliminating printing artifacts for high addressable binary digital output such as digital copies using an optimized ordered error diffusion method with dynamically computable quantization error and dynamic binary output calculation.
BACKGROUND AND SUMMARY
[0002] When standard error diffusion is applied to scanned documents in the copy image path, many isolated dots are created in the resultant image. Some print engines are not capable of printing/reproducing these isolated pixels accurately and systematically, which leads to unwanted image quality artifacts in the copies, such as uneven and patchy image areas. The image quality of text and line art is also impacted, even in the case of high addressable printing.
[0003] Rank order error diffusion (ROED), such as disclosed by (i) R. Loce et al., in U.S. application Ser. No. 09/968,651, filed Oct. 1, 2001, (U.S. Publication 20030090729) for, “RANK-ORDER ERROR DIFFUSION IMAGE PROCESSING”; (ii) R. Loce et al., in U.S. application Ser. No. 11/034,057, filed Jan. 13, 2005, for “SYSTEMS AND METHODS FOR CONTROLLING A TONE REPRODUCTION CURVE USING ERROR DIFFUSION”; (iii) B. Xu et al., U.S. application Ser. No. 11/013,787, filed Dec. 17, 2004 for “SYSTEMS AND METHODS FOR RANK-ORDER ERROR DIFFUSION IMAGE PROCESSING”; and (iv) Y. Zhang et al., U.S. application Ser. No. 10/923,116, filed Aug. 20, 2004, for “UNIFORMITY COMPENSATION IN HALFTONED IMAGES”, all of which are hereby incorporated in their entirety for their teachings, has numerous applications and is an excellent starting step for eliminating artifacts in non high addressable output. However, some artifacts are likely to remain. In the high addressable binary image context, rank order error diffusion combined with compact high addressable pixel creation, as described for example in (i) U.S. application Ser. No. 11/034,057; (ii) U.S. application Ser. No. 11/013,787; and (iii) U.S. Pat. No. 6,683,702 to R. Loce et al., for “Compact-Dot Reproduction of Scanned Halftone Screens,” also incorporated by reference in its entirety, generates unwanted patterning artifacts.
[0004] Implementation of rank order error diffusion as described in (i) U.S. application Ser. No. 09/968,651; or (ii) U.S. application Ser. No. 11/104,758, by R. Loce et al., filed Apr. 13, 2005, for “BLENDED ERROR DIFFUSION AND ADAPTIVE QUANTIZATION”,” also hereby incorporated by reference in its entirety, may be prohibitive in high-speed image paths. Rank order error diffusion is also disclosed in: U.S. application Ser. No. 11/218,966, by R. Loce et al., filed Sep. 2, 2005 for “COLOR MANAGEMENT OF HALFTONED IMAGES ”, which is also hereby incorporated by reference in its entirety.
[0005] Accordingly, a modified and less computationally intensive ordered error diffusion method, a different technique of generating the high addressable binary output, and a different technique of calculating the quantization error based on local context, are needed for the copy path to meet increased throughput speed and image quality requirements. The disclosed system and method provide a binary image generation method using ordered error diffusion with optimized and improved image processing speed and image quality for eliminating printing artifacts for digital output such as copies.
[0006] Disclosed in embodiments herein is a method for processing an input image, comprising: creating binary output by thresholding a current grayscale input image pixel and an associated intermediate predicted pixel value; calculating a pixel quantization error based upon the current image pixel value and the intermediate predicted pixel value; ordering a plurality of neighboring pixels of the current pixel located in a predefined processing window according to their gray values; diffusing a maximum possible amount of quantization error for the current image pixel sequentially to a subset of the plurality of neighboring pixels of the current pixel, where the subset of the plurality of neighbors are selected in accordance with the sign of quantization error; and repeating the steps above for each input pixel in the image to produce an error-diffused output image.
[0007] Also disclosed in embodiments herein is a method creating a halftoned image, comprising: receiving a pixel value from an input image; selecting an processing window encompassing M neighboring pixels; selecting a threshold; thresholding the pixel value with the selected threshold to make a binary marking decision; calculating a quantization error value based on the pixel value and the binary marking decision; and diffusing quantization error to at least one selected neighboring pixel(s) N within the diffusion mask M, based on the calculated error value, the selection being based on pixel values of a plurality of neighboring pixels within the diffusion window.
[0008] Further disclosed in embodiments herein is a digital reprographic system, comprising: an image source; an image processor, for processing each input pixel of an input image from said image source to produce an error-diffused output image, said image processor including a thresholder for creating binary output and an associated intermediate predicted pixel value as a function of a current image pixel; a pixel error calculator for calculating pixel quantization error based upon the current image pixel value and the intermediate predicted pixel value; a pixel ordering circuit for ordering the current input image pixel's M neighboring pixels located in a predefined processing window according to their gray values, said ordering circuit further diffusing the quantization error for the current image pixel sequentially to N out of the M neighbors of the current pixel, where N is not greater than M; where the N neighbors are selected depending on the sign of quantization error, and an image output terminal for outputting the error-diffused output image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a flow diagram illustrating aspects of an embodiment of the method disclosed herein;
[0010] FIG. 2 is a block diagram of a portion of an image processing system operative to perform the method of FIG. 1 ;
[0011] FIG. 3 is an illustration of an exemplary error diffusion window to which the method of FIG. 1 may be employed;
[0012] FIGS. 4 and 5 are illustrative representations of the dynamically computable quantization error and dynamic binary output calculation; and
[0013] FIG. 6 is a flow diagram illustrating an alternative process employed with the method of FIG. 1 .
DETAILED DESCRIPTION
[0014] The following disclosure sets forth embodiments for a system and method. However, it will be appreciated that the disclosed features and functions, and alternatives thereof, may be combined into alternative systems or applications. For example, in FIG. 1 , there is depicted a flowchart that depicts the primary operations of the disclosed method. Similarly, FIG. 2 depicts a schematic block diagram of a digital reprographic or multifunction system wherein certain functional components are identified as providing an embodiment suitable for operation of the system as described relative to FIG. 1 .
[0015] Referring briefly to FIG. 3 , there is depicted an example of a processing window for use with an error diffusion operation in accordance with an aspect of the disclosure that follows. In particular, window 310 , includes a plurality of pixels (a, b . . . j) located at defined positions (0, 1, . . . , 9) adjoining a current pixel “p” ( 320 ). As used herein, the pixels in the window are temporarily stored in an array of size M (e.g., edarray[10] where edarray[i] corresponds to position i in window 310 ).
[0016] Referring to FIG. 1 , there is depicted a method 110 for processing a continuous tone or multi-quantization level input image, high addressableto produce possibly high addressable binary output image representative thereof and without print engine artifacts. Method 110 comprises creating a binary output by thresholding a current grayscale input image pixel and an associated intermediate predicted pixel value. It will be appreciated that the disclosed method finds particular use in high addressable images, and one embodiment hereof contemplates such a possibility as will be further described relative to FIGS. 4 and 5 . Respectively, FIGS. 4 and 5 illustrate the manner in which thresholding may be performed for a 2× and a 1× (non) high addressable case. In the 2× case of FIG. 4 , depending upon the current pixel value (p) and the intermediate predicted value (predval), the possibly binary high addressable output values are 00, 01, 10, or 11, and the pixel error (pixerr) to be propagated is calculated as a function of the current pixel value (p) and the intermediate predicted value predval (e.g., for p=215 and predval=200, pixerr=−40). In other words, a binary output is created by thresholding a current grayscale input image pixel and a intermediate predicted pixel value, producing a high addressable binary representation of the grayscale input image pixel, where the quantization error for the current pixel is a function of the high addressable binary representation.
[0017] In one embodiment, predval is determined as a function of the current pixel (p) and the next adjacent pixel (a) as depicted in FIG. 3 , where
predval= wa·a+wp·p,
and where wa and wp are respective weighting variables. The thresholding operation depicted in FIG. 5 is similar, but is directed to a 1× (non high addressable) case, and hence the outputs are simply a single binary value.
[0018] Returning to FIG. 1 , operation 120 of the method 110 further comprises calculating a pixel error based upon the current image pixel value and the intermediate predicted pixel value. As noted above, the function used to calculate quantization error (pixerr) is a function of the current pixel (p) and the intermediate predicted value (predval), as represented in the examples of FIGS. 4 and 5 . It will be appreciated that the disclosed method of calculating quantization error is different that that suggested by the Loce et al. as noted above. After thresholding, the quantization error for the current image pixel is diffused sequentially to N out of the M neighbors of the current pixel, where N is not greater than M; where the N neighbors are the N biggest or N smallest pixel values in the window of M neighboring pixels depending if the quantization error is positive or negative, respectively, The N neighbors are picked from the edarray[M] in the order corresponding to the sign of the quantization error (increasing if the sign of the quantization error is negative, decreasing if the sign is positive). A saddr[M] memory array or buffer is used as an address buffer, wherein the addresses point to the edarray[i] values in the respective (increasing or decreasing) order. More specifically, the process may be generally characterized by the following code section:
if (pixerr >= 0) for all i=0,..,N { deltaer = pixerr if (value at saddr[i] + deltaer> 255) deltaer = 255 − value at saddr[i] pixerr = pixerr − deltaer value at saddr[i] = value at saddr[i] + deltaer } else for all i=0,..,N { deltaer = pixerr if (value at saddr[i] + deltaer<0) deltaer = − value at saddr[i] pixerr = pixerr − deltaer value at saddr[i] = value at saddr[i] + deltaer }
[0019] Continuing with FIG. 1 , the ordering of the current input image pixel's M neighboring pixels in the processing window is accomplished as depicted at 130 —according to the gray values of the neighboring pixels. As indicated in before, a saddr[10] memory array or buffer is used as an address buffer, wherein the addresses point to the edarray[i] values in the respective (increasing or decreasing) order. Therefore, as the image is scanned from left to right and top to bottom, the ordering can be implemented in parallel in hardware and/or (as the processing window “slides”) only the new pixels have to be ordered with respect to the overlapping old ones.
[0020] The diffusion operation 140 intentionally diffuses a maximum possible amount of quantization error for the current image pixel, sequentially, to the N neighbors of the current pixel. The diffusion process is applied in this instance only to the first N (e.g., N=4) ordered neighbors in the processing window (out of M neighbors). In one embodiment the following values were used: M=10 and N=4. As will be appreciated, other combinations may be employed depending on the imaging characteristics of the system and the hardware.
[0021] As the pixels are ordered it is possible to pre-calculate (perhaps using a lookup table) how much error remains to saturate each pixel in the processing window (of size 10 in this embodiment) and at what point the pixel error will be consumed. This index and partial sums may be used in instantly performing the ordered error diffusion operation 140 , by knowing that all the pixels in the processing window with the calculated sum (see code below) less or equal to the pixel error (pixerr) become 0 or 255 (in an 8-bit per pixel imaging system):
satsum = 0; index=0; if (pixerr >= 0) { for (i=0; i<9; i++) { satsum=satsum + 255 − edarray[i]; if( satsum > pixerr ) { index = i; break; } } else { for (i=0; i<9; i++) { satsum=satsum−edarray[i]; if( satsum > pixerr ) { index = i; break; } } }
[0022] Furthermore, as represented by operation 150 of FIG. 1 , the process is repeated using the steps above until the input pixels in the image have been processed to produce an error-diffused output image. The processing is likely done in raster order, but other processing orders (e.g., serpentine) are feasible.
[0023] Referring to FIG. 2 , a portion of an image processing system 204 operative to perform the method disclosed above, including performing ordered error diffusion, includes an image source such as a digital or digitizing scanner 208 to produce an image 210 , which may be stored in memory 212 (e.g., magnetic media, RAM, etc.). The image 210 is passed to a pixel and neighborhood selector 214 , a pixel value sorter 218 , a thresholder 222 , a marker 226 , an ordered error diffuser 230 , and an output device such as an image output terminal 234 (e.g., a laser printer, photoprinter, etc.).
[0024] The pixel and neighborhood selector 214 selects a processing path or space-filling curve for processing the pixels of an image 210 . Additionally, the pixel and neighborhood selector 214 selects or generates a diffusion mask or set of diffusion masks that is compatible with a selected processing path. The processing path selection can be based on input received from a system operator or based on an analysis of the image and known or default rendering preferences, as described for example in U.S. Patent Application 2003/0090729 by Loce et al., published May 15, 2003, for a “Rank-Order Error Diffusion Image Processing.”
[0025] Selection of a preferred rendering characteristic is interpreted by the pixel and neighborhood selector 214 as a request for the use of a related processing path. Selection of a diffusion mask or set of masks may be based on a default, selected space-filling curve or may be based on operator input. The operator input may be an explicit mask selection, or may again be implied through the selection of a preferred rendering characteristic. Alternatively, the pixel and neighborhood selector 214 may analyze the image 210 and automatically select a space filling curve and diffusion mask(s) based on characteristics of the image.
[0026] Once the processing path and diffusion mask(s) have been selected, the pixel and neighborhood selector 214 follows the processing path working sequentially through the input image and selecting pixels of interest and neighboring pixels from the image and delivers information about them to the pixel value sorter 218 and the thresholder 222 . The pixel value sorter 218 receives information about the current pixel and the neighboring pixels. The thresholder 222 simply receives information about the current pixel and its right neighbor.
[0027] For example, the pixel value sorter 218 simply receives pixel value information. Optionally, the pixel ranker 218 also receives pixel position information. The value sorter 218 orders the neighboring pixels based on their values. Optionally, the pixel value sorter 218 applies spatial weights to the pixel values of the neighboring pixels before sorting the neighboring pixels. Appropriate spatial weights may be either predetermined default values, indicated by an operator selected rendering preference, or are based on an analysis of the image performed by the pixel value sorter 218 . Alternatively, the spatial weights include consideration of lightness or darkness variance of the neighboring pixels (i.e., processing generally uniform light or dark regions of the image preferentially. The pixel sorter 218 passes pixel information including, for example, pixel values, pixel ranks and pixel position information to the error diffuser 230 .
[0028] The thresholder 222 receives pixel value and pixel location information about a current pixel. The thresholder 222 compares the pixel value of the current pixel to a threshold value. The threshold value may be a constant value (e.g., binth=127), used to compare to all the pixel values of the image or the threshold value may vary. For example, the threshold value may be taken from a halftone screen. The thresholder, however, operates in a manner consistent with FIGS. 4 and 5 , where the output is a function of not only the threshold applied relative to the pixel value (p), but also as a function of the level of the intermediate predicted pixel value (predval) as described above. The thresholder then passes the results of the comparison to the marker 226 . For example, the thresholder 222 tells the marker 226 whether or not the pixel value of the current pixel is above or below the threshold value and whether or not the intermediate predicted pixel value (predval) is above or below the threshold value (output=0 or 1 in the 1× case as described in FIG. 4 ; output=00, 01, 10 or 11 in the 2× case as described in FIG. 5 ), thereby permitting marker to record a binary indication of a mark. The thresholder also passes the pixel value of the current pixel on to the error diffuser 230 . The threshold value for the current pixel and the threshold value for the predicted pixel value do not need to be the same.
[0029] The marker 226 makes a marking decision based on the results received from the thresholder. For example, if the pixel value is above the threshold value the marker decides to place a mark in a position in an output image corresponding to the current pixel. The output image may be an electronic image stored in an electronic memory or buffer. Alternatively, the output image may be an image formed by an outputting device such as an image output terminal 234 . The marker 226 also passes a value related to the marking decision to the error diffuser 230 . For example, the marker passes to the error diffuser 230 a value corresponding to a fully saturated mark, such as, for example, 255 (in an eight-bit system) or a value corresponding to a fully unsaturated mark (white or no mark), such as, for example zero.
[0030] The error diffuser 230 compares the value received from the marker to the pixel value of the current pixel and calculates an error value. The error diffuser then transfers or distributes error to one or more neighboring pixels N (from within the diffusion window 310 ). The error transfer or distribution is based on the sorting performed by the pixel value sorter 218 . Therefore, the error transfer or distribution is based on lightness or darkness of the neighboring pixels, as indicated by one or more pixel values of the pixels. Optionally, the sorting, and therefore the error transfer or distribution, is additionally based on the spatial position of the neighboring pixels. For example, a distance of neighboring pixels from a current pixel may be taken into account during the ranking. Alternatively or additionally, the positions of the neighboring pixels relative to an associated halftone dot are accounted for during the sorting. As explained above, all the error may be transferred to a plurality of pixels N, where N≦M. Error can also be transferred or distributed in a weighted or non-weighted manner. Whether weighted or not, error can further be transferred or distributed in a clipped or limited manner or in an unlimited manner.
[0031] By transferring or distributing error, the error diffuser 230 modifies or updates pixel values of some of the neighboring pixels from the image 210 . The pixel and neighborhood selector 214 then selects a new current pixel and a new related set of neighboring pixels based on the previously selected window. The functional blocks 214 , 218 , 222 , 226 , 230 then repeat their functions for the new current pixel.
[0032] While the image is being processed, or when the entire image has been processed, the marking decisions made by the marker 226 can be delivered to the outputting device 234 , or temporarily stored in a memory such as memory device 212 . As noted previously, the outputting device can be a binary outputting device or a multi-quantization level outputting device. In a xerographic environment the outputting device 234 is a xerographic printer. Xerographic printers are known to include a fuser, a developer, and an imaging member for receiving an exposure source (e.g., light) in response to the marks for the image. In other environments the outputting device 234 may be a display or other printing device such as an ink jet, lithographic or ionographic printer.
[0033] The above-described portion of an image processing system 204 , operative to perform the method of FIG. 2 can be implemented in many ways. For example, the pixel and neighboring pixel selector 214 , pixel value sorter 218 , thresholder 222 , marker 226 , and error diffuser 230 may be implemented in software or in dedicated hardware components operating under software control. The software is stored in a computer memory and run on one or more computational devices such as, for example, a microprocessor(s) or digital signal processor(s). The functional blocks 214 , 218 , 222 , 226 , 230 can be physically located in, or performed by, a single device or can be distributed over an interconnected computer network (not shown).
[0034] Having described the general steps in accordance with the method of FIG. 1 and the system depicted in FIG. 1 , attention is now turned to further alternatives to the disclosed embodiments. More specifically, the method described above may further comprise resetting the quantization error to zero upon detecting a region of the input image having pixel values consistently near one extreme (all light or all dark) of the gray scale. The error is reset each time the pixels in the window are all light or all dark and the error is in a certain range to avoid generating dots/holes in very light/dark regions as controlled by the following code section:
( if (edarray[i]<=lowth for all i=0,..,9) OR if (edarray[i]>=highth for all i=0,..,9) ) AND if errth1 <= pixerr <=errth2 then pixerr=0
[0035] As will be appreciated, the lower threshold (lowth) and higher threshold (highth) used to determine whether a region of pixels lies near an extreme of the continuous tone range, may be predefined. (i.e., lowth defining the range of light areas whereas highth defines the range of dark areas). In one embodiment, the lowth variable was set equal to 5, and the highth threshold was set equal to 250. The additional thresholds, errth 1 and errth 2 , control the magnitude of error that may be reset. In one embodiment, the errth 1 variable was set equal to −127, and the errth 2 threshold was set equal to 5. If errth 1 =−127 and errth 2 =127 then any amount of quantization error may be reset.
[0036] Further contemplated in accordance with an aspect of the disclosed method is the use of statistical features simultaneously, when ordering the pixels in the processing window (max, min, mean, etc.), so that if the window is in a continuous tone area then the process switches to standard error diffusion. The advantage of such an approach is that typically standard error diffusion performs better on contone regions of scanned images.
[0037] Alternatively, if segmentation tags are already available in the image processing pipeline (e.g., text & line, halftone (any frequency), and contone/pictorial/photo) a choice may be made between the method described herein and standard error diffusion. An illustration of processing in accordance with this alternative embodiment is depicted in FIG. 6 . Referring to FIG. 6 , there is illustrated a segmentation pre-processing where the input image is first segmented ( 620 ) and processed in accordance with other image processing operations (e.g., enhancement, filtering, etc.) 630 , to produce an output image. If the image, or a region thereof, is a continuous tone (contone) region, as detected at 640 , then standard error diffusion is applied as represented by 650 . Otherwise, in the event that a region is not identified as a contone segment, then processing continues in accordance with one of the embodiments described above. Although the flowchart of FIG. 6 indicates a dynamic or real-time segmentation and tagging operation, it is further contemplated that the pipeline may temporarily store segmentation information relative to an image and that the method, therefore, includes retrieving stored knowledge relating to the input image (such as segmentation tags); and based upon such knowledge, processing portions of the image using only standard error diffusion.
[0038] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | The disclosed system and method provide a binary image generation method. Used, for example, in a digital reprographic system, the method is suitable for eliminating printing artifacts for high addressable binary digital output, such as digital copies, using an optimized ordered error diffusion method with dynamically computable quantization error and dynamic binary output calculation. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 11/976,585, filed on Oct. 25, 2007, now U.S. Pat. No. ______, which is a continuation application of U.S. patent application Ser. No. 11/513,092, filed on Aug. 31, 2006, which issued on Oct. 7, 2008 as U.S. Pat. No. 7,433,650, which, in turn, is a continuation application of U.S. patent application Ser. No. 10/916,402, filed on Aug. 12, 2004, which issued on Oct. 10, 2006 as U.S. Pat. No. 7,120,420, which is a continuation application of U.S. patent Ser. No. 10/315,145, filed on Dec. 10, 2002, which issued on Sep. 21, 2004 as U.S. Pat. No. 6,795,700, and which claims priority of U.S. Provisional Patent Application Ser. No. 60/409,936, filed on Sep. 12, 2002. The subject matter of this earlier filed applications noted above is hereby incorporated by reference.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates to devices and networks that utilize wireless computer networks and methods of creating incentives for establishment and continued operation of wireless computer networks. The present invention further relates to methods and networks that allow users to access wireless services from wireless hotspots without requiring an account with each wireless hotspot location. Additionally, the present invention also provides incentives to rapidly expand the growth of wireless services to create an economic base of wireless services users and wireless hotspots locations.
[0004] 2. Description of Related Art
[0005] The emergence of what are commonly called wireless hotspots has increased the mobility of wireless users and allowed mobile users to access network resources without requiring a physical connection to the large network. Many of these wireless hotspots have appeared in coffee shops and libraries, and allow users with wireless communication equipment to communicate with local area networks and wide area networks as they move about. The locations that provide the access do so to attract customers or because, in the case of libraries, they see such access as an extension of their governmental mandate. However, the equipment, monitoring and access services are not free, and the provider of the hotspot has to bear the burden of those expenses. As an example, a T-1 digital connection can cost approximately $1000 per month in 2002 rates to provide such a level of service. If the expansion of wireless hotspots is to continue so that they become ubiquitous, one possibility is for the persons using the hotspots to take up some portion of the costs.
[0006] In addition, there is also a “chicken or the egg” type problem with wireless access. Since the relative number of users of wireless devices in 2002 is not high, establishments do not generally have any incentive to provide wireless service for a small number of users. Similarly, while the number of establishments offering wireless services is small, users of the wireless devices do not generally have any incentive to sign up for those services if they are available in only a few places. One of the benefits of having consumers pay for the access services is that this would allow for the party receiving payments to create incentives to expand wireless access and thus increase the amount of payments received by the party receiving payments.
[0007] As such, there is a need for a method or mechanism that can create incentives for wireless devices and wireless hotspots to spread the use of wireless access. In addition, there is also a need for a system and a method that can monitor the use of existing services offered by wireless hotspot to wireless devices and provide incentives to expand the existing services based on use.
SUMMARY OF THE INVENTION
[0008] It is an object of this invention to overcome the drawbacks of the above-described conventional network devices and methods. The present invention is directed to software applications and systems that allow for controls to be placed on the type and amount of data received and sent based on access criteria. Those controls are important in that they allow the end user or the device to control the amount of data received from or sent to the wireless network that the system will process and display.
[0009] According to one aspect of this invention, a process of creating incentives for wireless hotspots by a service provider is disclosed. An access point is provided to a wireless hotspot for wireless devices to wirelessly connect to a larger network in a non-private location. Use of the access point for a portable device is authenticated by requiring submission of an account identifier to the service provider and a user of the portable device is billed for use of the access point. Use statistics are evaluated of the access point of the wireless hotspot by portables devices and an inducement is provided to the non-private location based on the evaluated use statistics.
[0010] Alternatively, the use statistics may be the number of users of the access point of the wireless hotspot or the types of services utilized by users of the access point of the wireless hotspot. Also, the authentication of use of the access point for a portable device may be through requiring submission of an account identifier to one of a wireless telephone service provider and a landline telephone service provider. The inducements may include providing a proprietor of the wireless hotspot with a portion of revenue received by the service provider based on the step of billing a user of the portable device for use of the access point. The inducements may also include providing subsidized access to the access point of the wireless hotspot for certain users affiliated with the wireless hotspot.
[0011] The process may include advertising services available from the wireless hotspot to users of the access point of the wireless hotspot, where the advertisement may be made through the access point to users of the access point of the wireless hotspot or through a wireless telephone network. Additionally, the inducement may include upgrading equipment utilized by the access point, where enhanced equipment may be provided to the wireless hotspot to provide greater bandwidth access to portable devices accessing the access point. Also, the inducement may include providing specialized content to the wireless hotspot.
[0012] According to another embodiment of the invention, a system for monitoring of wireless hotspots and creating incentives for wireless hotspots by a service provider is disclosed. The system includes first providing means for providing an access point to a wireless hotspot for wireless devices to wirelessly connect to a larger network in a non-private location and authenticating means for authenticating use of the access point for a portable device by requiring submission of an account identifier to the service provider. The system further includes billing means for billing a user of the portable device for use of the access point, evaluating means for evaluating the use statistics of the access point of the wireless hotspot by portable devices and second providing means for providing an inducement to the non-private location based on the evaluated use statistics.
[0013] In another embodiment, a system for monitoring of wireless hotspots and creating incentives for wireless hotspots by a service provider is disclosed. The system includes a first provider for providing an access point to a wireless hotspot for wireless devices to wirelessly connect to a larger network in a non-private location and an authenticator for authenticating use of the access point for a portable device by requiring submission of an account identifier to the service provider. The system also includes an accounting system for billing a user of the portable device for use of the access point, an evaluator for evaluating the use statistics of the access point of the wireless hotspot by portables devices and a second provider for providing an inducement to the non-private location based on the evaluated use statistics.
[0014] These and other objects of the present invention will be described in or be apparent from the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For the present invention to be easily understood and readily practiced, preferred embodiments will now be described, for purposes of illustration and not limitation, in conjunction with the following figures:
[0016] FIG. 1 is a schematic representation of a wireless telephone system having multiple cells, according to one embodiment of the present invention;
[0017] FIG. 2 illustrates a schematic representation of a wireless hotspot with an access point and several wireless devices, according to one embodiment of the present invention;
[0018] FIG. 3 illustrates a schematic of a wireless hotspot with connections to different network entities, according to an embodiment of the present invention;
[0019] FIG. 4 provides a schematic representation of the good and services exchanged to provide incentives for wireless access;
[0020] FIG. 5 illustrates a flowchart of the process of providing incentives for wireless access, according to an alternate embodiment of the present invention;
[0021] FIG. 6 illustrates a flowchart of the process of providing incentives for wireless access, according to another embodiment of the present invention; and
[0022] FIG. 7 illustrates a flowchart of the process of providing incentives for wireless access, according to one embodiment of this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] The present invention provides a system and a method for creating incentives to establish hotspot locations. Part of the incentive system allows users of the wireless hotspot to provide identifying information and be billed later for their usage. In one embodiment, the user could supply a wireless or landline telephone number and the user's account with the wireless telephone service provider would be billed. The present invention allows for wireless or landline telephone service providers or third party service providers to provide wireless hotspot equipment and service to locations to increase the use of their services and increase their profits through billing of users.
[0024] The process of creating incentives for wireless access may be carried out by different candidates that seek to benefit from the expansion of wireless services. One candidate for offering these services is landline telephone and wireless telephone providers, where those providers already provide landline, cellular and other wireless telephone data services to their users. Following a similar model as that used for mobile telephones, access to wireless hotspots can be coordinated through wireless telephone service providers, with the wireless telephone service providers assisting in authentication of users, monitoring of usage, and billing of users for usage.
[0025] Another candidate for offering wireless hotspot services would be a third party that supplies services to the wireless hotspot locations, provides authentication of users and processes and forwards billing information to the billing party. Thus, the third party would provide the interface between the hotspots and an entity with which the user of the hotspot has an account. The third party could be a telephone company or a wireless telephone company or another service provider.
[0026] A general cellular telephone network is illustrated in FIG. 1 . Multiple cells 111 b , 112 b and 113 b are established through the use of antennas 111 a , 112 a and 113 a . Devices 101 - 104 having access to the cellular telephone network are able to move from cell to cell and maintain access with the network. Each antenna 111 a - 113 a can be connected through link 120 with a service provider 130 . The service provider 130 controls access to the network and coordinates the handing-off of access as the devices pass between the cells. The service provider identifies each device and routes communication to the proper location of the particular device. The devices 101 - 104 may be cellular telephones, computers with wireless modems, or other devices that exchange information with the service provider.
[0027] A general wireless hotspot installation is illustrated in FIG. 2 . The hotspot is controlled through an access point 200 , with the access point having an antenna 201 a to establish a wireless access zone 201 b . The wireless access may be made through an IEEE 802.11 standard local area network (LAN) or other type of wireless network. Devices 210 - 212 within the hotspot are able to communicate with the larger network 230 through communication with the access point 200 . The access point 200 has a communication link 220 with the larger network 230 and the access point acts to enable communication between the devices 210 - 212 and the larger network and between the devices. As examples, the devices 210 - 212 may be computers equipped with 802.11 access cards, personal data assistants enabled for wireless access, cellular telephones having multiple means for wireless access or comparable devices. The larger network may be the Internet or some private wide area network.
[0028] FIG. 3 illustrates one embodiment of the present invention. A wireless hotspot is illustrated, with the coverage of the hotspot set by the access point 300 through an antenna 301 a . The range of the hotspot is illustrated by the range 301 b . Devices 310 and 311 within the range 301 b may potentially establish a connection with the hotspot. The access to the access point is controlled through the access controller 305 that may be hardware, firmware, software or a combination thereof. A communication connection 315 is established between the access point 300 and the larger network 330 where that connection is modulated by a router 308 .
[0029] Also illustrated in FIG. 3 is a wireless or landline telephone service provider 340 . The service provider 340 contains a database 342 of users of the telephone network. The wireless or landline telephone service provider provides services through an antenna 321 a , through a connection 320 , to provide a coverage area 321 b . The coverage area 321 b for the wireless telephone service may also include some or all of the wireless hotspot range 301 b.
[0030] FIG. 4 provides a schematic view of the goods, services and information exchanged between parties in order to create incentives. The wireless hotspot provider provides services to the portable device user, such as network access to a larger network, be it the Internet or a private intranet. The hotspot provider acts as a conduit for the portable device user to the larger network, and can also provide content that is specific to the hotspot. The latter type of content data may be menu items if the hotspot proprietor provides food or drink or may be information about access to a color printer if the hotspot provides access to such a color printer. The hotspot provider also can provide advertising for available services, advertising ads for sponsors of the hotspot, or advertising of other entities that have contracted to advertising served to users. In terms of goods, services and information provided by the portable device provides payments to the hotspot. That payment can be direct payment for services, a portion of payments received through revue sharing, and increased sales revenue because of additional customers brought in through the offering of wireless services. Additionally, the portable device user may provide feedback to the hotspot provider. Such feedback may assist the hotspot provider and other entities to tailor their services to specific types of users that are desired.
[0031] Also, in FIG. 4 , the hotspot provider also interacts with either a wireless telephone provider or a landline telephone provider. In the case of either entity, the hotspot provider provides feedback about the amount and types of services that are being used by portable device user. Such feedback is important because it allows the telephone provider to determine if services to the hotspot provider should be expanded, decreased or maintained at a present level. The hotspot provider also provides information about new users that may sign up for services through the hotspot. In addition, the hotspot provider also provides advertising data to the wireless or landline telephone provider, so that updated information about the capabilities of the hotspot can be advertised to the portable device users, as discussed below.
[0032] FIG. 4 also shows the goods, services and information provided to the hotspot provider from the wireless or landline telephone provider. A first incentive that may be provided to the hotspots would be equipment. Such equipment may be provided to the hotspot with, for example, the proviso that services be provided through the telephone provider. In that case, the hotspot provider would be able to offer services and not required to front the expenses for the wireless access equipment. As part of that arrangement, the telephone provider may also provide network services to the hotspot and can also provide content to the hotspot. Such content may be specific to the hotspot, such that only certain types of hotspots may carry specific content, e.g. a network gaming environment may only be provided to a specific coffee shop locations to provide an extra incentive to visit those locations.
[0033] Additionally, subsidies may also be provided to the hotspot provider. These subsidies may be in the form of reduced cost access to network services for the hotspot proprietor and their employees. The subsidies could also be in the form of a rebate for extra equipment installed in a hotspot provider. The telephone provider may also provide upgrades to the services and/or equipment of the hotspot based on the usage of the hotspot or other criteria. Also, the telephone provider and the hotspot provider may engage in a revenue sharing agreement between them so that the hotspot provider receives a portion or a set amount for the amount of revenue that is provided to the telephone provider because of the access provided by the hotspot. Lastly, the telephone provider may also provide incentives for users that may be passed along to the user. Such incentives could be, for example, coupons to be found in the hotspot location for reduced costs for access or incentives to be passed along to the user through the advertising by the hotspot, as discussed above.
[0034] Also illustrated in FIG. 4 are examples of goods, services and data that are exchanged between the portable device user and either the wireless or landline telephone provider. Included among those may be user incentives, where the incentives could be directly sent to the user offering reduced costs or other inducements. For example, a user may receive such a message as a part of the user's download of data through their wireless telephone. Also, the telephone provider may also advertise the services for the hotspot location, providing locations of and services provided by the hotspot locations. As part of receiving access, the portable device user provides payment to the telephone provider, where the monitoring and billing of the access may be handled by the telephone provider. The telephone provider may also provide services directly, such as wireless telephone services and the telephone provider may also receive feedback about the user's experience with gaining and maintaining access to the larger network through the hotspot location.
[0035] The process of creating incentives for establishment of wireless hotspots, according to one embodiment, is illustrated in FIG. 4 . The first step 401 calls for providing an access point for wireless devices to wirelessly connect to a larger network in a non-private location. It is noted that other embodiments of the present invention can provide an access point in a private location, but the incentives would be different since all of the users would need to have access to the private location to use the private location. After the access point is provided, users seeking to access services of the access point are required to submit an account identifier from a service provider, in step 402 , such as a wireless telephone service provider. If the account identifier is authenticated, then the user is allowed access. It is noted that the account identifier may be a single datum, such as a telephone number, or may be a series of data, such as a telephone number, password, etc. or may be a series of responses to queries from an authenticating entity.
[0036] The use of the access point is monitored and the user is billed by the service provider for that usage, in step 403 . This billing may be made on the basis of how much time the user spent logged on to the access point, may be based on the bandwidth used by the user, or may be billed based on another agreement between the user and the service provider. Additionally, incentives can be provided to the non-private location based on use of the access point, in step 404 . The incentives could include discounted services for the proprietor of the non-private location or some form of payment back to the proprietor. Such incentives would depend on the use of the access point by the users so that the proprietor would have an incentive to advertise the services provided by the access point. This advertising can alert the users of special attributes of the hotspot that may match certain requirements of the user. Such attributes could include voice over IP, video streaming, or detail the expected bandwidth that a user of the hotspot should be able to use. As an example, a hotspot location could provide for rapid picture uploading and that specific service may be advertised to interested users. Additionally, the services offered by the hotspot locations may be bundled, so that users may select the type or service that they want to be authorized for.
[0037] In another embodiment of the present invention, a third party would act as an agent for the service provider and would create the incentive for establishing the hotspot locations. In this embodiment, the service provider, such as a wireless telephone provider 350 would have account information for the user in its database 352 . The third party company 340 would act as a go-between and would maintain its own records of users in its own database 342 . The benefit of the third party company in this embodiment of the present invention is that the company would provide the interface between the wireless hotspot and the service provider and would not require any direct interaction between the service provider and the wireless hotspot. Another benefit of the third party company embodiment is that users could supply account data for accounts they have with entities other than the wireless telephone service provider, such as a television cable company or an Internet service provider.
[0038] The process of creating incentives for establishment of wireless hotspots, according to the latter embodiment, is illustrated in FIG. 5 . The first step 501 calls for providing an access point for wireless devices to wireless connect to a larger network in a non-private location. After the access point is provided, users seeking to access services of the access point are required to submit an account identifier from an appropriate entity, in step 502 , such as a wireless telephone service provider or other service provider. If the account identifier is authenticated, then the user is allowed access. The use of the access point by the user is logged until the use of the access point is terminated, in step 503 . After that, the information about the user's activities is provided to the service provider in a format that the service provider can use to bill the user.
[0039] The present invention is also directed to monitoring and augmenting the services provided by the hotspots based on use. An example of the process is illustrated in FIG. 6 . Data are collected on the use of the access point by the users of the wireless devices, in step 601 and that data is used to make allocation decisions, in step 602 . Based on the allocation decision, greater services can be provided to the hotspot location when the decision is made favorably, in step 603 . Thus, if an access point has a high usage and users are not fully able to use the services of the hotspot, then the access point can be provided with greater capacity. Such incentives would be in the interest of the service provider or third party company because it may allow for greater use and greater profitability of the hotspot location.
[0040] It is noted that the present application is directed, at least in part, to wireless hotspots. The use of the term wireless hotspot or hotspot is applicable to any wireless access point. The term wireless hotspot or hotspot, as used in the specification and claims, should not be construed to be limited to a single type of locale or be construed as providing access according to only a particular wireless access format, such as the IEEE 802.11 standard. It would also be within the scope of the invention to implement the disclosed elements of the invention in discrete electronic components, thereby taking advantage of the functional aspects of the invention. Additionally, the present invention can be implemented totally or partially through software.
[0041] Although the invention has been described based upon these preferred embodiments, it would be apparent to those of skilled in the art that certain modifications, variations, and alternative constructions would be apparent, while remaining within the spirit and scope of the invention. In order to determine the metes and bounds of the invention, therefore, reference should be made to the appended claims. | A process of creating incentives for wireless hotspots by a service provider is disclosed. An access point is provided to a wireless hotspot for wireless devices to wirelessly connect to a larger network in a publicly accessible location. Use of the access point for a portable device is authenticated by requesting submission of an account identifier to the service provider and billing data for a user of the portable device for use of the access point is generated. Use statistics are evaluated of the access point of the wireless hotspot by portables devices and an inducement is provided to the publicly accessible location based on the evaluated use statistics. | 6 |
TECHNICAL FIELD
This invention pertains to a container for storing photographic prints and, more particularly, this invention relates to stackable containers having separate compartments for storing the prints and developed negative film strips.
BACKGROUND OF THE INVENTION
Photographic laboratories process roll film into strips of developed negative film and individual positive prints. The prints and film are returned to the customer in a package, usually a pair of paper envelopes. The inner envelope usually has a separate pocket for storage of the strips of developed film. The envelopes are used for a variety of print sizes such as 4×6 and 3×5 inches and strips of film such as 110 and 35 mm. The prints and strips of film can slide about. Once the adhesive seal of the envelopes are broken, the flap is usually torn. In any case, the open flap allows dirt and moisture into the envelope and onto the surface of the prints.
Many photographs are taken as a family history and as remembrances of childhood and of relatives no longer alive. They are valuable family mementos. Also photographic prints and film are stored by companies for commercial or forensic reasons. However, photographic prints tend to curl after they are dried at the end of processing. The soft, loosely filled envelopes also curl making it impractical to stack the envelopes. Most envelopes end up in a random pile in a box or a drawer. They tend to become disorganized over the years and are unsightly and unmanageable when a particular roll of film is sought. Furthermore, the low profile of the edges of the envelopes precludes edge labeling.
Sometimes, the pictures are returned in a cardboard box which can be a bit more rigid and protective, but is much more expensive. U.S. Pat. No. 4,413,734 to Newcombe discloses a cardboard box for storing film, not photos. Such simple boxes can not economically segregate the photos from the negatives and are not rigid nor square enough for stacking. Cardboard boxes can be insufficiently strong to provide permanent protection for the film, absorb moisture and soften during storage. Furthermore, most cardboards are made from kraft pulp. The residual sulfate salts and/or acidic lignins in the cardboard can react with and degrade the silver and silver salts in the negatives and photograph prints over long periods of time.
Plastic containers are not subject to degradation by moisture, can be stronger than cardboard and can be made of materials that are inert and do not degrade nor react with the silver or silver halide images in the negative films and positive prints.
The positive and negative storage container disclosed in U.S. Pat. No. 5,016,752 is on the market. The container has the overall shape and configuration of a book. The cover is connected to the base by a live hinge side wall. A storage compartment is formed on the inside of the cover and guides are provided to store prints in the base. The container includes many different parts requiring expensive molds. This container is much more expensive than paper envelopes and would not be considered for use in replacing the traditional envelopes in which developed prints are returned to the customer from the processor.
A more intricate photograph print storage system is disclosed in U.S. Pat. No. 4,473,154. A spring based slide arrangement shuttles the prints to a viewing window.
U.S. Pat. No. 4,095,694 to Jost discloses several different plastic container designs for photos and negatives. Separate compartments are provided for photos and negatives, each accessible through a pivoting lid. This design is very expensive because each container requires several different plastic parts which must be separately molded at considerable extra cost.
U.S. Pat. No. 3,710,977 to Enden et al. discloses a light-tight container for storing light sensitive sheets and exposed sheets that may be made from cardboard or plastic including an ejecting mechanism.
U.S. Pat. No. 4,545,486 to Bostic discloses a plastic tray for storing a stack of photos. An additional recess in the bottom of the tray is sized to accept negatives. The photographic prints and negatives are not segregated so that the negatives could be disturbed whenever the photos are accessed. A separate plastic cover snaps on to the top of the tray. Bostic states that several of the trays could be stacked, but for larger numbers of trays, he requires a special rack with slots for the trays. Again, the storage unit is formed of several separate plastic parts. This increases the cost and complexity of the storage unit.
SUMMARY OF THE INVENTION
A container for safe storage of photographic prints and/or strips of negative film is provided by the present invention. The storage container has a first compartment for storing the photographic prints and an optional, second compartment for receiving the strips of film. The prints can be accessed separately from the strips of film with no concern that the strips will slip out of their compartment. The containers of the invention when stacked on top of each other reliably engage mating male and female structures allowing stacking as high or higher than a typical bookcase shelf such as 12-16 inches. The container of the invention is readily made by a single molding operation and a die cutting step. The cost of manufacture is much less than the prior plastic containers. In fact, the cost is so low that the container of the invention could be supplied by the processor to package the prints and negative strips from a single roll of film.
The storage container of the invention is formed of an inner rigid, rectangular, plastic perimeter member and an outer flexible membrane. The inner member provides a structural central frame about which a 3 sided membrane is positioned. The central frame has a base, 3 fixed side walls and a front wall hinged to the base wall by means of a live hinge. The base wall and 3 side walls define a compartment for storing photographic prints. The base wall can be raised from the lower edge of the side walls and can contain a channel for receiving strips of negatives.
The front edge of the lower panel of the membrane contains an aperture which engages a clip mounted on the lower forward edge of the central frame. The bottom edges of the side walls of the frame can be provided with small ledges to guide and retain the lower panel of the membrane.
As the lower panel of the membrane is slid onto the guides and into engagement with the clip, it forms a cover for the channel that can be used to store the negative strips, thus providing a closed compartment for the strips of film. The intermediate panel of the membrane closes the access to the film strip compartment and the top panel of the membrane closes and covers the compartment for storing the prints. Means are provided on the side walls and the cover for latching the cover and retaining the top panel of the membrane in closed position. The presence of a stack of photos in the upper compartment can act as a reinforcement for the top panel of the membrane.
The bottom edges of the side wall of the central frame contains projections which engage the side walls and/or cover of the adjacent storage container providing reliable stacking of the units. The bottom wall of the frame can contain a pin that is received in the same aperture as the latch for the cover. Vertical stops can be provided on the inner side walls of the frame to engage the projections from the adjacent storage container. The vertical stops can also act as spacers for the print compartments. A further spacer can be mounted at the rear end of the base wall to space the prints from the rear wall. The position of the end spacer depends on the length of the photographic prints.
A basic mold can be used to manufacture containers having a compartment for larger prints such as 4×6 inches. The mold can be modified with inserts to form inboard guides for smaller prints such as 31/2×5 inch prints.
This invention only requires molding one integral member as a central frame for a photograph and/or negative film container. The container of the invention does not contain 6 external molded plastic walls to form a rectangular enclosure for the photos and negatives, nor does it require separate molded parts to form such an enclosure. Rather, the container of the invention utilizes a low cost cardboard or paperboard membrane that wraps about the central plastic frame to form 3 of the enclosing walls. As previously discussed, cardboard and paperboard can contain acid materials that can react with the color dies or silver grains in positive prints or negatives. The invention uses specially treated, non-acid paperboard. To further extend longevity of the membrane, the top and bottom surface of the paperboard can be coated with a thin coating of resin. The coatings encapsulate the paperboard and prevent absorption of moisture. The coatings also isolate any acid chemicals within the paperboard preventing the chemicals from contacting the stored prints and negatives. The coatings can be transparent or opaque. A preferred coating for the front surface is a high gloss, resin such as an acrylic esterpolymer. A thermoplastic film can be thermally laminated onto the cardboard such as a polyester or polyethylene film to provide an attractive, shiny surface. The coating on the inside surface need not be high gloss resin. It can be a clear resin such as emulsion polymerized polyethylene. The resin coatings can contain an ultraviolet absorber to increase the useful life of the resin coatings and paperboard membrane.
The flexible membrane is positioned by projections from the central frame that align and space the membrane away from the central frame so as to create chambers between the frame and membrane that hold the photos and negatives. This arrangement has numerous advantages.
The membrane is easily and cheaply manufactured by die cutting and scoring. The membrane can be customized with information embossed or printed thereon. Hence, the container may be made to carry the name and advertising of the film processor at essentially no additional cost. If the container were all plastic, individual and expensive molds would have to be made for each of the thousands of retailers that utilize the container to store processed film.
The frame can be made from many plastics. Thermoplastic molding resins are preferred. Resins that evolve gasses that can degrade the film or print such as polystyrene or ABS should be avoided. Suitable resins are linear polyesters such as Mylar or polyalkylene resins such as polyethylene or polypropylene. The ideal resin for the frame, polypropylene, is not practically markable. However, paperboard is markable with simple, well known, low cost printing methods. The paperboard, by itself, is not rigid enough to be protective, durable, and stackable. But with the central plastic frame, all the desired mechanical characteristics are achieved. Thus, the unique combination of a rigid plastic frame with a flexible, coated paperboard membrane gives performance better than either material used separately.
Some projections from the central frame locate the stack of photos. Other projections from the central frame form guides to allow stacking of the frames upon each other to considerable heights. Still other projections form the hinged cover catch and lock the membrane into place about the frame. All of these projecting means may be molded as a part of the single central frame due to the fact the frame is centrally positioned and operates as a sort of backbone to the structure, rather than being a hollow walled enclosing box as in the prior art.
These advantages and many other features, attendant advantages and benefits will become apparent as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the container of this invention in the closed configuration shown stacked between adjacent like containers;
FIG. 2 is a perspective view of a container for storing 31/2×5 inch photographic prints with the cover open to show photographic prints stored inside;
FIG. 3 is a perspective view of a container for storing 4×6 inch photographic prints with the cover shown open;
FIG. 4 is a view in section of the stack of container shown in FIG. 1 taken on line 4--4 of FIG. 1;
FIG. 5 is a view in section taken along line 5--5 of FIG. 4;
FIG. 6 is a view in section taken on line 6--6 of FIG. 4; and
FIG. 7 is a bottom view in elevation of the frame of the container of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-6, and principally to FIGS. 2-3, two versions of photographic print and negative film strip containers 10 and 10' of this invention, are illustrated with the covers 12, 12' disposed in an open position. The storage containers 10, 10' of the invention include a central, hollow, generally rectangular frame 14, 14' and a three paneled, flexible membrane 16, 16' enclosing the frame 14, 14'. The central frame 14, 14' comprises a generally planar, rigid plastic structure that incorporates numerous projecting means extending out from central frame 14, 14' so as to accomplish a variety of functions. The membrane 16, 16' has live hinges 13, 13' and 15, 15' provided by score lines 17, 17' and 19, 19'. The flexible membrane 16, 16' is wrapped about the various projecting means. The membrane bends along the score lines 17, 17' and 19, 19'. The panels 21, 21', 23, 23' and 25, 25' form the top, end and bottom exterior walls of the container. The outer surface of the membrane 16, 16' can be coated with a layer 27, 27' of high gloss resin and the inner surface of the membrane 16, 16' can be coated with a layer 29, 29' of low gloss resin.
Frame 14, 14' is molded with an integral hinged cap 18, 18' that bends about a live hinge 20, 20'. Hinge 20, 20' comprises a scored line of plastic that is more flexible. Cap 18, 18' can have an exterior recess 22, 22' within which an adhesive label may be positioned to identify the contents of the container as shown in FIG. 1. Membrane 16, 16' has a narrower tab portion 24, 24' at the end of the cover part 11, 11' that is trapped under cap 18, 18' in the closed position. The hollow cap 18, 18' can contain vertical walls 49, 49' which reinforce the cap and prevent photoprints 27, 27' from sliding forward when the cap is closed. The cap can contain a recessed groove 31, 31' to facilitate opening the cap 18, 18'. At the end opposite from the cap 18, 18' central frame 14, 14' has an end wall 26, 26' around which membrane 16, 16' wraps. The other end of membrane 16, 16' has an aperture 28, 28' that slides up and over a ramped catch 30, 30' so as to hold the end of membrane 16, 16' at the bottom of the cap end of frame 14, 14'. Catch 30, 30' is easily molded as a projection from the central frame 14, 14' by providing a hole 32, in the intermediate panel 48 of the frame 14, 14' as shown in FIG. 7.
The frame includes an end wall 26 and side walls 38 and an intermediate panel 48. The panel 48 is positioned above the lower edge of the side walls 38. A series of raised horizontal runners 50, 52 are connected to the inner, bottom edge 51 of the side walls 38 and form grooves 54 with the panel 48 for slidingly receiving the bottom panel 25 of the membrane 16. The side walls 38 are reinforced by projections 34. The projections 34 end below the top edge of the side walls 38 forming horizontal ledges 35 for supporting the top panel 21 of the membrane in a recessed position. The inner, vertical edges 37 of the projections 34 can function as side guides for a cavity 36 for receiving large photoprints 80 such as 4×6 inch prints as shown in FIG. 3.
A rear retainer 39 with a horizontal lip 40 forms the back limit for the cavity 36. The cap 18 forms the front face of the cavity 36. The rear print retainer 39 can be connected to a support rib 41. The lip 40 is disposed in the same plane as the ledges 35 and forms another point of support for the top panel 21 or cover 12 or the membrane 16.
The same mold and container can also be adapted to store smaller prints 27 such as 31/2×5 inch prints as shown in FIG. 2. In this version of the container 10, side guides 43 are provided inboard of the side walls 38. The rear retainer 39 is moved forward to the rear edge of the prints 4 to form a smaller cavity 45. The rib 41 is longer, extending from rear wall 26 of the frame to the retainer 39.
An optional compartment 58 for storing strips 52 of negative film can be provided since panel 48 is raised above the lower edges 51 of the side walls 38. Reinforcement ribs 54, 56 connected to the bottom face of the panel 48 can form the side walls of film compartment 58. The bottom panel 25 of the membrane forms another side of the compartment 58. A partial front wall 57 forms the front wall of the compartment and the intermediate panel 23 of the membrane 16 closes the compartment 58 when the membrane 16 is in closed condition. The ramped catch 30 is mounted on the inner face of the front wall 57.
As shown in FIG. 7, the panel 48 can be provided with a large oval slot 60 to aid in sliding the strips 62 of film out of the compartment 58. The elongated side apertures 66 are provided to aid in molding the horizontal runners 50, 52, the semicircular aperture 64 is to permit molding of the rear photoprint retainer 39. Circular side apertures, not shown, can be provided to mold the side guides and the front aperture 70 is provided for molding the clip assembly for the membrane.
The bottom and top surfaces of the frame contain several different interlocking structures which cooperate to permit stacking of the photoprint containers 10, 10', 10'", etc. as shown in FIG. 1. The bottom wall as previously described, contains horizontal guides or runners. These runners are disposed slightly inboard of the side wall 38.
The top edges 71 of the side walls 38 form a rigid strong surface upon which identical containers can be stacked. The side walls 38 are reinforced by the projections 34. The horizontal runners 50, 52 are placed slightly inboard of the outer face of the side walls 38 to expose the lower edges 76 of the walls 38. The runners 50, 52 may be provided with pads 78. Pins 90 may be provided at the forward end of the frame on the bottom face 81 of a set of walls 92, 94 slightly set in from the side walls 38. The walls 92, 94 also contains pins 100 extending upwardly from the top edge 102 of the side walls 92, 94. The walls 92, 94 are covered by the side walls 104, 106 of the cap 18 and the pins 100 are partially received in apertures 108 in the top wall 110 of the cap when the cap is closed.
When the containers are stacked, the pins 90 are received in the open portion of the apertures 108. The runners 50, 52 are received within the side walls 38 and rest on the membrane panel 21 which seats on the ledges 35 of the projections 34. The lower edges 76 of the side walls 38 rest on the upper edges 71 of the side walls 38 of the next adjacent container 10'.
All of these alignment and guide projections cooperate to insure that the containers may be stacked to considerable heights, one upon the other. Since only the rigid plastic parts engage each other, and the flexible markable membrane is recessed below the plane of engagement, accurate, stable, aligned stacking is guaranteed. Of course, other types of aligning and guiding projections could be designed that would work as well.
It is to be realized that only preferred embodiments of the invention have been described and that numerous substitutions, modifications and alterations are permissible without departing from the spirit and scope of the invention as defined in the following claims. | A storage container holding photographs and/or negatives in segregated chambers in which a central polypropylene frame is wrapped with a resin coated non-acid paperboard membrane. The membrane is spaced away from the frame by a variety of projections so as to form the chambers. The central frame is rigid and dimensionally consistent to allow stacking of the containers even though the paperboard membrane is flexible and forms 3 exterior walls of the container. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from German Patent Application No. 102010005821.1, filed Jan. 27, 2010, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The technical field relates to a machine having a shaft rotatable in at least one lubricated bearing, and in particular the lubricant supply of this bearing.
BACKGROUND
A machine having a shaft rotatable in a lubricated bearing is known from DE 33 20 086 C2, in which a lubricant duct for lubricating the bearing extends axially in the interior of the shaft. In that the lubricant duct is guided along the shaft, lubricant points are also reachable which are difficult to supply in other ways, typically via ducts guided in a housing of the machine. The lubricant duct in the interior of a shaft can be long, however, and its cross-section is narrowly limited, because it cannot weaken the shaft, on the one hand, but the diameter of the shaft is to be as small as possible, on the other hand, so that, both for reasons of cost and also to avoid unnecessary friction losses, the diameter of the bearings receiving the shaft may be kept as smallest possible. It is thus necessary to supply lubricant from a lubricant source at elevated pressure. A pump required for this purpose increases both the costs of the machines and also the breakdown risk.
In view of the foregoing, at least one object is therefore to specify a machine having a first shaft rotatable in at least one lubricated bearing and a lubricant duct extending along the first shaft for lubricating the bearing, which manages without an external pump for supplying the lubricant at elevated pressure. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
The at least one object is achieved in that, in such a machine, a turbine, having blades engaging radially in the lubricant duct and oriented warped to the axis of the first shaft, is situated in the lubricant duct. Because of their orientation, the blades provide the lubricant circulating in the lubricant duct with an impulse in the axial direction, so that the pressure of the lubricant in the duct is elevated downstream from the turbine and sufficient lubrication of the bearing can be ensured via the duct.
The turbine is preferably connected rotationally fixed to the shaft. Such a turbine does not require parts rotatable in relation to the shaft on its part and is therefore maintenance-free and nearly indestructible in normal operation of the machine. The lubricant duct can have a widened area on a first end of the shaft, in which the turbine is inserted and in which it is preferably held in a friction-locked or formfitting manner. The turbine can be installed in a conceivably simple manner by insertion in the widened area. The blades of the turbine preferably terminate flush with an end of the shaft, in order to acquire lubricant standing at the end of the shaft and draw it into the lubricant duct.
The turbine can be implemented in a simple way, in that a plurality of holes oriented warped to the axis are formed in a main body. The blades are each formed by intermediate walls between adjacent holes. In order to avoid an imbalance, the holes are expediently transferable congruently into one another by a rotation around the axis of the turbine. The warped holes may be fused with one another to form a single axial passage. If the warped holes diverge toward an outlet side of the turbine, the centrifugal force acting on lubricant flowing through during the rotation of the turbine can also contribute to the conveyance action of the turbine.
In order to supply the turbine with lubricant, high pressure is not required at the intake of the turbine or at the end of the first shaft on which the turbine is attached. It is thus possible in particular to feed the turbine via a drop catcher, which is attached on the circumference of a rotating wheel immersed in a lubricant reservoir, in order to collect lubricant spun off of the wheel.
The machine is preferably a stepped transmission, in particular a shift transmission or a double-clutch transmission for a motor vehicle.
The rotating wheel immersed in the lubricant reservoir can particularly be a ring gear of a differential in such a transmission.
The impulse increases achievable using the turbine, it is possible to supply still one or more additional lubrication points downstream from the first shaft via the lubricant duct running through the first shaft. Alternatively, the turbine can also be situated between two lubrication points of a multipart supply line, in order to compensate for pressure losses along the supply line or volume losses on the lubrication point located upstream, and also ensure a sufficient lubricant feed to the lubrication point further located downstream. In particular, bearings of the first and at least one second shaft may be supplied with lubricant, in that a lubricant duct in this second shaft is connected in series to the lubricant duct of the first shaft, the second shaft being able to be situated both upstream and also downstream from the first shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
FIG. 1 shows a double-clutch transmission in an axial section;
FIG. 2 shows the double-clutch transmission in a schematic cross-section;
FIG. 3 shows a detail view of a housing wall of the transmission having a drop catcher fastened on the housing wall;
FIG. 4 shows a perspective view of a turbine for lubricant oil conveyance;
FIG. 5 shows a section through the turbine in a plane shifted parallel to the axis of the turbine; and
FIG. 6 shows a section through the turbine along plane VI-VI from FIG. 5 .
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description.
FIG. 1 shows a schematic section through a double-clutch transmission for a motor vehicle. A double clutch 1 , which is known per se, is situated between the output shaft 2 of an engine (not shown) and two input shafts 3 , 4 of the transmission, which are situated concentrically to one another on the same axis, to alternately apply torque to the input shaft 3 or the input shaft 4 .
Multiple gearwheels 5 , 6 , 7 are installed rotationally fixed on the input shafts 3 , 4 , which in turn mesh with gearwheels 8 to 11 on two parallel lay shafts 12 , 13 . The gearwheels 8 to 11 of the lay shafts 12 , 13 are fixable in a rotationally fixed manner on the lay shafts 12 , 13 via locking synchronization devices 14 to 17 . A third lay shaft 18 carries gearwheels 19 , 20 , which mesh with gearwheels 21 , 22 of the lay shaft 12 . In that, for example, the locking synchronization device 15 couples the gearwheel 22 to the lay shaft 12 , a first gear of the transmission can be implemented by torque transmission between the gearwheels 5 , 8 , 21 , 19 , 20 , 22 .
In order to allow shifting between the gears without torque interruption, the second gear, like all even-numbered gears, is assigned to the hollow input shaft 4 , while the odd-numbered gears are produced via the inner input shaft 3 , which extends through the hollow input shaft 4 . Since the principles of such double-clutch transmissions have been previously published in various forms, they do not need to be explained in detail here.
Every lay shaft 12 , 13 , 18 carries a pinion 23 , 24 , 25 , which meshes with a ring gear 26 of a differential 27 . In that a locking synchronization device 28 locks the gearwheels 19 , 20 on the lay shaft 18 , a reverse gear can be generated via its pinion 25 .
FIG. 2 illustrates the location of the axes of the differential 27 , the input shafts 3 , 4 , and the lay shafts 12 , 13 , 18 in a housing 29 , which encloses the transmission. Some of the gearwheels of the transmission are shown as circles concentric to the axes in FIG. 2
The ring gear 26 of the differential 27 extends furthest down of all gearwheels and is immersed on a part of its circumference in the oil sump 30 . In order to keep splashing losses small, the oil level 31 , which is indicated as a dot-dash line, is set when the transmission is stationary so that the gearwheels of the shafts 3 , 4 , 12 , 13 , 18 are not immersed and their teeth which mesh with one another are lubricated by oil mist swirled up by the ring gear 26 . When the transmission is running, the oil from the sump 30 is distributed everywhere in the housing 29 . Oil which runs off of the shafts 3 , 4 , 12 , 13 and their gearwheels first reaches a temporary store 34 , which lies somewhat higher than the oil sump 30 in the housing 29 and is separated from the oil sump 30 by an inner wall 32 . A narrow gap 33 at the lower end of the inner wall 32 allows a delayed backflow of the oil into the sump 30 . This has the result that in operation, the oil level of the sump 30 drops to a level 31 ′, which is still sufficient to wet the teeth of the ring gear 26 . The splashing losses of the transmission in continuous operation are thus close to zero.
FIG. 3 shows a perspective detail view of an inner side of a wall 35 of the housing 29 enclosing the transmission. A roomy recess 36 , which is provided to accommodate a part of the differential 27 , fills up a majority of the lower area of the wall 35 . Recesses 37 , 38 , 39 are shown all around the recess 36 , in each case for an end section of the lay shafts 13 , 12 , or 18 , respectively. While the recesses 37 , 38 are essentially delimited by ribs 40 protruding from the wall 35 , the recess 39 is indented in the wall 35 , and the end of a hole 41 can be seen on its floor, which extends within the wall 35 to a drop catcher 42 . The drop catcher 42 has a cross-section curved like a horn having an open end 43 , which faces toward the ring gear 26 (not shown in FIG. 3 ) to catch oil, which the teeth of the ring gear 26 entrain from the oil sump 30 during its rotation and subsequently spin off. The collected oil reaches the recess 39 via the drop catcher 42 and the hole 41 and stands at a front end of the lay shaft 18 there.
As shown in FIG. 1 , a duct 44 extends over the entire length of the lay shaft 18 , and spur lines (not shown in FIG. 1 for the sake of clarity) branching from the duct 44 lead to roller bearings 45 , 46 adjacent to the ends of the lay shaft 18 , in order to supply them with oil. In order to convey the oil throughput through the duct 44 , a turbine 47 is inserted into a widened area on the end of the lay shaft 18 facing toward the recesses 39 . FIG. 4 , FIG. 5 , and FIG. 6 show this turbine 47 in a perspective view or in section.
The turbine 47 is, as shown in FIG. 4 , a one-piece metal body essentially having the form of a flat cylinder, through which a passage 48 extends in the axial direction. The passage 48 is obtained by multiple drilling or milling steps. Multiple holes 49 , five here, are advanced at uniform angular intervals to one another warped to the axis of symmetry through the body of the turbine 47 ; i.e., each rotation of the turbine 47 by 2π/5 around its axis of symmetry transfers the turbine 47 into itself. The diameter of the holes 49 is selected so that they fuse into a single passage 48 . FIG. 5 shows a section through the turbine 47 along an axis—identified by 50 here—of such a hole 49 , a second hole 49 may be seen in the section.
FIG. 6 shows the turbine in section along the plane VI-VI, which is perpendicular to the hole axis 50 , from FIG. 5 . In this section, walls 51 , which remain between the individual holes 49 and protrude radially inward into the passage 48 , may be seen, which give oil penetrated therein an impulse in the axial direction when the turbine 47 rotates. As also shown in the section of FIG. 6 , the holes 49 approach closer and closer to the outer circumference of the turbine on the downstream side of the turbine 47 . Therefore, not only the warped orientation of the holes 49 and walls 51 , but rather also the centrifugal force acting in the rotating turbine 47 drive the oil through the turbine 47 . A dynamic pressure can thus be built up downstream from the turbine 47 in the duct 44 , which ensures a sufficient oil supply of the roller bearings 45 , 46 and additionally also allows the supply of roller bearings of the lay shafts 12 , 13 and the input shafts 3 , 4 via lines 52 , which, as shown in FIG. 1 , connect the downstream end of the duct 44 to ducts 54 , 55 , 56 of these shafts in a wall 53 of the transmission housing facing away from the double clutch 1 and the differential 27 .
To increase the oil pressure in the ducts 54 , 55 , 56 , the shafts 3 , 12 , 13 may also be provided with turbines 47 on the input side, i.e., on their end facing away from the double clutch 1 .
It is also conceivable to only provide the shafts 3 , 12 , 13 located downstream with turbines 47 , in order to ensure a lubrication of their roller bearings which is qualitatively equivalent to the lubrication of the roller bearings 45 , 46 .
The embodiments have been described above especially with reference to a transmission having double clutch, since such transmissions represent a preferred area of application. The increased space requirement of the double clutch 1 in comparison to a typical single clutch results in strong contouring of the wall 35 , having a projection 57 protruding far into the transmission housing 29 around the input shafts, which makes the oil supply of the roller bearings 58 , which bear the shafts 3 , 4 , 12 , 13 on the side of the wall 35 , difficult via lines guided in the wall 35 . However, it is obvious that the invention is also usable in other constructions of transmissions or in general for the oil supply of any desired lubrication points in diverse types of machines.
While at least one exemplary embodiment has been presented in the foregoing summary and detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. | A machine has a shaft rotatable in at least one lubricated bearing. A lubricant duct for lubricating the bearing extends along the first shaft. A turbine, having blades engaging radially in the lubricant duct and oriented warped to the axis of the first shaft, is situated in the lubricant duct. | 5 |
This application is a continuation-in-part of application Ser. No. 769,194, filed Aug. 23, 1985, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to surgery. And more particularly to the orthopedics of reconstructive and aesthetic surgery including a bone prothesis and to a surgical method of implanting the prothesis on the malar, or cheek bone, of a patient.
2. Description of the Prior Art
The medical speciality of facial cosmetic surgery, reconstructive and plastic surgery involves reconstruction of the cutaneous tissues around the neck and face, which is performed to correct defects and to remove the marks of time.
It has also been developed to improve, or correct, the facial features of a patient. For example, Rhytidoplasty, or face lift, is performed to remove excess skin and tighten the remaining skin to give a more youthful appearance to an older person. Rhinoplasty has been developed to improve the shape and contour of the patient's proboscis. Blepharoplasty is performed to remove wrinkles and bulges around the eyelids.
Many deformities by birth, accident, infection, cancer removal, or surgical necessity may need reconstruction by implanting prothesis as well as reconstructing the bony facial skeleton.
Surgical implants have also been developed in conjunction with these surgical techniques to also alter the appearance of the chin and nose by implanting a prothesis. The chin implant is surgically inserted and positioned on the mandible to buildup the chin and give it a more pleasing appearance. This procedure is called Mentoplasty. An example of such an implant is disclosed in Wagner, U.S. Pat. No. 4,344,191.
The inventor of the present invention, who is a Plastic Surgeon, saw the continued need for new surgical implants and new plastic surgery procedures in an ongoing effort to improve the effectiveness of plastic surgery. As a result of this need, the inventor invented the malar implant and the surgical procedure for correctly implanting it on the patient.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a malar implant positioned between the malar-zygomatic bone complex and the fleshy portion of the side of the face commonly referred to as the cheek for increasing the prominence of the cheek below the eye orbit of the patient. The prominent appearing cheek bones impart a more handsome or pleasing appearance to the facial features of a patient.
Another object of the present invention is to provide a malar or cheek implant which will raise the cheeks of an older patient to lessen the effects of aging thereby giving a patient a more youthful appearance after the implantation of the left and right pair of malar implants.
It is another object of this invention to provide for a surgical procedure for inserting the malar implant on the malar-zygomatic bone complex of the patient.
Another object is for restoration of the facial skeleton after traumatic injury, or accident, to the malar, zygomatic and chin regions.
The malar implant is intended for both reconstructive and cosmetic plastic surgery. It is positioned adjacent to the human eye socket and overlies the malar-zygomatic bone complex. The implant is comprised of a 3-dimensional asymmetrical implant which is molded or fashioned from an inert plastic material, or silicone sold under the trademark Silastic. The implant generally has an outer and inner surface. The outer surface has a distinct convex surface which forms the prominence of the cheek area after the implant is in place. The inner surface of the implant includes a concave depression, or recess. The complementary concave depression of the malar implant fits the overal contour and curves of the zygomatic bone in the area of the implant almost precisely. The posterior contour of the outer surface of the malar implant is shaped to mimic the normal anatomy of the facial skeleton.
The outer surface and the inner surface of the implant merge to form an upper edge, a lower edge, a leading or anterior edge and a trailing or posterior edge. The corner where the anterior edge and the upper edge merge is generally positioned below the infraorbital notch below the eye socket or orbit. The anterior edge is receded sufficiently to avoid and to provide space for the infraorbital foramen when in place on the patient. The upper edge forms an orbital rim surface below the orbital rim of the patient. The trailing or posterior edge can include a zygomatic extension for causing part of the zygomatic arch of the patient to appear more prominent after the implant is in place on the patient.
In another embodiment of the implant, the anterior edge includes a maxilla extension extending from the lower region of the anterior edge to enhance the anterior maxilla and lower orbit region when necessary or desirable.
In yet another embodiment, the aforementioned anterior maxilla extension includes a hook-shaped extension having a cut-away for avoiding and providing space for the infraorbital foramen and the infraorbital notch. The hook-shaped extension creates an orbital rim surface extension which is juxtaposed along the rim surface formed by the upper edge of the implant.
In still yet another embodiment of the invention, the modification is where the anterior edge and the lower edge converge to form a curvilinear edge from the anterior edge-lower edge juncture up to the anterior edge-upper edge juncture. The point where the anterior edge and the posterior edge meet is very rounded. The silhoutte of this embodiment resembles a four-pointed diamond shape having four sides with the bottom point almost indistinguishable; one lateral point is adjacent the zygomatic arch; the other lateral point is adjacent the infraorbital foramen; the top point is adjacent the orbit; and the bottom nearly muticous point lies adjacent the maxilla bone.
The malar implant can be fabricated by means of molding a solid, biologically inert, pliant, flexible and compressible material such as plastic, or a silicone rubber sold under the brand name Silastic. The implant could have of a jell-filled sac construction if desired. The malar implant could be fabricated as a rigid piece of plastic if desired. It may also be fashioned from other bio-implantable materials.
It is to be recognized and understood that under normal conditions there will be a pair of identical mirror image shaped implants implanted one in the left cheek and the other in the right cheek of the patient. The implant could be tailored somewhat to the individual patient to form a custom fit against the malar-zygomatic complex of the patient. However, the pliant and flexible nature of the implants should allow this complementary fitting without much customization required beforehand or during the surgical operation.
The malar implants can be offered in three sizes; small, medium and large to accomodate the normal range of patients' facial skeleton sizes. It can also be modified into other sizes if necessary.
There is a surgical operation or method of implanting the prothesis in the patient which includes the steps of making the appropriate incisions, creating a pocket for receiving the implant, inserting the implant with the appropriate tools and repairing the incision with routine closure techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of the first embodiment of the malar implant properly positioned below the patient's orbit with the anterior edge positioned slightly below the infraorbital notch and avoiding the infraorbital foramen.
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 1.
FIG. 3 is a perspective view of the facial skeleton showing the implant of FIG. 1 properly positioned on the malar-zygomatic bone complex.
FIG. 4 is a cross-sectional view taken along the line 4--4 of FIG. 3.
FIG. 5 illustrates a perspective view of the facial skeleton showing the left and right implants of a second embodiment of the implant properly positioned on the malar-zygomatic bone complex.
FIG. 6 is a perspective view of a third embodiment of a pair of implants properly positioned on the malar-zygomatic bone complex of the skull.
FIG. 7 is a perspective view of the left and right implants of a fourth emodiment of the malar implant properly positioned on the malar-zygomatic bone complex of the skull or facial skeleton.
FIG. 8 illustrates a perspective view of an alternative embodiment of the Malar Implant having an inferior extension extending below the lower edge.
FIG. 9 is a transverse cross sectional view of the extended implant taken along the lines 9--9 of FIG. 8.
FIG. 10 is a longitudinal cross sectional view taken along the lines 10--10 of FIG. 8.
FIG. 11 is a fragmentary perspective view of the facial skeleton showing the implant in FIG. 8 properly positioned on the Malar - Zygomatic Bone complex.
FIG. 12 illustrates a perspective view of another embodiment of the Malar Implant.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now to FIG. 1, there is illustrated the first embodiment of the malar implant overlying the malar-zygomatic bone complex on the left side of the patient. It is generally labelled as No. 10. The implant 10 has a 3-dimensional asymmetrical configuration. There is an outer surface means 12 illustrated as a generally convex surface having an area of greatest prominence at the apex 14 at the lower mid-region of the outer surface 12. The outer face 12 forms a prominent appearing cheek bone when the implant 10 is implanted on the patient.
The inner surface means 16 is illustrated as a generally concave surface, or deep recess in the backside of the implant, which forms a complementary fit with the underlying cheekbone region of the patient. The cheekbone region includes the superior maxilla and zygoma bones which form the malar-zygomatic complex. The cheekbone is the prominence below the eye that is formed by the zygomatic bone. The malar bone is a four-pointed bone on each side of the face, uniting the frontal and superior maxillary bones with the zygomatic process of the maxilla.
FIG. 2 shows a cross-sectional view of the implant 10 of FIG. 1 taken along the lines 2--2 of FIG. 1. The greatest prominence of the outer face is clearly illustrated in FIG. 2 as the apex 14. The outer surface has an overall convex shape. A longitudinal cross-sectional view of the outer surface illustrates a convex surface. Transverse cross-sectional views of the outer surface illustrate a variable convex contour. The transverse contour is most acute at the area of greatest prominence, and becomes less acute on either side of 14. The concave inner surface also has a complementary area of greatest depression positioned underneath 14. The longitudinal cross-sectional view of the inner surface illustrates a generally concave contour. Transverse cross-sectional views of the inner surface disclose a variable concave contour. The concave contour of the transverse cross-section is most acute at the area of greatest depression, and becomes less acute on either side of the depression.
Referring back to FIG. 1, the outer surface 12 and the inner surface 16 merge at the superior portion of the implant to form the upper edge 18, and they merge at the inferior portion to form the lower edge 20. The outer and inner surfaces merge at the anterior portion to form the anterior edge 22, and they taper at the posterior portion to form the posterior edge 24.
The anterior edge 22 includes a maxilla extension 26 extending from the lower region where the anterior edge 22 and the lower edge 20 converge. The portion of the implant above this lower region is sufficiently receded, or indented, to avoid and to provide space for the infraorbital foramen 28 when the implant is correctly positioned on the patient.
The infraorbital foramen is an opening, or orifice, in the maxilla bone to provide a passageway for several vessels including the infraorbital nerves to the facial area of the cheek and upper lip. Physical contact with these nerves by the implant would result in discomfort and perhaps disabling symptoms in the immediate area and down into the upper lip and cheek area innervated by the infraorbital nerve.
Part of the upper edge 18 formed at the superior portion of the implant forms an orbital rim surface 19. This orbital rim surface is positioned below and generally parallels the lower edge of the orbit 30, or eye socket, of the facial skeleton. The distance between the orbit and the orbital rim surface 19 is about 4 millimeters.
The posterior edge 24 of the implant 10 includes a zygomatic extension means 32 where the lower edge 20 and the posterior edge 24 converge. The zygomatic extension means is illustrated as a tapered tail 32 extending from the posterior edge 24. The zygomatic extension 32 overlays part of the zygomatic arch 34.
FIG. 3 illustrates the human skull with the left malar implant 10 correctly positioned on the left side of the face over the malar zygomatic complex and below the orbit 30. It is positioned posterior to the infraorbital foramen 28. The anterior end of the orbital rim surface 19 is positioned below the infraorbital notch 29. The right malar implant 11 is likewise correctly positioned on the right side of the face. The left implant 10 and the right implant 11 are for the most part mirror images of each other and are positioned on the facial skeleton in a mirror image fashion. In practice, the two implants would be sold in pairs with an L and an R imprinted on the left and right implant respectively to avoid confusion by the attending surgeon. There would also be placed a dot on the superior portion to avoid the mistake of placing either of the implants upside down in the cheek.
FIG. 4 is a cross-sectional view of the implant 10 taken along the lines 4--4 of FIG. 3. This view illustrates the cross-section of the malar zygomatic complex 36 in cooperation with the inner concave surface 16 of the implant. The zygomatic extension 32 is positioned against the zygomatic arch 34. The posterior contour of the trailing edge of the zygomatic extension 32 of the implant 10 fits the contour of the skeleton in that area almost precisely. The posterior contour of the zygomatic extension 32 and the outer surface 12 are shaped to mimic the normal anatomy of the facial skeleton. As a result of this contouring, the implanted protheses give very natural appearing cheeks on both sides of the face.
FIG. 5 illustrates a mirror image pair of second embodiments 50 and 52 of the malar implant. It is fitted to the malar zygomatic complex in the same manner as the first embodiment 10 is fitted. The implant 50 has the same elements as the implant 10 has. It has a convex front surface 12 with an apex or area of greatest prominence 14, a back surface face 16 with an area of greatest depression, a lower edge 20, an upper edge 18, an anterior edge 22, and a posterior edge 24. The second embodiment has the same crosssections as are illustrated in FIGS. 2 & 4. The implant 50 has a silhoutte which resembles a four-pointed diamond shape having four sides in a very general sense. One lateral point 58 is adjacent the infraorbital foramen; the other lateral point 54 is adjacent the zygomatic arch; the top point 56 is adjacent the orbit; and the bottom point 60 is adjacent the maxilla bone. Beginning at the top point 56 and going in a clockwise direction, the first side is the posterior edge 24, the second side is the lower edge 20, the third side is the anterior edge 22, and the fourth side is the upper edge 18. The lower edge 20 and the anterior edge 22 meet to form a very rounded corner. The combination of the lower edge and the anterior edge appear to form a curvilinear edge because of the nearly indistinguishable corner.
A third embodiment 70 of the malar implant is illustrated in FIG. 6. Its configuration is nearly identical to the implant 10 shown in FIG. 1 with the addition of a hook-shaped extension means 72 formed as part of the ancillary maxilla extension 26. The hook-shaped extension means is illustrated as a hook-shaped extension having a cutaway 74 for avoiding and providing space for the infraorbital foramen, and an infraorbital rim extension medially 76 juxtaposed with the orbital rim surface 19 for more definition of the cheek area anterior to the infraorbital foramen 72. The mirror image of the implant 70 is numbered 71.
A fourth embodiment of the malar implant is numbered 80, and is illustrated in FIG. 7. The configuration is nearly identical to the malar implant 10 which has already been described, and illustrated in FIGS. 1 through 3, with the additional feature of having the zygomatic extension labelled as 32 in FIG. 1 extending further backwards towards the ear. This feature 84 gives more definition to the zygoma. The mirror image of the implant 80 is numbered 82.
The four described malar implants should give the surgeon, using his skill and judgment, enough inventory to choose and fashion the appropriate implant to be used on a particular patient. Some patients have a more rounded face, some have a narrow gauntlike appearance, while others fall into the normal category.
Referring now to FIG. 8, there is illustrated an alternative embodiment of the Malar Implant, specifically the left sided one 99. This is an alternative style of the Malar Implant. The posterior extension 100 overlying the Zygoma has been modified to create a better imitation of Mother Nature and to give a better contour to the implant. The lower edge has been extended downwardly creating an inferior extension 101 of this style of the implant. This is done to mimmick Mother Nature and to create a pleasing aesthetic shape. In effect, the implant is changing Mother Nature. The upper two-thirds or so of this implant covers the bone and becomes fixed by encapsulation. The lower one-third or so would be about 0.1 to 2.5 centimeters and extends below the bone into the soft tissue. The implant then is maintained in place by the capsule formation around the silicon comprising the implant which essentially acts like a sling in the inferior aspect; holding it in position and in place as well as being held in place by the musculature on the skull on the one side and on the subtutaneous tissues on the other side. Maxilary extensions with holes for the infra orbital nerves are optional and can be designed into it. As the implant is lying on the zygomatic muscle group, the reconstruction of the image of the malar bone appears to be much large by 2 to 4 centimeters than is the actual case of the patient. The transverse cross sectional view of the implant (FIG. 9) taken in conjunction with the longitudinal cross sectional view of the implant, FIG. 10, indicates that there is an area of greatest prominence 104 on the outer surface. FIG. 8 illustrates the zygomatic extension 100, the orbital rim surface 102, the area of greatest prominence 104, the anterior maxila extension 106. The outer convex surface is shown in FIG. 8 and cross sections of the inner concave and outer convex surfaces are shown by cross sectional views in FIGS. 9 and 10. The outer convex surface in the lower mid-region thereof has a convex surface in both a longitudinal and transverse cross section such that at an intersection 104 of the surface forms a maximum apex to yield an area of greatest prominence for forming a naturally appearing cheekbone when implanted. The inner concave surface in the lower mid-region thereof has a concave surface in both a longitudinal and transverse cross-section such that at the intersection 108 of the inner concave surface forms a maximum depression to provide a complementary fit adjacent to the underlying zygomatic bone.
FIG. 12 shows another style of the Malar Implant generally designated as 110. The discussions regarding the implant shown in FIGS. 1 through 7 apply to this implant also. The modifications are where the upper edge 112 meets the anterior edge 114 at a point labeled No. 116. This point 116 is rounded off and tapered more so that the anterior edge 114 is slanted away from the infraorbital foramen. Additionally the posterior edge 118 meets with the upper edge 112 forming another modified point 126 which is not as prominent as that shown in FIG. 1. Additionally, where the lower edge 120 and the posterior edge 118 merge there is not as much of a extended zygomatic extension 124 as is shown in FIG. 1. The implant of FIG. 12 has the tips more rounded and a less prominent zygomatic extension. Again, the implant shown in FIG. 12 can be produced in generally three sizes, small, medium and large, to cover the anticipated range of patient's cheekbones. The concave surface of the implants generally have the area of greatest recess or depression to be placed against the zygomatic arch or cheekbone to keep it in position. It must be kept in mind, however, that due to injury or disease, occasionally the patient's cheekbone is not prominent enough and accordingly the concave area has to be modified somewhat and custom fitted so that it complements the surface as actually found in a particular patient. The end result is as before, because the convex outer surface is the one that creates the prominent appearing cheekbone. The concave surface will compensate for the abnormalities occasionally found in the patient.
METHOD OF INSERTING THE PROTHESES
The terms prothesis and implant are used interchangeably to denote the implants described herein, although it is to be understood that the method, or surgical procedure to be described, would cover any type of chin implant, not just those described herein. The surgical procedure includes the following steps:
1. Local or general anesthesia by surgeon's choice - normal anesthesia routine used in blepharoplasty or rhytidectomy procedures is recommended;
2. making a lower infratarsal blepharoplasty incision;
3. elevating a skin-orbicularis muscle flap;
4. using a fixation forcep to separate the orbital septum and its fat contents from the lower eyelid;
5. creating a subperiosteal space, or pocket, to extend from the lateralorbital rim to expand laterally, outward and down on the facial skeleton both toward the zygoma and down underneath the infraorbital foramen;
6. undermining if necessary around the lateral orbital rim.
The implant is properly positioned when the anterior tip of the orbital rim 19 is below the infraorbital notch 29, and the implant is posterior to the infraorbital foramen 28.
The lower edge 20 on the inferior extension 101 of the implant of FIG. 8 would extend and embed itself into that soft tissue that one can grab and which is termed by the layman as the cheek. The cheek includes several muscles and fatty tissues. The two face muscles known as Zygomaticus major and Zygomaticus minor originate or attach to the Zygomatic arch and behind the maxillary arch, respectively. The attachments of the muscles to the bones are called elevators. The two muscles referred to are the upper muscles of the upper lip, one of which draws the upper lip backwards, and the other one draws the upper lip up and out.
The Terino implants are held in place by the lower edge 20 on the inferior extension 101 which when implanted will cause the body to react to this foreign object by encapsulating the lower edge of the implant by forming a type of collagen fibrosis which will not stick to the implant but will snugly hold the lower edge 20 on extension 101 in place by forming a pocket to keep the implant from drifting downwards. The inner surface lying adjacent to the bone arch also serves to keep the implant from drifting.
The malar implant acts as a spacer to build up the insufficient prominence of the cheekbone. The outer face 12 of the implant is a replica of what the cheekbone would look like if the patient had a prominent cheekbone. The implant is intended to mimic the natural contours of a prominent cheekbone. The implant is positioned under the soft tissue of the cheek, and after healing, will give the patient the appearance of attractive high cheekbones.
Obviously, many modifications and variations are possible in light of the above teachings. It is therefore to be understood that the full scope of the invention is not limited to the details disclosed herein and may be practiced otherwise than as specifically described. | A malar implant molded from silastic material is surgically implanted behind the soft tissue of the cheek and over the malar zygomatic complex to buildup the prominence of the cheekbone. The implant has a convex front surface and a concave back surface for close fitting to the cheekbone. The front surface includes a prominence to replicate the prominence of a high cheekbone and the posterior end tapers off. This structure, after implantation appears natural and gives the appearance of attractive high cheekbones on the patient. The protheses come in left and right mirror image pairs for implantation on the left and right cheeks by practicing a new surgical procedure. | 0 |
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